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By H. W. Graham

The young metallurgist of today who thinks casually of the technical literature of the steel industry might conclude that little has been published concerning the Bessemer process. This conclusion is true as relating to the last decade or two, but there is a fairly voluminous Bessemer literature in the period of 1860 to 1910. Since that time, however, an entirely new level of metallurgical knowledge of steelmaking has been reached; and the present paper is simply an effort to look broadly from this new level and to bring the recorded history of the process up to date. It is an effort to appraise the acid Bessemer method of steelmaking in the light of today's technical knowledge thereof. In this paper matters of history will be dealt with only insofar as they contribute to an understanding of today's situation. Attention will be directed to the apparent causes of past developments in seeking to perceive the true direction of trends now in existence and effective as bearing upon future developments. The paper will discuss the economics of the Bessemer process, but only to the extent that will bear upon the metallurgist's understanding of his responsibility. The problem of the quality of Bessemer steel will be reviewed and examples will be given of the technical data upon which the reasoning of the paper is based. Matters of engineering design, mechanical maintenance, operation and metallurgical investigation will be surveyed. Comparisons will be made between the Bessemer and open-hearth processes for the sake of clear and ready understanding. Production First of all it is considered logical and informative to show how much Bessemer steel has been and is being produced, and the relation of that production to the tonllage made by the open-hearth process. Table 1 shows the tonnages made by the two processes in representative years. It is to be noted that these figures are in net tons of 2000, lb., whereas previous to 1940 the Institute figures were compiled in gross tons. id open-hearth production and steel going into castings are included, since separated data are not available for the early years of the period covered. The ratio shown in Table I is merely the Bessemer tonnage for a given year divided by the open-hearth tonnage of the same

Jan 1, 1941

By H. D. Kessler, Joseph B. McAndrew

WHEN there is occasion to make structural use of metals at temperatures above 900°C (1652°F), the choice of alloys is severely limited, and those materials which meet special requirements as to density, strength, toughness, and resistance to creep, oxidation, or fatigue at such temperatures are at a premium. Any new type of high temperature alloy which is found to be outstanding with respect to several of these properties is therefore likely to find special applications for which it is uniquely advantageous as compared to other alloys. Such is the case with the 7 titanium-aluminum alloys. This y phase is an intermediate phase based on the composition TiAl, and extends from about 35.5 to 44.5 wt pct Al at temperatures up to 1000°C, above which the field broadens to include 60 pct A1 at 1340°C.' The alloys of principal interest have a narrow melting range, with 7 forming by the peri-tectic reaction, melt + ß=y at about 1460°C. Unlike most intermediate phases, the binary alloys containing titanium and aluminum in approximately equiatomic proportion possess low room temperature hardness,' in addition to which they have low density, good resistance to oxidation, and relatively high modulus of elasticity.' Unpublished work done at Armour Research Foundation showed

Jan 1, 1957

By Rudolph Emmel

The mines operated by the South American Development Co. are located in the Zaruma mining district of southwestern Ecuador. They are near the old mining town of Zaruma, which is the only important city in the canton of the same name. The district is situated in the upper end of a valley lying between two spurs of the Cordillera, one of which may be considered the Coast Range and the other an intermediate range. The mining camp proper, known as Portovelo, and the plant are 2.4 km. south of Zaruma, on the north bank of the Amarillo River, a tributary of the Tumbes River, which flows southwestward through Peru to the Pacific. Portovelo is difficult of access; it is reached from Guayaquil by means of river steamers and muleback. 'Embarking at Guayaquil, the route is down the Guayas River, across the Jambeli Canal, and up the Santa Rosa River to Santa Rosa, a distance of 177 km. From Santa Rosa, the road or trail follows the Santa Rosa River, then across the summit of the Coast Range into Portovelo, a distance of 74 km.—a two-day trip on muleback. The mining property of the South American Development Co. comprises 297 lode claims and 142 placer claims. The combined lode claims cover an area, roughly rectangular in shape, 9000 m. long from north to south by 4000 m. wide; the northern edge of the rectangle is about 3000 m. north of the central plaza of Zaruma. Mineral lands in Ecuador are held by virtue of an annual tax per claim paid to the central government, no surface rights being included. HiSTOry The Zaruma mine has been worked by white men since 1549, probably before that it was worked by Indians. The followers of Pizarro, led by traces of gold in the sands of the Tumbes River, followed that stream to its source, worked the gold veins that they found and established the city of Zaruma. Among the mines worked by them were th Sesmo, Leonora, Viscaya, and Mina Grande. Only the soft ores at the outcrop were

