Transport Phenomenon and Rate Processes in Metallurgy P.

Naresh B151916,E4 MME

Assignment-1

1. Explain the principles of transport phenomenon that are applicable in metallurgical

engineering starting from ore to refining and heat treatment and lloy design thatyou
have encountered with all theexamples
Ans: The study of rate processing brodly involves two subjects, transport phenomenon and
reaction kinetics. Let us take an example of Sulphur removal in blast furnace to understand the rate
processing.
[S]+(O2-) = (S2-)+[O]
The reaction involves three steps in general.
i. Transfor of sulphur and oxygen ions from the bulk of metal and slag phases respectivelyto
the slag metalinterface,
ii. Chemical reaction at the interface
iii. Transfer of reaction products, namely sulphur ions and oxygen to bulk slag andmetal
phases respectively from the reactionzone.

Step i and iii involves transfer of ions/materials between bulk phases and reaction zone, so it is
known as the study of transport phenomenon and the ii step is reaction kinetics.
A reaction is accompanied by either absorption or evolution of heat causing temperature
gradients in the system. This results in flow of heat through the phases.
Basic principles of transport phenomenon are of two types, first principle is concerned with the accounting
of basic quantities like momentum, heat, mass, etc. It is basically talks about conservation of these
quantities. Whereas second principle is about the rate and the direaction towards which a process will
proceed under a given set of conditions. It is defined as the rate of flow of a quantity per unti area per unit
time in proportional to the gradient or potential.
Basic principles of reaction kinetics where the factors which effect rate of the concerned reaction is studied.
A reaction consists of reactants and products, the rate of the reation may refer to the rate of change of the
concentrations of either reactants or products with respect to time.
A number of metallurgical processes such as roasting and solid state reduction, involves gas-
solid reactions where the steady state heat conducton therory is used.
During heat treatment processes the effect of diffusion of a component is coupled with phase
transformations or chemical reactions occuring in the system. Typical examples of such processes are
case-hardening, carburization of steels, carbonitriding, nitriding, cyanidation. During refining also mass
transfer studies helps like zone refining, vaccumdegassing

2. Distinguish between the Newtonian and non-Newtonian fluids? Where do you find
situations for the typical fluid behaviors during metallurgical processing? Classify the
fluids based on their behavior based on their relationship between viscosity and the shear
stress. What is the difference between thefollowing

a. Idealfluid
b. Dilatants fluid
c. Pseudo plasticfluid
d. Thixotropic fluid
Transport Phenomenon and Rate Processes in Metallurgy P.Naresh,B151916 ,E4 M ME

Ans: Newtonian fluids have a constant viscosity that doesn’t change, no matter the pressure
being applied to the fluid. This also means they don’t compress.
Non-Newtonian fluids are just the opposite, if enough force is applied to these fluids, their viscosity will
change. These fluids are broken up into two categories, dilatants, which get thicker when force is applied, and
pseudoplastics, which get thinner under the same circumstances.

The study of the flow of fluids constitutes the most significant part of the analytical study of
transport phenomenon in metallurgical process systems such as reactors. The main aim of the
study of the flow of fluids in metallurgical processes is either to obtain the velocity of pressure
profiles inside the systems or liquid metal flow systems as a function of time or to find thepressure
drop across reactor for a given mass or volume flowrate.
Ideal Fluid: An Ideal Fluid is a fluid which is incompressible in nature and that has no viscosity.
In practical, no fluid is ideal fluid because all the fluids have some viscosity. Thus, it is also called
as Imaginary Fluid or Binghamplastics.
Dilatant fluids, also known as shear thickening fluids, are liquids or solutions whose viscosity
increases as stress is applied. They are an example of non-Newtonian fluids, as they do not have a
linear shear stress versus shear rate rate, which is unique to Newtonian fluids.
There are also such things as shear thinning fluids, or pseudoplastics, which display the opposite
properties of dilatant materials; as more stress is applied to pseudoplastics the viscosity decreases
(or shear rateincreases).
There are also such things as shear thinning fluids, or pseudoplastics, which display the opposite
properties of dilatant materials; as more stress is applied to pseudoplastics the viscosity decreases
(or shear rateincreases).

