NAME OF COURSE
REFRACTORIES III
NQF
LEVEL
NQF
CREDITS
0.083
COURSE CODE
RFC321T
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
1.
Welcome ................................................................................................................ 6
2.
2.2
3.
4.
Attendance..................................................................................................... 10
4.2
4.2
4.3
1.
2.
1.2
1.3
Course outcomes........................................................................................... 12
Assessment ...................................................................................................... 13
PAGE 3 OF 18
2.1
2.2
2.3
2.4
2.5
Moderation.................................................................................................. 14
2.6
Promotion requirements................................................................................. 14
3.
3.2
3.3
4.
5.
sample collection............................................................................................... 20
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.
3.1
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
PRESCRIBED RESOURCES
CATEGORY
DESCRIPTION
BOOKS
COMPUTER &
SOFTWARE
WHERE TO FIND
COST
LEVY
MS Word
MS Excel
PAGE 7 OF 18
EQUIPMENT
Oven
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
Rexxon
Corporation, RSA
0-620-25867-5
CRNIGLIA, SC
& BARNA, GL
1992
Park
Ridge:
Noyes
Publications
08-8155-13046
GUIDES
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 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
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
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
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 %
10
10
10
20
Experimental Procedure
10
Actual
marks%
30
10
PAGE 13 OF 18
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
3.
3.1
DURATION
THEME
SCHEDULED DATE*
1 WEEK
Wednesdays 13:00-15:00
2 WEEK
Wednesdays 13:00-15:00
PAGE 14 OF 18
3.2
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:
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
PAGE 15 OF 18
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
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
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.
1.1.1.1.
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:
PAGE 17 OF 18
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 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:
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:
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)
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.
2.
Determine the effect of course sand and fine silica in the samples.
3.
PAGE 21 OF 18
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.
2.
PAGE 22 OF 18