Jan 1, 1925

By D. K. Crampton

The object of this work was to obtain and correlate information on effect of internal stress in variously drawn tubes on several properties. Also, a simple approximate method of comparing types of stress distribution in such variously drawn tubes was sought. There is also included some work on comparison of single and polycrystalline materials and effect of different types of operation and preferred orientation. Preparation of Material A series of tubes was drawn to study the effect of the type and degree of final reduction on various physical properties and the approximate distribution of stress intensity across the tube wall. The material used all came from a single heat of 70-30 brass melted in a regular production Ajax-Wyatt induction furnace. The analysis of the metal as cast was: copper, 70.36 per cent; lead, 0.04; iron, 0.02; zinc, balance. The material was cast in "shells" with 4 in. outside diameter and in. wall thickness. It was drawn part way down according to the usual standard mill schedule and then by suitable individual schedules to finish by a variety of types and degrees of drawing to the same final cases in every instance; namely, 0.750 in. outside diameter by 0.080 in. wall thickness. The exact final draws, together with the percentage area reductions, diameter reductions and gage reductions are given in Table 1. In fabricating these tubes, rather unusual precautions were observed to insure the elimination of ail variables not under immediate study. All intermediate anneals were carried out at about 1200" F. down to the so-called "cut-in size"; namely, 17/16 by 3/16 in. From this point on, all anneals were made at from 1050' to 1100" F. The greatest care was used all through to have the tubes as free from minor surface defects as possible. When such defects were visible on intermediate sizes they were carefully filed out. On the final draw to 3/4-in diameter the die was aligned with the greatest possible precision in order to insure as straight a tube as possible

Jan 1, 1933

By Frederick Laist

While remodeling No. 1 section of the concentrator at the Washoe Reduction Works of the Anaconda Copper Mining Co. during the summer of 1912, for the purpose of ascertaining what additional metal recoveries could be made by improvements in concentration practice which had been developed by the staff of the Boston & Montana Reduction Department, at Great Falls, it was deemed advisable to carry on some experiments on the treatment of the regular mill tailings by roasting and leaching, to see whether the losses of metal values might not be still further decreased. In the course of these experiments about 5,000 tons of tailings were roasted, and of the resulting calcine about 200 tons were leached. The results were so satisfactory that it was decided to continue the work on a larger scale, particularly as regards the leaching end of the process, and construction work on an 80-ton roasting and leaching plant was accordingly commenced during the latter part of February, 1913, and is being pushed as rapidly as possible. 80-Ton Leaching Plant. This plant will consist of one 20-ft. roasting furnace of the Mac-Dougall type, specially adapted to the work of roasting for leaching; two leaching tanks, 32 ft. in diameter by 12 ft. deep, together with the necessary solution tanks, air lifts, precipitating launders, etc. It has been decided to precipitate the copper from solution on scrap iron, so as not to hamper the roasting and leaching departments by any weakness that might develop in the precipitating department. It is, however, the intention to experiment with a number of different methods of precipitation; for example, by electrolysis and by hydrogen sulphide. The acid required for the operation of this plant will be purchased, ad the quantity required is not sufficient to justify the installation of an acid plant. An acid plant will, however, be established in con-

Jan 1, 1914

By R. A. Hadfield

The present tribute to a great pioneer in the steel industry, with the accompanying remarks upon the town of Sheffield, which has remained to this day what his invention made it, an important center of that industry, originally formed a part of the paper on "Iron Alloys," prepared, at the invitation of the Council of the Institute, for the Chicago meeting of August, 1893. That paper, begun with the intention of dealing with many alloys of iron, became, of necessity, through the limitations of time on the part of the writer and of space in the Transactions of the Institute, mainly a discussion of the principal modern commercial alloy of iron, manganese-steel; and much introductory and general matter was consequently omitted. The Secretary suggested, however, that this particular portion would be interesting and appropriate as a separate contribution, and I therefore present it as such, offering the foregoing statement simply as an explanation of its incomplete character. If I had undertaken to write a paper upon this subject alone, I should have felt myself bound to bestow upon it more elaborate research and to treat it with more abundant details. It was in the immediate neighborhood of Sheffield that the first successful process for the fusion of steel on a commercial scale saw the light. The late Dr. Percy, a leading authority in general metallurgy, says: " Formerly, so far as I am aware, steel was never melted and cast after its production; and in only one instance, viz., that of wootz was it ever molten during its production.....Now, by the fusion and casting of steel after its production its heterogeneousness is remedied, and ingots of the metal may be procured of perfectly uniform composition throughout; and for the practical solution of this important problem we are indebted to Benjamin Huntsman, of Sheffield." As a recent American journal appropriately remarks: " Huntsman's patient efforts, at last rewarded with success, entitle him to an elevated niche among the heroes of industry. The invention of cast-steel was second

