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By Karl Fetters, John Chipman

The relationship between the composition of the slag and that of the underlying metal during the refining of a heat of liquid steel may best be studied in the light of the two broad physicochemical concepts of equilibrium and reaction rate. Actual steel-making processes, typified by basic open-hearth practice, involve such complexities of operating variables that it is impossible to distinguish with any degree of certainty between the general limiting conditions imposed by chemical equilibrium and the effects associated with rates of diffusion or of chemical reaction. Further advances in the physical chemistry of steelmaking will depend upon our ability to distinguish clearly between these two kinds of effects, and the experimental work that must be done falls naturally into two classifications. The first is the study of chemical equilibrium that cannot be carried out with assurance under operating conditions but must be done in the laboratory. The second is the -subject of rates of reaction and diffusion and the mechanism of the process as a whole, which can best be studied under operating conditions. The latter is not entirely independent of the former, since its interpretation often requires a knowledge of the equilibrium state. It is the purpose of this and of several papers that will follow to present the results of labora- tory investigations of equilibria involving liquid steel and slag. Open-hearth slag is a complex mixture containing at least eight major components and perhaps twice as many whose influence may be classified as probably minor. It is not surprising that progress toward a complete understanding of such a material at high temperatures has been slow. Attempts to apply the established principles of physical chemistry to the behavior of the individual components of this mixture have been beset by an almost complete lack of data on its chemical properties in the liquid state. This has necessitated the adoption of various methods of approximation based upon such assumptions as, for example, that for a given component the ratio of its mol fraction in the slag to that in the metal is a constant, or that the molecular composition of the liquid slag is the same as its crystalline constitution after solidification. From the thermo-dynamic viewpoint, such assumptions are merely useful dodges, which enable one to hazard a guess as to the magnitude of the more fundamental quantities, the chemical potentials and activities of the components of slag. The problem of determining the activity of each substance in an eight-component svstem seems too complex to be undertaken without the aid of generalizations derived from experimental data on similar systems containing a smaller number of components. Accordingly, it was planned in the present investigation to study the equilibrium of molten iron with the simplest

Jan 1, 1941

By Robert B. Sosman

The relative temperature distribution within a coke oven and among the ovens in a battery can be obtained automatically for the operator's guidance by sighting a total-radiation pyrometer on the face of the coke as it is pushed out, and recording the surface temperature. Keeping the instrument clean and keeping its view of the coke unobstructed by smoke and dust are the principal problems. Typical records from three plants are presented in this paper, showing that the temperature patterns are reproducible. Development OF Method The method of coke pyrometry described in this paper was introduced in 1936 by E. A. Lee, then Assistant Superintendent, now Superintendent, of the Coke Plant at Lorain Works, National Tube Co., Lorain, Ohio. At the request of the Coke Committee of the United States Steel Corporation, the Research Laboratory of the Corporation undertook to adapt the method to the somewhat different conditions met with at the Gary Works of the Carnegie-Illinois Steel Corporation, Gary, Ind., and at the Clairton Works of the same Corporation at Clairton, Pa. This work was done in cooperation with the Leeds and Northrup Co. of Philadelphia and later with the Brown Instrument Co. Division of Minneapolis-Honeywell Regulator Co., Philadelphia. We of the Research Laboratory wish to express our appreci- ation of the courtesies extended by Mr. Lee, by A. N. Cole, Superintendent of the Gary coke plant, and by D. P. Finney, Assistant General Superintendent in charge of coke-plant operations at Clairton. We are also indebted to the instrument companies for the loan of a part of the equipment. At Gary and Clairton the instruments were installed and various experiments were made by J. W. Bain, of the Research Laboratory of the United States Steel Corporation. Pyrometry of Coke The coke inside a by-product oven is almost completely inaccessible to pyro-metric instruments. The temperature in the walls can conceivably be measured with thermocouples, but the atmosphere is usually strongly reducing, a condition well known to be destructive to the accuracy of the customary high-temperature couples. In some plants, periodic readings are taken with an optical pyrometer sighted into the top of the combustion flues. This is a useful measure for safety and general control, as it tends to prevent the damage that would result from overheating of the ovens. It does not, however, tell much about the temperature of the coke itself, because of the continually changing gradient in the wall between the coke and the combustion chamber. The best indication of the temperature of the coke itself must therefore be obtained by observation of the product as it is pushed out of the oven. The human eye is very sensitive to variations in brightness of a surface, and particularly to differences in brightness over a continuous hot surface.

