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By Herbert H. Kellogg

Deposits of high-silica kaolinite clays occur at many places in central Pennsylvania. These white clays were formed apparently by weathering of argillaceous quartzite and limestone. Their geology, distribution and use have been reported by Leighton.1 The larger deposits have been mined from time to time, and the clay, after washing to remove coarse sand, has found use as rubber filler, foundry clay, and in white cements. In general, the clay from these deposits contains too much grit (quartz) to be useful as paper filler, and the silica content is too high to make it useful as china clay for ceramic ware. Gravity methods for the separation of quartz from these clays have failed because of the extremely fine size of the quartz grains, but by the methods of froth flotation described in this paper these sandy kaolins can be made to yield a purified kaolinite that has a chemical composition close to that of good-grade Georgia kaolins, and is free enough from grit to be used as a paper filler. As by-products of the separation, a fine ( — 325-mesh) sand assaying 95.5 per cent SiO2, and a very fine (—3-micron) clay are produced. The possible ceramic uses of these products are being investigated at The Pennsylvania State College. Experimental Procedure The Sample.—The clay sample used in these tests was obtained from a small mine near Tyrone, Pa. It had already been washed to remove coarse sand, and represented the finished product of this small mine and washery. Microscopic examination showed that the clay was composed almost entirely of the minerals quartz and kaolinite, and that the quartz was present mostly in particles larger than one micron, while the kaolinite particles generally were less than 20 microns in size. The kaolinite and quartz particles were physically separable by blunging the clay in water with a suitable dispersant. Preparation of Flotalion Feed.—By the addition of NaOH in an amount equal to 3 lb. per ton of solids, the clay was completely dispersed in water. Flotation feed was prepared by allowing a dispersed suspension (10 per cent solids) of the clay to stand for the period of time required for a 2.5-micron particle of quartz to settle from the top of the container to the bottom. After this settling period the suspension was decanted from the settled solids. The settled solids were redispersed in water and the separation was repeated once. The two fine fractions were then combined. Thus the clay was divided into a fine and a coarse fraction by size separation at approximately 2.5 microns.* The fine frac- . tion was found to have a considerably lower sand content than the raw clay (Table I), and was not treated further. The coarse fraction formed the flotation feed for all the tests described in this paper. A size separation of this type can be

Jan 1, 1948

By E. J. Pasierb, H. W. Paxton

Mavkers ill a diffusion couple in the iron-chromium system move towards the high chromium side indicating Dcr > DFe at the marker composition. By a combituztion of measurements of D& and D a: a function of composition, this is also shown independently. DFe is calculated as a function of composition. and shown to be in reasonable agreement with measured values by other workers. MEASUREMENTS of marker movements in diffusion couples have been used from time to time to demonstrate that a vacancy or interstitial mechanism may be operative. Since there is a possibility that ring diffusion1 may be operative in chromium, the present experiments are of interest in showing some non-ring mechanism in iron-chromium alloys around the equiatomic composition. EXPERIMENTAL PROCEDURE The movement of markers originally at the interface between 1-in. sq sections of pure Cr (6 mm thick) and outer slabs of 30 Cr-70 Fe alloy was followed as a function of time at temperatures from 1150" to 1425"C, in a Kanthal-wound furnace. Temperature control was +5°C over extended periods. The analyses of these alloys are given in Table I. Selection of suitable markers presented a considerable experimental problem; the eventual solution was to draw quartz rod down to 0.01 cm and seat this in V-grooves 0.01 cm deep on each side of the chromium prior to welding. A preliminary experiment in which the groove was machined in the alloy gave identical results. Welding was accomplished by passing a heavy current through specimens under moderate pressure in a helium atmosphere. This method produced good welds with a planar interface as shown by subsequent metallo-graphic investigation. Any markers which did not adequately fill their groove and showed subsequent contamination from the atmosphere during heat treatment were not considered reliable. The composite sample was ground and metal-lographically polished on the four sides perpendicular to the interface. Fiducial marks (deep milled slots) were made outside the diffusion zone to check on total volume change. All necessary measurements were made on a metallograph reading to +0.0005 cm. The samples were wrapped in tantalum foil and given diffusion anneals for times to 200 hr in carefully purified dry hydrogen in a sealed McDanel porcelain tube. Chromium-zirconium chips were introduced near the specimen as an additional getter. The specimens were cooled relatively slowly after the diffusion anneal to preserve the McDanel tube but no significant error in effective time at temperature was thereby introduced. At least 1 mm was ground off the surface before measurements were taken. It was observed that the grain size following short diffusion anneals was several mm and was appreciably larger in the 30 Cr alloy than in the pure Cr. No significant grain boundary penetration was present as indicated by the etch limit. The results are presented in the next section. Measurements of D were made by standard sectioning techniques with chemical analysis. Machining difficulties limited the

