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By J. Chupak, D. J. Salley, G. L. Simard

Radiotracers were demonstrated to be of considerable value in a study of the interaction of dithiophosphate with galena. The interaction had characteristics of both chemisorption and chemical reaction, being complex because of the nature of the galena surface. Sorption was rapid and markedly reversible, and flotation occurred at relatively small amounts of dithiophosphate sorbed.

Jan 3, 1950

By D. G. Oss, S. E. Erickson

An automatic control method for the ferrosilicon heavy media process maintains media density within 0.01 specific gravity points. Continued demands for higher grade, competitive products from the Mesabi Range have resulted in experimental work such as that detailed for one concentrator. Various methods, step by step procedures and instruments used at an iron ore beneficiation plant in the development of an automatic control system are described. Work continues and it is hoped that further applications of control instrumentation can be made in the next operating season. The need for instrumentation and automatic control of the various parameters in the heavy media process of iron ore beneficiation has been apparent for some time. Continued demands for higher grade, competitive products from the Mesabi Range have made it necessary to increase the efficiency of the process in every possible way. In a typical heavy media flow scheme for iron ore beneficiation (Fig. 1) a sized, prepared feed (generally about —1% in. to +% in.) is fed to a heavy media separatory vessel, along with a ferrosilicon slurry. A separation of the feed is made on the basis of specific gravity. Low density particles overflow a tailings discharge weir, while high density ore particles sink to the bottom of the high density pool and are moved away to the concentrate discharge chute. Both products are passed over drainage screens and then are cleaned thoroughly of attached ferrosilicon on wash screens. Float material is generally stockpiled, while the sink product is shipped as a final concentrate. Undersize from the drain screens is returned directly to the circulating media sump. Wash screen undersize is cleaned of contaminating ore particles and slimes by passing through magnetic separators. Provision is also made for splitting a portion of the tailings drain undersize into the cleaning circuit if necessary for control of depth of tailings overflow, or for additional cleaning as required. Cleaned ferrosilicon is stored in a densifier and returned to the Circulating media sump as make-up material. Dilution water is also added to this sump to maintain a desired specific gravity of the circulating media. As in any process, operational intelligence is secured only by keeping records of the process variables. Generally apeaking, plant operators have neither the inclination nor the time to keep complete and detailed records of these variables over the course of their shift. Before instrumentation was added to aid the operator, specific gravity was measured by weighing a given volume of pulp at intervals of from 30 to 60 min. Scale readings were made at the beginning and end of each shift. No records were kept of operating conditions, such as rpm of the separatory ves-sel, media level in the machine, tons per hour of the products, and so forth. These items were recorded only when spot checks were made by the metallurgical staff. CONTlNlJOUS DENSITY RECORDING The first process instrument used, other than the usual ammeter on the drive motor of the separatory vessel, was a nuclear density gauge and its associated circular chart recorder. These instruments were used to indicate and record specific gravity of the circulating media. This was a tremendous aid to the operator in that tie was able to observe and correct the specific gravity at any time. There was also added incentive to make frequent corrections because of the permanent record made by the recorder of the densities. The addition of the nuclear density gauge was influential in securing optimum quality and recovery of the heavy media product. Manual control was improved, and it became possible for a good operator to main control within f.05 specific gravity units. This compares with an unknown quantity, estimated at f0.15 gravity units, when manual measurement and control was used. An example of the improvement in manual control over the course of one season's operations is shown in Fig. 2. Chart A is typical of the records made shortly after the gauge was installed. Needless to say, it was difficult for operators and foremen alike