Jan 1, 1943

By W. F. Holbrook, C. E. Wood, E. P. Barrett

THE high-frequency laboratory induction furnace with a rotating liquid crucible enables research workers to conduct certain investigations heretofore very difficult or impossible to realize because vessels are not obtainable that are capable of resisting the physical conditions or the chemical actions to which they are subjected. Applications for patents covering commercial uses of centrifugal liquid crucibles were filed in the United States in 1919,1 in France in 1925, in the United States and Germany in 1926,2 and in France in 1927.3 In 1928, Schuette and Maier,4 of the Bureau of Mines, reported the construction of a whirling table beneath a high-frequency induction furnace. SHAPE AND SIZE OF CENTRIFUGAL LIQUID CRUCIBLES When a vessel containing a liquid is rotated, the inner surface of the liquid takes the shape of a paraboloid under the simultaneous action of centrifugal force and gravity. The internal dimensions of the paraboloid rotating liquid crucible are governed by the diameter of the container and .its speed of rotation. Melted Wood's metal was poured into cylinders 2 1/2 in. in diameter, which were rotated at 180, 300, and 468 r.p.m. When the metal was solid, a slurry of plaster of Paris was added, and rotation continued until the plaster had set. Fig. 1, a photograph of sections of the cylinders, shows the effect of speed of rotation of the containers upon the shape of the inner surface of the rotating liquid crucibles. TYPES OF FURNACES Three types of high-frequency induction laboratory furnaces using liquid-metal crucibles were designed and constructed by the Blast

Jan 1, 1938

By Henry J. Miller, Marcella Linderman

During some experiments made by Henry J. Miller, partly in Germany and partly in the United States, in which it was found necessary to melt metals in quantities up to 60 kg. in a vacuum or under low pressures of hydrogen, molybdenum was tried as the resistor in the electric melting furnaces. Molybdenum ribbons 16 by 0.55 mm. and 18 by 0.45 mm. were used as resistors. The furnaces were of the type shown in Fig. 1. About the heating tube, Y, are wound parallel resistors of molybdenum ribbon from the water-cooled electrodes, El, Ez. The whole is within a copper container having outlets for the removal or introduction of gases and a window, W, for observation, the space about the heating tube and electrodes being filled with insulating material. The life of the molybdenum used as the resistor was found to depend very much on the manner of using it, its failure being due in some cases to thinning by evaporation or chemical reaction and in others to hardening, which prevented it from following the expansions and shrinking of the heating tubing without cracking. As such failures are often rather expensive in commercial work, it was thought worth while to determine the causes. The factors influencing the behavior of molybdenum resistors used in this manner may be briefly stated as follows:

By S. Leber, R. F. Hehemann

Diffusion coefficients for the Cb-W system were measured using couples prepared from poly crystalline, commercially pure metals. The diffusion coefficients, measured in the temperature range between 1700° and 2300°C, decreased exponentially as the tungsten concentration was increased from 0 to 50 at. pct, then decreased abruptly at higher concentrations. A decrease of two orders of magnitude was observed over the entin? compositional range. The diffusion coefficients were in the range defined by the self-difiusion coefficients of the individual elements, indicating their general validity. An activation energy of 60,500 cal per mole was measured for the 20 pct W composition. Such low values, when compared with energies over 100,000 cal per mole for the pure constituent elements, indicated that transport mechanisnzs more rapid than volume diffusion were contributing substantially to inter dijfusion. Difference should, therefore, be expected between these data and the intrinsic diffusion coefficients. These differences should be significant in the kinetics of 'transport phenomena in practical systems. CONSIDERABLE attention has been devoted in recent years to the mechanical behavior and other properties of the refractory metals and their alloys. The Cb-W system has been of special interest as a base for the development of more complex compositions of commercial interest. In spite of the importance of mass transport to all aspects of elevated-temperature behavior, and especially to the production of alloys by powder-metallurgy techniques, little attention has been paid to diffusion in the Cb-W system. Results from a previous study of this system1 appeared to be anomalously high. The present investigation is, therefore, an attempt to obtain more accurate diffusion coefficients in this system. Intrinsic diffusion coefficients, of primary importance from the theoretical viewpoint, can only be obtained accurately from studies utilizing compositional gradients approaching zero. However, many practical problems involve diffusion under significant concentration gradients. The diffusion coefficients determined in this investigation were, therefore, obtained from couples prepared from elemental metals. The data obtained should be of value in the analysis of problems such as homogenization during powder-metallurgy alloying or reactions between base and clad in coated structures. In this vein, the investigation was conducted on poly crystalline materials of commercial purity. PROCEDURE Diffusion couples were prepared by sandwiching a columbium sheet between two sheets of tungsten. The composite was welded around all edges, the tungsten forming a protective can for the columbium. The composite was soaked for 4 min at 1600°C in a hydrogen-atmosphere furnace, quickly forged to 40 pct reduction in thickness, and then rapidly cooled to room tempera-

