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By Arvid Anderson

THE weathering of copper-bearing ores with the formation of a water-soluble salt and the recovery of the metal by leaching and evaporation or precipitation, are processes long known, which have at various times been utilized with more or less commercial success. It is commonly assumed that the technical principles involved are quite simple and their application to a particular case easy. If these assumptions were true, we should anticipate a long list of uniformly successful leaching operations, which is not the case, and one would be justified only in calling attention to either unique or peculiar features of any particular enterprise; whereas, in studying the problems of the recovery of copper from the old workings of the Ohio Copper Co. in the light of available descriptions of other leaching projects, we have not found the assistance hoped for to guide us to the best realization of our own opportunities. It appears desirable, therefore, to call attention to these guiding principles, together with a description of the facts of accomplishment. Justification lies in the fact that the leaching and precipitation of copper at the Ohio Copper Co. mine in Bingham Canyon, Utah, is successful. This success is measured by an average monthly production of 600,000 lb. of copper at an average operating cost, to date, of 3.85 cents per pound at the company's workings, or 6.32 cents per pound after paying shipping and smelter charges on the finished copper. A total of 17,076,099 lb. of copper had been shipped to the smelter from the beginning of operations, August, 1922, to April 1, 1925. Probably these results can be bettered with further study and realization of the factors involved and the devising of methods of meeting them. It is now an assured fact that the enterprise will have a relatively long and continuously profitable life and that its reserves will not, nor cannot, be suddenly and permanently depleted.

Jan 9, 1925

By Clarence E. Sims, Donald W. Williams, George A. Moore

INTRODUCTION DURING the past several years the steel casting industry has made studies of heavy castings in which the test bar has been taken from heavy sections rather than from attached or separately cast coupons. It has been noted that the ductility properties of these heavy sections are often lower than those normally expected. Such lowered ductility is usually accompanied by a spotty test bar fracture and the ductility values often can be greatly improved if a low-temperature aging treatment is given to the casting. A loss of ductility of this type is considered "abnormal," since it is not accompanied by an increase of tensile strength or hardness, and "temporary" when the ductility can be restored by aging. The cure of such an abnormal condition represents a real improvement in the quality of the steel. Some hundreds of previous investigations, largely qualitative in nature, have established beyond reasonable doubt that hydrogen is normally present in newly manufactured steel and that this gas, in small amounts, can cause a temporary abnormal loss of ductility. The commonly observed association of high gas content and low ductility has given strong evidence for the presumption that hydrogen, possibly assisted by other gases, is the primary cause of the low ductility observed. Accordingly, the Steel Founders' Society of America has, since Nov. 1, 1944, sponsored investigations at Battelle Memorial Institute whose primary objective is to obtain quantitative information on the relation of the amount of hydrogen and nitrogen in steel, together with associated methods of steelmaking and treatment, to low-ductility effects and porosity. In order that these investigations might proceed on a quantitative basis, hydrogen analyses of a precision considerably higher than any previously reported in the literature were necessary. The method chosen was selected entirely on the basis that it had the highest probability of freedom from uncontrollable errors and will be described in detail in another publication.1 Briefly, the method used consisted of the hot extraction of solid pieces of steel weighing from 45 to 50 g in a highly evacuated quartz tube maintained at 1050°C (1925°F) for a period 0f approximately 40 hr. The greatest precautions were taken to eliminate blanks and insure a sound gas-collection system. Vacuum and temperature conditions were maintained automatically. Mercury-filled risers were used for the introduction of samples in order that the system could be degassed thoroughly in

Jan 1, 1948

By J. W. Mitchell

Season cracking of 70-30 cartridge brass cases of small arms and artillery ammunition has been under investigation at the Frankford Arsenal for many years. The nature of this stress-corrosion failure has been found to be intergranular. Much of this work, however, has been directed toward improvements in method of manufacturing the cases so as to reduce the tendency to season crack and little progress had been made toward finding the source of the chemical agent producing the inter- granular corrosion. Ammonia has been shown to produce season cracking in brass and is known to be present in certain atmospheres, particularly industrial, in sufficient concentration to cause cracking. However, in the case of small arms ammunition, the hypothesis that atmospheric ammonia is the cause will not hold, since small arms ammunition is hermetically sealed during storage and yet occasional lots are found to have cracked after 3 to 5 yr. storage. Much of the early study of season cracking in small arms ammunition was done by Nicholas H. Murdza of the Frank- ford Arsenal. In 1936, he suggested that the corrosive agent might be one of the decomposition products of smokeless powder and mentioned nitrogen oxides specifically. Then in 1937, Murdza suggested that the breakdown of smokeless powder in storage resulted in the formation not only of nitrogen oxides but also ammonia