Jan 1, 1895

By F. J. Radd, R. L. McGlasson

The mechanisms of corrosion and corrosion fatigue damages to sucker rods are examined from a fundamental electrochemical viewpoint, and the relationships of sucker rod microstructures to these damaging effects are defined. The common corrosive agents in crude oil production and storage are discussed as to types of attacks that they cause. The variations of fatigue strength with alloy content, surface preparation, and stress ranges are analyzed. Finally, conclusions are drawn as to how microstructures largely influence and control sucker rod performance. INTRODUCTION Greater than 90 per cent of the crude oil produced by artificial lift methods is produced through sucker rod pumping systems. In the USA each year more than $14 million is spent for sucker rods in new and old pumping installations. It is important to make this investment a wise one. Essentially, the sucker rod system is a long series of steel rods, operating under alternating stress loadings and under mechanical vibrations, which connect the surface power source with the subsurface pump. These rods often operate in a variety of corrosive media, including water, brines, carbon dioxide, hydrogen sul-fide, and air. Basically, this paper is concerned with the problem of the behavior of certain steels in various corrosive media under high and dynamic stress patterns. The main objective of this paper is to show how, once the stress effects and the corrosive environments are defined, one can still realize structural control and beneficial influence upon corrosion and corrosion fatigue. FUNDAMENTAL DEFINITIONS AND ANALYSIS In the corrosion and stress behavior of this solid state mixture of iron and iron carbide called steel, one must analyze upon what major factors does its service life depend and of what, exactly, is steel composed. The former question can be referred to two external factors and two internal factors. The two major external factors are: 1. the nature of the stress patterns — size and range of stresses present 2. the nature of the corrosion — erosion environment — the corrodent and/or wear involved The two fundamental internal factors that govern the strength and useful life of a steel both in normal duty and in heavy-duty corrosion service are: 1. the nature of the steel volume properties 2. the nature of the steel surface properties For the latter question normal steel is defined as a solid mixture of iron and iron carbide particles, generally with certain accidental and intentional elements present. (The amount of iron carbide present is determined by the carbon content of the steel.) These additional elements generally dissolve into either the iron (ferrite) or the iron carbide (cementite) components.

Jan 1, 1955

By A. R. Kinkel

THE Shasta copper-zinc district of northern California lies in the foothills of the Klamath Mountains at the northern end of the Sacramento Valley. It contains two main areas of base-metal ore deposits, the East Shasta and West Shasta districts shown in Fig. 1. The East Shasta includes the area from the Afterthought mine, near the settlement of Ingot on U. S. highway 299 East, to the Bully Hill mine, on the north side of the Pit River, 9 miles to the northwest. The West Shasta, a well-defined northeast-trending district about 8 miles long and 2 miles wide, west of the Sacramento River, Fig. 2, is the western part of the ore-bearing area formerly known as the Shasta copper belt. Referred to in the older writings as a copper arc, this belt was thought to form a crescent extending entirely around the head of the Sacramento Valley, the convex side to the north. Recent studies by the U. S. Geological Survey in cooperation with the California State Division of Mines show that there are two districts, one at each end of the so-called copper arc, which are distinct in geologic structure and ore occurrences, and that there is only sporadic and unconnected copper mineralization between them. Ore deposits of the two districts are similar in mineralogy, that is, they are largely massive pyritic ores containing copper and zinc with minor amounts of gold and silver, but the structure and structural control of ore deposition are different. The ores of the East Shasta district are replacements of steeply dipping shear zones in Triassic rhyolite and shale, whereas those of the West Shasta district are replacements of gently dipping rhyolite of Middle Devonian age and are essentially flat-lying. Thus there is marked lateral control of orebodies by shear zones in the East Shasta district and equally marked vertical control of orebodies by the stratigraphy in the West Shasta district. Geologic Setting The Paleozoic rocks of the West Shasta district range in age from Middle Devonian (?) to Missis-sippian. The oldest formation exposed is the Copley greenstone, probably Middle Devonian. It is composed of volcanic flows, volcanic breccias, and tuffs, all of mafic composition, but contains minor amounts of shale and rhyolitic tuff. Largely submarine in origin, it rests upon a base of older marine sediments, as shown diagrammatically in Fig. 3. The lower part of the formation is made up principally of flows, many of which are ellipsoidal, and the upper part contains most of the pyroclastic material. The formation is at least 3700 ft thick. The Balaklala rhyolite overlying the Copley greenstone is made up of many rhyolitic flows and beds