Jan 1, 1967

By Frank H. Riddle, Wilfrid R. Foster

GENERAL treatment of the various minerals of importance in refractories appears in the chapter entitled "Refractories" elsewhere in this volume. The present chapter is restricted to a discussion of minerals of the sillimanite group and brings up to date the excellent information contributed by Prof. Paul F. Kerr to the first edition (1937). Since the appearance of that edition, the status of the group has changed some- what. Kyanite remains the preferred source material for mullite refractories but total consumption of kyanite has increased considerably.85 The exigencies of World War II forced an increased dependence on domestic sources and led to an intensification of the search for higher-grade deposits of kyanite and allied minerals. The first discovery of massive kyanite similar to that of India has been reported from Georgia.37 British East Africa has joined India as a substantial supplier of our imported kyanite, but that from India continues to hold preference.85 During World War II, prices of both domestic and foreign grades reached peaks unparalleled since the earliest years of the use of kyanite and as yet have shown no tendency to return to prewar levels. Topaz, by virtue of the deposit outlined in South Carolina, merits inclusion in the group.20,36,95 Large andalusite deposits, which threaten to rival our one large domestic occurrence, have been found in Russia.69,88 Sillimanite has not yet attained an important position among these useful minerals because of the lack of accessible deposits of high-quality material in adequate supply.37,50,58 Tests by the Bureau of Mines have indicated the possibilities of economically beneficiating low-grade sillimanite and kyanite.105.106,140 Government, university, and industrial

Jan 1, 1949

By Charles E. Nelson

THIS paper will outline briefly the practices commonly followed in this country for the melting and refining of magnesium and its alloys. The processes used for the various forms of primary magnesium, as jar as there are differences in the physical shape or behavior, will be discussed. The refining of general fine scrap or secondary magnesium was presented in an earlier paper and will be discussed briefly.1 Inasmuch as the use of fluxes is an essential part of all the melting and refining processes, this paper will deal with these in sufficient detail to point out their unique characteristics, in order to make their use more effective. The outline of this discussion will closely follow that of an earlier paper,2 with such changes and additions as seem necessary to bring it up to date. TYPES OF MELTING PRACTICE All melting and refining processes for magnesium and its alloys require the use of fluxes. These fluxes have a magnesium chloride base and other halide salts or oxides are added to give a density or behavior exactly suited to the particular melting practice. The successful handling of magnesium depends upon the proper use of the correct fluxes. There are four general methods of melting, summarized in the following paragraphs and treated in more detail in the section on Melting and Refining. Open-pot Method The open-pot method makes use of No. 230 flux, which provides protection during melting and a molten pool of flux into which the solid magnesium melts. The flux is stirred through the molten metal bath and agglomerates oxide or similar foreign bodies;, on quiet standing, it separates away, leaving the refined metal ball floating in an encircling layer of molten flux. It forms only a thin fluid film over the surface of the molten metal, which may be parted for hand-ladling processes and tends to cover the metal again after the ladle is removed. A very light dusting of the pot surface with fresh flux immediately after the ladle is removed is desirable. The open-pot method is used generally in the following processes: (I) alloying and remelting in the production of ingot, (2) in sand foundries for premelting and to a smaller extent for the production of small castings, (3) in permanent-mold founding for premelting and also direct ladling to castings, (4) for continuous methods of preparing metal in the production of billets or ingots from which wrought products are fabricated, (5) in general scrap recovery. Crucible Process The crucible process makes use of No. 310 flux, which has the property of being thinly fluid at the start, to provide protection and refining qualities, and then drys out or thickens after a time, leaving a protecting crust on the pot surface until the time of casting. At that time it can be readily skimmed off or held back, thus allowing the contents of the crucible to

Jan 1, 1946

By M. H. Merriss

In the last few years, there have been developed at the plant of the Nichols Copper Co., Laurel Hill, 'Borough of Queens, New York City, improvements in electrolytic copper refining by the series system that have materially increased the flexibility and economy of that system. The purpose of this paper is to discuss, as of interest to refiners and to those who have copper to refine, as well as to the engineering profession in general, the changes' that have taken place resulting in wider application and increased efficiency of the series system. Copper is electrolytically refined in two ways, which are spoken of as the "multiple system" and the "series system." In both systems, the electrolytic tanks are in series electrically. In the multiple system the electrodes in a single tank are in multiple or in parallel, thus: There are two important adaptations of the series process, one represented by the series electrolytic tank room at the Baltimore Copper, Smelting & Rolling Co., Baltimore, Md., and the other by that of the Nichols Copper Co.'s plant. At Baltimore, the anode is rolled to perfect

Jan 1, 1926

By Reinhardt Thiessen

UNDER sulfur in coal, is usually understood that form of sulfur which is combined with iron and known as pyrite. It occurs in the form of halls, lenses, nodules, continuous layers, thin sheets, or flakes, both in horizontal planes and vertical cleavage fissures. But pyrites also occur as very fine microscopic particles, or nodules, disseminated through the compact coal. This form has had but very little consideration. Finally, there is sulfur in coal in an amicroscopic form (not visible with an ordinary microscope), probably combined with the organic matter that exists -in tile coal. This form has had considerable attention from a scientific standpoint, but has probably not been recognized enough on the economic side. One or the other, or both, of these two latter forms may comprise the larger part of the sulfur content of coal, especially after it has been washed or otherwise prepared for use.

