You are on page 1of 22

FACULTY OF ENGINEERING AND THE BUILT ENVIRONMENT

DEPARTMENT OF METALLURGICAL ENGINEERING

STUDENT LABORATORY GUIDE

NAME OF COURSE
REFRACTORIES III
NQF
LEVEL

NQF
CREDITS

0.083

QUALIFICATION & SAQA ID

Diploma in Metallurgical Engineering

COURSE CODE

RFC321T

Compiled by DR M.B. SHONGWE (Ms MERCY RAMAKOKOVHU)


(2016)

COPYRIGHT : Tshwane University of Technology


Private Bag X680
PRETORIA
0001

Printed
and
distributed quotations
by :
All rights reserved. Apart from
any
reasonable
for the purposes
of research criticism or review as permitted under the Copyright Act, no part
FACULTY or
OFtransmitted
ENGINEERING
AND
of this book may be reproduced
in any
form or by any means,
ENVIRONMENT
electronic or mechanical, BUILT
including
photocopy and recording, without
permission in writing from the publisher.
Tshwane University of Technology
Private Bag X680
Pretoria
0001

PAGE 2 OF 18

ORGANISATIONAL COMPONENT CONTENTS:

1.

Welcome ................................................................................................................ 6

2.

LABORATORY Staff .............................................................................................. 6


2.1

Contact Details ................................................................................................ 6

2.2

Staff availability ................................................................................................ 7

3.

Requirements, resources and recommended material........................................ 7


3.1

4.

Code of conduct ................................................................................................ 10


4.1

Attendance..................................................................................................... 10

4.2

Classroom behaviour ..................................................................................... 10

4.2

Laboratory, Hearlth & Safety Rules And Regulations .................................... 10

4.3

Responsibilities of students ........................................................................... 11

1.

2.

Requirements for the course............................................................................ 7

Overview of the course ..................................................................................... 12


1.1

Purpose of the course .................................................................................... 12

1.2

Links to other subjects ................................................................................... 12

1.3

Course outcomes........................................................................................... 12
Assessment ...................................................................................................... 13

PAGE 3 OF 18

2.1

Assessment methods and criteria ................................................................. 13

2.2

Assessment rules .......................................................................................... 13

2.3

Marking system .............................................................................................. 13

2.4

predicate/Year mark ...................................................................................... 14

2.5

Moderation.................................................................................................. 14

2.6

Promotion requirements................................................................................. 14

3.

Laboratory course content and schedule .......................................................... 14


3.1

Schedule of laboratory sessions and assignments ........................................ 14

3.2

Learning outcomes and assessment criteria.................................................. 15

3.3

Generic outcomes and critical cross-field outcomes ...................................... 15

4.

Glossary of terms .............................................................................................. 16

5.

Assessment Records ........................................................................................ 17


5.2

Example or guidelines of a practical report .................................................... 17

sample collection............................................................................................... 20

Experiment 1: Apparent porosity.................................................................. 20


Apparatus and Materials ........................................ Error! Bookmark not defined.
Procedure ............................................................................................................ 21
Report writing....................................................................................................... 21

Experiment 2: Thermal shock resistance and Microscopic analysis ........ 21


PAGE 4 OF 18

Apparatus and Materials ...................................................................................... 22


Procedure ............................................................................................................ 22
Report writing....................................................................................................... 22

PAGE 5 OF 18

SECTION

1.

ORGANISATIONAL
COMPONENT

WELCOME

Welcome to laboratory session of Refractories III. This part of the course provides continuity to advanced
knowledge in the field of Refractory materials used in metallurgy and is offered via experimental work, problembased work or project-based work over three weeks. The course is structured in such a way as to master
theoretical concepts and principles and various practical skills to complement the major courses in the
qualification. We trust you will enjoy the course, and find it interesting and informative.

2.

