Recycling of Metallllic Waste and Environmental Protection

At the end of this course, the students should be able to: 1. appreciate that in all mineral and metal value addition chain, safety of lives comes before economic gain; 2. internalise that environmental protection of both flora and fauna should be taken before, during and after metallurgical operations; 3. explain some safety procedures and environmental protection guidelines; and 4. ensure qualitative secondary production of iron and steel through recycling of metallic waste.

Safety precautions, environmental protection and regulations for mineral processing, metal extraction, melting, casting, forming and finishing operations. Environmental risk analysis; environmental ethics and environmental control technology. Introduction to urban mining: recycling of iron and steel scraps, recycling of metallic waste especially waste electrical electronics (WEE) to recover precious metals. Minimum Academic Standards Equipment List of Required New Laboratories and Equipment The laboratories in the metallurgical engineering programmes should be upgraded to the following seven laboratories. The required laboratories for the metallurgical engineering programme are as follows: 1. Mineralogical Analysis and Mineral Processing Laboratory 2. Facilities for Metallographic Studies and Microscopy 3. Ferrous Extractive Metallurgy Research Laboratory 4. Non- Ferrous Extractive Metallurgy Research Laboratory 5. Engineering Failure Analysis Workshop and Laboratory (For metallic materials) 6. Foundry Laboratory Facilities and Testing/Measuring Equipment 7. General Metallurgical Laboratory Facilities Mineralogical Analysis and Mineral Processing Laboratory The required equipment for characterisation and preliminary process design of minerals include but are not limited to the following: 1. Set of sieves 2. Vibrating shakers 3. Ore microscope for petrographic investigation 4. Atomic absorption spectrophotometer (AAS) with Au, Ag, Pb, Cu, Zn, Pt lamps for chemical analysis of precision metals. 5. X-ray diffractometer (with box file) for mineralogical assemblage of an ore. 6. X-ray florescence for chemical analysis of base metals. 7. Scanning electron microscope. 8. PH meter 9. PH electrodes 10. Laboratory sample divider The required equipment in this laboratory and their accessories include but are not only limited to the following: Top loading balance Comminution and particle size analysis equipment and accessories: 1. Crushers of various categories 2. Grinders of various categories 3. Set of sieves of all sizes with sieving machine for particle size analysis 4. Vibrating shakers 5. Particle size analyser 6. Physical concentration equipment and accessories 7. Gravity separation equipment which include a. Shaking Table b. Air float c. Jig d. Dense media separation e. Spiral f. Gravity concentrator g. Viscometer h. Magnetic separator i. Electrostatic separator j. Physico-chemical concentration equipment and accessories i. Froth flotation cell ii. Coal gold agglomeration apparatus Facilities for Metallographic Studies and Microscopy 1. Olympus Microscope, BHT 312 with PM 10 photomicrographic outfit, Ref. No. N-MKH-340- E with facilities for dark field and bright field. 2. Photomicrographic outfit, Olympus PM6, No. N-NMX-450-030F 3. Adapter for use of PM6 with stereoscopic microscope No. N-NMX-4520-502B 4. Illuminator, Olympus Model LSG-2 NO N-NMC0-200-010T 5. Illuminator, Olympus Model LSG-2 NO N-NMC0-215-010F 6. Achromatic objectives magnifications X4, X10, X20, X40, X100, X250, X500 7. Nikon Photomicrographic Attachments, microflex FX-Series (Complete with 35mm camera, mechanical shutter mechanism-photocell and direct reading exposuremeter) 8. Extra lenses for Nikon system: CF objectives Lenses, M.PLAN 50X, 100X and 200X 9. Standard Buehler Metallograph (or Versmet – 2 Metallograph, Unitron Instruments) 10. Belt grinder for rough grinding of metallographic specimens 11. Buehler metallographic rotary polishing wheels (ECOMET I and ECOMET II) 12. Wet grinding deck (to take 4 trips of emery paper) 13. Buehler polishing cloth (Selvyt and Nylon