VŠTE:NE_VTE Production techn. for the eco. - Course Information

NE_VTE Production technology for the economy

Extent and Intensity

2/2/0. 5 credit(s). Type of Completion: zk (examination).

Teacher(s)

Ing. Kamil Koza (seminar tutor)
doc. Ing. Ladislav Socha, MBA, Ph.D. (seminar tutor)

Guaranteed by

doc. Ing. Ladislav Socha, MBA, Ph.D.
Environmental Research Department – Faculty of Technology – Rector – Institute of Technology and Business in České Budějovice
Supplier department: Environmental Research Department – Faculty of Technology – Rector – Institute of Technology and Business in České Budějovice

Timetable of Seminar Groups

NE_VTE/NE5: Sat 29. 3. 8:00–9:30 B3, 9:40–11:10 B3, 11:25–12:55 B3, Sat 12. 4. 8:00–9:30 B3, 9:40–11:10 B3, 11:25–12:55 B3, Sat 10. 5. 8:00–9:30 B3, 9:40–11:10 B3, L. Socha
NE_VTE/P01: Wed 14:50–16:20 B5, L. Socha
NE_VTE/S01: Wed 16:30–18:00 B5, L. Socha

Prerequisites (in Czech)

NE_SMT Engineering materials for economists

Course Enrolment Limitations

The course is offered to students of any study field.

Course objectives supported by learning outcomes

The course is aimed at acquiring knowledge of progressive technologies of production of technical materials used in engineering practice. Attention is paid to the basic technological links between raw material sources, production technology, processing of metals and their alloys. Students will gain an understanding of the nature of technological processes of recycling, production, processing and casting of metals and their alloys, which contribute significantly to the performance of metallic materials. The course also provides an insight into modern GREEN technologies for the production of ferrous and non-ferrous alloys with a focus on carbon footprint reduction, energy efficiency improvement, use of renewable resources, recycling and reuse of materials and application of low carbon technologies. Students will learn about the capabilities of modern GREEN technologies that significantly reduce environmental impact, representing a responsible approach to environmental protection while implementing environmentally friendly manufacturing technologies that also promote industrial sustainability. This knowledge is the basis for gaining an understanding of how engineering materials can be applied in engineering practice. The study therefore results in knowledge and competences in the transfer of technical and technological know-how to the economic management processes of production companies with regard to the modern trend of industrial sustainability with a lower ecological footprint and more environmentally friendly. The study allows to gain unique knowledge of basic and modern GREEN technologies for recycling, production and processing of metals and their alloys within a comprehensive technological chain during the study of economics and management.

Learning outcomes

Upon completion of the course, the student will be able to:
- define the basic classification of steels, cast irons and non-ferrous alloys and characterize the mechanical and technological properties of these materials;
- characterize the requirements of modern society on the trend of implementation of GREEN technologies in engineering practice;
- to describe basic processes, refining technologies and secondary metallurgy used during metallurgical treatment of steel, cast irons and nonferrous metals;
- characterize GREEN technological processes for recycling, manufacturing, processing and casting of steels, cast irons and non-ferrous metals in practice;
- apply theoretical and practical knowledge of metallurgy to the management of metallurgical processing of steels, cast irons and non-ferrous metals;
- define the influence of GREEN technologies in reducing the environmental impact when implementing environmentally friendly production technologies that support industrial sustainability
- use their knowledge of foundry technologies to make decisions on the use of appropriate metallurgical process in the production of steels, cast irons and non-ferrous metals;
- identify the basic types of metallurgical defects, their causes and how they can be eliminated.