Jan 1, 1945

By Ole Singstad

The legislatures of New York and New Jersey, determined in 1919 that a vehicular tunnel should be built under the Hudson River. On July 1, 1919, an engineering staff was organized with the late Clifford M. Holland as chief engineer. After preliminary investigation it was decided to build the tunnel from Canal St., New York, to 12th St., Jersey City, which is the center of the heaviest traffic across the Hudson River. It was also decided to build two tunnels—one for west-bound traffic and one for east-bound—the tunnels to be of cast iron, built up of segments and bolted together, each tunnel to have a roadway 20 ft. wide and a clear head room of 13 ft. 6 in. The tunnels have an exterior diameter of 29 ft. 6 in. The interior lining is of concrete, the sidewalls, tiled with a vitreous white tile, and the roadways are paved with granite block. The entrances and exits at both ends are separated by two blocks so as to reduce traffic congestion. Basis of Ventilation It was recognized very early that one of the most important problems confronting the engineers was a proper ventilation system. It was estimated that each tunnel as planned would have a traffic capacity of 1900 vehicles per hr. The tunnels are 8500 ft. long between portals, and it was considered that the ventilation should be based on all of these vehicles being operated by gasoline engines. That presented a problem in ventilation unlike any other either in magnitude or character. There have been vehicular tunnels built in Europe, principally in London, but they are shorter and have a smaller traffic capacity. Up to the present time, at least, they have handled a very large percentage of horsedrawn vehicles so that the necessary ventilation has been provided for by the natural draft through the portals and open shafts. Within the last few years, however, a small mechanical ventilating plant has been installed in the Blackwall Tunnel, which has been in operation about 27 years. I might mention that at the time this work was started, it was considered by many that the problem of ventilation was insuperable and it

Jan 1, 1927

By H. G. Dwyer

CONSIDERATION for future expansion influenced the design of the new smelter at Chuquicamata. The section of the smelter now going into operation, while large, represents only little more than half of the ultimate plant. Equipment for the direct smelting of raw concentrates has been arranged in the conventional manner although needless details have been eliminated wherever possible while mechanical and electrical features not usually found in copper smelters have been incorporated. Access is afforded to all equipment but platforms and walkways have been held to a minimum. The poling and other platforms in the converter aisle, normally subjected to battering by ladles and other heavy equipment in transit, are of concrete construction with steel grid armor embedded in the exposed surfaces. Noticeably absent are the many platforms formerly required for the handling of converter flux since this material is charged to the converters through the side walls of the converter uptake hoods. Clear space with ample headroom is provided under each converter and converter puncher's platform to permit clean-up by small bulldozers. Remote controls have been introduced at many points. Electrical control rooms and control centers have been conveniently located. An electrical tunnel with cross tunnels and escapeways is situated under the entire length of the converter aisle for power feed lines. Skull breaking facilities are in a separate building near the smelter. A silica-slurry building with brick storage area is adjacent to the smelter building so that elevator service is available to both buildings. A smelter office, a change house and lunchroom are provided in convenient locations. Units of the smelter as presently constructed are shown in the plan and table on page 1194. The ultimate smelter will house 7 reverberatory furnaces, 14 waste-heat boilers, 9 Peirce Smith converters, 4 casting furnaces serving 2 casting wheels, and one holding furnace serving a straightline casting machine. Additional crane requirements in the converter aisle will necessitate the installation of special hoisting equipment in space already provided in a raised section of the roof over the casting end of the aisle. Thus a complete crane may be lifted high enough above the crane rails to permit the passing of another crane underneath thereby giving all cranes full use of repair facilities already installed. For the collection of gases, 2 dust chambers, each with separate stacks, will collect converter gases and 2 balloon flues with separate stacks will collect reverberatory furnace gases. Extensions necessary to complete the ultimate plant will be possible with little interruption to normal operations since the future converters and reverberatory furnaces will be added at the east end while additional casting facilities will be added at the west end of the present plant. The future units may be added singly or all at one time depending on requirements.

Jan 1, 1952

By Richard D. Hagni

Mississippi Valley-type ore deposits contain significant quantities of minor elements, which are present partly in the form of separate mineral phases and partly in solid solution in the major sulfide phases for which these deposits are exploited. These elements, as separate phases, are: copper, mainly in chalcopyrite and enargite; cobalt and nickel, chiefly in thiospinels and bravoite; rare earth elements associated with certain fluorites; and native gold. Many economically important minor elements occur in solid solution in sphalerite, including silver, cadmium, iron, germanium, gallium, indium, thallium, cobalt, nickel, and mercury. Significant amounts of silver and antimony, and perhaps very small amounts of gold, are present in solid solution in galena. Chalcopyrite may contain small amounts of silver, molybdenum, bismuth, cadmium, cobalt, and nickel. Marcasite and pyrite may contain silver, thallium, cobalt, and nickel. Although some of the minor elements contained in the Mississippi Valley-type deposits are currently recovered at the smelters and refineries, many are lost in tailings, sludges, and slags; consequently, important quantities of these elements are potentially recoverable as non-conventional resources.