Jan 1, 1961

By F. H. Kihlstedt

The Larap iron deposits, 125 miles east of Manila, are the biggest high-grade iron deposits in the Philippines, and have in seven years produced nearly 4 million tons of 60 per cent ore. Magnetic surveying followed by churn and diamond drilling cheaply developed a score of million tons. The ore zone is a wedge of metamorphic rocks in fresh, Miocene sediments overlain by agglomerates, which seem to have filled a river valley eroded in the sediments. A mild overthrust of the competent agglomerates crumbled the shale in front. Solutions gradually turned it into more competent hornfels and deposited pyrite, then magnetite and pyrite in the pores. As the temperature rose large bodies of magnetite with some pyrite were deposited by replacement and in open cavities in tensional areas of overthrust shears. At still higher temperature magnetite and calcium-magnesium silicates formed other bodies in similar cavities, and finally the thrust zone was invaded by syenite porphyry, causing high-temperature alteration products. Possibly, as temperature abated, more high-grade ore was deposited. The complicated faulting indicates dynamic, chronological and spatial changes of mineralization rather than zoning in a static system. Noncommercial copper, molybdenum and some gold accompanied the iron mineralization. In the thirties the Philippines gained a justified reputation as a country of considerable mineral wealth. Traces of Chinese workings show that these earliest travelers and traders had in a small way exploited the latent gold resources in the Islands. The Spaniards continued this for centuries, but did not succeed in establishing any steady mining industry. Modern technology was required to get it started. The rapid development in the last decade before the war got its impetus from several financial factors, the return to sugar growers of previously collected taxes, the influx of Spanish capital during the civil war in Spain, the influx of Chinese capital when the Japanese started their "China incident," and others. Directly or indirectly much of this capital reached the mining industry; in particular, gold mining. Out of the turmoil of an exceptional mining boom emerged a sufficient number of good and well managed gold properties to send the production to a level above that of any single state in the United States at the time. Other ore deposits besides those of gold also received their share, and for a country without any heavy industries at

Jan 1, 1949

By F. H. Kihlstedt

The Larap iron deposits, 125 miles east of Manila, are the biggest high-grade iron deposits in the Philippines, and have in seven years produced nearly 4 million tons of 60 per cent ore. Magnetic surveying followed by churn and diamond drilling cheaply developed a score of million tons. The ore zone is a wedge of metamorphic rocks in fresh, Miocene sediments overlain by agglomerates, which seem to have filled a river valley eroded in the sediments. A mild overthrust of the competent agglomerates crumbled the shale in front. Solutions gradually turned it into more competent hornfels and deposited pyrite, then magnetite and pyrite in the pores. As the temperature rose large bodies of magnetite with some pyrite were deposited by replacement and in open cavities in tensional areas of overthrust shears. At still higher temperature magnetite and calcium-magnesium silicates formed other bodies in similar cavities, and finally the thrust zone was invaded by syenite porphyry, causing high-temperature alteration products. Possibly, as temperature abated, more high-grade ore was deposited. The complicated faulting indicates dynamic, chronological and spatial changes of mineralization rather than zoning in a static system. Noncommercial copper, molybdenum and some gold accompanied the iron mineralization. In the thirties the Philippines gained a justified reputation as a country of considerable mineral wealth. Traces of Chinese workings show that these earliest travelers and traders had in a small way exploited the latent gold resources in the Islands. The Spaniards continued this for centuries, but did not succeed in establishing any steady mining industry. Modern technology was required to get it started. The rapid development in the last decade before the war got its impetus from several financial factors, the return to sugar growers of previously collected taxes, the influx of Spanish capital during the civil war in Spain, the influx of Chinese capital when the Japanese started their "China incident," and others. Directly or indirectly much of this capital reached the mining industry; in particular, gold mining. Out of the turmoil of an exceptional mining boom emerged a sufficient number of good and well managed gold properties to send the production to a level above that of any single state in the United States at the time. Other ore deposits besides those of gold also received their share, and for a country without any heavy industries at