Syllabus

• Lectures:
• 1. Introduction to production technologies – importance, current status and perspectives of individual technologies, trend of GREEN technologies in production, ecological aspects of steel, cast iron and non-ferrous metals production.
• 2. Characteristics of steel classification and marking, principles of charge preparation for steel melting, possibilities of using recycled materials and secondary raw materials, basic metallurgical reactions and technological procedures of GREEN technologies.
• 3. Technology and principle of primary steelmaking – oxygen converters, electric arc furnaces, sustainable approaches to steel production by implementing GREEN principles.
• 4. Treatment of steel on units for secondary metallurgy – ladle furnaces and vacuum stations.
• 5. Steel casting, course of castings solidification, defects in castings, opportunities to increase the efficiency of quality production – mould casting, ingot moulds and continuous casting.
• 6. Basic classification of cast irons, principles of charge preparation for production of cast iron, recycling options and use of renewable resources and GREEN practices.
• 7. Foundry equipment and melting processes – cupola furnace, electric and induction furnace, use of recycled materials, secondary raw materials, increasing the efficiency of GREEN technologies.
• 8. Characteristics of metallurgical processes of production and secondary metallurgy treatment of cast irons – basic metallurgical reactions, inoculation and modification and GREEN technology processes.
• 9. Casting production, foundry mixtures and moulds, ecology of foundry mixtures, carbon footprint reduction, energy efficiency improvement, types of patterns, gating system, classification and characteristics of metallurgical defects in cast irons.
• 10. Basic types of aluminium, magnesium, copper and zinc alloys – chemical composition, charge materials, recycling options and use of renewable resources and GREEN practices.
• 11. Material properties of non-ferrous alloys – mechanical, physical and technological.
• 12. Principles of metallurgical treatment – melting and holding furnaces, modification, inoculation, refining processes, sustainable approaches to non-ferrous metal production by implementing GREEN technologies.
• 13.
• Basic casting methods of non-ferrous alloys – expendable and metal moulds, possibilities to increase the efficiency of quality production, classification of defects in non-ferrous castings, inspection of castings and repair of defects.
• Seminars:
• 1. Introduction seminar → work with standards → characteristics, classification, marking of steels, cast irons and nonferrous metals; introduction to the principles of GREEN technologies in engineering; safety instructions for visits of foundry plants.
• 2. Laboratory practice → steel crystallization process modelling → preparation and execution of crystallization modelling, setting different technological conditions according to the principles of GREEN technologies, evaluation and drafting of a laboratory report.
• 3. Laboratory practice → Influence of casting parameters on development of shrinkage porosity → preparation and execution of laboratory casting, setting different technological conditions according to the principles of GREEN technologies, evaluation and drafting of a laboratory report.
• 4. Laboratory practice → Study of heterogeneity of steel castings → preparation and execution of segregation study of selected steel grades, setting different technological conditions according to the principles of GREEN technologies, evaluation and drafting of a laboratory report.
• 5. Excursion → Introduction of basic and GREEN steel production technologies through educational videos from Czech and foreign steelworks.
• 6. Calculation practice → Cast iron inoculation and modification → determination of metallurgical effects of inoculation and modification on melts, setting different technological conditions according to the principles of GREEN technologies, drafting of a calculation report according to the individual assignments.
• 7. Laboratory practice → Light microscopy → preparation of various cast iron grade samples → analysis of structures and determination of individual cast irons types, evaluation and drafting of a laboratory report.
• 8. Excursion → Current state of the foundry industry and assessment of the possibility of implementing GREEN technologies in the conditions of Czech and foreign foundries through educational videos.
• 9. Laboratory practice → Physical modelling of aluminium alloy refining → preparation and execution of physical modelling on FDU (Foundry Degassing Unit) model, setting different technological conditions according to the principles of GREEN technologies, evaluation and drafting of a laboratory report.
• 10. Laboratory practice → Thermal analysis of non-ferrous metal alloys → preparation and melting of selected alloys, thermal analysis, evaluation and drafting of a laboratory report.
• 11. Laboratory practice → Determination of aluminium alloys gassing → preparation and melting of selected alloys, determination of gassing via Dichte Index, Straube-Pffeifer test, Drosstest, setting different technological conditions according to the principles of GREEN technologies, evaluation and drafting of a laboratory report.
• 12. Excursion → Current state of the aluminium and zinc foundry industry and assessment of the possibilities of implementing GREEN technologies in Czech and foreign non-ferrous foundries.
• 13. Revision for the test, focusing on the discussed topics and individual seminars.

Literature

required literature
• MACHEK, V., 2015. Kovové materiály 4: výroba a zpracování ocelí a litin. Praha: České vysoké učení technické. ISBN 978-80-01-05686-8.
• QUADER, M. A. et. al. A comprehensive review on energy efficient CO2 breakthrough technologies for sustainable green iron and steel manufacturing. Renewable and Sustainable Energy Reviews. 2015, vol. 50, pp. 594-614.
• FAN, Z., FRIEDMANN, S. J. Low-carbon production of iron and steel: Technology options, economic assessment, and policy. Joule. 2021, vol. 5, no. 4, pp. 829-862.
• FISCHEDICK, M. et. al. Techno-economic evaluation of innovative steel production technologies. Journal of Cleaner Production. 2014, vol. 84, pp. 563-580.
• SAHOO, M. a S. SAHU, 2014. Principles of Metal Casting. 3rd ed. [s. l.]: McGraw Hill Professional. ISBN 9780071789752.
• NĚMEC, M., B. BEDNÁŘ a B. BRYKSÍ STUNOVÁ, 2016. Teorie slévání. 2. vyd. Praha: České vysoké učení technické. ISBN 978-80-01-06026-1.
• MATUCHA, J. a I. NOVÁ, 2014. Slévárenské formy. Liberec: Technická univerzita. ISBN 978-80-7494-083-5.
• LI, Ch-L., DONG, L., SUN, X-M. Study on the Impact on Environment in Ductile Iron Production. Advanced Materials Research. 2011, vol. 183, pp. 367-371.
• MICHNA, Š. a L. MICHNOVÁ, 2014. Neželezné kovy. Děčín: Štefan Michna, Lenka Michnová. ISBN 978-80-260-7132-7.
• MICHNA, Š., 2015. Technologie a zpracování hliníkových materiálů. 2. vyd. Ústí nad Labem: Štefan Michna. ISBN 978-80-260-7706-0.
• RAABE, D. et. al. Making sustainable aluminum by recycling scrap: The science of “dirty” alloys. Progress in Materials Science. 2022, vol. 128.
• GHOSH, M., BANERJEE, P. S., RAY, H. S. Examining Energy and Environment Issues in Non-ferrous Metallurgy in the Light of Industrial Metabolism. Journal of Materials and Environmental Science. 2014, vol. 5, no. 2, pp. 380-389.