LABORATORY STAFF

2.1

CONTACT DETAILS

NAME

Dr M. Shongwe

CAMPUS

Pretoria

ROOM
NO

3-714

TEL NO
E-MAIL

ShongweMB@tut.ac.za

CONSULTATIO
N TIMES

12:30-13:30

ACADEMIC
FUNCTION

Lecturer

Friday

Ms Z. Maswuma

Pretoria

2-328

wozeth@yahoo.com

12:30 13:30
Assistants

Mr SP mahlangu

Pretoria

3-G05

sbu.mahlangu1@gmail.com

Friday

PAGE 6 OF 18

2.2

STAFF AVAILABILITY

If, after attending class and making every effort from your side to master content, you still have problems with
understanding key concepts or principles or their application, lecturers are available for consultation.
The general rules regarding consultation and/or mentorship:

No unauthorized entry into the lab will be allowed outside practical times and consultation times.

Please adhere to consultation times for each lecturer, technologist or mentor involved with the course.

3.

REQUIREMENTS, RESOURCES AND RECOMMENDED MATERIAL.

3.1

REQUIREMENTS FOR THE COURSE

3.1.1

PRESCRIBED RESOURCES

The following tables indicate what literature and other resources are essential for successful completion of this
course. You are strongly advised to acquire all the prescribed resources. Please not that access to computers

operating Excel is imperative.

PRESCRIBED RESOURCES

CATEGORY

DESCRIPTION

BOOKS

COMPUTER &
SOFTWARE

WHERE TO FIND

COST

LEVY

Arcadia Book Store

MS Word

Electronic Resource Center

MS Excel

PAGE 7 OF 18

EQUIPMENT

Oven

Compression Strength Tester

Scale

PAGE 8 OF 18

3.1.2

RECOMMENDED RESOURCES

The following recommend resources will enhance your understanding and knowledge in this course, and you are
encouraged to use the following additional resources.

RECOMMENDED RESOURCES

CATEGORY

AUTHOR

NAME

PUBLISHER

ISBN NO

BOOKS

Hloben .P

Refractory Materials- Major industrial


application , 2000

Rexxon
Corporation, RSA

0-620-25867-5

CRNIGLIA, SC
& BARNA, GL
1992

Handbook of industrial refractories


technology. Principles, types ,properties
and applications

Park
Ridge:
Noyes
Publications

08-8155-13046

GUIDES

RECOMMENDED ELECTRONIC MATERIAL & WEBSITES

WEBSITES

www.sciencedirect.com

www.scopus.com

PAGE 9 OF 18

4.

CODE OF CONDUCT

Please take note of the following regulations. These regulations are in addition to the standard rules and
regulations as determined by the TUT. Please familiarise yourself with the TUT rules and regulations as set out in
the student diaries received on registration.

4.1

ATTENDANCE

Attendance of all practical sessions is of primary importance. It is the learners responsibility to sign the
register each week. A 100% attendance is mandatory for all practicals. The level of absenteeism will lead to
exclusion from the final moderation at the end of the year, which means that you will fail the practical.
Excuses will not be accepted for missing a laboratory session. All students should make prior arrangements
to ensure that all activities are completed (see schedule).
4.2

CLASSROOM BEHAVIOUR

In this class, a "safe environment" in which students are free to ask questions or say what is
on their mind will be created. Students will be encouraged to get to know one another.

4.2

Groups and individual discussions will take place in every lecture; therefore preparation before class is
very essential.

The lecturer will only explain in class the principles and applications of the process. It is your own
responsibility by means of self-study of the notes provided and auxiliary sources.

The lecturer expects self study and self-discipline from you, the student. It is important to stay up to
date with your studies to enjoy the full benefits.

LABORATORY, HEALTH & SAFETY RULES AND REGULATIONS

Laboratory work can be extremely dangerous. Although every effort has been made to eliminate the use of
explosive, highly toxic, and carcinogenic substances from the experiments you will perform, there is a certain
unavoidable hazard associated with the use of a variety of chemicals and glassware. You are expected to learn
and adhere to the following general safety guidelines to ensure a safe laboratory environment for yourself and
your fellow students.