3. Define the term viscosity. Based on the kinetic theory of gases, what does viscosity
depend on and how does it get corrected based on the molecular interaction. Explain the
terms involved in determining theviscosity.
Ans: The viscosity of a fluid is a measure of its resistance to deformation at a given rate.
The simplest theoretical approach for the calculation of viscosity at low densities is based on
kinetic theory which leads to the realtion
μ=2 mkT
2 3
3d π
where d and m are the diameter and mass of the molecules, respectively, k is Boltzmann's
constant and T is the absolute temperature. This expression was modified by Chapman-Enskog to
take into account the interaction among particles. And based on these molecular interactions they
obtained the realtion
μ = 2.6693*10(-5)(MT)1/2/ σ2Ωu
where M is the molecular weight of the gas, sigma the characteristic diameter of gas particles
and Ωu a function called dimensionless temperature.

4. Comment on the viscosity of metals using the Chapman model and his assumptions. What are reduced
parameters of temperature, volume and viscosity. What is therelationship
Transport Phenomenon and Rate Processes in Metallurgy P.Naresh,B151916 ,E4 M ME

proposed by Andrade on viscosity of metals at their melting temperature. Is Arrhenius

type relation valid for the viscosity of metals

a. What changes do you find when a eutectic or congruent melting is found in aphase
diagram of analloy.
b. Comment on viscosity of slags and the role of feldspar and alumina on viscosityof
slags

Ans: The most satisfactory theory for the visocity of liquid metals has been put by
Chapman, who proposed a model for the viscosity of pure liquid metals on the basis of the
presence of spherical atoms and has suggested that the potential difference betweeen
neighbouring atoms would be a function of the distance Φ(r) between the atoms (r) and an energy
parameter(ε), characteristic of the metal given by the relation

where δ is the interatomic distance in the close-packed metal crystal at 0K in Å.

Chapman assumed that all liquid metals obey the same function Φ(r) and that all of them have a
reduced viscosity μ* , which is a function of a reduced temperature T* and a reduced volume V*,
where the functional relationship is given by

and μ*, T*, V* are given by

μ =viscosity of the liquid metal, poise

δ = interatomic distance, Å
N0= Avogadro's number M
=atomic weight
R= universal gas constant, erg mol-1K-
1
T= absolute temperature, K
kB = Boltzmonn constant
ε=energy parameter characteristic of specific
metal ƞ=number of atoms per unit volume

The relationship proposed by Andrade between the viscosities and the melting points of the
metals is
Transport Phenomenon and Rate Processes in Metallurgy P.Naresh,B151916 ,E4 M ME

μm= viscosity, poise

Tm= melting point, K
M=atomic weight
V=atom volume, cm 3
C= a contant= 6.12*10-4

a) i. The viscosity tends to have a maximum value at the composition where a congruently
melting comound isformed.
ii. The viscosity has a minimum value at the composition where a eutectic is formed

b) Most of the common slags are derived from oxides, although of late a few fluoride-based slags have
found application in secondary refining processes.An oxide is considered to be acidic, when dissolved in the
molten slag, it acquires additional oxygen ions to form complex anions whereas a basic oxide ionises to
contribute oxygen ions to the melt. The most common acidic constituent in oxide slags is silica (SiO2), and
the viscosity of pure liquid SiO2, and its variation with the addition of basic oxides like lime (CaO),
magnesia (MgO), sodium oxide (Na2O),etc.
Al2O3 is cannot strcitly be classified as an acidic or a basic oxide as it can behave both ways,
depending onn the overall composition. In metallurgical slags, AL2O3 is important in blast
furnace slags whereas the basicity is low. Therefore, it behaves as an acidic constituent and may
form (AlO3)3- anions in the melt. In general Al2O3 is found to slightly increase the viscosity
when added to a binary silicate.