Jan 1, 1962

By R. Schumann

THE expression "unit process " comes up with increasing frequency in discussions among metallurgists and mineral engineers, especially among those concerned with training the next generation. The unit process approach characterizes a significant advance along the road from metallurgy as an empirical art to metallurgy as a branch of engineering. The purposes of this paper are to define and list the unit processes in specific terms, to indicate the scientific and engineering principles basic to all the unit processes, and finally to show how these ideas have been applied to a reorganization of instruction in chemical metallurgy. UNIT OPERATIONS AND UNIT PROCESSES Metals are extracted from ores and other raw materials by stepwise procedures. In general, each metallic element is extracted by a different procedure. For many of the metals there is a choice of several flowsheets. However, the procedures all have steps in common. In fact, the many different flowsheets are all made up of a relatively small number of steps which are combined in different groups and sequences. For example, crushing, screening, roasting, sintering, melting, and gaseous reduction are steps which each appear in the flowsheets for extracting the majority of the metals. The individual steps or flowsheet units can be designated as unit operations or unit processes. These terms are well established in the field of chemical engineering, as the American Institute of Chemical Engineers' definition of chemical engineering shows: " Chemical engineering is that branch of engineering concerned with the development and application of manufacturing processes in which chemical or certain physical changes of materials are involved. These processes may usually be resolved into a coordinated series of unit physical operations and unit chemical processes. The work of the chemical engineer is concerned primarily with the design, construction, and operation of equipment and plants in which these unit operations and processes are applied. Chemistry, physics, and mathematics are the underlying sciences of chemical engineering, and economics its guide in practice."1a In this definition, the distinction between unit operations and unit processes is that the unit operations are physical while the unit processes are chemical. Table I gives a list of the principal unit operations and unit processes of chemical engineering, taken from Shreve. lb Table 2 lists the principal unit operations and unit processes used for metal extraction. The division between unit operations and unit processes is similar to the chemical engineers' distinction and also corresponds approximately to the division of labor between mineral dressing and chemical metallurgy which has been customary in the past. Furthermore, it will be noted that in the proposed classification the unit processes primarily involve chemical reactions and/or changes in state of aggregation; the unit operations, primarily do not involve either bulk

Jan 1, 1948

By Samuel E. Doak

The utilization of rotary kilns, of the well-known cement type, for the preparation of iron ores for the blast furnace, has become of considerable economic importance within the past 10 years in certain localities, notably those where the native ores are lean. Such kilns may be used simply for the agglomeration of ores too fine to be charged into the blast furnace (i.e., ores whose, loss in the dust catchers is excessive, and whose fineness is detrimental to the working of the furnace), or for the desulphurization of lump and fine ores the sulphur content of which does not exceed 6 or 7 per cent. The desulphurizing action can be combined with that of agglomeration provided the kiln is sufficiently large. Other processes have been developed for the same purpose, but while I am not able to draw a comparison between them by reason of lack of sufficient data, it is safe to say that the kiln, if properly dimensioned for the character of ore to be treated, will compare favorably in its results, both as to economy and quality of product, with any other process. It is not, however, as well adapted for the treatment of flue dust as is a sintering operation, on account of the large percentage of fine coke contained therein. Any combustible entering the kiln at its feed end renders the process very much more expensive and unsatisfactory on account of the difficulty of controlling the temperature, also because of the rapidity with which long "rings" form, due to the increased heat at the cooler end of the kiln. The greatest value of the kiln at present is in the treatment of pyrites cinder; that is, the residue from pyrites ore after the extraction of the greater part of the sulphur. This cinder, while high in iron content, has too much sulphur remaining in it to be allowed to form a large part of the blast-furnace burden, without further treatment. It will range in metallic iron from 42 per cent., representing a very low-grade cinder from a domestic pyrites, to 64 per cent. of the residue from the best Spanish ore, and the corresponding silica content will vary from the maximum of about 25 per cent. to 11/2 per cent. The residual sulphur depends largely on the type of burner used in the original desulphurization. In general, the leanest original ores retain the greatest amounts of sulphur. In modern practice the percentage of sulphur in the cinder is rarely as great as six, and seldom lower than one and one-half. Average analyses for iron, silica, and sulphur of the cinders that have come under my personal observation are as follows:

Jan 1, 1916

By R. H. Foley

It is difficult to consider any seam as unsuitable for longwall mining operation for something like 95% of British coal is produced by this system. The following is a brief report on how they do it-their techniques and equipment. Depth of working in British mines varies from about 150 ft to more than 3000 ft, with the average being about 1300 ft. Average seam thickness is approximately 40 in., but working seams vary from 16 in. to as much as 14 ft.

Jan 8, 1965

By Charles M. Haas

WHEN minable ore has been located, the problem of mining is synonymous with the problem of movement --movement of men and equipment to mine the ore, and movement of the ore from the earth to the mills. In slusher drifts and shafts, on shovels and dragline excavators, on churn drills and bulldozers, wire rope is essential to the transportation of men, ore, overburden, and equipment. Although a casual glance creates the impression that all wire ropes are alike, there are crucial differences between ropes. Strand diameter, number of strands, weave, core, and resistance to corrosion all decide the type of job a wire rope can do, and where and how long it can do that job. These factors are, of course, the responsibility of the rope manufacturer. Beyond this, he can extend his function into the mine itself by advising users on the use, care, and maintenance of these sinews of the mining industry. This article, then, covers both the manufacturing and end-use aspects of wire ropes.