Jan 9, 1919

By Henry S. Washington

During the last twenty years or so the chemical investigation of rocks has made great advances, and it is now generally recognized that a knowledge of the chemical composition is as essential as that of the texture or mineral composition—if not more so—for the proper classification of rocks and study of their origin and relationships. Rock-analyses have vastly increased in number and, what is of greater importance, in quality. New and improved methods permit of greater accuracy than was possible in the early days, and the list of chemical constituents frequently determined has risen from the seven or eight of the greater part of the nineteenth century, to twenty or more. Indeed, rock-analyses with determinations of so many constituents are now commonly made by the chemists of the United States and Australia, while in Germany, Great Britain, France, and Italy the rarer constituents are determined more frequently than formerly. As a consequence of this modern, accurate work, it has been discovered that some elements which were formerly supposed to be rare are of wide-spread occurrence and are often present in considerable amount. The fact is further being developed that the elements tend to show certain relations of occurrence or abundance in connection with each other. This is a fact which is applicable to the rarer elements, and which also finds a broad geological and petrological expression in the recognition of petrographic provinces. We are beginning to obtain some definite, though as yet rudimentary, knowledge of the distribution of the elements among igneous rocks. Some of the results along these lines obtained by study of the vast accumulation of analytical data now available are well known to petrologists, while others do not seem to be so gener-

Jan 1, 1909

By R. S. Wagner, C. E. Miller, H. Brown

A dc field was applied to liquid BI-Sx or Au-Ge alloys of eutectic composition. The liquid alloys were kept at a temperature slightly above the eutectic. The concentration changes due to electrodijfusion are large enough to cause nuclcation and growth of the primary phases at the respective electrodes. Nearly complete separation of Bi-Sn eutectic was obtained as well as substantial separation of Au-Ge eutectic. The effect of an electric field on the solute distrihn-tion was itluestignted itt tlirectiortally solidified rods of a dilute Bi-Sn (0.5 al. pc,t Bi) alloy. Field-freezing was carried out in small-diameter cupillay tubes to avoid cotuectice mixing -of the liquid. The relative sollcte corzcentratioi, Cs/Co , was rneusred by n radioac1il.e tracer netlod. Cs/Co can be made both largev than unity or srialler than the equilibiuwz distvibrrlion c.oejyicienl, k, , oiler a substattiul portion of the soliclifi&apos;erl rocls. A direct current, passed through a liquid-metal solution, can cause substantial concentration changes by electrodiffusion. The magnitude of the change depends on the difference in ionic mobilities of the atomic species in solution. Electrodiffusion has been studied in many binary and ternary liquid alloys.&apos;y2 It was found that the rate of material transport decreases with time for a constant applied field, as a concentration gradient is established in the solution. A steady-state concentration profile is achieved when electro-diffusion is compensated by chemical diffusion. This may seem to limit the use of electrodif fusion for metallurgical application. However, a way of utilizing the effect of electrodiffusion is to combine it with crystallization or controlled freezing. rakin was first to propose this as a new method of separating metal alloys of eutectic composition at temperatures slightly above the eutectic temperature. It was possible by this method to separate Bi-Sn and Bi-Cd eutectics into their component phases. Angus et al discussed the possibility that the effective distribution coefficient, keff, could be varied by proper application of an electric field during solidification. The combination of electrodiffusion and solidification, called field-freezing, was discussed in detail by Pfann and aner. It was shown that field-freezing can be used as a crystal-growth process, an efficient method for eutectic separation, and a new means of changing the effective distribution coefficient. k,ff, beyond the usual range of ko < k,ff < 1. The liquid layer adjacent to the solid-liquid interface can be either increased or depleted in solute due to