Jan 1, 1956

By Benjamin Lustman, Robert F. Mehl

THE study of the high-temperature oxidation of pure metals, intensively pursued experimentally since the pioneer work of Pilling and Bedworth1 and supplemented by the recent theoretical work of Wagner2 is now well advanced. The important field of low-temperature oxidation-i.e., oxidation extending only through the temper color range of thicknesses with the formation of thin oxide layers in the range from o to 1000-2000 Angstroms-has not, however, reached so satisfactory a state, owing largely to the experimental difficulties that attend the formation and study of thin films; most of the work has been performed on abraded specimens whose surface irregularities approximated the thickness of the films formed. It has been pointed out that the rates of oxidation of different crystal faces are different and that the difference may be related to the orientation relationships that obtain between the metal crystal and the superimposed oxide crystal; it has also been suggested that this orientation dependence should manifest itself in rates of oxidation and perhaps also of corrosion in aggregates bearing preferred orientations. 3,4 An attempt to measure the rates of oxidation of different crystal faces of alpha iron demonstrated this difference in rate,4 but the dependence of rate on orientation was not simple; the method of measuring thickness, consisting of a color comparison with barium stearate multi-films of known thickness, was not wholly satisfactory. For these reasons it was felt that a study of the rate of oxidation of single crystals prepared with surfaces as smooth as possible, using a sensitive method giving true film thickness, should be profitable. Copper was chosen because of the ease of reduction of the primary oxide film and because the orientation relationships between metal and oxide and the composition of the oxide films formed at low temperatures are known; for thin films formed at low temperatures, Cu2O alone occurs.22-24 EXPERIMENTAL PROCEDURE Various methods of surface preparation were attempted in order to obtain a surface that would oxidize uniformly and reproducibly. Electrolytic polishing by the method of Jacquet5 and electrolytic and mechanical polishing followed by annealing in vacuum and in purified hydrogen at various temperatures were tested. The procedure finally adopted consisted in a fine metallographic polish followed by an anneal in purified hydrogen at temperatures of 900º to 1000°C. for 12 hr. or more. The surface so produced was very bright and smooth, with no trace of specular etching (though some grain-boundary etching was observed); indeed, fine scratches produced by the final polish were entirely removed by the high-temperature anneal.

Jan 1, 1941

By Michael A. Zappia

INTRODUCTION The San Manuel mine of Magmacopper Company is located approximately 72 km northeast of Tucson, Arizona. The mine, concentrator, smelter, electrolytic refinery and continuous rod casting are located on the west side of the San Pedro River valley. Ore Production: 58 1W mtpd Production To Date: Over 340 000 000 mt since 1956. Ore Grade: 0.70% net sulfide cu. As conceived at the present time, the San Manuel ore body is the lower half of what was originally an elliptical (In cross sect ion) cylinder same 2400 m long with major and minor cross sectional axes of 1500 m and 760 m. After emplacement, the cylinder was diagonally sliced along its long dimension by the San Manuel fault, which separated it into halves, moving the upper half same 2500 m down dip and bringing a wedge-shaped blanket of tertiary conglomerate into position over the lower segment of the cylinder. The lower segment is the San Manuel ore body. The upper part, moved down dip, is the Kalamazoo ore body. Originally, these were one ore body. The San Manuel ore body is a structurally weak and highly fractured quartz monzonite, the principal ore minerals being chalcopyrite, with small amounts of molybdenite. The present mining method is full gravity diagonal retreat panel caving by block. This is shown on Figure 2 , (Block Sequence 56, 57, 58, 59 --on the following page.) The ore mined is hoisted to the surface for transportation to the concentrator. BLOCK CAVING MINING SEQUENCE HISTORY The San Manuel mine was planned and developed as a full gravity block caving mine. It continues as a full gravity block caving mine. Since its initial start, the major changes in mining have been in the areas of ground support, rate of draw and undercut sequence. Ground weight resulting from block caving plays a dual role. It can cause extensive damage to ex- traction openings, yet it is necessary to break the ore into easily handled size. The ground- weight problem resolves itself into finding ways to make it manageable. The initial early ground support in the production areas consisted of timber sets and various combinations of steel and timber sets. This sup- port system proved unsatisfactory and a new support system utilizing concrete was developed. Concrete support, 30 cm to 45 cm thick, proved satisfactory. Rates of draw were experimented with. A draw rate of 45 cm to 61 cm (32 to 45 mt) per draw point per day was determined as optimum in con- trolling ground weight. Undercut sequence or mining sequence was recognized as a major contributing factor to ground weight. This is the most difficult factor to change. The lead time from primary development to undercut can be as much as two years. Initial Checkerboard Pattern The initial undercut sequence was in a checker- board pattern (Figure 2). Blocks Sequence 1, 2, 3, 4, 5, 6--next page.

