HMIE/HMET101:

INTRODUCTION TO MINERALS
INDUSTRY
ALLAN TSAPAYI
Introduction
o Course Instructor – Allan Tsapayi
o Room: D49
o Email: atsapayi@gmail.com
o Mobile: +263-773 242 203
 Our Constitution
1. Cellphones off or on silence
2. Punctuality
3. Adherence to time allocated for break time
4. Full participation
5. Respect for each other’s contribution
6. Nurture a spirit of helping one another
7. Maximize the time for discovering, learning
sharing and applying
8. If you are not sure, ASK!
9. One speaker at a time
10. Do not listen while eyes closed
My Career
 Degrees
 B.Sc.(Hons.) Metallurgy – Leeds University (1985)
 MBL- Business Leadership – UNISA (1996)
 MPhil. – Metallurgy (candidate) – UZ (2012)

 Began my career in Zimbabwe

 ZISCO Steel,
 BOC Gases,
 Astral Hardening
 BOC Gases
 Business
Printing
Dog food
Bottle store
Consultancy
 My Philosophy
 On Metallurgy
 Most exciting industry anywhere in the world
 Metallurgy is a positive force in creating a modern, vibrant society
 Metallurgy is changing significantly with respect to Sustainability
( environment, socio-political, techno-economic)

 On Education
 Learning and Teaching should be “FUN”
 Learning and Teaching should be “CHALLENGING”
 Co-operation is a key element to success
 There is no such thing as a “STUPID QUESTION”

 On Life
 If your career is half as satisfying as mine you are in for a great time
 Travel the World – there is so much diversity to see and enjoy
Aims
• To facilitate acquisition of the scientific
knowledge, technology and skills that
are effectively used in the processing of
available engineering materials
• To impart knowledge and skills on the
quality aspects of the end product.
Objectives
• Describe the basic principles of:
– Mineral Processing,
– Hydrometallurgy and
– Pyrometallurgy.
• Explain the essential difference between them
• Identify the physical and chemical properties of
minerals and there importance in the design of
metallurgical processing plants
Objectives
• Explain the rudimentary application of
metallurgical processes to the extraction of
metals from their ores
• To expose the student to the various metals
working processes methods
• To expose the student to the various metals
joining processes
• Identify the basic principles of the
environmental impacts of extractive
metallurgical processes
Course Outline

Patsime
 Mineral Processing
• Introduction to mineral processing;
– Minerals and ores;
– Economic justification of mineral processing;
• Mineral Processing steps:
– Comminution,
– Concentration,
– Mass balancing methods.
• The two product formula; recovery; ratio of
concentration; enrichment ratio; metallurgical
performance/accounting
Hydrometallurgy
• Definition.
– Unit processes in Hydrometallurgy;
– Leaching;
– Plant Scale leaching methods;
– Solid/liquid separation; solution purification;
– Recovery of metals from solution;
Electrometallurgy
• Faraday's Laws of electrolysis;
• Electrowinning and
• Electrorefining.
Pyrometallurgical extraction
and refining processes
• Ores;
– drying; calcination;
– roasting;
– agglomeration; smelting; matte smelting;
matte conversion; metal oxide smelting;
slags; slag/metal reactions; refining. nickel:
partial roasting and smelting; electrolytic
 Pyrometallurgical extraction
and refining processes cont
• Iron making and steelmaking;
– the iron making blast furnace;
• chemistry of iron making;
• the basic oxygen steelmaking process;
– chemistry of steelmaking,
• Extraction of copper from sulphides:
– matte smelting; conversion of matte into blister
copper; fire refining of blister copper.
• Extraction of nickel: partial roasting and smelting;
electrolytic process; Mond proces
Physical Metallurgy
• Bonding in solids; the metallic bond and
its consequences; the principal
crystallographic lattices in metals: BCC,
FCC and HCP; phases in alloys and
phase diagrams; the lever rule; principles
of strengthening mechanism in alloys;
mechanical properties, including fracture
toughness; principles of heat treatment
of metals and alloys.
Reference List
1. Fundamentals of modern manufacturing:
Materials, Processes and Systems by
Mikell P. Groover
2. Physical metallurgy principles, 3rd
Edition, Robert E. Reed-Hill and R.
Abbschian
Importance of Course
• The purpose of the course is to expose the
various processes that are used in metallurgy
to convert metals into useful engineering
materials.
Goals - Mine
 To impart knowledge
• fundamental knowledge
• experiential knowledge
 To teach you to “think” rather than “cook”
 To encourage you to consider a career path in
Metallurgy
 To encourage those who choose a Metallurgy
career to have an appreciation for Metallurgy
Goals - Yours
 To acquire knowledge
 To develop the skills to advance into our
upper-years Metallurgy courses
 To begin developing a successful career path
as a Metallurgical engineer
To get great jobs
To make money
To travel around the world
To work either in remote communities or large cities
To enjoy life to the greatest extent of your abilities
Teaching & Learning Environment
 Lectures
Arrangement
Monday & Fridays

 Tutorials, Seminars, Laboratories

To be arranged with certain companies
Teaching & Learning Environment
 Assignments – 3 in total

 Laboratories – 6 in total

 Term Assignment – groups of 2 or 3

Prepare a paper
Prepare a class presentation
Assignments

 Assignments are due one week after issue

 Late penalty is 1 mark / day including weekends
Laboratories

 Reports are due one week after completion

 Reports must be done per each visit
 Late penalty is 1 mark / day including weekends
Field Trip

To be organised
○ Foundries
○ Metal processing units
Term Projects

Groups of Students will prepare papers and make

presentations on subjects of interest

Impact of Climate Change on the Metallurgy Industry

Recycling Practices of Metallic materials
Sustainability in Mining
Metallurgy – a Global Industry
New Processing Technologies