Jan 1, 1967

By B. J. Kochanowsky

The idea of a portable crusher is not new. Many such crushers are available but they are small and designed for construction work. For many years the author has suggested, both in this country and in Europe, the building of larger portable crushers intended expressly for use in quarries or open pits. Although not applicable under all conditions, there are mining operations where a mobile crusher arrangement could be more profitable than the facilities now used. The primary use of a portable crusher, i.e., a crusher mounted on crawlers or tires, in the rock and mining industries is to reduce costs by permitting the substitution of conveyor belt haulage for truck or track haulage. The usual sequence of operations in surface mining is drilling, blasting, loading, haulage, and crushing. Haulage is normally accomplished by truck or track-mounted cars, the latter method being used for the longer distances. However, by using a portable crusher in the pit, the sequence of operations would be changed so that the crushing stage would occur before haulage (Fig. 1). Such a sequence would permit the use of conveyors to replace the more expensive truck or track haulage methods. Since most quarry and open pit operations normally require a crushing stage, the only additional costs incurred will be due to the investment required to purchase or construct a mobile arrangement for a crusher. But this factor has to be weighed against the advantages to be gained by conveyor haulage. As shown in Fig. 2, transportation of material by belt conveyor over short distances is less expensive than by truck. The inclination of the belt has no effect on belt speed; consequently, the hourly tonnage moved remains the same. Conversely, the output rate of trucks as expressed in tons or ton-miles per shift decreases proportionally to the haulage speed, which is considerably slowed by the steepness of the road (Fig. 3, left). Although maximum possible grades and maximum economic grades of haulage are greater for a belt than for a truck (over the same total lift), the longer haulage distances favor the use of trucks. Although power consumption for hauling on a grade increases for both conveyances, the rate of power consumption increases faster for trucks than for conveyor belts (Fig. 3, right). Since the output rate and related fixed costs are affected by the travel speed, total haulage costs with trucks would increase with the grade more rapidly than the similar costs of conveyor belts (Fig. 4). Travel distance, road grade, speed, size and number of pieces of equipment, efficiency of operation, and many other factors affect such haulage costs. In general terms it can be said that the shorter the distance, the steeper the grade, and the greater the output, the more advantageous the belt becomes in comparison to truck or track haulage. In addition to potential cost savings in haulage procedures, a portable crusher would allow better utilization and performance of shovels. Loading operations would not be interrupted as often by the necessity of waiting for cars or trucks. Unfortunately, the application of belts in open pits for haulage from bench sites is generally not practical under existing conditions because a belt fed directly by a mechanical shovel can be torn, damaged, or worn out quickly by the large rock fragments falling on it during loading. However, by using a mobile crusher this situation can be avoided. As shown in Fig. 1 (b), the shovel feeds rock into the crusher located behind it. The crushed material is initially transported by an extensible and/or movable belt, thence by a longer stationary conveyor to the plant where the material is subjected to further treatment by secondary crushing, screening, etc. The first-mentioned conveyor, needed to bridge the distance between the shovel and the stationary conveyor, is necessarily variable in length owing to the continuous movement of the shovel and the desire to keep the stationary belt at a safe distance from the bench during blasting operations. The remarkable part of mobile crusher operations is the extra-ordinarily high output per man-shift, the low maintenance and power requirements for haulage, and the increased output of the loading shovel. A cement quarry which has been using a portable crusher and conveyor since 1956 requires only three men to operate the shovel and crusher and to transport the crushed rock by belt from the quarry face to the screening plant. If truck haulage

Jan 1, 1961

G. O. SMITH,* Washington, D. C.—This program is itself a demonstration of the widespread interest in the subject of more efficient development and operation of oil fields. The statements of fact already presented and the views expressed are sufficient evidence that the engineering and economic principles fundamental to the idea of unit operation are much more generally accepted than they were even one year ago. And real progress has been made in putting these principles to the test. No one realizes better than I that the fight against waste, whether physical or economic, must be waged in the front-line trenches: Washington at best is only an observation post. Yet viewed from this distance the advance made in the last few months has been notable and to a high degree encouraging. Five years ago the Federal Oil Conservation Board, in its first contacts with the industry, raised the question, "How can new pools be explored without exploitation until new production is warranted by the country&apos;s needs?" Three and one-half years ago the Board, in its first report to the President, paid largest attention, among what it listed as fundamental conservation measures, to "cooperative methods in sane development of new fields." A year ago, in its third report, the Board again endorsed as the essential factor in conserving the nation&apos;s reserves of oil, "full cooperation in unit control, whether by voluntary agreement or by state enforcement." The function of this federal agency has been purely fact-finding and educational. The Oil Conservation Board early declared that the major part of its task was to help the industry "formulate the broader by-laws in the sense of conservation." And now, after these five years of eventful history in the oil industry, may I size up the situation as I see it from the Washington point of view? First of all, and fundamental to a successful issue, I have observed in the industry a gradual acceptance of technical opinion as the guide to executive action; and this has at last led to some agreement as to what procedure offers most promise. Analyzed in more detail, this highly desirable progress has consisted in "self-restraint actuated by enlightened self-interest." We see emerging the general desire of oil producers for efficiency in operation, which means low costs and high recovery. As shown by facts presented at this meeting, competition in drilling is in direct opposition to efficiency in oil production, in that such competition increases costs and lowers recovery. The only route to conservation of this natural resource and also of the capital and labor involved in making it available is through unit control, which substitutes cooperative, well-planned action for competitive, unregulated activity, forced by the individualism of a small minority of landowners or perhaps by a single operator. Or, in terms of actual experience, development of an oil field and its subsequent operation under unit control means the substitution of majority rule for minority rule, yet the minority enjoys to the full the resulting economic benefits. So far as it affects the public interest, unit operation of oil properties deserves unqualified approval. It means more oil from the same area over a longer period

