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By W. A. Sheaffer

Electric furnace installation and tough-pitch copper-casting operation at Canadian Copper Refiners Ltd. are described. General layout, power supply and control, refractories, induction pour hearth, casting equipment, metal temperature control, and oxygen-content control are discussed. E LECTRIC furnace at Canadian Copper Refiners Ltd. was put into operation in August 1949. The installation was designed primarily to melt electrolytic copper cathodes and to produce vertically cast tough-pitch shapes. To meet emergencies during reverberatory furnace shut-downs, provision was made for casting horizontal tough-pitch wire bars. Due to the ease with which metal temperatures, melting rates, oxygen content, and casting hours can be altered to suit production demands, the electric furnace has met the requirements admirably. General Layout The plant has been described by H. S. McKnight' and by J. H. Schloen and E. M. Elkin.2 Since these papers were written, the electric furnace has been installed in a 140 ft extension of the original casting building. The extension, 264 ft in width, is divided into one 24 ft and four 60 ft bays, each a continuation of similar bays in the older building. Fig. l, a partial floor plan of the extension, shows the location of major equipment. Power Supply and Control Power for the electric furnace and its auxiliary equipment is delivered by Quebec Hydro over two 12 kv three-phase, 60 cycle pole lines. One line is in use, while the second serves as an emergency standby. Connections for the electric furnace from these lines, which also feed the refinery power house, are made to a substation on Canadian Copper Refiners Ltd. property. Connections between this substation and the furnace transformer room are in underground conduit. The are-furnace transformer, 550 v auxiliary-equipment transformer, and 12 kv switchgear are in the transformer room near the furnace. Stepdown from 12 kv to are-furnace voltages is done by a 7500 kva oil-immersed water-cooled three-phase 60 cycle transformer. This unusually high kva rating is available because the arc furnace and transformer were adapted from a steel-melting unit. Secondary voltages are available in 16 steps between 251 and 95 v (across phases). A four-position tap changer, operated from the furnace switchboard is connected to taps yielding 199, 164.5, 127, and 115 v, respectively. The transformer primary feeder is equipped with a General Electric Magne-Blast circuit breaker. The pour hearth, casting wheel, bosh conveyor, and other auxiliary equipment are fed by a 12 kv to 550 v, 750 kva three-phase 60 cycle transformer. Graphite electrodes, 14 in., with tapered nipples are held in the are-furnace electrode arms with steel wedges. The arms, fed from the transformer secondary busbars by flexible cable bundles, are actuated by winch cables. Direct-current motors operating the winches are supplied by a 250 v motor-generator set. Power input to the furnace is controlled from the furnace switchboard. The board has the usual combination of remote controls for the 12 kv breaker and transformer tap changer, meters, overload relays, automatic and manual electrode motion controls, switchgear, etc. When power is on the furnace, automatic electrode feed is used; the power draw on a given voltage tap then is governed by current-limiting rheostats. The rheostats work through a Westinghouse bal-lanced-beam control circuit which, in turn, operates reversing contactors in the winch motor circuits. Arc Furnace The arc furnace is a standard-type NT Pittsburgh 'Lectromelt with inside shell diameter 12 ft 3¾ in. By hydraulic-lift cylinders, the furnace can be tilted forward to 39 ½ ° and backward to 5" from horizontal. A roof-swing cylinder is also installed but not used. Fig. 2 shows refractory-lining details. With the lining as shown, operating life between repairs is 6 to 9 months of two-shift casting operation. Charge slot, skim door, and roof refractories then are replaced completely, and any necessary repairs made to side walls. Bottom life is longer and the original under courses are still in service, while the top course was replaced in October 1951. The launder is lined with high chrome-magnesite trough brick backed by fireclay and insulating brick. The trough is covered with fireclay brick and asbestos sheet. At intervals, openings 12x6 in. are left in the permanent covering. These are covered with

Jan 1, 1956

By E. Lancaster-Jones

THE gravity magnitudes obtained by means of observations with the Eötvös balance in the field are necessarily resultant or total effects due to all abnormalities of mass distribution, including even the effects due to the ellipticity and rotational motion of the whole earth. Since the object of the survey is to isolate the effects which arise solely from some particular subterranean feature, and to deduce therefrom the configuration and extent of this feature, the first step is to eliminate from the observed effects all those due to "disturbing" (i, e., unwanted) features, whether above or below the surface of the ground. The disturbing features have different characteristics, according to their situation relative to the center of the balance and to the horizontal plane through the foot of the balance, or station point; this diversity was recognized by Eötvös, who divided the total effects into so-called Normal, Terrain, Topographical, Cartographical and Subterranean effects. This classification has been adhered to by most subsequent investigators, but the writer prefers to employ the term "three-dimensional," which really indicates the essential character of the class of effect known as "Subterranean," at any, rate from the standpoint of the computer of effects. Before disturbing effects can be eliminated, the features must be measured up or surveyed, whether by topographical, mining, or boring methods, and then the effects of each feature calculated and subtracted from the total observed effects. After this the problem of interpreting the residual effects will itself necessitate the computation of the assumed feature, or even a series of trial features.

Jan 1, 1928

By E. G. Deane

THE CHAIRMAN (P. G. BECKETT, Globe, Ariz.).-The mining of large orebodies has in the last few years been such a big factor in the copper output of this State, and, in fact, of the whole country, I feel that we should have some valuable discussion this evening on the various mining methods described in the papers which are to be read; and I hope you will start a discussion on Mr. Deane's paper. J. A. EDE, La Salle, Ill.-I would like to ask whether, the timbers being left in, they have any fires owing to that fact? E. G. DEANE.-No, we do not. The timbers in the mat seem to lose life. I cannot tell you exactly what change takes place, but they do not burn readily. There is undoubtedly a chemical change in them-a change that makes them lose all strength. I , spoke of the strength of the sills. When we first started, we put in 4 by 8 sills, but those sills had no more strength in 6 months than a 2-in. plank would have. .J. P. HODGSON, Bisbee, Ariz.- I would like to ask Mr. Deane if the central supply raise in the- center of the block has been satisfactory; and also whether in extracting the ore they put small raises up so that wheelbarrows are not used in the stope?