Jan 1, 1983

By Thomas T. Read

The purpose of the following research, as originally planned, was to investigate the influence of temperature upon the plate-amalgamation process. In order to consider the amalgamation process intelligently, it was first necessary to learn the nature of an amalgam. In the performance of this task it was found necessary to consult a large volume of literature and to perform experimental investigations. The conceptions of the nature of amalgams thus obtained have so important a bearing on the amalgamation-process as a whole, as well as upon the possible influences of temperature, that it was advisable to include them in the treatment of the subject. The broader title is therefore used, even though some features of the amalgamation process have been treated very briefly and others entirely omitted, there being nothing new to present regarding them and their development not required for a clear presentation of the matter in hand. I. Historical Introduction. Gold was one of the earliest metals known to man. Occurring in the metallic state, it could be picked up in nuggets or mashed, as gold dust, from the sand and gravel of streams. Interestiag descriptions of the processes employed in early times for the recovery of gold may be found in Pliny's Natural History and in the treatise by Agricola on ores and minerals. But little progress in the treatment of the ores of gold mas possible until efficient crushing machines were devised. This want was supplied by the introduction, about the beginning of the sixteenth century, of the stamp-mill to treat the ores of Saxony. Blanket-strakes, or similar devices, were used to catch the

Jan 1, 1907

By W. L. Honnold

Owing to a unique labor situation and other unusual circumstances, the mining methods of the Rand are hardly comparable with practice elsewhere. They are of considerable interest, however, and their importance is increased by the magnitude of the' industry with which they are identified, gold of $166,186,000 value, say 40 per cent. of the world's production, having been recovered from 25,701,954 tons of ore milled in 1914. In the sketchy remarks to follow, attention will first be drawn to some influential factors of general bearing, after which certain features at two mines of the writer's group will be referred to. It is hoped that engineers associated with similar or different conditions and practice will contribute to broaden the discussion. Before proceeding, recognition is due the generous assistance of C. E. Knecht and F. A. Unger. General Observations The principal mines are situated along the northern limit of an irregularly shaped geological basin, and extend in almost unbroken continuity over a distance of about 60 miles. As the boundaries are defined by vertical planes there are both "outcrop" and "deep-level" properties, all differing in size and in technical features. So much has been written in regard to the geology of the Rand that only a few pertinent features need here be recalled. Briefly, the ore deposits are profitably enriched portions of certain conglomerate beds or "reefs," rarely more than three, which are interposed between quartzite, or quartzite and slate, and lie so closely together that where more than one are mined they are dealt with as a working unit, although they may be stoped separately. Their collective extension is locally referred to as " the Reef." Along the outcrop the series dips more or less steeply, and in depth it flattehs, the latter tendency being most marked in the Far East Rand, where the bottom of the basin is nowhere so deep as to be inaccessible. Dikes and faults are a common feature throughout. They are,

Jan 1, 1916

By Walter B. M. Davidson

Phosphorus is one of the elements having the widest distribu tion, and phosphoric acid plays an important part in the composition of the crust of the earth. It is allied in various chemical combina- tions with many bases, of which lime, alumina and iron are the most common. It is difficult to state in what chemical combination phosphoric acid predominates in the crust of the earth, for while phosphate of lime, as the mineral which is sought for and found in deposits of economic value is the most familiar, it is probable that the phosphates of alumina and iron are the most usual forms in which phosphoric acid exists in all soils not essentially calcareous. It has been shown by thousands of analyses that all fertile soils contain from a trace to 0.5 per cent. of phosphoric acid. All limestones, dolomites and chalks contain it in proportions which, though usually small, are large enough to make careful analysis necessary in the selection of limestone as flux for iron-smelting. It is generally Trenton limestones that are found best for this purpose, the more recent strata being more phosphatic. In some places phosphoric acid replaces carbonic acid, and the limestone or chalk becomes phos phatic to a large degree, or sometimes pure phosphate of lime. The waters of the ocean, from very early periods, have contained phosphoric acid. Different analyses show varying contents; it is asserted that some portions of the Gulf Stream are more phos phatic than the surrounding waters of the Atlantic. Many springs, usually from limestone regions, contain soluble phosphates in vary ing quantities. I think it safe to assert that phosphorus is nearly the most widely and evenly distributed element on the surface of the earth, and probably the most subdivided. This can be readily understood when the important part which phosphoric acid plays and has played in the vital cosmos is taken into consideration. Phosphorus was on the earth in gaseous, liquid or solid form before the dawn of life, and since then all animal and vegetable creation have combined with the