Jan 9, 1951

By J. J. Pelley

NOT being a scientist, an engineer or a metallurgist, I consider it a very great honor indeed to be asked to address the American Institute of Mining and Metallurgical Engineers. Your program indicates that any lack of intricate and technical knowledge on my part in the field of metals will be well taken care of by others. Therefore, I believe any remarks that I have to make might well be devoted to the practical side of metals in railroad service and to the general railroad situation as I view it today. The experiments now being conducted on the railroads with so-called streamlined, light-weight trains and cars would not have been possible had it not been for scientific and engineering research in the past that made these lighter weight metals available. The railroads now have approximately forty units of these new trains in operation. Experi-ence with them will no doubt be a guidepost for future construction in that direction. While the best known experiments are in the passenger service, they are being extended into the freight service. Within the past three years there was constructed for the Association of American Railroads a new standard box car of ordinary carbon steel, in which, by reason of superior design, weight was reduced by 3500 to 4500 lb. under that of existing cars of like capacity. The Association is now testing a box car that weighs approximately six or seven tons less than practically all of the box cars of like capacity in service today. If these tests are successful a very large field for the use of lighter weight metals will immediately be opened, provided the costs of such metals are not too high. The fact that various experiments are being carried on with other classes of equipment constructed with so-called light-weight and non-corrosive metals no doubt will have a considerable effect upon the rebuild-ing of old equipment. The question then will be: How much can we afford to spend on the rebuilding of an old car weighing six to seven tons more than a new car constructed with the latest available materials?

Jan 1, 1936

By J. E. Warren, J. H. Hartsock

In the receipt of J. E. Warren and J. H. Hartsock's comments on our paper, "Aspects of Gas Deliverability", We wish to point out that all the physical characteristics we conceived as constant were absorbed in the gas deliverability constant of the individual well's performance, listed

By Walter Voskuil

ILLINOIS supplies coal to seven states in the Upper Mississippi Valley -Illinois, Missouri, Iowa, Minnesota, Wisconsin, and portions of the Dakotas, Nebraska and Kansas. In this same area are marketed large quantities of coal from West Virginia, Kentucky, Pennsylvania, and else-where; fuel oil from the crude petroleum supplies of the Mid-Continent fields, and natural gas from Louisiana, Kansas and the Texas Panhandle. The boundaries of this "Illinois coal-market area" are determined by competition from other coal fields and from other forms of fuel. Within the area so described 90 per cent of Illinois coal is marketed. Thus in the Southwest, an abundance of fuel-oil supplies and natural gas domi-nates the market almost to the exclusion of coal. The westward move-ment of Illinois coal in Kansas, Nebraska and the Dakotas is met by an eastward flow of high-grade coals from Colorado, Wyoming and Montana. In the lake-shore counties of Minnesota and Wisconsin, the market is dominated by Appalachian coals, cheaply carried over the Great Lakes and reaching the ports of Lake Michigan and at the head of Lake Superior. Illinois coals find their largest market in the southern and western sections of these two lake states. Only small quantities of Illinois coals are shipped east of the state line. This market area is occupied entirely by the neighboring coal fields of Indiana and the Appalachian coal fields in Ohio, West Virginia, Kentucky and Pennsylvania.

Jan 1, 1936

By Robert I. Jaffee, Walter L. Finlay

IN the broad survey of the nonferrous' metallic elements contained in this book, the reader may well be impressed by the wide range of property combinations offered by the many metals and alloys the metallurgist has prepared since before Kubla Khan. The diversity is great and the overlap is considerable. It is particularly surprising, then, to find the latest structural metal new- comer designated by such extravagant terms as "Cinderella Metal," "Wonder Metal," "Miracle Metal," "The Metal of Tomorrow," "Dream Metal or Nightmare?" and "The Middleweight Champion of the Structural Metals." Of these and others, the most appropriate designation for the metal involved, titanium, appears to be that of The Middleweight Champion. Its intermediate density of 4.5 and elastic modulus of 16 million is a unique combination between the lower density and modulus of magnesium and aluminum and the higher density and modulus of copper, nickel, and iron. It is light, strong, ductile, and corrosion resistant. A chemical neighbor in group IV of the Periodic Table, zirconium, is similar to titanium in many respects but is appreciably denser, 6.5 instead of 4.5, less stiff and relatively much less abundant. On the other hand, the resistance of zirconium to acids and alkalies is better than that of titanium. Also, compensating for its higher density, lower stiffness, and somewhat lower strength level compared with titanium, zirconium has much better permeability to slow neutrons and is much more suitable as a material of construction for nuclear reactors.