Jan 12, 1916

By James K. Stanley

WHEN a plastically deformed metal is heated to a certain temperature, it undergoes a complete change in microstructure, the consequence of which is a marked alteration of mechanical properties such as hardness, strength and ductility. This change in microstructure occurs by recrystallization and is a process involving the formation and growth of strain-free nuclei in the deformed matrix. These nuclei continue to form with time and grow until a new grain structure replaces the cold-worked structure. The formation of the nuclei in the deformed sheet of 1 per cent silicon ferrite is illustrated in Fig. 1. If a recrystallization is conducted isothermally, a measurement of the fraction of the matrix recrystallized plotted against time leads to an isothermal recrystallization curve, first established in 1942.1 Such recrystallization curves are shown in Fig. 4. These curves show that the recrystallization of a cold-worked metal is best considered as a rate process rather than a time independent process such as is suggested by the improperly named and misleading recrystallization diagrams involving deformation, temperature, and grain size. 2-5 Any study of the rate of recrystallization resolves itself into a study of the component rates of nucleation and growth. The previous paper' provided an account of the determination of the rates of nucleation; N, the number of nuclei formed per unit time per unit of unrecrystallized area, and growth, G, the radial growth in unit time, in the recrystallization of silicon ferrite (1 per cent Si). A method was developed to furnish experimental data for evaluating the effect of the recrystallization variables on N and G. The mathematical analysis for the derivation of the isothermal recrystallization curve was developed for a two-dimensional case (in thin sheets where the diameter of the recrystallized grain is greater than the sheet thickness). The present paper is a continuation of the study of recrystallization of 1 per cent silicon ferrite begun in 1942.1 In this work the effect of the factors deformation, temperature, grain size, composition, and recovery is studied with respect to the rates of nucleation and growth. At the same time it is shown how the cooperation of N and G affects the isothermal recrystallization curve. The study of these variables on N and G has a definite bearing on the mechanism of recrystallization and should lay a foundation for a rational theory on the subject. PROCEDURE The procedure used in these experiments was essentially the same as that described previously but in certain details some changes were made in the interests of speed. With few exceptions, the procedure is the same for the study of all the variables. Where the procedure is different from standard manipulations attention is called to this fact.

Jan 1, 1945

By Richard B. Greenwalt

INTRODUCTION Direct reduction of iron ores has unquestionably become established as an important step in the worldwide steelmaking industry. The history of this development has been long and fraught with difficulty. In 1800, Champlain suggested the direct reduction concept using carbon and a shallow hearth vessel. Roughly 100 years later, Jones attempted a commercial process using carbon and producer gas in a rotary kiln. During the early years of this century, numerous attempts were made to start commercial direct reduction plants using such processes as Hoganas, Wiberg, Krupp-Renn, and others. Most of these were short lived, being abandoned due to a variety of technical and economical factors. Today, however, a new generation of direct reduction processes has emerged. We enter 1977 with at least 40 commercial plants in operation using 15 processes in 14 countries. These plants have combined total annual capacity of roughly 10 million tonnes of direct reduced product. Many articles have been written, and projections made, concerning the future growth potential for direct reduction. As is al- ways the case with projections, the numbers vary, but the outlook does not. Anyone who participated in the years of effort that have gone into this field of endeavor should be excited and justly rewarded by noting the shape of the curve in Figure 1.

Jan 1, 1977

By Charles F. Ramseyer

The manufacture of iron and steel is one of the largest of our industries; and in point of size of single plant and equipment certainly the biggest of all industries. By the general public it is generally considered a prime example both of the marvelous technical advances achieved by modern science and engineering in the design and operation of equipment and of the efficiency of big business in the coordination of men and materials. Actually the operation of its basic processes has not changed significantly in either theory or fundamental design of equipment in the past 75 years. Though many other process industries have been born and developed, and not seldom completely revolutionized, during this period, the primary processes of making iron and steel are still carried out along the lines laid down, and in the equipment originated so long ago, by Bessemer, Siemens and Martin, and subsequently expanded to practically the modern scale by Carnegie, Schwab and Captain Bill Jones in the eighteen eighties and nineties. The application of the principles underlying the continuous counter-current physical and chemical interaction of solids, liquids and gases, which have been so successfully used in the rapid evolution of our chemical process industries, has been very largely lacking in the steel industry. In the days of the last-named giants, especially Carnegie, the steel industry made great and rapid technical progress. Carnegie's ever driving idea (as later with Ford in the production of automobiles) was the finding of new and better ways of making cheaper steel. Carnegie himself was a steelman, and so long as he dominated the industry its technical progress was rapid; and he, like Ford, was vastly successful financially as well, since his costs were continually being driven lower than those of his competitors by his advances in steelmaking technique.

Jan 1, 1935

By Charles F. Ramseyer

The manufacture of iron and steel is one of the largest of our industries; and in point of size of single plant and equipment certainly the biggest of all industries. By the general public it is generally considered a prime example both of the marvelous technical advances achieved by modern science and engineering in the design and operation of equipment and of the efficiency of big business in the coordination of men and materials. Actually the operation of its basic processes has not changed significantly in either theory or fundamental design of equipment in the past 75 years. Though many other process industries have been born and developed, and not seldom completely revolutionized, during this period, the primary processes of making iron and steel are still carried out along the lines laid down, and in the equipment originated so long ago, by Bessemer, Siemens and Martin, and subsequently expanded to practically the modern scale by Carnegie, Schwab and Captain Bill Jones in the eighteen eighties and nineties. The application of the principles underlying the continuous counter-current physical and chemical interaction of solids, liquids and gases, which have been so successfully used in the rapid evolution of our chemical process industries, has been very largely lacking in the steel industry. In the days of the last-named giants, especially Carnegie, the steel industry made great and rapid technical progress. Carnegie's ever driving idea (as later with Ford in the production of automobiles) was the finding of new and better ways of making cheaper steel. Carnegie himself was a steelman, and so long as he dominated the industry its technical progress was rapid; and he, like Ford, was vastly successful financially as well, since his costs were continually being driven lower than those of his competitors by his advances in steelmaking technique.