Jan 1, 1981

By G. Derge, R. E. Grace

A S detailed studies of mass transport in hetero- geneous systems are made, a knowledge of the chemical diffusion coefficients in various liquid and solid phases is necessary to understand the kinetics of any total reaction. For example, in zone refining some information must be available about the diffusion coefficients of various species in the liquid and solid regions near the moving interface. In liquid-liquid reactions, of which slag-metal reactions are of particular interest to metallurgists, the diffusion coefficient of a transferring species must be known accurately in both phases in order to predict a transfer coefficient for the over-all process. Diffusion data for various elements in liquid iron and iron-carbon alloys have been roughly deter-

Jan 1, 1959

By T. J. Nowak

The heat flow processes determining the injection and shut-in temperature logs in a water injection well have been analyzed and the theoretical basis for determining the water injectivity profiles from the temperature logs has been presented. Both the injection and the subsequent shut-in logs are necessary to resolve the injection interval into relative water intake strata; the former, to provide an accurate estimation of the thicknesses of the strata, and the latter to indicate the major and minor intake rates into the strata. A procedure is described for estimating the injectivity profile from the temperature logs and is applied to several temperature logs. For a water injection well, a comparison is made of the injectivity profiles obtained from the core analysis, the spinner survey, and the temperature logs. INTRODUCTION In secondary recovery of oil by water flooding, the injectivity profile is needed to obtain diagnostic evaluation of water intake distribution over the injection interval. If the distribution is unfavorable among the various strata, corrective measures can be taken to provide better control. Numerous methods have been developed for determining the injectivity profile from water velocity measurements in well bores. Often, dependence is placed upon core analyses and/or electric logs for estimating the relative water intakes over the injection interval. In many cases, the temperature log method described herein will give results more diagnostic than those obtained through use of the other available methods inasmuch as it is based upon the study of temperature disturbances in and around the well bore as a function of water flow in the well bore and in the formation. This method is the result of analyses of a number of temperature surveys made in water injection wells to determine the point of entry of the water into the formation. The material in this paper is presented in two sections: the first deals with the theoretical study of temperature survey data, and the second deals with the field application. PART I — THEORETICAL TREATMENT OF TEMPERATURE LOG DATA Before discussing the various aspects of heat flow relative to temperature log data, the phenomena that give rise to well bore temperatures — namely, the indigenous formation temperature and the associated rates of heat flow — will be considered. Geothermal Gradient The geothermal gradient is defined as the increment of depth at which the indigenous subsurface temperature increases by l°. It is caused by the continuous flow of heat outward from the interior of the earth. The flow of heat is an equilibrium process between the heat sources, the thermal conductivities of the formations, and the mean surface temperature. Therefore, there is no accumulation of heat energy in the path of heat transmission, and the geothermal gradient for a given formation will depend upon its thermal conductivity.

Jan 1, 1953

By Parke A. Hodges

CHROMIUM, one of the most vital of the strategic metals, has constantly increasing importance as research expands potential uses in alloy steel metallurgy. All signs point to a steadily growing use for chrome ore, and the general subject has received a great deal of attention recently.1 A relatively little known country, Southern Rhodesia produced a total of 5.949 million tons, or 18.6 pct of the total world chrome output, between 1906 and 1950, according to figures from the U. S. Dept. of Commerce. According to U. S. Bureau of Mines figures, Southern Rhodesia produced 291,525 tons in 1950 and 300,267 tons in 1951, or approximately 13 and 11 pct, respectively, of world production for the two years. In 1953 the Rhodesian Vanadium Corp. produced about 85,000 tons of which probably 7,000 tons were concentrate. Production by other companies was high. Large in themselves, the figures assume even greater significance because most of this output is of metallurgical grade.