Jan 1, 1893

By H. Rush Spedden, A. M. Gaudin

ALTHOUGH the number of minerals that are ferromagnetic) or highly paramagnetic is strictly limited, it has been known for some time that many minerals have slight but supposedly characteristic magnetic susceptibilities. With the exception of pyrrhotite, however, sulphides have been thought nonmagnetic. A new magnetic separator has been made available recently in limited quantity to research laboratories. This device, the Frantz Isodynamic Separator, has been used for the separation of various nonsulphides from each other. Its application to the separation of sulphides, however, does not seem to have been reported. In the Richards Mineral Dressing laboratories, the success achieved through the use of this device in separating associated sulphides has been so startling as to lead us to believe that it constitutes a magnificent adjunct to heavy-liquid separation and to quantitative mineragraphy as a tool for the mineral investigator. THE SEPARATOR The separator (Fig. I) consists of: I. A powerful magnet, the strength of which can be adjusted by means of a rheostat; 2. A vibrating chute of nonmagnetic metal on which the mineral to be separated is made to flow (Fig. 2); 3. A feed bin and adjustable feeder; 4. Receptacles for the collection of products; 5. Means for changing, setting, and accurately reading the two slopes of the chute; viz., the cross slope and longitudinal slope. The separator is made operative by the special shape of its pole pieces, which ensures a strongly converging field. It is said by the makers of the machine that the pole pieces apply a constant mechanical force to a particle of given susceptibility, regardless of its position in the operating space of the separators.* Susceptible particles, therefore, behave as though of lower specific gravity than under ordinary circumstances. This effect, combined with the slopes of the chute and the action of the vibrator, causes a stratification not unlike that obtainable on a shaking table. The chute is of rectangular cross section, and shallow; it is broadened toward the discharge end and divided longitudinally by a partition into two compartments that lead to the collecting receptacles. Although the separator probably can be used to make separations at fairly coarse

Jan 1, 1943

By C. G. Southmayd

ANYONE who has been confronted with the problem of predicting the performance of a sand-pump installation is vitally aware of the dearth of precise information that has been published on this important subject. Such data as have been collected are not readily available in a concise and readily usable form, so that many operators would find it a considerable chore to find the pertinent information required to undertake a detailed study. The purpose of this paper is to assemble such established data, correlate them with field experience and outline the factors that must be appraised in the determination of a satisfactory pump installation. The transportation of solids in solution is of vital interest to every mill superintendent and operator, and many of the factors that are involved in this hydraulic problem vary widely from installation to installation, and in some cases even from time to time on any one installation.. These include: type of solids (including shape of particles), size of solids (grind), percentages of fines (slimes), dilution of pulp, contour of pipe line, type of pipe, age of pipe line, effect that diameter of pipe has on characteristic flow conditions, and other factors. Some of these have been fairly well determined by experimental work but many still must be established through interpolating or extrapolating between values that have been derived from known field conditions. Most problems primarily concern the transportation of a definite weight of dry solids from one specific location to another. The type of material, shape of particles, grind and percentages of fines are established and very often the dilution at which the solids must be handled as well. The problem then evolves into a determination of the size, type and contour of the pipe line and the net effective head against which the pump must operate. Before discussing the determination of the head, it might be well to review the interrelationship between the pump discharge (capacity), the head developed by the pump and the pump speed, which will apply to any centrifugal pump installation. EFFECT OF PUMP SPEED Basically, the head developed by a centrifugal pump varies as the square of the pump speed and the discharge as the first power of the speed. However, even at constant speed a centrifugal pump will operate over a wide range of capacities, depending upon the head that must be developed to deliver the liquid or pulp to the end of the pipe line. This is shown graphically in Fig. I. If the pump in question is being driven at a constant speed of 900 r.p.m. it will deliver 500 U. S. gal. per min. against a head of 56 ft., 800 U. S. gal. per min. against a head of 50 ft., and so on. In other words, at this speed the capacity of the pump will be determined and limited by