types) 14. Buehler moulding compound (specimen mounting compound); plastic kit (plastic liquid and powder type) required 15. Alumina polishing powder (1.0μm and 0.6 μm) 16. Buehler emery paper rolls or strips for use on a 4-deck land polisher (sequence of 240, 320, 400 and 600 grits) 17. Scanning electron microscope (SEM) complete with accessories 18. Ion beam thinning equipment (for etching/thinning of TEM specimens) 19. Chemical thinning equipment (for etching/thinning of TEM specimens) 20. Films, plates and related auxiliary facilities for optical microscopy, SEM and TEM 21. Transmission scanning microscope (TEM) complete with accessories 22. Metallurgical microscopes 23. Enlarger 24. Metal enlargement easel mask 25. Dryer cabinet 26. Darkroom timer 27. Darkroom lamp Ferrous Extractive Metallurgy Research Laboratory Pyrometallurgical Laboratory 1. This laboratory should have equipment and accessories for roasting, calcination and agglomeration (nodulising, sintering, pelletising and briquetting). 2. Functional induction furnace for melting of iron and steel 3. Laboratory pelletising drum 4. ISO drum tester 5. Pellet hardness apparatus 6. Permeability testing equipment 7. Gas analysers for CO, H2, CO2, among others 8. Reducing furnace with accompanying chemical balance 9. Softening testing apparatus 10. Sinter grate machine 11. Digital temperature indicators reading - 250°C to 1600°C (or other appropriate temperature range) 12. Induction furnaces Coal and Coke-Making Laboratory This laboratory is meant for assessment of coals for metallurgical coke-making and relevant equipment and their accessories will be needed to carry out the following functions: 1. The following qualities of coals will be determined: petrography, coking and caking. 2. For petrography, equipment will be needed for reflectogram, macenal analysis and rank determination. 3. For coking, relevant equipment will be required for gray-king coke type, Geeseller, plastometer and dilatometer 4. For caking, equipment will be required for Roga index(RI) and free-swelling index (Psi) 5. Bomb calorimeter (for measuring ash contents of coal and coke) Non-Ferrous Extractive Metallurgical Research Laboratory Equipment for the following speciality of non-ferrous extractive metallurgy: 1. Pyrometallurgy equipment and accessories including furnaces and crucibles 2. Analysis of gold by fire-assay gravimetric method equipment and accessories 3. Hydrometallurgy equipment and accessories 4. Electrometallurgy equipment and accessories This laboratory will be dedicated to process design for: 1. Precious metals like gold, silver, and Platinum group of metals 2. Base metal like Cu, Pb, Zn, Ni, Sn 3. Most important non-ferrous industrial metal: Al, 4. Radioactive metals like uranium, plutonium and monazite 5. Rare earth elements like lithium and cerium Engineering Failure Analysis Workshop & Laboratory (For Metallic Materials) In this workshop, engineering materials (especially metals) integrity assessment will be carried out. The following equipment among others will be required: Destructive testing of metallic materials 1. Universal testing machine for tensile, compressive and hardness tests 2. Impact testing machine 3. Fatigue testing machine 4. Green testing machine Non-Destructive Test (NDT) The equipment and accessories required include the following: 1. Magnetic 2. Resonance 3. Eddy current effect 4. Dye penetrant Metallography: Equipment and accessories The equipment and accessories required include the following: 1. Bakelight 2. Polishing machine 3. Etchant 4. Metallurgical microscope Fractography Equipment and accessories Microscopy: Equipment and accessories 1. Optical Microscope 2. Scanning electron microscope (SEM) 3. Transmission electron microscope (TEM) 4. Stemming electron microscope 5. Scanning Transmission electron microscope (STEM) Foundry Laboratory Facilities and Testing/Measuring Equipment Equipment and tools for a foundry workshop: 1. The design shop 2. Pattern shop 3. Mould and core preparation section 4. Melting section 5. Finishing section So that students have necessary skills so as to be able to produce