Jan 8, 1954

By Edwin A. Rides

HISTORICAL ORIGIN OF THE EXPORT CREDIT AGENCIES Almost since the inception of international commerce sellers, having manufactured and/or sold and shipped goods to an overseas buyer, have been obliged to accept the risk that they will not be paid for one reason or another. There are many reasons why payment may not be forthcoming, for example, the goods may be lost at sea, or rejected by the buyer or the buyer nay simply not be creditworthy. These risks were brought into sharp relief as international trading became more sophisticated and the practice of giving credit to buyers gathered momentum. Inevitably enterprises sprang up which offered same mitigation of this exposure, accepting houses and later confirming houses and banks were prepared to assure acceptable credit risks an behalf of the seller, usually by discounting trade paper, and for many years the market ticked over reasonably satisfactorily. However, after the 1914-18 War international trade was at an extremely low ebb and its inherent risks were accentuated to a point where they were often commercially unacceptable. Yet a healthy and vigorous international market was indispensable to recovery of the world economy and a number of governments, led by the United Kingdom, perceived a need to offer their exporters a comprehensive form of insurance, particularly to facilitate the extension of credit to foreign buyers. In the United Kingdom the Export Credits Guarantee Department (ECGD) was set up to encourage trade through the provision of export credit insurance. Over the ensuing years others followed suit and now most of the developed trading nations and many developing nations have similar agencies. PRESENT DAY IDLE OF THE EXPORT CREDIT AGENCIES (ECAS ) Traditionally then the BA's role was to encourage trade through the provision to exporters of insurance against the risks of non-payment by overseas buyers of their goods and services. However, during the 1970's the manufacturing industries of most of the developed nations found themselves facing severe competition for business, particularly in the developing world. As a result the more aggressive ECA's began to introduce ancillary forms of cover designed to reduce exporters' risks outside of the credit field. For instance, most of the European agencies now have a form of cover against foreign exchange risks here contracts are denominated in currencies other than that of the exporter's country. Most of the agencies also provide cover to exporters against the risk of unfair calling of bid, advance payment, performance bonds etc and in certain countries, where high inflation rates were endemic, a form of cover against cost escalation. In certain circumstances it is also possible for an exporter to obtain cover against losses arising as a result of the involvency of a partner in a consortium or joint venture. These are all forms of insurance but, also during the 1970's, many of the national export credit programmes took a major step away from their original raison d'etre by facilitating the provision of preferential financing terns for the acquisition of capital equipment by an overseas buyer. This new line of business quickly became an important ingredient of major export financing packages and, as we shall see later, turned out to be extremely costly for the countries providing it.

Jan 1, 1985

By George G. Griswold

The Parkes process of lead refining is based on the fact that when zinc isemixed with molten lead bullion, it forms an alloy with the silver and gold. This alloy freezes at a higher temperature and is of a lower specific gravity than the lead. With proper regulation of the temperature, the alloy solidifies and floats on top of the lead bath, from which it is removed and the silver, gold, and zinc recovered. The alloy should contain the maximum amount of silver (Ag2Zn,). The usual practice is to make two additions of the zinc. The first addition gives an alloy, or zinc crust, the zinc of which is saturated and is treated for the recovery of its zinc and silver; the crust from the second addition contains an excess of zinc and is used for the first addition on the following kettle. The crust produced depends on a number of items: purity of bullion, temperature, care with which kettle work is performed, addition of zinc, pressure used in expelling lead from crust, etc. It is desirable to make the concentration of silver in the zinc crust as high as possible; otherwise an undue amount of byproducts is produced, which greatly increases the cost of refining. It was formerly considered good practice to make a concentration of 20 :1. That is to say, if the lead bullion assayed 150 oz. dorê per ton, the assay of the retort bullion recovered from the zinc crust should be 3000 oz. per ton. As a matter of fact, the concentration should never, except on bullion assaying over 300 oz., be so low, and with low-grade bullion it should be 50:1. In one lead refinery where, ordinarily, the work was good, on a bullion averaging about 200 oz. per ton, a concentration of 24:1 was common; but how it was obtained was known only to the foremen. Changes occurred, and under new foremen the kettle work fell off badly; the problem then was to bring about this greater concentration. As is customary, the refincry had a "schedule" for its 60-ton kettles, which gave the number of pounds of zinc required for all possible assays, on both the first and the second zincing. Using this schedule, high temperatures