Jan 1, 1946

By C. P. Fiske

THE pottery of the New Jersey Zinc Co. (of Pa.) is equipped to make three classes of refractories; namely, spelter vessels, spelter condensers; and high-grade fire-brick. The most important of these are the spelter vessels, on account of the extreme severity of the service which they must perform, necessitating great care in the selection of materials and in the whole process of manufacture. Next to the spelter vessels in importance? come the condensers, as large numbers are used in the manufacture of spelter, and improvements m quality result in material decreases in working cost. , While the fire-brick which form the laboratory, or high-temperature portion of the spelter furnaces, are placed at the foot of the list, they-are nevertheless of much importance, since high quality will decrease the frequency of the always expensive shutdowns for repairs. To promote simplicity, the manufacture of these three products will be described separately in this paper, except in so far as materials and the crushing and handling system common to all are concerned. Materials Bond Clay.-The bond clay used entirely at the Palmerton pottery is a St. Louis clay furnished by the Grand View Fire Clay Co. It is stored in a system of covered bins, and no attempt is made to weather -it in the, accepted sense of the term " weathering." Some years ago our clay was weathered before pugging, but we did not find the benefit sufficient to offset the additional handling and the loss. of clay incurred. Furthermore, we believe that the rotting of the pugged mix (described later), accomplishes the same results to better advantage. That there is some action taking place in the clay while stored in the covered bins, however, is, evidenced by an increase in volume which at times has caused damage to the retaining walls of the bins. We have at present a stock of bond clay weathering in the open, and when this is put into service an opportunity will be afforded for making comparisons-with the clay as usually handled.

Jan 10, 1917

By S. Skowronski

OvErpolEd copper, as commonly defined,- is copper which has been excessively reduced during the poling period of the refining process. Owing to its porosity, such coppcr is unfit for commercial purposes. The cause of this phenomenon is undoubtedly the lack of oxides in the copper, yet this does not completely explain it. Refined copper of the same "pitch" and "set" varies considerably in oxygen contents, and analyses of overpoled bars also show similar wide differences; moreover, it is possible to melt copper in 'crucibles so as to obtain bars that are practically free from oxygen although they show a "tough pitch" and "level set" surface. Frederick Johnson advances the following theory: The regulation of the quantity of oxygen in copper is the keynote of all copper refining. It is the presence of a well defined proportion of oxygen in the form of cuprous oxide, forming a copper-cuprous oxide eutectic, which enablcs copper to be cast free from blowholes. It seems that when oxygen is present, other gases are less soluble in molten copper; when oxygen is absent, or is present in insufficient quantity, the copper dissolves other gases, such as hydrogen and carbon monoxide, which are insoluble in the copper when solid, and, being rejected during the process of solidification, causes internal porosity and external ridges and excrescences.1 The "level set" of wire bars, etc., is entirely the result of a compromise between the occluded gases and cuprous oxide. With excess of the former the metal would be "overpitch" and spongy, while an excess of the latter would result in the metal being "underpitch" and brittle.2 The result of the absorption and subsequent expulsion of reducing gases, carbon monoxide and hydrogen,' and the effect of this action on the overpoling of copper are in dispute; the literature on the subject is full of contradictory statements and will continue to be so until better analytical methods have been developed. Sulfur, however, is tangible. The refiner can see it in his button sample and consequently attributes to it any trouble that may happen during the melting of the copper.

Jan 1, 1919

By Carl F. Floe, Michael B. Bever

THE possibility that carbon may be soluble in copper to a limited extent has been recognized for over a century. The quantitative investigation of this problem, however, requires more sensitive techniques than have formerly been available. Three recent developments have made possible more accurate determinations: the vacuum-fusion method of analysis, the production of copper of high purity and the availability of high-purity refractories, particularly graphite. In addition to its obvious theoretical interest, the problem of carbon solubility in copper is of practical importance. In the production of copper and of high-copper alloys, carbonaceous covers are frequently used. If even minute amounts of carbon are dissolved, insoluble carbon oxide gases will be formed when such metals are poured under oxidizing conditions. A mechanism of this kind could well be one of the principal causes of gas porosity in casting copper-base products. REVIEW OF LITERATURE In 1823 Vivian1 raised the question as to whether copper by overpoling becomes "combined with a minute portion of carbon." Karsten2 asserted, in 1832, that carbon reduces the high-temperature strength of pure copper, so that when the carbon content has reached 0.2 per cent the metal will be brittle at a dark red heat. According to Karsten, carbon contents of o.05 per cent make it difficult to hot-work copper. He also reported that the specific gravity of copper is 8.8969 and that it increases to 8.92 58 if the copper is cemented with carbon and then melted. He emphasized the difficulty of determining analytically the small amounts of carbon present in copper. The metal was removed by wet methods and the residue considered as carbon. At Percy's request, Dick,3 in 1856, carried out various working tests on copper that had been in prolonged contact with carbon, and found that the working properties of the metal had not been affected. He also attempted to determine the presence of carbon analytically. In one experiment the copper was dissolved and the residue was fused with litharge, and in another essentially a combustion analysis was made on a copper sample. In a final experiment, a sample was dissolved and the residue subsequently subjected to a combustion analysis. Indications of as much as o.005 per cent carbon were found, but Dick considered his work inconclusive largely because of the possible interference of sulphur. Percy4 concluded, from Dick's experiments and from some experimental work of his own, that the solubility of carbon in copper had not been established with