PAGE 10 OF 18

Students will not be allowed to do practicals if they arent wearing protective overcoats and any other
relevant safety equipment. Basic laboratory safety rules will be adhered to at all times while in the
laboratory.

It is the responsibility of all persons using the laboratory to immediately report any unsafe act or
condition by any person to the Lecturer or Technician.

A safety kit is available from the laboratory technician in the case of an emergency. In the event of a
hazardous incident or accident in the laboratory, report the incident to the lecturer and the laboratory
technician in charge.

After the incident or accident, the group involved will compile a formal report to explain the situation
and suggest prevention measure for the incident or accident. This will be handed over to the laboratory
technician within 24 hour of the incident or accident.
If a piece of equipment is defective, it must be reported immediately to the lecture or technician in
charge or any staff member present in the laboratory.

RESPONSIBILITIES OF STUDENTS

Registration: All students should ensure that they are allocated to groups for the practical lessons. A registration
list from the registrar is used to compile the list at the end of registration period.

Preparation: Students are expected to come to all practicals prepared thus it is essential that students research
certain aspects before entering the laboratory. Before any experiment is carried out, students are expected to:

Participate in risk assessment drill to establish the safe working procedures to control the hazards, and
the risks which could arise from the planned practical work. The risk assessment document attached in
the appendices identifies a set of hazard categories which are relevant to the practicals. Please make a
declaration on completion of the risk assessment and ensure that the mentor or supervisor involved
signs the assessments. Records would be kept by the Technician.

PAGE 11 OF 18

SECTION

1.

LEARNING COMPONENT

OVERVIEW OF THE COURSE

In this course the students will be given a broad introduction into refractory material as a branch of the greater
metallurgical fields in the Science, Technology and Engineering discipline. This course is intended to equip
students with the practical knowledge of various types of equipment and theoretical operation principles.
Although the emphasis is on theoretical aspects, practical questions on properties and testing of refractory
materials will to some extent be explored.
The study guide is structured in such a way that the focus of each study unit is highlighted by the expected
outcomes. Students are persuaded to access, interpret, organize and transfer information from the prescribed
textbooks and other literature to solve problems within a stipulated time frame. In some instances a few worked
out examples are available at the end of each study unit to elucidate the different methods of solving problems.

1.1

PURPOSE OF THE COURSE

The general objective of this subject is therefore to emphasize understanding and develop material related
problem-solving skills in students, rather than mere memorization of facts.

1.2

LINKS TO OTHER SUBJECTS

This course contributes to the programme outcomes related to engineering concepts within the Metallurgical
field and it can relate to other courses, such as Physical metallurgy, Practical metallurgy, Physics, Maths &
Chemistry. The knowledge of this course assists students in the understanding of other courses such as FerroAlloys Technology.

1.3

COURSE OUTCOMES

The learning schedule, as set out in section 3, and ways in which you will be guided to master the content, will
enable you to achieve the learning outcomes, as detailed under 3.

PAGE 12 OF 18

2.
2.1

ASSESSMENT
ASSESSMENT METHO DS AND CRITERIA

Assessment of this laboratory course will include experimental work and quizzes, as indicated in the schedule.
The purpose of assessment is to determine whether you have achieved the learning outcomes. The various
assessment methods therefore will focus on criteria that will enable the lecturer(s) to determine whether you
have achieved the learning outcomes and mastered the required skills. The assessment criteria relevant to each
learning outcome are detailed in paragraph 3. The practicals form part of the subject content Refractories III
where learners will be evaluated and assessed for their practical performance in the laboratory and their
theoretical knowledge of the concepts.

2.2

ASSESSMENT RULES

The general rules of TUT regarding assessment apply. You are advised to familiarise yourself with these rules, as
they are applied stringently. Some experiments have got short exercises attached to them, and these must be
completed (group-work or individual depending on final report) before a practical session commences. These
shall be submitted to the mentor before 16:00 as per submission deadline set below. 10 Marks will be deducted
per day for any late submissions. All reports shall be submitted typed in Times New Roman, 12pt, 1.5 linespacing and justified and all headings in the same font and bold. No hand written reports will be marked.
All reports should be submitted exactly a week after the day the practical took place. They should be submitted
before 16:00.

