This course establishes a framework for analysis of processes to convert waste streams or raw materials from the ground or ocean into refined metal ingots and related products. It covers pyrometallurgy, hydrometallurgy, electrometallurgy, and related processes at scales from kilograms of osmium to megatonnes of steel and aluminum (60-70% of each is made from recycled scrap in the US and EU). For each, it establishes the fundamentals of thermodynamics, kinetics, and scaling behavior, as well as process economics and life cycle emissions. Team projects conduct deep dives into an existing process in each of the three categories (pyro/hydro/electrometallurgy), discussing the fundamentals of its operation, and exploring how it is changing to improve cost and sustainability. This course is co-located with graduate course MTE 5849; students may not receive credit for both the undergraduate and graduate versions of the course.
This course will be offered in academic years ending in odd numbers.