Jan 1, 1924

By W. Julian Parton

Treatment of the breaker wash-water discharges to remove the suspended particles of finely divided material is usually most efficiently and economically accomplished in settling or thickening tanks. The purpose of these tanks is to separate the excess water from the solids by sedimentation whereby the solid particles suspended in the water are thickened by the force of gravity. The water overflowing these tanks is either reused for coal cleaning or discharged directly to the streams. The settled solids, which are in a relatively concentrated condition, forming a sludge or thick pulp, can be disposed of by pumping to a storage dam, by slushing into mine workings, by processing for recovery of coal, or filtering by vacuum or centrifugal means and discharging with the breaker refuse. The scope of this paper will be limited to the discussion of settling and thickening equipment, the factors that influence the settlement of solids, and a brief description of tests that can be made to determine the size of settling facilities required for any particular condition. The practical application of sedimentation to the treatment of coal falls into two groups, one of classification or hydro-separation, and the other of clarification and thickening. Classification may be employed to prepare a relatively low-grade fuel, which can be used as is or can be further processed separately. Clarification and thickening is employed where the primary objective is to recover a relatively dewatered solid and return a satisfactorily clear water to breaker or streams. Operation and Types oF Settling Equipment When a stream of water flows across a tank, the time required for a particle to travel from the feed inlet to the overflow must be a little greater than that required for the finest particles or flocs in the feed to settle out of the stream. Theoretically, the liquid in a settling tank should rise at a more or less constant rate throughout the area of the tank Under these conditions the rising velocity of the water must be less than the settling rate of the finest particles if clarification is to be obtained. When classification of particles is to be made in the tank, the overflow velocity must be greater than the settling velocity of the particles that are to be removed with the tank overflow. The performance of a settling tank, then, depends on the settling rate of the solids and the current velocities in the tank. The oldest types of sedimentation employ intermittent types of settling tanks of any convenient shape. Means are provided for filling the tank with pulp and allowing it to settle until quiet, for moving the clean liquor and for removing the thickened sludge. The operation is necessarily intermittent but a sufficient number of tanks is employed so that a continuous flow of clear water is maintained. Continuous methods for the sedimentation of slurries were developed in the metallurgical industry. Cones from which settled solids were discharged by gravity

Jan 1, 1947

By H. L. Riley, B. W. Gandrud

A froth flotation unit was added to the DeBardeleben Coal Corporation's Empire washer at Empire, Alabama, in the fall Of I94O following an investigation of possible ways and means of recovering coal values from settling-tank overflow or slurry. Officials of the DeBardeleben corporation hoped that some practical and reasonably economical way could be found for recovering fine coal from overflow water, although there had as yet been very little progress along this line in the Alabama coal fields. The Bureau of Mines was asked to cooperate in the project through its Southern Experiment Station, at University, Alabama. This paper presents a brief description of the process and the installation that resulted from the investigation of the overflow water or slurry problem at the Empire mine. The experimental data include' as a Part of this Paper were obtained during the course of the investigation in 1940 Since that time, however, the flotation unit has been running more or less continuously without significant operational changes and is still Performing pretty much in accordance with the data obtained in 1940. Flowsheet at Empire and Type of Coal Treated The Empire mine is developed on the Black Creek bed near the the border of the Warrior field. The coal in this bed is extremely low-ash and although there is an almost complete absence of bone coal and partings, the bed is so thin that, with mechanized mining, a high percentage of rock from roof and floor inevitably gets into the run-of-mine coal. The thickness of the Black Creek bed throughout the part of the Warrior field in which it is mined extensively is rarely over 30 in. and probably would average about 25 in, the coal is of the high-volatile A rank and of excellent quality, but as a result of admixture of roof and floor material, the run-of-mine product usually contains I ; to 20 pct rock by weight. he following is a proximate analysis on an "as-received " basis of a typical seam sample from the Empire mine:' moisture, 3.0 pet; volatile, 34.6 fixed carbon 58.3; ash, 4.1 This sample shelved 15,070 Btu per pound and 0.9 pct sulphur on a moisture-and-ash-free basis. In the Empire preparation plant the lump sizes above 3 in. are removed and hand-picked on a Marcus conveying Screen, the 3 to ? -in. size is removed by vibrating screens and washed in two Montgomery single-cell jigs, and the ?-in. to o slack is cleaned on four diagonal