Jan 1, 1949

By N. Schapiro, R. J. Gray, G. D. Coe

A petrographic and chemical investigation was conducted to determine the occurrence and distribution of the organic and inorganic forms of sulfur in various size and specific gravity fractions of a high volatile, A-rank, Pittsburgh seam coal. The investigation was conducted to aid in the resolution of the problem of how metallurgical coke of lower sulfur content can be produced from high sulfur coals. The Pittsburgh raw coal contains about 2.4% S in two dominant forms: pyritic and organic. Pyritic sulfur constitutes about 57% of the total sulfur in the raw coal and occurs in macroscopic and microscopic-size particles. A plant cleaning process mechanically separates between 50 and 60% of the pyritic sulfur, mainly the macroscopic particles. The organic sulfur constitutes 41% of the total sulfur in the raw coal and 55% of the sulfur in the washed coal. Thus, organic sulfur is not reduced by physical methods of separation. Organic sulfur occurs in all the coal entities, but in general, increases as the exinoid content of the coal increases. In this study, it was found that carbonizing certain selected low gravity coal fractions containing an average of 0.45% pyritic sulfur and 1.01% organic sulfur produced cokes containing an average of 0.22% pyritic sulfur and 0.91% organic sulfur. However, the organic sulfur in the coke is probably derived in part from the heating of pyrite in the presence of carbon. Thus, the total sulfur in the coal carbonized is the most important factor affecting the sulfur content of the coke produced. Concentration of microscopic pyritic and organic sulfur in the middling-type coal indicates the necessity for rejecting as much of this material as is economically feasible. Most of the sulfur introduced into the blast furnace originates from the coke. Although the sulfur content of the hot metal can be controlled by the addition of flux, the flux used restricts the productivity of the furnace by displacing ore and requires first to be smelted; therefore, low sulfur coke is highly desirable. Since the sulfur content of coke is dependent upon the sulfur content of the coals from which the coke is produced, low sulfur coals are required to produce low sulfur coke. In the western Pennsylvania area, large quantities of good coking coal are available from the Pittsburgh seam, but this coal unfortunately contains relatively large quantities of sulfur. To provide information that might be useful in reducing the sulfur content of this coal in the cleaning process, an investigation was conducted to determine the physical and chemical forms in which this sulfur occurs and with what petrographic components it might be associated. The Pittsburgh seam coal, like most other coals, contains two dominant forms of sulfur: one occurs as the minerals pyrite and/or marcasite and is referred to as pyritic sulfur; the other is combined with the coal substance and is called organic sulfur. Pyritic sulfur is amenable to physical methods of separation, whereas organic sulfur is not. Pyritic sulfur particles must be freed from the surrounding coal if they are to be removed in the washing process. Generally, this requires crushing; the required degree of crushing being a function of the size and distribution of the pyrite. The present investigation was conducted to 1) determine the size, distribution and association of sulfur-bearing minerals in the coal and 2) to determine whether the organic sulfur has a preferential association with specific coal entities. If a preferential association exists, this knowledge may be useful in devising a method for organic sulfur reduction. In addition, a study was made to determine the extent to which pyritic and organic forms of sulfur in the coal contribute to the sulfur in the coke produced from this coal. A representative 3%-ton sample of raw coal was crushed to —3 in. and screened into square-mesh sizes: 3 to 1 in., 1 to % in., % to % in., % in. to 10 mesh, 10 to 35 mesh, and 35 to 200 mesh. Separate samples of the -200-mesh fraction and the all-size composite were also collected. Each size fraction (except the -200 mesh) was fractionated on heavy liquids of the following specific gravities: 1.280, 1.300, 1.325, 1.350, 1.375, 1.400, 1.425, 1.450,