Jan 1, 1935

By M. C. Udy, C. H. Lorig

THROUGH the years much interest has been centered in attempting to develop a direct method of iron-ore reduction, to replace or supplement the present indirect blast-furnace process. It would not be difficult to produce a list of more than 500 patents dealing with the direct production of iron and steel, but the few of this type of process that have proved successful do not produce in competition with the blast furnace; they produce special products. A survey of the literature reveals that the equilibrium conditions for the reduction reactions (iron oxides with carbon monoxide and with hydrogen) have been fairly well established but that data on the rate of reaction are discordant, although the general effects of the variables are known. This dissertation deals with the rate of reduction of a magnetite concentrate with hydrogen. The following variables have been studied: bed depth, gas velocity, particle size and temperature. The behavior of a single particle was also studied. LITERATURE Two general factors should he considered in a study of reduction of iron oxide: (1) equilibrium relations, and (2) rate of reaction. The first factor, equilibrium, has received the attention of many investigators and the equilibria Fe3O4-FeO-H2-H2O, Fe304-FeO-CO-CO2, FeO-Fe-H2-H2O, FeO-Fe-CO-CO2 are fairly well established. Of the second factor, the rate of reaction, much less is known. Data are comparatively scarce and there is very little concordance. The discordance probably results from the large number of variables influencing the reactions. However, the general effect of the variables is known. Among these variables are temperature, gas velocity, particle size, porosity, gas composition (distance from equilibrium), presence of impurities, greater or less prevalence of side reactions, and even design of the apparatus itself. Wetherill and Furnas1 published an excellent paper in 1934. They point out that any one or more of five processes (the chemical reaction, diffusion of the reactant through the gas film, diffusion of the reactant through the solid phase, diffusion of the reaction product through the solid phase, or diffusion of the reaction product through the gas film) may be the slow process, and thus the rate-controlling process. It is regretted that the work of these authors was limited to experiments at one temperature, and that the range of gas compositions was limited. Langmuir2 has shown that heterogeneous reactions take place at phase boundaries.

Jan 1, 1942

By James W. Dally, William L. Fourney, Anders Ladegaard Peterson

For the past 3 years, the authors have been conducting research sponsored by the National Science Foundation (RANN) to improve the process of excavation by drilling and blasting. The approach followed has been experimental where the development of stress waves and fractures initiated at the bore hole have been investigated in order to obtain a complete understanding of the dynamic fracture process. The second step in the approach has been to introduce modifications in the drill and blast procedure which will permit closer control of the fracture process. The laboratory investigations involve high speed photography where the dynamic fracture process is recorded with a Cranz-Schardin 1, 2 multiple-spark camera. The camera is equipped with 16 spark gaps which are pulsed at 25 K volts to produce an intense but very short (0.5 sec) flash of light. The camera is capable of recording 16 photographs of a dynamic event at framing rates which can be varied from 30,000 to 1,500,000 frames per second. The exposure time is sufficiently short to stop motion associated with detonating explosive charges and to make visible the details of the fracture process at a bore hose. The bore hole in a massive intact rock formation is modelled with a two dimensional plate containing a circular hole to represent the bore hole. The model material employed is a transparent polyester known commercially as Homalite 100.* This polymeric material is extremely brittle as evidenced by its extremely low fracture toughness of [ ]. The fracture toughness is a measure of the ability of a material to resist the propagation of flaws or small cracks. In comparison, Schmidt3 has recently measured the fracture toughness of Salem limestone and determined [ ]. Thus, the Homalite 100 should closely model the brittle nature of rock where fractures occur at small flaws and propagate without any apparent plastic deformation. Homalite 100 is also birefringent, which indicates that it becomes optically anisotropic when subjected to either static or dynamic loads. Circularly polarized light is transmitted through the loaded Homalite 100 model in a polariscope4 and the birefringence produces an optical interference pattern which is called a fringe pattern. For dynamic photoelasticity, the multiple-spark camera is equipped with polaroid filters to produce the circularly polarized light required to generate the photoelastic fringe patterns. An example of a singlespark frame showing a fringe pattern from a typical experiment is presented in [Fig. 1]. The photograph was taken 0.000072 sec (72 sec) after the detonation of the explosive charge. The circular fringes are due to the outgoing dilatational or P type stress wave and travel with a velocity of 85,000 in. per sec (2260 m/sec) in the Homalite 100. The P wave is followed by a second lower velocity stress wave known as the shear or S type wave which propagates at a velocity of 49,000 in. per sec (1245 m/sec). In the local neighborhood of the bore hole, several radial cracks are visible. These cracks propagate at essentially a constant velocity of 15,000 in. per sec (380 m/sec) prior to arrest. The fringes about the crack tips and in the local region of the bore hole are primarily due to the residual gases contained in the bore hole after the explosive charge was detonated. Sixteen frames similar to this one are recorded during the experiment to give full field visualization of the dynamic event at 16 discrete times over its duration. The fringe order number N is related to the difference in the principal stresses of and 02 according to a stress optic law4: [ ] where f0 = material fringe value, and h = model thickness. The wholefield dynamic-fringe patterns provide a basis for simultaneously observing the interaction between propagating cracks and the stresses which drive these cracks. Fracture Control Experiments Improvements in the efficiency of the drill and blast procedures must involve close control of the fracture process following the detonation of an explosive charge in a bore hole. By control it is implied that the number of cracks initiated and the location of each crack on the wall of the bore hole can be specified. Control also, involves orienting each crack and maintaining the crack path and velocity until the specified crack length is achieved. If the entire fracture process can be controlled, then rounds can be designed to optimize volume removed. fragment size and minimize costs. One area of blasting where fracture control is vitally important is in underground excavation where the strength and stability of the rock walls must be maintained and smoothness and precision of the walls must be achieved. The smooth blasting method is one of the most commonly employed procedures for achieving some degree of fracture control. In smooth blasting, the central region of material is first removed, and then the final row of closely spaced undercharged or cushioned holes are fired to remove the final volume and produce a smooth wall. In some instances, unloaded or dummy holes between the loaded holes are recommended to guide the fracture plane. This investigation pertained to an evaluation of 3 features of the smooth blasting process. These included (a) the effect of stress reinforcement on fracture by simultaneously firing 2 charges; (b) the influence of a dummy hole on control of the fracture planes between 2 simultaneously fired charge holes; and (c) the influence of dummy hole spacing on fracture plane control.