the following items while still in school: a. Grinding disk for local grinders b. Aluminium pots, spoons and stove heads c. Break drum for automobiles d. Local axe heads e. Hand bills f. Wheel balancing weights g. Retort stand h. Railway brake block i. Damaged/failed part j. Test specimen weight scale; weighing range 0-210 gms, sensitivity 0.2 gms Design Office 1. Drawing board with stand 2. Tee-square 3. Drawing set (rotring) 4. Set-square (adjustable) 5. Tracing paper 6. Vernier calliper 7. Consumables, pencils, erasers and drawing sheets 8. Foundry analyser Pattern making shop 1. Hammer 2. Mallet 3. Punches 4. Stanley E-clamp 5. Stanley G-clamp 6. Vernier calliper 7. Tape rule 8. Wood drill machine 9. Stanley planer (smooth) 10. Stanley planer (Dutch) 11. Shrinkage allowance scale 12. Jig saw 13. Dovetarl saw 14. Chisel (turning) 15. Chisel (flat) 16. Oil stone 17. Files 18. Consumables include pencils, nails, adhesives, emery cloth. Mould and core making sections 1. Mould boxes or flasks 2. Sieve or mesh 3. Shovel 4. Rammer 5. Wheel barrow 6. Head pan 7. Gloves 8. Oven (core making) 9. Facing board 10. Soft brush 11. Bellows 12. Knife 13. Sprue pins (cut pipes) 14. Hand towel 15. Muller 16. Consumables in this section include bentonite resin. 17. Drying cabinet for foundry sand 18. Sand rammer 19. Electric permeability meter 20. Foundry moisture teller (for foundry sand) 21. Universal sand strength machine (motor driven) 22. Sand flowability meter for testing flowability of moulding sand 23. Impact penetration tester for testing compaction, plasticity and hardness of moulds 24. Laboratory sifter (for determination of grain size fractions of dry moulding sand) 25. Permeability metre (manually operated) for testing sand mould 26. Core drying oven for drying core sand test specimens 27. Continuous clay washer for removing all particles smaller than 0.02 mm simultaneously from two clay bonded foundry samples 28. Moulding machine for foundry 29. Moulding sand mixer, capacity 0-20 kg, 1-50 kg 30. Metal moulding boxes 31. Foundry moulding tool kit 32. Bench mounted sieve shaker Melting and casting section Furnace construction Laddle Carrier Tade Long bar Skimming bar Burner Drum for oil Gloves Fireproof coat Hose Muffle furnace for heat treatment Blower Morgan crucible tilting furnace for melting of cast iron and non-ferrous metals Lift-out crucible furnace for non-ferrous metals High frequency induction melting furnace Degasser for all non-ferrous alloys to be used in tilting furnaces and bale-out furnaces Foundry bellows Finishing section Metallurgical microscope with camera attachment Grinding machine (3 phases) GSW 30 Hand drilling machine Hacksaw Raw materials requirement: bentonite, moulding sand, diesel General Laboratory Facilities 1. Instron universal testing machine complete with accessories (floor and table types) with load cells and jaws for polymers and fibres 2. Automated X-ray powder diffraction system with all accessories 3. X-ray quantometer with all accessories 4. Chemical analysis equipment: Emission spectrometer equipped with all accessories 5. Metascope: Fluorescent analyser for quick composition analysis 6. Electron microprobe analyser 7. Charpy impact test equipment with all accessories 8. High temperature and room temperature creep testing machines complete with accessories 9. Fatigue testing machine complete with accessories 10. Pneumatic mounting press 11. Controlled atmosphere sintering furnace (Tem. up to 1450°C) 12. Single crystal growing furnace complete with accessories (Tem. up to 1550°C) 13. Vacuum equipment for vapour deposition plating 14. Potentiostat/galvanostat complete with all accessories The Department should see to it that the laboratory experiment manuals are updated and upgraded using the format below: MTE 308: Metallurgical Engineering Laboratory I 1. Mineralogical Analysis and Mineral Processing Laboratory 2. Ferrous and Non-Ferrous Metal Extraction Laboratory 3. Metallography Laboratory and Microscopy Laboratory MTE 415: Metallurgical Engineering Laboratory II 1. General Metallurgical Laboratory 2. (For Physical and Mechanical