Jan 1, 1930

By Luther W. Lennox

The purpose of this article is not to compare one type of grinding machinery with another and to conclude from a series of tests that one particular machine is superior to all others. Neither is the reader asked to tire himself with the details of many tests to prove the statements herein made. The Chilean mill stands today almost an outcast from the milling world. It ranks with the applicant for a job who has been given a trial along with others and condemned because he was not able to perform the definite task assigned as well as the others, and was forever eliminated. The judges did not tarry long enough to try this aspirant in a field of a slightly different nature. Even though it has been condemned, the writer contends that the published records will indicate that the trials were never shifted into the field of greatest efficiency for the . Chilean mill. Those of us who cling to this outcast as a fine grinder in our milling operations do not wish, naturally, to be condemned also, with the machine, and yet we feel that we are classed as behind the times, at least in this phase of our milling judgment. Hence there is considerable personal feeling in our efforts. During the last few years there have been published several papers on the relative merits of the various grinding machines. In two of these articles a comparison was made between Chilean mills and cylindrical grinders. In each case the Chilean mill came out second best from about all standpoints. The outstanding feature in these comparisons would seem to be the decided attempt to keep all conditions the same, so that each machine could be judged on its merit. As Mr. David Cole states,1 "We are inclined to regard a direct comparison of grinders arranged side by side, and making a product that affords as nearly as possible the same screen measure, as the Supreme Court in these grinding matters." The writer agrees that this is the very best method for true comparison between machines. The results in the two detailed tests should give the relative merits of the two grinders in doing the work assigned. And they probably do. The conclusion drawn in each case was adverse to the Chilean mill as a fine-grinding machine. However, the duty placed upon the machines was that of converting material that had already been

Jan 1, 1920

By B. M. Larsen, L. S. Darken

SOME years ago we collated all laboratory data then available to us on the distribution at equilibrium of manganese and of sulphur between metal and simple slags, and used the results in setting up an equation, which proved to be in accord with determinations of the distribution ratio of manganese and of sulphur between liquid steel and open-hearth slag, over a wide range of operating conditions. We now present an outline of our calculations and inferences on these two closely related questions, which are of especial importance because of the advisability of conserving manganese wherever possible. In general. our results show that in the open-hearth furnace equilibrium between metal and slag, with respect to both manganese and sulphur, is substantially attained during the finishing period of the heat, or in about a half hour to an hour after any additions were made. This implies that the end result will be identical whether manganese is added as alloy or metal to the liquid steel or as oxide to the slag. The proportion of total manganese retained by the steel is favored: (I) by use of the minimum amount of lime, consistent with other operating limitations, required to give a lime-silica ratio of about 2.4, which usually corresponds to a minimum practical slag volume; (2) by a high concentration in the slag of MnO relative to FeO; (3) by high operating temperature. Absorption of sulphur by the slag from the liquid metal is favored: (I) by large slag volume; (2-by a high concentration of active (or "free") lime and of manganese oxide dis) solved in the slag; (3) by low concentration of silica, iron oxide, and phosphate dissolved in the slag. DISTRIBUTION OF MANGANESE BETWEEN SLAG AND METAL AT EQUILIBRIUM On the basis that the distribution of manganese between liquid steel and slag is controlled by the reaction [FeO + Mn ;7± MnO + Fe [A] slag metal slag metal] the distribution at equilibrium, at a given temperature, is expressed by the equilibrium constant for this reaction, which is defined as [K" aFPI OFeO ? aMn] where a is the activity of the molecular species denoted by the subscript. The activity of each of the several components, although it is not known precisely, is approximately equal to the concentration of each component expressed as its mol fraction; that is, as the ratio of the number of mols of the given component to the total number of mols of all the molecular species present in the metal or slag, as the case may be. Moreover, since the activity, or concentration, of iron in the liquid metal is in fact substantially constant, the term aFe may he combined with K" to give a new constant K&apos;. Making these changes.

Jan 1, 1942

By Lawrence Addicks

ONE of the properties of copper, which has done much to give it its present prominent place among the useful metals, is its electrical conductivity, a property which has now become the chief criterion of &apos;the value of the commerical product. In pursuance of that distinctively American principle that, 1&apos; the best is none too good," metal of the highest conductivity is usually called for even where such extreme purity is of no advantage, for instance, in the making of brass and other alloys. The average brass-founder feels nervous unless his copper is so very pure that it shows a conductivity of 99 or 100 per cent., while the character of the zinc used is usually overlooked in his anxiety. Electrolytic refining has made it possible to produce copper of a&apos; very high degree of purity, the metallic impurities averaging but a few thousandths of 1 per cent.; oxygen, usually present in the form of cuprous oxide, bringing the total up to about a tenth of 1 per cent. The published data bearing upon the relationship between chemical purity and electrical conductivity is, however, very scant,&apos; nearly all the work that has been done having dealt with alloys carrying considerable quantities of the foreign elements. In this paper I have brought together the results of experiments extending over a period of several years that have been carried out with the idea of determining the amount of various elements which would lower the conductivity 3 or 4 per cent.-a series of impure coppers rather than alloys. There are many precautions necessary to keep the conditions