Jan 1, 1963

By J. T. Burwell

The crystal orientation in silicon iron that has been given a particular treatment described by Goss,l has been studied by Goss, by Bozorth2 and by Sixtus,3 but their results do not agree and are almost entirely qualitative. The following pages give a description of the orientation of the crystals in the material as determined by means of X-rays and expressed graphically in a pole figure. The treatment consists of hot-rolling the material into strip and then giving it two cycles of cold reduction followed by recrystallization. This produces remarkably good properties in the rolling direction, the product having a maximum permeability in this direction of more than 25,000 and a permeability at 16,000 Gauss of more than 2200. It is now generally agreed that Goss's original conclusion1 that the crystals in the final product are randomly oriented was incorrect, since Bozorth2 and Sixtus,3 using different methods, have shown that there is a decided preference in orientation. Those writers, however, expressed their results only in terms of one or more ideal orientations with deviations therefrom. X-ray Data A strip of the material containing 3.1 per cent Si, prepared by Goss,† 1.2 by 0.0125 in., was etched rapidly in warm dilute hydrochloric acid until it was 0.005 in. thick, in order to eliminate the effect of the two surface layers. The specimen was then mounted in an integrating camera similar to one described in the literature.4 The purpose of this camera is to translate the specimen during exposure, so that a statistically large number of grains contribute to the pattern photographed. The camera also allows the plane of the specimen to make various angles with the X-ray beam. An area 5 by 1.2 in. was scanned by a beam of unfiltered radiation from a molybdenum target tube operating at 37 kv., and the measurements were made principally on the peak of the white radiation. X-ray photographs were taken at intervals of 15" in a plane

Jan 1, 1940

By J. T. Burwell

The crystal orientation in silicon iron that has been given a particular treatment described by Goss,l has been studied by Goss, by Bozorth2 and by Sixtus,3 but their results do not agree and are almost entirely qualitative. The following pages give a description of the orientation of the crystals in the material as determined by means of X-rays and expressed graphically in a pole figure. The treatment consists of hot-rolling the material into strip and then giving it two cycles of cold reduction followed by recrystallization. This produces remarkably good properties in the rolling direction, the product having a maximum permeability in this direction of more than 25,000 and a permeability at 16,000 Gauss of more than 2200. It is now generally agreed that Goss's original conclusion1 that the crystals in the final product are randomly oriented was incorrect, since Bozorth2 and Sixtus,3 using different methods, have shown that there is a decided preference in orientation. Those writers, however, expressed their results only in terms of one or more ideal orientations with deviations therefrom. X-ray Data A strip of the material containing 3.1 per cent Si, prepared by Goss,† 1.2 by 0.0125 in., was etched rapidly in warm dilute hydrochloric acid until it was 0.005 in. thick, in order to eliminate the effect of the two surface layers. The specimen was then mounted in an integrating camera similar to one described in the literature.4 The purpose of this camera is to translate the specimen during exposure, so that a statistically large number of grains contribute to the pattern photographed. The camera also allows the plane of the specimen to make various angles with the X-ray beam. An area 5 by 1.2 in. was scanned by a beam of unfiltered radiation from a molybdenum target tube operating at 37 kv., and the measurements were made principally on the peak of the white radiation. X-ray photographs were taken at intervals of 15" in a plane

Jan 1, 1940

By Samuel Gibson Frantz, G. W. Jarman

The purpose of this paper is to relate briefly the development of magnetic separation and its extension from the separation of iron into its present use in the nonmetallic field, to suggest possible future extensions of its field of usefulness and its possible cooperation with other separating methods. The engineering design of separating machines, and statistics as to the number of machines in operation, types, their location and production are outside the scope of this paper. Specific data will be given, however, on certain selected applications. A large part of human endeavor consists in separating one thing from another; the good from the bad, the desired from the undesired. In fact, a philosopher might plausibly claim that separating things into categories and choosing between them is the object of thought itself. In dealing with matter, separation is nowhere more inherently necessary to attain our objects than in mining and metallurgy. Both our desire and our ability to make separations are results of the physical differences between things. Gross separations such as removing ore from worthless rock or coal from slate are usually made visually and depend upon form and color, which are physical properties. When the desired and the undesired things are intimately mixed, however, it becomes impractical to select visually even if the individual particles are readily recognizable to the eye, and some automatic way of making the particles separate themselves on the basis of their own inherent differences in physical properties must be resorted to. Some of the physical properties which have been used as a basis of separation are: color, shape, hardness, size, density, elasticity, surface propertics (surface tension in contact with liquids, etc.), electrical conductivity, dielectric constant, and magnetic susceptibility. Differences in these properties are used in the following methods of separation: color sorting, sifting, settlement in air and in liquids, float-sink methods, flotation, electrostatic and magnetic separation.