Metallurgy) Heat treatment and propertive??? testing Destructive Testing and Non-Destructive Testing 3. Foundry Workshop MTE 509: Metallurgical Engineering Laboratory III 1. Welding Workshop 2. Corrosion Control and Electroplating Laboratory 3. Engineering Failure Analysis Laboratory Staffing Academic Staff The NUC guidelines on staff/student ratio of 1:15 for Engineering and Technology departments shall apply. However, there should be a minimum of six full-time equivalents of Staff in the department. There is need to have a reasonable number of Staff with doctoral degrees as well as sufficient industrial experience. With a minimum load of 15 Units per semester for students and a minimum of six full-time equivalent of staff in each programme, staff should have a maximum of 15 contact hours per week for lectures, tutorials, practical’s and supervision of projects. NUC requirement encourages all academic staff to have PhD degrees; hence appointment of academic staff is preferably to the Lecturer cadre. Only in exceptional cases are candidates with great promise appointed to Graduate Assistant and Assistant Lecturer positions for the purpose of being developed to the Lecturer cadre as registered PhD candidates. Academic Support Personnel Teaching Assistant/Demonstrators to help lecturers in the conduct of tutorials, practical’s and field work. This category of personnel is not expected to be regular staff as they are to be paid on the basis of approved hourly rate. Administrative Support Staff The services of the administrative support staff are indispensable in the proper administration of the departments and faculty offices. It is important to recruit very competent senior staff that are computer literate. Technical Support Personnel The services of technical support staff, which are indispensable in the proper running of laboratories and workshop/studios are required. It is important to recruit very competent senior technical staff to maintain teaching and research equipment. They are also to undergo regular training to keep them abreast of development*s in equipment operation and maintenance. The minimum of academic staff to technical staff ratio of 5:1 should be maintained. Minimum Number of Staff Subject to the general standards specified by NUC: 1. there should be a minimum of two PhDs and four M.Eng degree holders full-time academic staff to mount the programme; 2. each workshop or laboratory should have an adequate number of staff with the right mix, such that each unit or section in that workshop or laboratory can run efficiently; and 3. there should be an adequate number of administrative staff of the appropriate caliber for the office of the Head of Department to run. Student/Staff Ratio The minimum staff-to-student ratio should be 1:15 from 200 level to 500 level. Library There must be adequate library facilities to cater for the interest of all the programmes in the faculty. These include current journals, handbooks, textbooks, manuals, codes of practice, standards and specifications in sufficient numbers. Classrooms, Laboratories, Workshops, Clinics and Offices Academic and Non-Academic Spaces The NUC recommends the following physical space requirement: Academic m2 Professor’s office 18.50 Head of Department’s office 18.50 Tutorial teaching staff space 13.50 Other teaching staff space 7.00 Technical staff space 7.00 Science staff research laboratory 16.50 Engineering staff research laboratory 14.50 Seminar space per student 1.85 Drawing office space (A.O. board) (Per student) 4.60 Drawing office space (A.I. board) (Per student) 3.70 Laboratory space 7.50 Non-Academic Secretarial space 7.00 Office Facilities S/No Office No in Room Facilities 1. HOD 1 Table, chairs, A/C, filing cabinet, bookshelves, computer unit, Secretary and facilities. 2. Professor Table, chairs, A/C, filing cabinet, bookshelves, computer unit, Secretary and facilities. 3. Reader 1 Table, chairs, A/C, filing cabinet, bookshelves, computer unit. 4. Senior 1 Table, chairs, A/C, filing cabinet, bookshelves, computer Lecturer unit. 5. Lecturer I 2 Table, chairs, fan, filing cabinet, bookshelves.