Mar 1, 1905

By Frederick Laist

THE ore from the Butte mines of the Anaconda company is quite siliceous; that is, it contains considerably less iron than is needed for the fluxing of the silica. The direct smelting of this ore, therefore, requires the addition of considerable fluxing material. The only flux available in sufficient quantity at Anaconda is limestone containing no metallic minerals. This necessarily makes the direct smelting of the ore so expensive that it is more profitable to subject the ore to a preliminary treatment by concentration. However, as the losses in the concentrator were very high, compared with the losses in the blast furnaces, it was found, by calculation, more profitable to send ores containing more than a given percentage of copper to the blast furnaces, in spite of the higher costs of treatment. The dividing point was dependent on various factors, the chief of which was the prevailing market price of -copper. It was customary, therefore, to segregate the ore as mined into two classes. Ore in the first class generally contained 5 per cent. or over of copper;: this was sent directly to the blast-furnace department. Second-class ore contained less than 5 per cent. of copper, and averaged around 3 per cent.; it went to the concentrating department. With the introduction of the flotation process, it was found possible to maintain an average recovery, as concentrates, of 96 per cent. At the same time, the cost of reverberatory smelting was very materially decreased by the use of pulverized coal. These two changes in practice made the blast furnaces unable to compete with the reverberatory furnaces on a cost basis. The distinction between first-.and second-class ore was therefore abandoned, and the ore was treated by concentration. Obviously, on ores as high in iron as the Butte ores, the concentrator, produces a product that is self-fluxing; in fact, it is possible to produce a

Jan 1, 1920

Several of the current concepts of brittle fracture involve consideration of, the existence of defects or flaws. Griffith 1 observed that the tensile strength of brittle materials was several orders of magnitude less than might be expected from the calculated strength of the molecular bonds. He was able to show that the stress concentration at the tip of an elliptical crack is sufficient to raise the local stress level many fold. He therefore proposed that real materials do contain such stress risers in the form of minute cracks and that this accounts for the rather large difference between theoretical and actual strengths of brittle materials. The degree of stress magnification depends to a great extent upon the orientation of the crack with respect to the general stress system, and to the general geometry of the crack. It is but a small step to extend the theory to include flaws and defects of other sorts which, though they may be less tractable mathematically than cracks, may still function as stress risers in a real sense in real materials. Brace 2 proposed that the application of the Griffith theory to rock material could be tested in two ways: "(a) by finding the orientation of cracks from which macroscopic fractures have developed and (b) comparing failure strengths from tests at different conditions of loading." In 1963 the author and coworkers at the Bureau of Mines, Twin Cities Mining Research Center, working on a problem involving relationships between strength, sonic velocity, and microstructure "eveloped an experimental technique to examine several somewhat similar questions; namely. does the frequency of occurrence of actual or potential stress risers dictate the relative strength of the material as proposed by Weibull;4 can actual flaws or defects in the rock structure be identified and related to strength and perhaps other properties in accordance with Griffith&apos;s theory; and is the anisotropic strength and elastic behavior of certain rocks related to the preferred orientation of these actual or potential stress risers? The experimental approach developed to answer these questions appears equally applicable to the testing of Griffith&apos;s theory as proposed by Brace. Basically the approach consists of a series of point-load tensile tests followed by petrofabric examination of thin sections prepared from the specimens in order to identify and apply a quantitative measure to microstructural defects which may have contributed to the failure process. In the point-load test, tensile stresses are induced by a compressive load applied to the center of a disc-shaped specimen by means of two opposing hemispherical indentors. Failure generally occurs as a single fracture parallel to the axis of loading and bisecting the disc. Because of the geometrical symmetrical the induced tensile stresses are symmetrical about the loading axis