Jan 1, 1979

By K. M. Rolls, R. M. Rose, H. B. Shukovsky

Studies of the phase structure, critical current density, and resistive critical magnetic field of a 45 pct Nb-55 pct Zr superconducting alloy after final-size heat treatments are reported in this paper. A combination of optical metallography, X-ray diffraction, and electrical-resistivity measurements were used to determine the phase structure. Superconductivity measurements, made with heat-treated wires, are correlated with microstructure. Although no quantitative relationship between microstructure and critical current density is found, it is shown that SINCE Kunzler1 as well as Berlincourt, Hake, and Leslie2 first described the high-field, high-current-density superconductivity of Nb-Zr alloys, it has be- the critical current density is highest when the microstructure is finely divided by fibering, coring, precipitation, or fine-scale phase dispersions. The resistive critical field is very sensitive to the compositions of the phases present. Since the alloy investigated here is near the maximum resistive critical field for the Nb-Zr system, any phase decomposition results in a lower H,. Elimination of the effects of cold work lowers H, also. A possible interpretation of the latter in terms of internal surface superconductivity is suggested. come apparent that the resistive critical field and the current-carrying capacity of such alloys are, in large measure, dependent on composition and processing. The resistive critical magnetic field (Hr) for low current densities has been found to increase progressively with zirconium content until a flat maximum is reached between 50 and 65 pet Zr.3 For any single composition, a characteristic maximum value of H, is attained by heavily cold-drawn wire.4 critical current density (J,) depends not only upon cold work but also, apparently, upon microstructure. Heat treatments of cold-worked wires generally

Jan 1, 1965

By S. H. Williston

IT not often that bore hole surveys can be checked by actual. civil engineering methods. A recent Arizona survey was checked by normal surveying methods and the comparison of the results should be of value to both oil and mining men. During the summer of 1948 the Phelps-Dodge Corporation, at its Copper Queen property near Bis-bee, Ariz., drilled a 1245 ft, 8 in. diarn, churn drillhole in a mineralized area and cased part of it, intending to use it to transfer mill tailings for stope fill. The hole, as frequently occurs, was not straight, and, in endeavoring to locate the bottom in the underground workings, they found no evidence of the hole at the underground coordinates directly below the surface location. The noise of the drilling tools was reasonably clear, but the direction of sound was uncertain. Preliminary tests with available equipment were not successful in locating the bottom of the hole. Because of the mineralized character of the area and the fact there was some casing in the hole, any magnetic method of well surveying would give results of doubtful value. Sperry-Sun gyroscopic well-surveying instruments were finally used to locate the bottom of the hole. These instruments consist of a gyroscope to determine azimuth and either a pendulum or bubble inclino-meter. A multiple shot camera photographs both instruments on a single film and superimposes the photograph of a watch. Coordination of depth with time at the surface makes it possible to select the corresponding picture for any depth. After making several runs of the empty instrument housing from the top of the hole to the bottom to make sure there were no obstructions in the hole, three surveys on wire line were completed during the afternoon. The three surveys, in which readings were taken at different points in the hole on each survey, were computed and gave the following locations of the bottom of the hole in relation to the surface collar: survey No. 1—24.92 N, 30.30 W; survey No. 2—24.24 N, 31.11 W; survey No. 3—26.54 N, 27.72 W. Then the data from the three surveys were combined into a single set of calculations which gave a location for the bottom of the hole: combined surveys—24.27 N, 30.16 W. (Fig. 1.) Immediately upon the determination of the coordinates at the bottom of the hole, a drift on the 1300 ft level was started toward the indicated loca- tion some 38 ft northwest of the coordinates of the surface location, The bottom of the hole was located within the drift round in which it was expected, and the transit survey run to the actual location of the hole indicated N 27.18, W 29.71. This shows a discrepancy between the well survey and the transit survey of 0.45 ft in the westerly direction and 2.91 ft in the northerly direction. All surveys, both gyroscopic and transit, fell well within the width of an ordinary drift. While this is satisfactory for almost any and all mining requirements, a theoretical examination was made as to reasons for the discrepancy. A study of the course of the hole indicates that considerable right turn or spiral existed, and in all probability the surveying instrument was pulled out of alignment while traversing the turn by approximately 0.05 ft at the top and another 0.05 ft in the opposite direction at the bottom of the instrument. If such an allowance were to be made, the survey calculations would almost exactly correspond with those determined by transit. This sort of discrepancy would be minimized by the use of stabilizing guides. It is unfortunate that physical laws probably effectively prevent the use of gyroscopic instruments in EX and AX diamond drill holes. The directive power of a gyroscope falls off inversely at some rate between the third power and the sixth power of the diameter. Present instruments can be run in casing 53/4 in. ID or over and might be adapted to somewhat smaller diameters, but the difficulty of reducing these diameters to 11/4 in. or 2 in. is almost insurmountable at the present time. Acknowledgment The author wishes to express his appreciation to the Phelps-Dodge Corporation for permission to publish this article, and to the Operating and Engineering Departments for their cooperation on the survey; also to Donald Hering, of the Sperry-Sun Well Surveying Co., who actually made the survey and calculated the results.