recommended literature
• BEDDOOES, J. a M. J. BIBBY, 1999. Principles of Metal Manufacturing Processes. [s. l.]: Butterworth-Heinemann. ISBN 9780080539553.
• ŠENBERGER, J., 2008. Metalurgie oceli na odlitky. Brno: VUTIUM. ISBN 978-80-214-3632-9.
• BHANDARI, S. et. al. Assessment for Replacing Coal and Petroleum Product with Green Hydrogen for Steel and Iron Production. American Journal of Modern Energy. 2024, vol. 10, no. 1, pp. 1-10.
• GAO, W. et. al. Comprehensive utilization of steel slag: A review. Powder Technology. 2023, vol. 422.
• SHATOKHA, V. Environmental Sustainability of the Iron and Steel Industry: Towards Reaching the Climate Goals. European Journal of Sustainable Development. 2016, vol. 5, no. 4, pp. 289-300.
• BROADBENT, C. Steel’s recyclability: demonstrating the benefits of recycling steel to achieve a circular economy. The International Journal of Life Cycle Assessment. 2016, vol. 21, pp. 1658-1665.
• JELÍNEK, P., 2007. Slévárenství. 5. vyd. Ostrava: VŠB-Technická univerzita Ostrava. ISBN 978-80-248-1282-3.
• VONDRÁK, V., J. HAMPL a A. HANUS, 2005. Metalurgie litin: mimopecní zpracování roztavené litiny. Ostrava: VŠB-Technická univerzita Ostrava. ISBN 80-248-0777-7.
• ZHU, Y., KEOLEIAN, G. A., COOPER, D. R. A parametric life cycle assessment model for ductile cast iron components. Resources, Conservation and Recycling. 2023, vol. 189.
• NĚMEC, M. a J. PROVAZNÍK, 2008. Slévárenské slitiny neželezných kovů. Praha: České vysoké učení technické. ISBN 978-80-01-04116-1.
• SILBERNAGEL, A., 2011. Struktura, vlastnosti, zkoušení a použití kovů. Ostrava: Kovosil. ISBN 978-80-903694-6-7.
• SCHARF, S. et. al. FOUNDRY 4.0: An innovative technology for sustainable and flexible process design in foundries. Procedia CIRP. 2021, vol. 98, pp. 73-78.
• DIOP, M. A. et. al. Green Power Furnaces in Aluminum Cast House for Scrap Preheating Using CO2-Flue Gas. Journal of Sustainable Metallurgy. 2021, vol. 7, pp. 46-59.

Forms of Teaching

Lecture
Seminar
Tutorial

Teaching Methods

Frontal Teaching
Group Teaching - Cooperation
Project Teaching
Brainstorming
Critical Thinking
Individual Work– Individual or Individualized Activity
Teaching Supported by Multimedia Technologies

Student Workload

Activities	Number of Hours of Study Workload
	Daily Study	Combined Study
Preparation for the Mid-term Test	12	12
Preparation for Lectures	26
Preparation for Seminars, Exercises, Tutorial	25	25
Preparation for the Final Test	15	15
Attendance on Lectures	26
Attendance on Seminars/Exercises/Tutorial/Excursion	26	78
Total:	130	130

Assessment Methods and Assesment Rate

Exam – written 70 %
Test – mid-term 30 %

Exam conditions

At the beginning of the semester, the teacher informs the students how to successfully complete the course. A continuous test will take place at the end of the semester (30 %). The exam will be written for 70 points (70%). In total, the student must meet min. 70% to pass the course successfully. Overall classification of the subject, i.e. points for the test (70 - 0) + points from the interim assessment (30 - 0): A 100 – 90, B 89.99 – 84, C 83.99 – 77, D 76.99 – 73 , E 72.99 - 70, FX 69.99 - 30, F 29.99 - 0.

Language of instruction

Czech

Teacher's information

Attendance in lessons is defined in a separate internal standard of ITB (Evidence of attendance of students at ITB). It is compulsory, except of the lectures, for full-time students to attend 70 % lesson of the subjet in a semester.

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