Jan 1, 1967

By D. Geoffry Minnes, Ray Blair, Stanley J. LeFond

Nepheline syenite is a silica deficient crystal-line rock consisting of albite and microcline feldspars and nepheline, together with varying but small amounts of mafic silicates and other accessory minerals. Nepheline-bearing rocks are widely distributed around the world but only in Canada, Norway, the Union of Soviet Socialist Republics, and the United States are deposits worked commercially, Because of its low melting point and fluxing ability, nepheline syenite was investigated in the early 1900s by many students of glass and ceramics. Although the nepheline syenite deposits in Methuen Township, Ont., Canada, were discovered as early as 1897 it wasn&apos;t until 1935 that the first mill was erected to produce nepheline syenite products. In Canada, nepheline syenite deposits are worked by Indusmin Ltd. and International Minerals and Chemical Corp. (Canada) Ltd. who have combined production capacity in excess of 1800 stpd. Between 1935 and 1972 seven million tons valued at $78 million were produced from the Methuen Township deposits. In Norway, the Norsk Nefelin Div. of Elkem Spigerverket has produced nepheline syenite from a deposit on Stjernöy Island in western Finland since early 1960. Production has increased from 8 kt in 1961 to over 200 kt in 1980. Nepheline syenite has been under investigation in the Union of Soviet Socialist Republics (USSR) since at least 1928. In 1951 the first commercial alumina works was brought on stream at Volkhov, near Leningrad, utilizing nepheline concentrates from the Kola peninsula as mill feed. Since then two others have been completed and more are planned. Large quantities of portland cement, sodium carbonate, and potassium carbonate are produced in conjunction with the alumina. A material called nepheline syenite, but actually a pulaskite, is produced in Pulaski County, Arkansas, by the McGeorge Construction Co. for construction aggregates and by the 3M Co. for roofing granules. The Dome Fill Co. purchases the fines and uses them in the preparation of enclosed construction fill. Production is over 2,000,000 stpy. Chap. 16 on "Feldspar, Nepheline Syenite, and Aplite" in the 3rd ed. of Industrial Minerals and Rocks (Castle and Gillson, 1960) and Nepheline Syenite Deposits of Southern Ontario (Hewitt, 1960) contain excellent accounts of earlier commercial development of nepheline syenite as a glass and ceramic material. As in the 4th ed., this chapter deals mostly with the period since 1960 and with matters not previously reported in detail. An English monograph on Nepheline-Syenite and Phonolite (Allen et al., 1968) is a complete survey, at the time, of nepheline syenite which, with its very complete list of references, is an excellent source book. End Uses Nepheline syenite from the Canadian and Norwegian producers finds use primarily in the manufacture of glass and ceramics. One producer also makes several grades of nephellne syenite that are useful as extender pigments and fillers in paint, plastics, and rubber. In the Soviet Union nepheline is used in increasing quantities in the manufacture of alumina, alkali carbonates, and portland cement and to a lesser degree it is used in the manufacture of colored container glass.

Jan 1, 1983

By R. A. Morse, W. O. Keller

The properties of limestone reservoir rocks such as the distribution and degree of continuity of the pore systems, and the relative volumes and permeabilities of the systems making up the complex cause large variations between performance of individual limestone reservoirs and their susceptibility to secondary recovery methods. The effects of these factors on the mechanism of fluid flow cannot be adequately evaluated with presently developed concepts, laboratory data, and geological information. The observance and interpretation of the performance of individual limestone reservoirs provides, at present, the most adequate approach for evaluating the integrated effects upon performance of the many. now immeasurable variations in the properties of limestone reservoirs. INTRODUCTION The development and application of techniques for increasing the efficiency of oil recovery from natural reservoirs is a problem of primary importance to the industry. During the past several years, a great deal of effort has been expended by the technical personnel of the industry toward the improvement of present known methods of oil recovery. and evaluating the factors which control the susceptibility of particular reservoir types to economic application of secondary recovery methods. Providing adequate and accurate laboratory data on the properties of the reservoir rock and its contained fluids. together with good production statistics, are available, methods have been evolved for estimating with reasonable accuracy the performance of an oil reservoir under either continued natural depletion or conditions imposed by introducing additional displacing fluid into the reservoir from an extraneous source through the injection of gas and/or water. The susceptibility of limestone reservoirs to secondary recovery by gas injection is very much dependent upon gas-oil relative permeability relationships for the reservoir in question. In a rock formation in which the porosity is of the intergranular type such as is found in sand stones and some non-fractured dolomites, a representative sample of the pore structure can be obtained in a small core plug. In this type of reservoir, it has been shown that relative permeability data obtained from laboratory experiments can be Properly applied to evaluate the flow relationships actually observed during the depletion of a reservoir. In addition, a good idea of the fraction of the reservoir which will be swept by the injected gas may be obtained from the spacing pattern used and the permeability profile of cored wells. From these data, it has been demonstrated that reliable estimates of performance and recoveries under gas injection operations can be made for reservoirs in which the Porosity is of the intergranular type. Limestone reservoirs on the other hand often present much more complex problems. One reason that the performance of limestone reservoirs is so variable is that there may be, in reality. two or more pore systems, the integrated performance of which will depend upon the physical properties of each system and their inter-relationship. For instance, in a limestone reservoir, the main pore structure, as far as void spaces for storage of hydrocarbons is concerned, may be represented by the intergranular openings of the rock. Usually in limes and dolomites, the intergranular pore openings are very small and the matrix permeabilities extremely low. Often, as in the case of Many dolomite and oolitic lime reservoirs, this is the only pore system, and performance is observed to be very similar to that of a sand stone of similar permeability. However, in the great majority of&apos; the limestone reservoirs, there is present, in addition to the intergranular pore system, a complementary system of openings caused by fracturing or solution.&apos;,&apos; The openings in the latter system are usually many times more permeable than the intergranular pore system due to their much larger size, and may contribute almost all the fluid carrying capacity of the formation, even though their volume may be a very small part of the total pore space in the reservoir. Obviously, the performance of such a complex under either primary or secondary control will deend upon the distribution and degree of continuity of both systems, the relative volumes and permeabilities of the

Jan 1, 1949