Jan 1, 1932

By Sir Robert Hadfield

(New York Meeting, February, 1913.) THE Hadfield method of producing sound steel ingots has been the subject of a paper 1 read before the Iron and Steel Institute, so that it will be unnecessary to describe it fully here. The object of the method is to make possible the production of steel ingots in which the pipe is almost entirely obliterated, and it is applicable particularly to the production of sound ingots, from which good rails could be rolled. The method in brief consists in casting the ingots on cars, usually with the small end down. Each ingot mold is provided with a sand top, rammed up in the well-known manner. After the mold is filled to the desired height with steel, a layer of slag about 0.5 in. thick is placed upon it and the balance of the mold is then filled with charcoal. Then, through suitable piping, an air blast is directed in numerous jets upon the charcoal, which is burned thereby, the combustion supplying additional beat to the top of the ingot, which helps to keep the top fluid and to retard its solidification, while the lower parts are rapidly losing heat by its transfer to the mold. By-one plan the ingots are cast in molds placed upon bogies, movable trucks, or platforms, in the position A, Fig. 1. The ingots are cast vertically on bogies, say four or more ingots on each bogie, as may be found most convenient, and the upper surface of the steel is maintained in a molted condition during the transit of the ingots from the casting pit to the stripper. This is effected by a series of air pipes, for example, three in number, with jets or holes on the under surface of such pipes, placed preferably horizontally, arranged in such a manner as to cause jets of air to impinge on the upper surface of the ingots. These holes or jets are made throughout the entire length of the overhead pipes, the length of such pipes being

Jan 4, 1913

By Howard N. Eavenson

Waste of coal, or perhaps more properly the percentage of its recovery in mining, has keenly interested me during an experience of over a half century in coal mining. In the early part of that time and until a few years after World War I the use of better mining plans and supervision resulted in an increased recovery. Since then, and particularly since controlled prices have been effective and mechanized mining has been extensively practiced, the tendency has all been toward lesser recovery in mining. The purpose of this paper is not to criticize the methods being used, which after all are the result of economic forces, nor to point to any particular mining method or to any locality where the best recovery is obtained, but to call attention to the tremendous waste of our national coal resources that is constantly continuing. A possible method of reducing this loss will be suggested, but without any illusions that it will be followed or that such attention will be paid to it. Average Recovery The actual average percentage of recovery of coal in the ground is not known. Many papers giving figures of recovery have been published but no definite base of measurement has been agreed upon by those presenting the data. As an example, the Pittsburgh bed can be considered—it has produced a greater output than any other and has been sold or leased at higher prices in place than any other coal bed. Over a large part of its area where high prices have prevailed it has been customary for many years to draw pillars. In these mines it has been usually assumed that the average recovery was higher than in other beds and percentages of recovery of 85 to 95 per cent are usually said to be realized. In all of these mines, however, it has been customary to leave from 4 to 8 in. in the bottom, and 10 to 16 in. in the roof; thus from 14 to 24 in. of coal has been left in the mines out of a total seam thickness of about 96 in., or 15 to 25 per cent of the total coal. No attempt is made to mine this coal for metallurgical purposes, owing to its impurities, although this unmined coal is of excellent quality and better than much of the coal used for steam purposes. If we add to this discard the coal usually lost in mining and those parts of the bed 'that must be left because of bad seam conditions, barrier pillars, reservations for buildings, gas and oil wells, one can easily see that the actual recovery from this bed cannot be more than 65 to 75 per cent. In addition, the rooster or rider or wild coal over the mining bed—often 3 to 4 ft. of coal, high in ash and sulphur but still good steam coal—is hardly ever mined, nor is any attempt made to mine it. It is safe to say that from a broad economic viewpoint not more than 50 to 60 per cent of the fuel value of this great seam is actually being recovered.