2.3

MARKING SYSTEM

The marks will be allocated, particularly with respect to experimental work, problem-based work, project-based
work and assignments. Marks from each experiment will be credited according the marking scale shown below.
(Show this Table in the front of your submitted report)

GUIDELINES

Mark %

General Impression: Neatness and Correct format

10

Abstract: Briefly description of the work

10

Introduction: Places the work in context

10

Literature Survey: Used sufficient relevant sources and acknowledges.

20

Experimental Procedure

10

Results & Discussions: Precision, accuracy and use of statistical


methods. Logical Outlay with problems stated and solved clearly
Conclusions & References: Scientific & Justifiable Format and a

Actual
marks%

30
10

PAGE 13 OF 18

minimum of five references should be used


Total (marks)

100

Total (%)

100

2.4

PREDICATE/YEAR MARK

The laboratory mark will be calculated as an average of all the marks from the practical reports. This contributes
20% (see ITS) towards the final mark of the subject Refractories III.

2.5

MODERATION

Moderation of the practicals will be conducted by the Lab coordinator and the Subject Lecturer in the
department.

2.6

PROMOTION REQUIREMEN TS

The minimum total mark required to pass the practical is 50%.

3.

LABORATORY COURSE CONTENT AND SCHEDULE

This course comprises of an experimental component, problem-based component and a project-based


component. Your mastery of the required skills is assessed at regular intervals. More importantly, the
application of theory is assessed through problem-based- or project-based assignments or projects. This
practical class will cover the experiment in the application of metallurgical engineering. This will familiarize the
students with the principle, parameters, design and operation of different machinery used in mineral processing.
The students need to have knowledge of the application of different mineral extraction processes so that they
are able to identify and optimize problem areas in industry. This knowledge is basic for all metallurgical
engineers.

3.1

SCHEDULE OF LABORATORY SESSIONS AND ASSIGNMENTS

DURATION

THEME

SCHEDULED DATE*

1 WEEK

Effect of impurities on brick properties; Effect


of silica particle size on brick composition

Wednesdays 13:00-15:00

2 WEEK

Compressive strength tests

Wednesdays 13:00-15:00

PAGE 14 OF 18

3.2

LEARNING OUTCOMES AND ASSESSMENT CRITERIA

The following tables clearly indicate what you have to achieve (the learning outcomes) and how you will be
assessed (assessment criteria) to determine whether you have achieved the required knowledge and
competences:

LEARNING OUTCOME 1:

Using science and technology effectively and critically, showing responsibility towards the environment and
health of others.

Assessment criteria

Assessment method

Upon successful completion of this course, the student should be able to:

Operate all equipments


Obtained knowledge on properties and testing of Refractories
Conduct investigations using a microscope

Project Based Individual


Reports

LEARNING OUTCOME 2

Communicating effectively using visual, mathematical, language and technical skills. The student should be
able to communicate technical information and present technical progress information using defined
format.

Assessment criteria

Assessment method

Upon successful completion of this course, the student will be able to:

3.3

Generate appropriate data and information using available resources


Interpret technical data
Generate, construct and deliver a technical presentation.

Project Based Individual


Reports

GENERIC OUTCOMES AND CRITICAL CROSS -FIELD OUTCOMES

PAGE 15 OF 18

Compliance with Critical cross-field Outcomes

Compliance with Generic Engineering and Built


Environment Outcomes

Using science and technology effectively and


critically, showing responsibility towards the
environment and health of others.

Assessment of the presentation of Scientific &


Justifiable Format of arguments

Communicating
effectively
using
visual,
mathematical, language and technical skills.

Report writing
comprehension

4.

skills,

language,

synergy

and

GLOSSARY OF TERMS

The following technical terms are used in this course, and you should be familiar with these terms and their
meanings.