Jan 1, 1951

By S. H. Williston

IT not often that bore hole surveys can be checked by actual. civil engineering methods. A recent Arizona survey was checked by normal surveying methods and the comparison of the results should be of value to both oil and mining men. During the summer of 1948 the Phelps-Dodge Corporation, at its Copper Queen property near Bis-bee, Ariz., drilled a 1245 ft, 8 in. diarn, churn drillhole in a mineralized area and cased part of it, intending to use it to transfer mill tailings for stope fill. The hole, as frequently occurs, was not straight, and, in endeavoring to locate the bottom in the underground workings, they found no evidence of the hole at the underground coordinates directly below the surface location. The noise of the drilling tools was reasonably clear, but the direction of sound was uncertain. Preliminary tests with available equipment were not successful in locating the bottom of the hole. Because of the mineralized character of the area and the fact there was some casing in the hole, any magnetic method of well surveying would give results of doubtful value. Sperry-Sun gyroscopic well-surveying instruments were finally used to locate the bottom of the hole. These instruments consist of a gyroscope to determine azimuth and either a pendulum or bubble inclino-meter. A multiple shot camera photographs both instruments on a single film and superimposes the photograph of a watch. Coordination of depth with time at the surface makes it possible to select the corresponding picture for any depth. After making several runs of the empty instrument housing from the top of the hole to the bottom to make sure there were no obstructions in the hole, three surveys on wire line were completed during the afternoon. The three surveys, in which readings were taken at different points in the hole on each survey, were computed and gave the following locations of the bottom of the hole in relation to the surface collar: survey No. 1—24.92 N, 30.30 W; survey No. 2—24.24 N, 31.11 W; survey No. 3—26.54 N, 27.72 W. Then the data from the three surveys were combined into a single set of calculations which gave a location for the bottom of the hole: combined surveys—24.27 N, 30.16 W. (Fig. 1.) Immediately upon the determination of the coordinates at the bottom of the hole, a drift on the 1300 ft level was started toward the indicated loca- tion some 38 ft northwest of the coordinates of the surface location, The bottom of the hole was located within the drift round in which it was expected, and the transit survey run to the actual location of the hole indicated N 27.18, W 29.71. This shows a discrepancy between the well survey and the transit survey of 0.45 ft in the westerly direction and 2.91 ft in the northerly direction. All surveys, both gyroscopic and transit, fell well within the width of an ordinary drift. While this is satisfactory for almost any and all mining requirements, a theoretical examination was made as to reasons for the discrepancy. A study of the course of the hole indicates that considerable right turn or spiral existed, and in all probability the surveying instrument was pulled out of alignment while traversing the turn by approximately 0.05 ft at the top and another 0.05 ft in the opposite direction at the bottom of the instrument. If such an allowance were to be made, the survey calculations would almost exactly correspond with those determined by transit. This sort of discrepancy would be minimized by the use of stabilizing guides. It is unfortunate that physical laws probably effectively prevent the use of gyroscopic instruments in EX and AX diamond drill holes. The directive power of a gyroscope falls off inversely at some rate between the third power and the sixth power of the diameter. Present instruments can be run in casing 53/4 in. ID or over and might be adapted to somewhat smaller diameters, but the difficulty of reducing these diameters to 11/4 in. or 2 in. is almost insurmountable at the present time. Acknowledgment The author wishes to express his appreciation to the Phelps-Dodge Corporation for permission to publish this article, and to the Operating and Engineering Departments for their cooperation on the survey; also to Donald Hering, of the Sperry-Sun Well Surveying Co., who actually made the survey and calculated the results.

Jan 1, 1951

By L. C. De Jong, J. F. Shirley, M. L. Campbell

At the Southern Peru Copper operation in Toque-pala, Peru, a new process flowsheet for the recovery of byproduct molybdenite has proved successful in dealing with complex and highly variable ores. This paper describes the process and the functions of each of the chemicals used. The Toquepala concentrator of the Southern Peru Copper Corp., located approximately 720 miles southeast of Lima near the Chilean border, processes a daily 36,500 tons of ore containing between 0.50 and 3.00% copper. The molybdenite content in the ore also varies greatly ranging from essentially nothing to as high as 0.15%. The 1966 yearly averages were approximately 1.20% copper and 0.03% molybdenite. The Toquepala porphyry deposit is a mushroom-shaped ore body consisting of a flat-lying enriched zone of predominant chalcocite with a stem-like extension of hypogene chalcopyrite ore in depth within and around a large breccia pipe.1 The underlying chalcopyrite ore has not been reached; however, due to the presence of a major post orebody fault, predominantly chalcopyrite ore is present in the north side of the pit. Most of the molybdenite occurs either as small, fine granular, pulverulent masses in vugs or empty voids of breccia, or as thin foliated masses and narrow thread-like filling in rock joints and fractures. The normal occurrence of quartz gangue with the molybdenite gives some basis for correlating the molybdenite mineralization to some later periods of silicification. On April 18, 1962, the molybdenite recovery plant at Toquepala went on stream, approximately 27 months after the copper concentrator had been in production. The plant was designed and built by Southern Peru Copper Corp.'s engineering and mechanical departments. The basic method chosen for separating the molybdenite from the copper concentrate was the sodium hypochlorite-sodium ferrocyan-ide process. The selection of this process was based on the results of an extensive testing program performed by the Colorado School of Mines Research Foundation, Inc. and the economic conditions of the area. The originally designed process could never be fully implemented due to a lack of sodium hypo-chlorite and has had to be continually modified to satisfy the requirements of the kaleidoscope of ores from the mine. The three basic problems that plague the operation of any molybdenite recovery plant are all present at Toquepala in large measure. Both the quantity of plant feed and the quantity of molybdenite contained in the plant feed are continuously changing. Even more detrimental to an efficient operation is the fact that the copper mineralization in the feed frequently changes once in every 24 hours and occasionally once a shift. From the point of view of the molyb-