Jan 1, 1947

By Howard N. Eavenson

Waste of coal, or perhaps more properly the percentage of its recovery in mining, has keenly interested me during an experience of over a half century in coal mining. In the early part of that time and until a few years after World War I the use of better mining plans and supervision resulted in an increased recovery. Since then, and particularly since controlled prices have been effective and mechanized mining has been extensively practiced, the tendency has all been toward lesser recovery in mining. The purpose of this paper is not to criticize the methods being used, which after all are the result of economic forces, nor to point to any particular mining method or to any locality where the best recovery is obtained, but to call attention to the tremendous waste of our national coal resources that is constantly continuing. A possible method of reducing this loss will be suggested, but without any illusions that it will be followed or that such attention will be paid to it. Average Recovery The actual average percentage of recovery of coal in the ground is not known. Many papers giving figures of recovery have been published but no definite base of measurement has been agreed upon by those presenting the data. As an example, the Pittsburgh bed can be considered—it has produced a greater output than any other and has been sold or leased at higher prices in place than any other coal bed. Over a large part of its area where high prices have prevailed it has been customary for many years to draw pillars. In these mines it has been usually assumed that the average recovery was higher than in other beds and percentages of recovery of 85 to 95 per cent are usually said to be realized. In all of these mines, however, it has been customary to leave from 4 to 8 in. in the bottom, and 10 to 16 in. in the roof; thus from 14 to 24 in. of coal has been left in the mines out of a total seam thickness of about 96 in., or 15 to 25 per cent of the total coal. No attempt is made to mine this coal for metallurgical purposes, owing to its impurities, although this unmined coal is of excellent quality and better than much of the coal used for steam purposes. If we add to this discard the coal usually lost in mining and those parts of the bed 'that must be left because of bad seam conditions, barrier pillars, reservations for buildings, gas and oil wells, one can easily see that the actual recovery from this bed cannot be more than 65 to 75 per cent. In addition, the rooster or rider or wild coal over the mining bed—often 3 to 4 ft. of coal, high in ash and sulphur but still good steam coal—is hardly ever mined, nor is any attempt made to mine it. It is safe to say that from a broad economic viewpoint not more than 50 to 60 per cent of the fuel value of this great seam is actually being recovered.

Jan 1, 1947

By Leo F. Reinartz

Part III of a four-part series on the history of steelmaking in the US, describes furnace developments, improvements during the last few decades, and the contribution of the AIME. THE invention of the dolomite machine was a great boon to the open-hearth furnaceman. By speeding up bottom making, it helped to increase tons per hour and decrease cost. The first homemade unit was built and operated before 1925 at the South Side works of Jones & Laughlin Steel Corp., Pittsburgh The first commercial machine, similar to those known today, was built for the Donner Steel Co., Buffalo, N. Y., in 1925. Heavy slab buckstays, 6 in. by 15 in., supplanted lighter I-beam buckstays as furnace framework in the middle 1920's. They greatly improved the rigidity of the furnace binding. Although the first sloping back wall had been in- stalled prior to 1920 on a small basic open-hearth foundry furnace at Columbus, Ohio, the impetus to install such back walls universally in ingots shops came after S. Naismith installed the first one on an open-hearth furnace at Illinois Steel Company's South works in June 1924. Before that event, back- wall life had already been improved somewhat by the use of chrome rock or metal-encased basic brick. Here again, these changes heralded major for- ward steps in furnace design, decreased costs, in- creased production, and improved safety and working conditions on the back standing of the furnace. Fuels Up to 1930, a number of different kinds of fuel were used to melt and refine steel in American open hearth furnaces. During World War I, powdered coal was used in a few plants as an open-hearth fuel, but because of the high sulfur and ash content in the coals, many operational difficulties arose. There were also dust, explosion, and accident hazards, so that after the War its use was discontinued. In some steel-manufacturing centers, natural gas was available as a fuel and gave good performance. In most steel-manufacturing centers, operators had to rely on producer gas made from bituminous coals in producer gas houses. Low-sulfur low-ash, high-fusion coals required for the manufacture of such gas were not readily available. The quality of producer gas was uncertain. The gas had to be pre-heated. Maintenance problems connected with the use of this fuel were serious. Tons per hour per month was unsatisfactory. Although petroleum had been first discovered by Edwin L. Drake at Titusville, Pa., in 1859, it was not until the early 1930's that heavy fuel oil residues for open-hearth use began to appear on the market. They were cheap; the calorific value was high, and it was not necessary to pass this fuel through the checkers to preheat it. Various plants began to use such oil as an open-hearth fuel. Others used it in combinations with tar, coke-oven, and/or blast-furnace gases. Because of its low calorific value, blast-furnace gas had to be preheated in the checkers. These fuels were cleaner and more dependable than producer gas. The dirty gas house adjacent to the open-hearth shop was no longer needed, and