Jan 1, 1953

By F. T. Davis

The annual review of mineral dressing was the subject of considerable discussion at the MBD meeting in New York last February. Because the amount of material now being published is so imposing, it was generally agreed that reviewers should try only to cite the items of importance. In order to conserve even more space, it was agreed to omit bibliographies. In reading these reviews, and those of the past two or three years, one is impressed by the advances in materials handling, the enlargement and the advances in automation of unit process equipment. Although there has been development of a variety of new concentration principles in flotation, magnetic separation, et al., the design of these principles into new plants has not been widespread. The probable reason is that the plants being built today are so large and costly that few are able to face the risk of any significant degree of experimentation. There are exceptions to this; for example, some of the chemical processes, but these are usually because there was no conventional process available. This situation should change in time as the ores amenable to our conventional methods become depleted.

Jan 2, 1967

Jan 1, 1939

Jan 1, 1948

Jan 1, 1948

By W. D. Klopp, R. I. Jaffee, H. R. Ogden, D. J. Maykuth

The purification of commercial-purity tantalum powder by vacuum sintering in the temperature range 2600° to 2860°C has been investigated. Mixtures of tantalum oxide and tantalum carbide were sintered at 1800° and 2200°C. Tantalum bars containing 1 pct additions of oxygen, nitrogen, and carbon. were sintered in the range 1800° to 2600°C. Anulyses were conducted on the sititeyed mixtures to determine the extent of removal of oxygen, nitrogen, and carbon at each sintering condition. The mechanism for remova1 of each impurity, and the conditions necessary for preparing ductile tantalum by vacuum sintering are discussed. INTEREST in the refractory metals has been stimulated in recent years by the need for structural materials capable of operating at temperatures of 1100°C and higher. These metals include columbium (niobium) (mp 2468°C), molybdenum (mp 2620°C), tantalum (mp 2996°C), rhenium (mp 3160°C), and tung- sten (mp 3415°C). In addition to its high melting point, tantalum possesses the advantages of forming a solid, nonvolatile oxide at temperatures of interest and of being ductile and easy to fabricate. The classic method of consolidating tantalum from powder refined from the ores is by vacuum sintering at temperatures on the order of 2600°C. This sintering treatment both densifies the compacted powder bars and purifies the metal by causing impurities to boil out. The present work was undertaken to provide more quantative data on the relationship between sintering conditions and purity and to determine the mechanisms of impurity removal.

Jan 1, 1961

Jan 1, 1894

By M. M. Fidlar, Ralph E. Esarey

A marked decrease in drilling during 1937 in Indiana seemed to have no undesirable effect upon the oil and gas industry. Instead, production figures for oil showed a small increase over those for the preceding year, although not so much gas was marketed as in 1936. Drilling activity was centered in proven areas, and the proportion of dry holes to the number of wells drilled decreased somewhat. During 1937, including old wells drilled to deeper horizons, 134 wells were completed in Indiana, of which 39 were oil wells, 39 gas wells, and 56 dry holes. Nearly 75 per cent of the holes were drilled in proven areas. Of the 36 wells drilled in wildcat areas, only four found commercial production. Wildcat wells were especially numerous in Vigo, Pike, Perry and Spencer Counties. Exploratory drilling activity in Vigo County resulted in part from the drilling of the discovery well in the new Prairie Creek field. In Pike County, wildcat wells were drilled in the search for new supplies of gas to meet the demand in the southwestern portion of Indiana. Drilling in both proven and wildcat areas in Perry and Spencer Counties continued to be heavy, because of the presence of shallow Missis-sippian sands and the resulting low cost of drilling and equipping. At the end of the year, 42 of the wells started in 1937 were not completed. Only a few locations were drilled in the old Trenton field, but the wells, many of them 40 years old, continued to furnish a small supply of gas for domestic consumption. Oil production in the Jay County portion of the Trenton area was nearly twice that of 1936, owing in part to a vacuum system installed on several leases. The Harrison County (Laconia) gas field is being developed northward to offset water encroaching from the south. This water in the black shale threatens to put an end to the steady production that this field has furnished for many years. During 1937, the Oaktown gas field again furnished more gas than any other field, but production in that area showed a marked decrease over the marketed gas for 1936. During the early months of the year, seven wells were completed in the Oaktown field to bring the total number of producing wells to over 40. At present, all the operators in the area are