Jan 1, 1968

By J. W. Downey, R. A. Morris, M. V. Nevitt

An experimental survey has determined the occurrence of Ti2 Ni-type phases in binary and ternary alloys of Ti, Zr, or Hf with first, second, or third long-period transition metals and also in ternary systems in which 0 is the third component. The existence of eleven previously unreported isomorphs is cited and some approximate phase boundaries are given. Lattice parameters are reported for the new phases. The periodic table relationships involved in the occurrence of the phase are discussed. A previous paper' reported the occurrence of a group of Ti2Ni-type phases (structure-type E93) containing Zr in combination with Rh, Ir, and Pt, and Hf in combination with Rh, Pd, Ir, and Pt, and cited evidence to show that all of the Zr phases and the Hf-Pd phase are not binary phases but occur only when 0 is present. More recently one of the present authors found that in the ternary systems of Ti and 0 with Cr, Mn, Fe, Co, and Ni the occurrence of the Ti2Ni-type phase could be correlated qualitatively with valency electron concentration, and that the role of 0 appeared to be that of an electron acceptor.' This paper describes the results of a broader investigation of the occurrence of Ti2Ni-type phases in binary and ternary systems containing Ti, Zr, or Hf. EXPERIMENTAL PROCEDURE Alloys were prepared by arc melting. The purity of the metals Zr, Rh, Hf, Ir, Pd, and Pt was given in the previous paper.' The additional materials used for this work were metals with a minimum purity of 99.9 pct and reagent grade ZrO2, TiO2, Cr2O3, and NiO. Chemical analysis of several alloys in each system indicated good agreement between intended compositions and cast-button compositions. For the heat treatment precautions were taken to avoid oxygen contamination. The specimens were wrapped in Mo foil and sealed in fused quartz tubes at a room temperature pressure of 1 x mm of Hg. These capsules were then annealed in a vacuum furnace at an external pressure of 5 X mm of Hg. Since the major constituent in most of the alloys studied was the brittle Ti2Ni-type phase, Debye-Scherrer patterns with sharp lines could be obtained with powder crushed from the annealed solid samples without being reannealed. Metallographic, X-ray diffraction, and density determination techniques previously described1, 2 were used. RESULTS AND DISCUSSION Zr-Rh-O, Zr-Ir-Oand Zr-Pt-O Systems-Figs. 1 through 3 show the approximate boundaries of the Ti2Ni-type phase fields at the temperatures indicated in the ternary systems Zr-Rh-O, Zr-Ir-O and Zr-Pt-0. In each isothermal section the Ti2Ni-type phase field is labeled E and the unidentified binary phase found in the previous work' is labeled ?. The dotted lines, which are not phase boundaries, correspond to the composition (Zr2 B)1-xOx. In each system the Ti2Ni-type phase field is displaced to the high-Zr side of this composition line. However, the departures from Zr2B stoichiometry for the metal components are not as high as Zr3B, as was inferred from the previous work. Lattice parameters of the Ti2Ni-type phases in the alloys shown as triangular data points in Figs. 1 through 3 are given in Table IA. The probable compositions of the Ti2Ni-type phases have been estimated from the isothermal sections. Although there are a few exceptions that probably result from uncertainties in phase boundary location and from the effect of variation of oxygen content, the generalization can be

Jan 1, 1961

By AIME AIME

PAST President R. C. Allen, then State Geologist of Michigan, gave George Corless his first job-tracing ?magnetic? with the dip compass in northern Wisconsin. His second job was also with a man now Past President of the Institute-"Chief" Buehler, for whom he worked at Joplin three years. Then came seven years as geologist and later as assistant manager of the Chanute Spelter Co., a subsidiary of The American Metal Co., Ltd. His entrance into the oil business was not planned. During a lull in the zinc industry in July, 1926, he stopped at Houston, after a trip to the Rio Grande Valley, and was so impressed with the city that he decided to migrate. His first job there was with the Texas Company, whose impressive building across from the Post Office caught his eye after he had mailed a letter saying that he was settling in Houston and would not be home until Christmas. Some months later, A.I.M.E. Past President Philip N. Moore learned that he was in. Houston and wrote an unsolicited recommendation that resulted in his present employment with the Humble Oil & Refining Co. Today he is superintendent of the Gulf Coast Division of its production department. The Division extends from Jackson County, Texas, to New Orleans, and includes such pools as Sugarland, Conroe, Toni Ball, Thompsons, Anahuac, and Friendswood. -

Jan 1, 1938

By C. W. Spencer, B. F. Addis, G. H. Bishop, C. A. Steidel

STUDIES of the inter granular attack of metals by liquids have generally been confined to polycrys-talline specimens. This note reports the results of preliminary studies of the penetration of bismuth-rich Ni-Bi liquids into oriented bicrystal specimens of nickel. It is found that isothermal penetration follows a parabolic rate law and shows a definite anisatropy with respect to direction on the grain boundary surface. Nickel bicrystals containing < 100> tilt boundaries were grown using the Czochralski method. Relative misorientation of the parent crystals was controlled to ± 1deg. The boundaries are straight in the growth direction, i.e., the common <100>, and generally straight in the transverse direction, as shown in Fig. 1. The starting material, Inco HPM grade nickel was contained in a recrystallized alumina crucible and maintained under argon. Bicrystals typically contain 30 ppm C, less than 10 ppm S, O, N, and 50 ppm residual metallics, principally iron and silicon. Specimens, as schematically illustrated in Fig. l(c),were cut from bicrystal ingots using a thin water-cooled abrasive wheel. To insure removal of all residual strain, which accelerates the penetration, specimens were round through 600 grit silicon-carbide, chemically polished, and annealed for 4 hr at 1375°C under argon. The procedure described by Cheney et al.1 for exposing specimens to