Jan 1, 1945

By Ben Gumpertz

The important factors in any study of the screening of sand with a gravel envelope, as applied to use in oil wells, are: (I) sand size and shape, (z) gravel size and shape, (3) ratio of gravel size to sand size, (4) flow velocity, (5) viscosity of the fluid. Perhaps the first extensive investigation of the function of gravel in screening sand was performed by Coberly and Wagner,' from which the following conclusion was drawn: "The diameter of the largest grains in a single classified sand suitable for gravel packing is approximately 13 times the grain size at the ten-percentile analysis of the formation sample." ?;his applies to sands classified by Tyler screens and is for gravel grains of the maximum size that could be used to form a stable bridge. Field practice has shown that the screening effect of a given gravel for a given sand apparently varies with the flow velocity." Also, it has been assumed by some operators that the thickness of the walls of the gravel envelope surrounding the well has little effect upon the screening process. It is thought by others that a narrow envelope of gravel might form an ineffective screen. Thus the purposes of this work are: 1. To investigate the effect of gravel-sand size ratio upon screening action under the condition of varying flow velocities. 2. To investigate the effect upon screening action of varying the thickness of the gravel screen. 3. To investigate sand migration in the gravel screen and the effect of flow velocity and gravel size upon sand migration. Description of Apparatus In an attempt to reproduce field conditions for the purposes of this investigation, a flow tube was constructed, according to the manner of Urenj3 to represent a radial drainage segment of an oil sand. To arrive at the dimensions of the flow tube, a radial drainage segment of rectangular cross section was assumed to define an area of z sq. in. on the face of a well 6 in. in diameter. From this the dimensions of the segment were calculated out to a distance of 5 ft. from the face of the well. By computing cross-sectional areas at a number of sections along the rectangular segment and transforming these areas into the circular form, a drainage cone was obtained having everywhere the same cross-sectional area as the drainage element of rectangular cross section. To construct the apparatus, two sections of pipe of 7%-in. inside diameter, one 13 in. and the other 4 ft. long, were joined by a bolted flange. A mandrel having the dimensions of the drainage cone was centered in the pipe and a neat cement mixture was cast around it. A protective gasket was placed between the two sections of pipe so that the cement body could be separated at that point. When the mandrel was withdrawn a drainage cone was obtained (Fig. I).

Jan 1, 1941

By C. M. Marquardt

Tramp iron and steel moving on a conveyor belt cause small currents to be generated in a coil situated in a strong magnetic field, which are converted to an alternating current and are amplified. The output voltage from the amplifier fires a thyratron with a relay in its anode circuit, which actuates a howler and simultaneously drops a spot of marker material on the belt. THE problem of tramp iron removal from moving ore belts is a long standing one. When heavy ore streams are carried on a belt, magnetic pulleys and strong surface magnets fail to remove tramp buried in the ore stream. Tramp iron buried in the ore stream cannot be pulled from the bed by surface magnets and is carried past the magnetic pulley by the falling ore stream. With the increased use of detachable bits the problem of the detection and removal of tramp has become more necessary and difficult. Several types of tramp detectors have been developed. It would serve no practical purpose here to review exhaustively the literature on the subject. Methods of tramp detection used are: (1) The magnetic method, wherein the small current generated by the magnetized tramp passing a Coil is used. (2) The unbalanced oscillator method wherein the tank circuit of a stable radio- or audio-frequency oscillator is unbalanced causing a change of frequency or a change in plate current due to changes in eddy currents, hysteresis, or dielectric because of the presence of tramp. (3) The bridge methods wherein the impedance of one leg of an alternating current inductive bridge is changed due to the presence of conducting tramp. Each of these methods of tramp detection has its field of usefulness. The second and third methods are excellent for oxide iron ores, coal, sand and gravel, grain, etc. However, these latter methods are not suitable for use on ores that contain rich conducting sulphides, since a large piece of pyrite or galena will cause the same detector response as a piece of tramp iron. At the Caselton, Nevada, plant of the Combined Metals Reduction Co., sulphide ores are treated; therefore, it was necessary that a tramp detector operating on only the magnetic properties of the tramp iron be used. Tramp iron detectors of this type operate on the principle that if a piece of tramp iron moves near a coil in a high intensity, steady magnetic field, the presence of the moving tramp iron causes the magnetic flux lines through the coil to change. This induces a mall current in the Coil. In series with the Coil is generally placed a relay sensitive to currents of 1 to 3 microamp. When the tramp iron passes near the coil the flux linkages change, causing this very sensitive relay to actuate. Since the contacts of such a relay are very small it must actuate a second relay capable of breaking a larger current