5. Calculate the viscosity of the following materials at their melting points by takingthe
necessary data from the database of materials of density, melting point and densitya.
Gold b. Aluminum c. Iron d. Nickel e. Copper f. Tungsten
Comment on the viscosity and which material is easy to cast and why?

Ans: Using Andrade equation we can find viscosity of the materials using melting
points and densitites of materials.

μm= viscosity, poise

Tm= melting point, K
M=atomic weight
V=atom volume, cm 3
C= a contant= 6.12*10-4Volume

can be written as V=M/

a.Gold M = 196.97
Tm = 1337.58 K
= 19.3 g/cc
Transport Phenomenon and Rate Processes in Metallurgy P.Naresh,B151916 ,E4 M ME

μm= 6.12*10-4[(1337.58*196.97) 1/2(196.97/19.3)-2/3

= 6.67 * 10-2Poise
b. Aluminum M = 26.98
Tm = 993 K
= 2.702 g/cc

μm = 6.12*10-4[(993*26.98)1/2(26.98/2.702)-2/3
= 2.16*10-2Poise
c. Iron M = 55.847
Tm = 1808 K
= 7.874 g/cc

μm = 6.12*10 -4[(1808*55.847) 1/2(55.847/7.874) -2/3

= 5.27*10-2Poise

d. Nickel M = 58.70
Tm = 1726 K
= 8.9 g/cc

μm = 6.12*10-4[(1726*58.70)1/2(58.70/8.9)-2/3
= 5.53*10-2Poise
e. Copper M = 63.546
Tm = 1357.6 K
= 8.96 g/cc

μm = 6.12*10 -4[(1357.6*63.546) 1/2(63.546/8.96)-2/3

= 4.87*10-2Poise
f. Tungsten M = 183.85
Tm = 3680 K
= 19.35 g/cc

μm = 6.12*10 -4[(3680*183.85) 1/2(183.85/19.35) -2/3

= 11.22*10-2Poise
Aluminum can be casted easily, because it has very low viscosity that means low resistivity to
flow. Tungsten is difficult to cast, beacuse it has high value of viscosity that means high resistance
to flow.

6. Derive an equation of viscosity by stokes method of a spherical particle of radius R with a

density of s falling in a liquid of density l with a terminal velocityVt.

Ans: Particle falling from rest, accelerates due to gravity, reaches a constant velocity which is
know as terminal velocity.
Transport Phenomenon and Rate Processes in Metallurgy P.Naresh,B151916, ,E4 MME

In this form the terminal velocity of the particle can be found. The terminal velocity determines
how long it will take a particle to separate from the fluid in which it is suspended. To derive
this terminal velocity we need to balance the forces
i. Particle weight,m Pg
ii. Fluid displaced,m Fg
iii. Drag force, F acts againes the partcileweight
iv. force due to acceleration
All forces mustbalance
mpg+mpa=mFg+F
mpg+ mp(dv/dt)=mFg+F
For a spherical particle, Stokes showed F=3dμv
where d diameter of sphere
μ= viscosity of fluid
v= velocity
v is the relative velocity between particle and fluid
when particle reaches terminal velocit, it does not accelerate
therefore dv/dt=0
for a sphere, volume =π/6d 3
Assume, density of fluid = f NOTE: mass=volume*density density
of particle is = p

π/6d3p g= /6d3fg+3πdμvt

simplifying the above equation we can get

vt= d2g( p - f )/18μ

Assumptions:
i. Equation is obtained for a single, smooth surface sphere of diameterd.
ii. The sphere is falling homogenousliquid
iii. No effect of other particles that are present in thefluid
iv. paricle is size much larger the molecules in thefluid