Jan 1, 1938

By David Moskowitz, Ira Binder, Robert Steinitz

THE hard refractory borides of the transition elements of the 4th, 5th, and 6th groups of the Periodic System have been the subject of a number of recent investigations.'-' It is well known now that most of these elements form several different borides, and Kiessling8 has summarized the rules which govern to some extent the arrangements of the boron atoms in the various structures. Melting points of a few borides have been published." The systems Fe-B, Ni-B, and Co-B have been reported," but, as these borides are rather low melting, they are outside of the groups of boron compounds considered here. Brewer' has tested the stability of various borides and estimated a number of eutectic temperatures between different borides, but in no case was the complete system of a transition metal and boron investigated. The phase diagram becomes of special importance if the preparation of the borides from the elements in powdered form is considered; the lowest eutectic temperature will determine the first appearance of a liquid phase. Also, the knowledge of high temperature phases, if they exist, is important for the preparation of bodies from these borides by hot pressing or sintering. During the investigation of various metal borides,7 it was found that there were more boride phases existing in the Mo-B system than reported by Kiessling." They occur, however, only at temperatures above 1500°C and were, therefore, not found by him. This led to a study of the equilibrium diagram of the Mo-B system. ranging from 0 to 25 pct B and from room temperature to the liquidus. Part of this investigation was reported during the "Research in Progress" session at the 1952 Annual Meeting of the AIME.11 Raw Materials and Preparation of the Borides The raw materials used were commercial molybdenum and boron powder, both supplied by the Molybdenum Corp. of America. The molybdenum powder was 99+ pct pure? while the boron powder contained about 83 to 85 pct B. A large percentage of the impurities in this powder was oxygen, with the rest formed by iron, calcium, and unknown substances. The low purity of the boron used was, however, not considered detrimental to the final product, as most of the impurities evaporated at the high temperatures at which the borides were formed. The final product always had a minimum purity of 96 to 98 pct (figured as molybdenum and boron), with carbon, iron, and probably oxygen being the remaining products. Carbon is usually present as graphite. The chemical analyses always confirmed the compositions which corresponded to the crystallographic structures as determined by X-ray diffraction, and the boron content of the finished product agreed closely with that of the starting mixture; no boron was lost during the boride preparation. The chemical analysis methods employed for molybdenum and boron were previously described by Blumenthal.12,13 The powders were mixed by hand in the desired proportions, compressed at room temperature under low pressure, and then heated under hydrogen to about 1500" to 1700°C in a graphite crucible to form the borides. Usually, the three well-known borides Mo,B, MOB, and Mo,B,, which are stable at room temperatures, were prepared in this way, and all other compositions were made by mixing these borides in various ratios or by the addition of molybdenum or boron powders for the very low or very high boron contents. Preparation of two-phase compositions directly from the elemental powders was tried only occasionally to check whether equilibrium could be reached in this way. Experimental Procedures The stable borides were mixed in the desired ratios and heated under hydrogen in graphite crucibles to various temperatures. The well insulated crucibles were heated in a high frequency induction furnace. Special care was taken to obtain exact temperature measurement, which proved much more difficult than originally anticipated. It is believed that individual temperature measurements have an error of less than ±25ºC, while melting or transformation temperatures are accurate within ±50°C. The temperatures were measured with an optical pyrometer which was aimed at the closed end of a graphite tube extending down into the crucible. close to the samples. Attempts to measure directly through the hydrogen exit stack failed. The crucible arrangement is shown in Fig. 1. Heating was done at a slow rate to be sure that the temperature inside the crucible was uniform. The specimens were kept at the final temperature for about 30 min. For the investigation of high temperature phases, some samples were quenched. They were heated, without atmosphere protection, in a very small graphite crucible which could be rapidly removed from the high frequency coil, and dropped into water. These quenched samples were afterwards annealed to establish the equilibrium at lower temperatures. The melting points or the positions of the solidus and liquidus lines were determined by heating the specimens to various temperatures and examining them at room temperature for evidence of a liquid phase. These results were checked later on by thermal arrest curves, especially to determine the exact position of the eutectic temperature line. For this purpose about 200 g of the boride were melted in a graphite crucible, in an arrangement similar to Fig. 1. Slow cooling was assured by very good

Jan 1, 1953

Jan 1, 1942