Jan 1, 1951

By J. Rogers, H. F. A. Hergt, K. L. Sutherland

IN 1938 Ralston4 reviewed the many attempts to find a satisfactory collector for the separation of cassiterite from its ores and in 1944 Dean and Ambrose2 summarized some further attempts. Generally, soaps and amines are effective but nonselective collectors. We have discovered that reagents containing either the polar group -SO4- or _S03- are excellent collectors for cassiterite and promise to be selective.1 The response to these reagents of cassiterite and of minerals commonly associated with it was studied, using the captive-bubble technique. Using these fundamental data, the practicability of separation and concentration of tin was investigated by flotation tests in a 2000gram Denver cell. EXPERIMENTAL METHODS Reagents All inorganic reagents were of Analar grade. The preparation and purification of sodium cetyl sulphate, cetyl trimethyl-ammonium bromide, laurylamine and cetylamine have been previously described.5 The other collectors were commercial surface-active agents, which were used without purification. Tests Captive-bubble Tests and Cylinder Flotation Tests have been previously described.5-10 The full lines shown in the figures relating solution composition to contact (flotation) distinguish solutions in which contact (flotation) is possible from those in which it is not. The curve is derived by successive approximation and the accuracy is ±0.2 pH units and ± 5 mg. per liter of collector or depressant. Solution compositions for which it was shown experimentally that contact or flotation is possible are marked by a circle, those for which it is not possible, by a cross, and those for which it is doubtful by a cross within a circle. It is assumed that at all other solution compositions within (without) the curve, contact or flotation is possible (not possible). After testing in the collector solution, the mineral was removed, washed, and tested by the captive-bubble method in water, or floated in a cylinder with frother only. In this way the composition of solutions in which a mineral was conditioned but in which properties of the collector solution prevented contact or flotation can be defined. The composition of solutions in which conditioning was possible lie between the full and broken curve, and the experimental results are indicated by a square. The curves show the limits of composition of solutions in which flotation in a cell would be possible but many factors other than those considered in these tests determine recovery and grade of a given mineral in practice. Flotation Tests in 500 and 2000-gram Denver Submachines.--Melbourne tap water, containing 12 parts calcium, 6 parts

Jan 1, 1947

By Julian Szekely

Through the simultaneous statement of Maxwell's equations. the turbulent Navier-Stokes equations and the differential thermal energy balance equation, a mathematical representation has been developed for heat transfer and fluid flow in electric arc furnaces. In broad outline the theoretical predictions appear to be consistent with experimental measurements. A discussion is presented of the general arc furnace control and optimization problem, together with the potential for the incorporation of the mathematical model given in the paper, into future control and optimization schemes. ELECTRIC ARC FURNACE STEELMAKING accounts for about 24% of the total steel produced in the U.S., consuming about 550kw-hr/ton of steel which amounts to about 1.4x1010 kw-hr annually. The percentage of steel produced by the electric arc furnace route has doubled since 1960 and is expected to increase further in the foreseeable future, particularly with the more extensive use of direct reduction technology. Table I shows, in terms of percentages, the principal items that contribute to the cost of running an electric arc furnace. It is seen that in addition to the fixed costs (labor, depreciation, taxes etc.) electrode costs and power consumption are the dominant inputs, and it follows that process changes that would ultimately reduce any of these cost components would have a significant impact on the efficiency of the operation. There are three main areas where progress in arc furnace design and operation must be directed in the next decade (Committee on Technology, 1981). 1. Increased furnace productivity 2. Reduction in processing cost 3. Improvement in the thermal efficiency of the furnace An estimate of the current operating efficiency of the electric arc furnaces may be obtained by comparing the theoretical minimum energy consumption per ton of steel with those achieved in operational practice. Theoretically 330-360 kw-hrs of electricity are required to melt one ton of cold scrap. For superheating, 8-12 kWh per 100°F are required. The actual energy requirements are given in Table II. It is seen that furnaces currently operate at 70-80% efficiency, with the major heat loss from the furnace resulting from the waste gases (Committee on Technology, 1981). While it is apparent that operational experience has produced a technology that is reasonably energy efficient this has been achieved in the almost complete absence of any detailed knowledge concerning the fundamental heat transfer mechanisms occuring in the furnace. The purpose of the present paper is to present a case for the usefulness of mathematical models in increasing the thermal efficiency of furnaces by investigating these heat transfer mechanisms and then combining this knowledge with existing electrode regulator mechanisms to produce truly efficient power cycles for melting and refining. In particular, existing mathematical models describing convection, radiation, and electro-magnetism in the furnace should be employed, and the development of optimization models which balance the cost of electrodes and energy against the thermal efficience of the furnace should be undertaken. Recent work in this laboratory (Szekely, McKelliget, 1981, 1982, 1983; Szekely, McKelliget, Choudhary, 1983) has made a useful start towards solving the problem of heat transfer within the electric arc furnace but the work still needs to be directly related to existing furnace power cycles and tested against plant scale measurements.