Jan 1, 1962

By N. W. Johnson

Mount Isa Mines Limited (Isamine) has process control computers in the major surface plants -- lead smelter, copper smelter, lead/zinc concentrator, and copper concentrator. HP computers are used to implement the more complex stabilizing control loops and control schemes aimed at optimizing plant performance. The choice of control strategies is discussed with particular reference to long-term performance in metallurgical plants. These control schemes must be understood by the process metallurgists who are responsible for the performance and initial fault finding. Major emphasis has been placed on the ability of the control systems to handle most of the common plant upset conditions as well as providing improved performance under normal operating conditions. To illustrate the approaches adopted, the lead/zinc concentrator crushing system and the process bag- house control system for lead smelter off-gas handling are reviewed in detail. The improvements in both of these areas resulting from control systems implementation are discussed.

Jan 1, 1984

By B. E. Sundquist

The various methods based on solution models for obtaining free energies of mixing from miscibility-gap data have been applied to a number of binary-alloy systems. For nine of these systems there exist experimental thermodynamic data that permit a comparison of the results to experiment. It was found that the method of van der Toorn and Tiedema almost invariably leads to results that are physically unacceptable and that vary drastically with small changes in the miscibility-gap parameters. The subregular solution model is found in all cases, except the Al-Zn, Fe-Cr, and Cu-Pb systems, to exaggerate the free energy of mixing by 30 pct or more. The model developed by Lumsden is found to give results that are often in excellent agreement with experiment and which exaggerate the free energy of mixing by no more than 30 pct. These results and others give evidence that the Lumsden treatment of the effect of unequal atomic sizes and of imperfect configurational randomness due to deviations of AB bond energies from the mean of AA and BB bond energies is adequate for most systems. ANALYTIC expressions are frequently proposed for the dependence on composition of the activities of the components of a solution. Because the development of solution theory is incomplete, these expressions contain parameters which must be determined by experiment. The measurement of activities is often difficult and consequently such measurements are less readily available than are measurements of phase equilibria which, under certain conditions, can also be used to evaluate these parameters. For example, suppose it is known that two structurally dissimilar phases, each of known composition, in an n-com-ponent system are at equilibrium at a given temperature and pressure. n equations can be set up in terms of these parameters expressing the equality of the chemical potential of each component in the two phases. In addition, one can write the Gibbs-Duhem equation for each phase that also contains these parameters. Thus, if these n + 2 equations contain n + 2 parameters, these parameters can be determined (at the temperature in question) from the phase diagram alone. If the average number of parameters in each expression for the activity of a given component in a given phase is V then there will be 2nV parameters involved. Equating 2nV to n + 2 shows that, for n + 2, V = 1. If the temperature dependence of each parameter were to be expressed in some explicit form one could use equilibrium conditions at a number of temperatures to increase V. The situation is much improved when the two phases in equilibrium are structurally similar. It can then be assumed that, stably or metastably, two phases will become one at higher temperatures. Thus the number of parameters involved becomes nV instead of 2nV. Hence, V = 2 for n = 2 using only one temperature. (It is implied here that the activity expressions used are valid over the entire composition range.) In this investigation only the equilibrium of two structurally similar, two-component phases (miscibility-gap systems) will be considered. The various proposed solution models will be applied to a number of these systems and the results compared with available experimental results. All of the analytic expressions that have been proposed for the free energy of mixing of a two-component system are of the form where ?Gmix is the free energy of mixing per mole of solution, N1 and N2 are the mole fractions of components 1 and 2, respectively, and f(Ni, T) is some function of composition and temperature. In the "ideal" solution model f = 0. In the "regular" solution model f = a constant. Since these two models permit only a symmetric equilibrium diagram they will not be considered further here. The simplest model that permits a nonsymmetric miscibility envelope is the so-called "subregular" solution model proposed by Hardy.1 This model gives where the Ci(T) are functions of temperature only. The same expression for f is obtained from the "linear a function" model proposed by Darken and Gurry2 and applied to miscibility-gap systems by Wriedt.3 This model requires that the a function defined by be a linear function of composition (yi is the activity coefficient of component i). This model is not purely hypothetical for it has been found2 to hold true for a number of systems. It is readily shown3 that the f(Nl, T) obtained from this model is of the form given in Eq. [2]. It will be noted that the subregular solution model contains only two parameters and hence both of them can be determined at any desired temperature below the critical temperature, Tc, for a miscibility-gap systems in the manner described previously. At T, the two constants can be determined by equating the second and third derivatives of ?Cmix with composition to zero. Another two-parameter model was proposed by Lumsden4 who set