Jan 1, 1961

By B. H. Caudle, L. G. Davies, I. H. Silberberg

This paper presents a method of predicting the recovery and performance of a five-spot steam injection project, in which a realistic approach to pattern sweepout efficiencies is made. Published methods for radial systems were modified for the five-spot pattern by approximating the stream lines with straight lines radiating from the injection well and then converging to the producing well. In each radial segment, the position of the steam front and the temperature profile ahead of the steam front were determined by heat balance equations, which included an estimation of heat losses to surrounding formations. The location of the saturations behind the cold water front was determined from a Buckley-Leverett solution to the material balance equation. Results from this program show steamflood recovery in a five-spot pattern to be considerably less than that predicted for true linear or radial flow systems. For a specific reservoir containing 900-cp oil, a steamflood in a purely radial flow system was predicted to recover more than 75 percent of the original oil in place when 2 PV of water had been injected as steam. A five-spot steamflood with otherwise identical properties was predicted to recover 10 percent of the original oil in place when 0.15 PV of water had been injected as steam and to recover almost no oil thereafter. A cold water five-spot flood in this system was predicted to recover approximately W percent of the oil in place with I PV of water injected. For a five-spot pattern in an example reservoir with 10-cp oil, steam injection similarly showed lower ultimate recovery than water injection but no improvement in recovery rule. Introduction The thermal recovery method considered in this study is steam injection in a five-spot pattern. Pattern steam injection has been given little attention in the past, possibly because of some rather obvious disadvantages. Unless steam temperature is maintained throughout the entire swept area, the process will revert to simple waterflood with all heat being lost prior to reaching the oil bank. Also, the oil viscosity reduction takes place near the steam front and not around the producing wellbore, so that low producing rates must still be endured. This is the reason for the success of the steam stimulation, or cyclic injection, in which the fluids are produced from the same well used for injection. On the other hand, steamflooding can offer some advantages. Oil displacement is by four methods: (1) mechanical displacement by the condensed water, (2) viscosity reduction of the crude oil, (3) swelling of the crude oil, and (4) distillation of the crude oil in the steam zone. Although dependent upon the crude, laboratory experiments have shown displacements up to 80 percent by steamflooding. In addition, steam is a good heat transport medium, since it is cheap and has a high heat content. Previous Investigations Previous publications have reported methods for predicting recovery in a steamflood for linear and radial systems. Since no pattern sweep efficiency is taken into consideration, the recovery even from a radial system must be greater than from more realistic geometries such as the very common five-spot patterns. Probably the broadest coverage is given by Willman who reported experimental results and offered a method of predicting recovery for a radial flow system. They concluded that both hot water and steam injection recover more oil than an ordinary waterflood, and that steam injection could yield recoveries "as much as 100 percent greater than by water flood." They also concluded that both the heat requirements for a reservoir and the residual oil remaining in the reservoir after steam injection were independent of the amount of oil originally in place, that short exploitation times were desirable, and that a high percentage of net sand in the reservoir with a high initial oil saturation was desirable. The method assumes that the flood occurs in three concentric cylindrical zones: (1) an inner steam zone, (2) a central hot water zone, and (3) an outer cold waterflood zone. Displacement in the steam zone is based on laboratory-determined residual oil saturations while the hot water and cold water zones use the conventional Buckley-Leverett equations. Although the results shown by Willman et al. are for a radial system flowing out from the well to an assumed external circular boundary, their equations did

