Metallurgy with Engineer Jay

Conveyor Belt Startup

Starting up a series of conveyor belts is initiated from downstream going up( Down-Up Approach). This approach facilitates a flawless flow of material downstream eliminating possible buildups.

Before that is initiated, field operators must ensure that all guards are put back in place, all conveyor belts surroundings are clear of any personnel and all pull wires are reset. Once this is done, the operator should confirm field operation readiness with the control room to energize the belts.

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This month we are going to focus more on production.
1. The common methods
2.
3. Gas cooling
4. Safe handling
5.
i)
ii) off gas
6. Hazards associated with Acid and how to handle them.

Stay on this page as we continue learning about , specifically Sulphuric acid production in this month.

With advancement of technology, comes simulation. And the mining industry is not exempted from this development.

In light of this, it is highly advised that engineers in the mining sector familiarize themselves with simulation softwares. And in the same thought, I too have decided to familiarize myself with it.

I'll therefore be sharing some software names and basics of they work for those that may be interested.

Good day.

https://youtu.be/zCznMbj2Yn4

Quick recap of steel metallurgy

Steel Metallurgy - Principles of Metallurgy Steel is the widest used metal, in this video we look at what constitutes a steel, what properties can be effected, what chemical elements we add to steel an...

Perfect MET

An Ellingham diagram shows the relation between temperature and the stability of a compound. It is basically a graphical representation of Gibbs Energy Flow.

In metallurgy, we make use of the Ellingham diagram to plot the reduction process equations. This helps us to find the most suitable reducing agent when we reduce oxides to give us pure metals. Let us take a look at some important properties of the Ellingham Diagram

Here ΔG is plotted in relation to the temperature. The slope of the curve is the entropy and the intercept represents the enthalpy.
As you know the ΔH (enthalpy) is not affected by the temperature
Even ΔS that is the entropy is unaffected by the temperature. However, there is a condition here, that a phase change should not occur.
We will plot the temperature on the Y-axis and the ΔG on the X axis
Metals that have curves at the bottom of the diagram reduce the metals found more towards the top
The reaction of metal with air can be generally represented as

M (s) + O2 (g) → MO (s)

Now when reducing metal oxides the ΔH is almost always negative (exothermic) reaction. Also since in the reaction (as seen above), we are going from the gaseous state to the solid state ΔS is also negative. Hence as the temperature increases, the value of TΔS will also increase, and the slope of the reaction goes upwards

Exceptions to Ellingham Diagram
There are cases when the entropy is not negative, and the slope will not be upwards. Let us take a look at few such examples

C(s) + O2 (g) → CO2 (g): Entropy of solids is negligible. So here one molecule of gas is resulting in one molecule of gas. Hence there is almost no net entropy. So there will be no slope, it is completely horizontal.
2C (s)+ O2 (g) → 2CO (g): Here one mole of gas is giving you two moles of gas as products. So here the entropy will be positive. And as a result, this curve will go downwards.
Limitations of Ellingham Diagram
It does not consider the kinetics of the reactions.
Also, it does not provide complete information about the oxides and their formations. Say for example more than one oxide is possible. The diagram gives us no representation of this scenario
Uses of Ellingham Diagram
1) Alumino Thermic Process

The Ellingham curve on the graph actually lies lower than most of the other metals such as iron. This essentially means Aluminium can be used as a reducing agent for oxides of all the metals that lie above it in the graph. Since aluminium oxide is more stable it is used in the extraction of chromium by a thermite process.

2) Extraction of Iron

Extraction of iron from its oxide is done in a blast furnace. Here the ore mixes with coke and limestone in the furnace. Actually, the reduction of the iron oxides happens at different temperatures. The lower part of the furnace is kept at a much higher temperature than the top. This process was developed after understanding the reactions with the help of thermodynamics. These reactions are as follows

At temperatures of 500-800 K

3Fe2O3 + CO → 2 Fe3O4 + CO2

Fe3O4 + 4CO → 3Fe + 4 CO2

Fe2O3 + CO → 2FeO + CO2

At temperatures of 900-1500 K

C + CO2 → 2CO

FeO + CO → Fe + CO2

July ending

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