Jan 1, 1967

Adams, Bernard, Student, South Dakota School of Mines. Rapid City, S. D. &apos;30 Ahlskog, Harold A., Student, Washington State College Pullman, Wash. &apos;30 Aldridge, John, Student, New Mexico School of Mines Socorro, N M. &apos;30 Almstrom, Adne A., Student, Met. Engrg., Washington State College Pullman, Wash. &apos;29 Ancell, Virgil F., Student, Missouri School of Mines Rolla, Mo. &apos;30 Ankudinoff, N., Mill Draftsman, Arthur G McKee & (:o., 2422 Euclid Ave., Cleveland, Ohio. &apos;30 Apablasa, Salvador C., Student, Univ. of California Los Angeles, Cal. &apos;31 Armstrong, Robert H., Student, Lafayette College Easton, Pa. &apos;31 Armstrong, Thomas E., Student, Univ. of California Los Angeles, Cal &apos;31 Aud, Robert A., Student, Lafayette College Easton, Pa. &apos;30 Backus, Robert Small, Student, Mass.- Inst. of Tech . Cambridge, Mass. &apos;30 Bailey, William C., Student, Univ. of California Los Angeles, Cal &apos;30 Banning, Lloyd H., Student, South Dakota State School of Mines Rapid City, S D. &apos;81 Barclay, M. G., Student, Colorado School of Mines Golden, Colo. &apos;30 Barger, Thomas, Student, Univ. of North Dakota Grand Forks, N. D. &apos;29 Barker, C. L., Student, Colorado School of Mines Golden, Colo. &apos;30 Barker, Edgar Morgan. Student, Univ. of Utah Salt Lake City, Utah. &apos;31 Barnwell, Earl E., Student, Oregon State College. Corvallis, Ore. &apos;30 Bartholomees, Geo. C Box 304, Bonne Terre, Mo. &apos;29 Bartholomees, Louis P., Student, Colorado School of Mines Golden, Colo. &apos;30 Bary, Robert L., Student, Univ. of Kansas Lawrence, Kans. &apos;30 Basham, Lester G., Student, South Dakota School of Mines Rapid City, S D. &apos;31 Bates, Walter H., Student, School of Mines, Univ. of Utah .. Salt Lake City, Utah. &apos;30 Beardshear, George T., Student, South Dakota State School of Mines.Rapid City, S D. &apos;31

Jan 1, 1923

By R. K. Iyengar, G. C. Duderstadt

An investigation was carried out to determine the effect of Ca-Si additions on the dissolved oxygen content of liquid steel. An apparent equilibrium was reached after holding the melt for some time when the total oxygen content of the melt was identical with the dissolved oxygen. Results of the investigation show that for deoxidation with silicon and manganese the apparent equilibrium is reached after 8 to 12 min and the oxygen content of the melt is in good agreement with values reported in the literature for similar steel compositions. Ca-Si additions decrease the dissolved oxygen content appreciably below that obtained with Si-Mn deoxidation. It is postulated that some calcium dissolved in liquid steel at the time of its vaporization combines with dissolved oxygen to form CaO which then fluxes the manganese silicate, thereby lowering the activity of the deoxidation products. Slow flotation of calcium silicate inclusions is attributed to their slower growth rate. An addition of aluminum (to yield <0.005 pct Alsol) prior to introduction of Ca-Si improves the kinetics of removal of resulting deoxidation products. WITH the introduction of continuous casting of billets and blooms, application of calcium-containing alloys for deoxidation purposes has gained new interest. More so than in conventional ingot casting, the degree of control of the dissolved and total oxygen contents in steel for continuous casting can determine the success or failure of the operation because these affect both surface (pinholes) and internal quality of the billets. Of the available deoxidizers, only silicon has so far found wide application. However, in the typical range of application (0.20/0.30 pct Si), it is too weak a deoxidizer to suppress pinhole frequency to the level desirable for all but the least demanding appli-cations (approximately 10/50 pinholes per sq ft, de-pending on degree of subsequent reduction). On the other hand, Vincent&apos; has shown that it requires ap-proximately 0.007/0.008 pct A1 soluble in the steel to suppress pinhole formation to <10 pinholes per sq ft. In view of the difficulty of consistently maintaining this aluminum level and the associated problem of tundish nozzle constriction2 when aluminum is added to the ladle, steelmakers have searched for other de-oxidation alloys to circumvent the problem. Calcium-containing alloys offer such a possibility. When employed as a partial substitute for silicon, CaSi (30 pct Ca/60 pct Si) additions are reported to yield adequate pinhole contro1.3 Its use simultaneously preserves the "fluidity" of the steel and ensures good castability.4 Oxygen contents as low as 0.007 to 0.014 pct have been obtained with CaSi additions varying between 3 to 8 lb per ton.5-7 Due to the high degree of vaporization of calcium at the temperature of molten steel and the different methods used to introduce it into the liquid, the reported results show considerable scatter and lack of consistency. According to several investiga- deoxidation tors, the flotation characteristics of CaSi products are not as favorable as those found for alumi-num but are similar to those established for silicates with low alumina content.678 Thus, cleanliness ratings were improved when CaSi was replaced by a com-bination of Si + A1 followed by CaMnSi additions.5,9 In view of the lack of a comprehensive description of the deoxidation potential of CaSi alloys, a study was undertaken of the effect of CaSi additions on oxygen content in comparison to Si + Mn and Si + Mn + Al. The alloy chosen for this study contained 63 pct Si, 32 pct Ca, <3 pct Al, and 2.5 pct Fe. EXPERIMENTAL PROCEDURE The experiments were divided in three groups as shown in Table I. In each group, the CaSi addition was increased successively while maintaining the melt composition constant. The experiments in the third group were designed to determine the effect of prede-oxidation with small amounts of aluminum. Ingot iron, containing 0.02 to 0.03 pct C and 0.03 to 0.05 pct Mn, was melted in a 100-lb magnesia crucible. Pig iron was added to the melt under air in an induction furnace to attain the desired carbon content of 0.05 to 0.15 pct and thereby control the initial oxygen content of the melt between 0.04 and 0.015 pct. After removal of the slag, the furnace was sealed and argon was introduced through an opening in the graphite cover, Fig. 1. When the desired temperature was reached, electrolytic manganese was added to the melt and pin samples were taken (7 mm silica tubing) to establish initial oxygen content. To obtain maximum efficiency, CaSi and metallic silicon were introduced in a sealed steel pipe into the bath. This procedure assured minimum loss of calcium through vaporization as the deoxidants were always released at the bottom of the melt. Samples were taken at regular intervals and quenched in water. Temperature of the bath was measured with a Pt/Pt-10 pct Rh thermocouple. Portions of the pin sample were used for oxygen analysis; five determinations per sample were made to obtain average oxygen content. Oxygen analyses were made by the inert carrier gas fusion method with frequent cross checks with the vacuum fusion method.

Jan 1, 1970