Jan 1, 1984

By Thomas S. Blair

I FEEL a certain sense of responsibility in bringing before you the subject of the direct process in iron manufacture. I am aware that, in such a body as I have now the honor of addressing, there are few who are not already so well informed upon its past history that it would be a weariness to them to listen to anything else than an account of practical success. Yet, to claim that success involves so much that, if I do not make good my claim, I deservedly expose myself to severe criticism. The whole literature of the art, so far as it relates to the direct process, is, up to this time, but a history of failure. It is safe to say that more money, time, and talent have been fruitlessly spent in the pursuit of this object than in all the other unsuccessful efforts in the whole line of iron metallurgy. A distinguished authority in patent law has remarked that " the invention records of the United States and of foreign countries are filled with the waifs and abandoned relics of these abortive struggles." Dr. Percy, whose great work may be taken as an epitome of all that was worth mention, whether useful or curious, in pig-iron metallurgy, up to the date of its publication (1864), after giving elaborate accounts of various attempts at the direct process, condenses his own opinion of all that had been then effected, into a brief but summary comment upon a pamphlet of one of the sanguine inventors who had said: "It is evident that the present mode of working iron

Jan 1, 1874

By S. Floreen, H. W. Hayden

The effects of additions of iridium, rhodium, ruthenium, and platinum on the mechanical properties of Fe-C alloys were determined. Each alloying element significantly improved the toughness. The results support the general correlation that substitutional alloying elements that stabilize austenite are beneficial to toughness, but the reason for this improvement is not obvious at this time. The effects of substitutional alloying elements on the toughness of steel has long been a subject of both practical and theoretical interest. Despite the obvious importance of this subject, there has been little progress toward understanding the mechanisms by which alloying elements influence the fracture behavior. In some cases the deleterious effects of alloying elements have been shown to be due to mechanisms such as embrit-tlement of prior austenite grain boundaries or inhibition of cross slip in the ferrite lattice. In other cases, however, the reasons for the change in properties are not clear. This is particularly true for elements, such as nickel, that improve the resistance to brittle fracture. Several investigators'-3 have pointed out that there is a correlation between an alloying element's phase diagram with iron and its effect on toughness. Those substitutional alloying elements that stabilize austenite generally are beneficial to toughness, while ferrite-stabilizing elements generally are detrimental to toughness. The word "generally" should be emphasized, because exceptions to this rule can be found. Nevertheless, this correlation does offer a starting point at which to try to understand the effects of alloying elements on toughness. Thus far only two austenite-stabilizing elements, manganese and nickel, have been considered. In order to test the validity of this correlation several other austenite-stabilizing elements were evaluated. The noble metals, iridium, rhodium, ruthenium, and platinum, have binary phase diagrams with iron similar to the Fe-Ni and Fe-Mn diagrams. That is, each element expands the austenite field, and also higher concentrations of each element produce martensitic transformations at low temperatures. Presumably then, each of these elements should improve the toughness of steel. The present study was conducted to determine if this were so. EXPERIMENTAL PROCEDURE The alloys were made as l-lb air-induction melts using electrolytic iron and commercially pure noble metals. Each heat was initially deoxidized by a carbon boil, and further carbon was added to attempt to produce a 0.05 wt pct C content in each alloy. Before pouring, a final refining addition of 0.2 wt pct A1 and 0.1 wt pct Ti was made to each heat. The alloys were cast in a copper mold to produce ingots approximately 1 in. in diam and 5 in. long. The chemical compositions of the alloys tested are given in Table I. The residual nitrogen, aluminum, and titanium contents were all relatively constant at 0.003, 0.03, and 0.02 pct, respectively. The carbon

Jan 1, 1968