Jan 1, 1949

By J. W. Halley, T. S. Washburn

RIMMING steels derive their name from their action during solidification in the molds. As a result of incomplete deoxidation, gas is evolved during freezing, and the metal has a characteristic rolling action. The metal rises along the mold walls and descends in the center of the ingot. This action keeps the top of the ingot open and the advancing rim of solid metal can be seen. The rim grows until the rolling action is insufficient to prevent the top of the ingot from freezing or until the action is stopped by capping the ingot with a heavy plate. The violence of the reaction and its characteristics, such as growth or drop in the molds, are determined by the composition, the furnace practice, and the deoxidation in the ladle and in the molds. Though rimming steels represent a large proportion of the amount of plain carbon steel made, they have received comparatively little attention in the technical literature. The manufacture of rimming steels has been described by Hibbard, 1, 2 Fleming,3 Pierce4 and Jackson.5 The reactions occurring during rimming have been considered from the theoretical point of view by Chipman and Samarin.7 The structure of rimmed-steel ingots has been discussed by Nead and one of the present authors.6 Meyer,8 in studying segregation, investigated the distribution of carbon, sulphur and phosphorus in rimmed-steel ingots by analyzing the rim and core of blooms. In their studies of segregation, the Joint Committee of the Iron and Steel Institute and the British Iron and Steel Federations studied distribution in one billet and one ingot of rimmed steel.. A detailed study of the distribution throughout the ingot has not been published. The present investigation was undertaken to determine accurately the distribution of carbon, manganese and sulphur in normal rimmed ingots and the general distribution of other common elements present. The study included some work on the effect of pouring conditions and furnace practice on the distribution, though there is still much to be done in this direction. The structure of a rimmed ingot that has been split by dynamiting and a schematic diagram of the zones in the ingot are illustrated in Fig. 1.

Jan 1, 1938

By E. A. Reilly, G. R. Gardner, F. P. Lasseter

THE methods that may be applied to the treatment of slurries and water, as these are related to practical coal-preparation problems, are concerned essentially with the movements of solids suspended in water. It is assumed that there are no fundamental differences between the principles involved in the treatment of coal slurries and the phenomena encountered in general mineral-dressing practice, and the latter are presented in some detail. Basic principles are correlated with present practice for both the anthracite and the bituminous coal. fields, and meth¬ods are discussed which are designed to utilize best all the material subjected to treatment and suggest a sound approach to the solution of problems relating to the return of clear water to process or to streams. In order to approach the practical phases of the subject with sufficient understanding of the basic principles, it is necessary to discuss two types of phenomena that are applicable. The first is flocculation and the second is sedimentation. Descriptive matter is given covering the various meth¬ods and types of equipment employed to conduct these operations, with emphasis on their application to water and coal-slurry treatment.

Jan 1, 1943

By Samuel M. Cassidy, George M. Rigg

During 1937 a program was begun to mechanize and modernize the then 28-year old Isabella mine of the Weirton Coal Co., which is on the Monongahela River, in Fayette County, Pennsylvania, at one edge of what is generally known as the Coke Region. Weirton Coal Co. is a subsidiary of the National Steel Corporation, and produces metallurgical grade coking coal for the Weirton Steel Co., Weirton, W. Va. Improvements subsequently made included a cleaning plant for washing the entire mine output, shovel-action track-mounted machines for mechanically loading all the coal, universal-type track-mounted cutting and shearing machines, post drills, 8-wheel mine cars of 10 tons capacity, cable-reel gathering locomotives and other auxiliary equipment. This paper presents the factors, reasons and results of decided changes from the mining system generally prevailing in the region, as well as abandonment of selective mining practices in favor of complete seam extraction. Coal-seam Conditions Fig. 1 illustrates the Pittsburgh coal seam on the property. Cover over the seam averages 450 ft., and 675 ft. is the maxi- mum. Main roof varies from very weak to medium strong; usually it disintegrates rapidly on exposure to air. The "wild" coal makes a fairly strong immediate roof if supported by crossbars and if unbroken affords a seal to the main roof. The draw slate is very weak and treacherous. The floor is characterized by numerous irregular bottom rolls, or "horsebacks," protruding from a few inches up to 3 ft. into the coal. Some are soft, but many are hard and flintlike. Although the bottom slate usually is hard, the underlying fire clay causes it to buckle and heave readily with any moderate increase in roof pressure or where damp. As a whole, the bottom is weaker than the main roof. The coal is characterized by numerous closely jointed face and butt cleats and a woody, springy nature when shot, both having a decided influence on face practices. As shown in Fig. I, at both the top and bottom of the main coal seam is a layer of coal of higher ash and sulphur content than the body of coal in the middle. Factors That Influence the Mining System Equipment was bought and organization for mechanical loading was made on the basis of working each mechanical unit as near its full capacity as possible, to lessen investment cost and obtain best operating efficiency. This led to combination double and triple-shift operation at the start, and, very shortly, to all sections being triple shifted.

Jan 1, 1947