Abrasion

Alkali resistance

Apparent porosity

Basic refractory

Bulk Density

Calcination

Carbonization

Hydration tendency

Magnesia

Ramming

Reference temperature

PAGE 16 OF 18

Sources used for the compilation of the glossary:


1. https://www.iso.org/obp/ui/#iso:std:iso:836:ed-1:v1:en

5.

ASSESSMENT RECORD S

The following test and examination are attached to serve as examples of the implementation of the assessment
criteria and assessment method, as listed in the table 3.1, and you should be familiar with these examples to
prepare and orientate yourself of how the various assessment criteria are used and applied in the various
assessment methods.

5.2

EXAMPLE OR GUIDELINES OF A PRACTICAL REPOR T

This is only a brief discussion of report writing. The purpose of the report is to transfer knowledge to a wide
variety of people. The structure of the report therefore is very important. All reports have to be typed and
presented as specified in the following framework:

Always use Arial -12 point font as letter type, Justify the text and use 1.5 line spacing.
Do not add extra spaces in the text to give the document more volume.
In the literature chapter, provide a reference at the end of every applicable paragraph.
Carry on with sub headings as necessary. You are allowed to use up to for numbers, i.e., 2.2.1.3 and
there should be an hierarchy of headings, e.g.
1.

TITLE: bold, capital letters, 14 point

1.1. FIRST HEADING: bold, capital letter, 12 point


1.1.1.

Next Level: bold, small caps, 12 point

1.1.1.1.

Next level: regular, small caps. 12 point

Students must adhere to the report format as much as possible. The technical report consists of the following:
FRONT COVER PAGES
Title page
The title page consists of:

The level of study


Title of practical

PAGE 17 OF 18

Full name of the author(s)


Student number
Date submitted
The title is a short description of the practical

Acknowledgements
List all of the assistance received during the practical and writing of the report.
Abstract
The abstract is a condensed statement of the most important aspects and information. The abstract contains the
following:

The primary objectives and scope


Methods used
Factual findings and achievements as concisely and informative as possible.

The abstract should be as brief as possible and direct. It should be more than half a page. The wording must not
be the same as in the text.
Table of contents
It is a complete list of numbered headings and subheadings, together with the respective page numbers.
BODY
Introduction
The introduction should provide details on most of the following points:

Objectives and nature


Statement of the problem, sub-problems
Purpose of the study, motivation for study
Method and approach to the study
Extent of the project
Limitations

The introduction should be preferably not longer than one page.


Theory / Literature Survey
This section gives the reader background information on the relevant topic and outlined discussion of relevant
laws, theories or fundamental concepts and to give a clear statement of the authors assumptions.
It should be about 3 to 4 pages long.
PAGE 18 OF 18

Experimental Procedure
In this section the equipment, planning and procedure is discussed. It should be as detailed as possible. Please
do not copy the practical manual as is.
Results and Calculations
The findings / data of all experiments conducted are included in this section. They should be analyzed and
interpreted, but not discussed. Details of data and tables may also be included under this topic and referred to
in the analysis / interpretation of the data obtained.
Discussion of Results
This section, in which the results are discussed deals with the following:

Significance of the findings


Reliability of the findings and using of statistical methods
Comparison and evaluation with theory
Explanation of unusual findings
Limitations and extent of possible errors
Effectiveness of the methods.

Unnecessary theory should be avoided under this section. Discussion should be straight to the point and as
factual as possible. It should be clear as to how and why the author of the report came to his / her conclusions. It
is very crucial to consistently emphasize more on the applicability of the experimental findings as compared to
the theoretical Engineering principles. Substantiate impressively on the approval or disapproval emanating from
your factual findings.
Conclusion and Recommendations
The section is clear and orderly presentation of the findings and deductions made. This section should be
entirely based on your discussion, and recommendations must also be suggested with respect to the real
industrial application i.e. how costs could be reduced and effectiveness of the principle be modified to suit its
practical application.
Lists of sources consulted
Every report should list and acknowledge all literature and other sources of information used by including full
details in the list of sources consulted. A source in the reference list must be referred to in the text and vice
versa. The reference list is not numbered and in alphabetical order. Any entry looks as follows:
Note punctuation and italics
A reference source in the text to the source of information consulted should give the following details:

PAGE 19 OF 18

BOOK: (Surname of author, year of publication & page number of the relevant information in the source)
Example:
FONTANA, M. G., 1987, Corrosion Engineering, 3rd edition, McGraw-Hill Book Company, New York.
ARTICLE: Authours surname, followed by initials, year of publication, title of the atile, name of the journal,
volume of journal and page numbers of the journal.
Example:
BAWEJA, D., ROPER, H. and SIRIVIVATNANON, V., 1993, Relationships between anodic polarization and
corrosion of steel in concrete, Cement and Concrete Research, Vol. 23, pp: 1418-1430.
WEBSITE:
Example:
http://www.corrosion-doctors.org/experiments/rust-chemistry.htm, Date accessed: 27/10/2004
APPENDIX / APPENDICES
Supplementary information to the text, or information which is either bulky or break up the flow of the text,
should be placed in the extras.

SAMPLE COLLECTION

Each group (10 members) needs to collect 1,5 kg silica (sand) wherever you can find it. You can look around
the campus.
Each group (10 members) needs to collect 100g of impurities wherever you can find it. Pieces of buck fallen
from a tree will do.
Each group will make three refractory bricks with different compositions - A total of 6 bricks (2 per composition)

EXPERIMENT 1: (A) EFFECT OF IMPURITIES ON BRICK PROPERTIES


(B) EFFECT OF SILICA PARTICLE SIZE ON BRICK PROPERTIES

Refractory bricks are used in the lining of furnaces, kilns, fireboxes as well as fireplaces. For greater energy
efficiencies, even though refractory bricks are built to withstand high temperatures, they will usually have low
thermal conductivity. Impurities in the material composition of the bricks can cause major problems, as they will
affect the performance of the bricks. Different material compositions are used in making the bricks, depending
on the Intended application.

PAGE 20 OF 18

High Alumina
Silica (course and fine)
Ferrochrome
Impurities
Water
Scale
Mild Steel Mould
Furnace

PROCEDURE A
1. Obtain raw materials (silica, high alumina, ferrochrome and impurities)
2. Weigh raw materials individually. (1kg Sample: 40% High alumina, 30% Sand, 5% Impurities, 25%
Ferrochrome)
3. Grind the impurities in a ball mill for 20 minutes.
4. Mix raw materials with water. (125ml)
5. Weight the resultant sample and record the mass.
6. Dry the sample
7. Fire the sample
8. Perform thermal shock tests

PROCEDURE B
1.
2.
3.
4.

Obtain the raw materials [silica - course; grind the other to +150m - 320m), high alumina and
ferrochrome)]
Weigh raw materials individually. (1kg Sample: 40% High alumina, 30% sand course, 30%
Ferrochrome) first sample
(1kg Sample: 40% High alumina, 30% fine sand, 30% Ferrochrome) second sample
Follow the rest of the steps in PROCEDURE A (4 8).

REPORT WRITING

1.

Determine the effect of impurities in the sample.

2.

Determine the effect of course sand and fine silica in the samples.

3.

Determine if the samples were resistant to thermal shock.

EXPERIMENT 2: COMPRESSIVE STRENGTH TEST


Under normal and industrial applications, refractories undergo compressive strength tests to determine
the load carrying capacity as well as the durability of the bricks. Some materials fracture at their
compressive strength limit, while others deform irreversibly, so a given amount of deformation may be
considered as the limit for compressive load.

PAGE 21 OF 18

APPARATUS AND MATERIALS

Compression Testing Machine

Scale

Steel container

PROCEDURE
1. Determine the dimensions of the bricks.
2. Weigh the bricks.
3. Place sample on testing machine.
4. Apply load.
5. Record reading when failure of specimen occurs.
6. Remove the brick from testing machine.
REPORT WRITING
1.

Calculate the compressive strength

2.

Calculate the cold crushing strength

PAGE 22 OF 18

You might also like