Jan 1, 1969

By E. C. Harder

INTRODUCTION FEW mineral deposits have in recent years attracted such general and Widespread attention as the Brazilian iron-ore deposits, due mainly to the quantities of rich ore occurring here, in contrast to the ever-decreasing grade of ores shipped from many large producing iron-ore districts of the world. The general average grade of the iron ores shipped from the Lake Superior district' has decreased to approximately 50 per cent., natural, in recent years. The Rubio ore of Bilbao, Spain,2 in 1890 averaged 55.5 per cent. metallic iron, dried; in 1902, 52.8 per cent., While at the present time a large proportion of the ores shipped from Bilbao are obtained by reworking the old dumps. In northern Sweden, where large magnetite deposits have only in recent years been extensively developed, selective mining is even now necessary in order to obtain high-grade Bessemer ores. During the last two years the iron ores of Chile have attracted much attention on account of the activities of the Bethlehem Steel Co. and others in the Chilean iron-ore region. Many of these ores are of good grade, yielding 67 and even 68 per cent. metallic iron, but judging from the Writer's observations in this region a large proportion of them Will be found to he of non-Bessemer grade. The most important variety of iron ore in Brazil is hard, dense to specular hematite, occurring in Minas Geraes. A large number (89) of analyses of this type of ore have been averaged, 3 giving the following composition: Per Cent. Iron 69.65 Phosphorus 0.0125 Silica 0.24 Combined H,0 0.38

Jan 10, 1914

By Frank Firmstone

In April, 1873, No. 2 furnace at the Glendon Iron Works being out of blast, it was decided to alter it from an open to a closed top. The three side flues, through which a part of the gas was formerly taken off, were 15 feet below the top, and as, for various reasons, it was not convenient to cut new flues through the brickwork at the top, as is commonly done with closed-top furnaces, a modification of Coingt's charger was employed. This apparatus, as figured by De Vathaire,* consists of a cup or hopper, like that used with the cup and cone, and a central pipe for taking off the gas, which descends some distance into the furnace, and has a projection around it forming a seat for a ring of a triangular cross-section, which closes the opening between the cup and the central gas-pipe. The charge is put into the cup, and by lowering the ring, is thrown into the furnace, a part going outside of the ring toward the walls, and a part through the inside toward the gas-pipe. In this form the apparatus was not applicable, for: 1st. With a gas-pipe three feet in diameter, in a top eight feet in diameter, the openings left by lowering the ring would not be large enough to let lump coal pass through. 2d. For the charger to shut tight, the ring must bear equally against the projection made for it on the gas-pipe, and against the edge of the cup. This would not be difficult to effect when the apparatus is first put up, but a comparatively small change in the relative position of the parts, such as is almost certain to occur from expansion, would cause the ring to touch the pipe or the cup, whichever happened to be the lower, first, and leave a leak between it (the ring) and the other. In the plan adopted (Figs. 5 and 6, Plate I), the central opening in the ring is closed by the bottom of the gas-pipe, whereby more room is left for the passage of the stock when the charger is open, than if the pipe descended into the furnace; and the pipe, instead of being rigidly supported, rests on the ring, when the charger is closed, and follows it for two or three inches as it opens, until stopped by the counter-balance lever C. When the ring is raised to close the furnace top, it comes in contact first with the bottom edge of the gas-pipe, then both are raised together, until stopped by the ring touching the edge of the cup. In this way a good joint is made at both places.

By A. M. Hall

SULPHUR, even in small amounts, may often be harmful to nickel and high-nickel alloys, causing impairment of mechanical strength and destruction of malleability and ductility, as shown by Merica and Waltenberg.1,2 It may act. either in the form of nonmetallic inclusions produced in the liquid state during furnacing or as reaction products resulting from its diffusion into the solid metal. In recognizing the action of this element, ability to identify its various forms by means of the microscope is often of considerable importance, especially when direct quantitative methods are inapplicable. [ ] Of the sulphur compounds associated with nickel and high-nickel alloys, the sulphides that may be found in malleable nickel, Monel? and Inconel? are an important group. These sulphides were investigated by metallographic methods in order to provide descriptive data by which to identify them. The nominal compositions of malleable nickel, Monet and Inconel are given in Table I. The term "sulphide" is employed here in a very general sense, to designate a substance in which sulphur and one or more metallic elements are combined. The term includes any combinations of compounds and solid solutions. METHOD OF INVESTIGATION Three groups of small laboratory melts were made, one group to represent each of the three types of alloy under investigation. Within each group, a number of ingots with a sufficient variety of chemical analyses were prepared so that the effect of each of the elements entering the complete commercial alloy could be isolated and observed. In most cases, to facilitate metallographic study by exaggerating the number and size of the resulting sulphides, somewhat greater amounts of the minor elements were added than are present in the commercial alloys. Likewise, considerably more sulphur was added than is normal, but not enough to complicate the system. Transverse sections were cut at a point one third of the distance from the butt to the head of each ingot, polished and examined with an inverted stage metallograph equipped with a combination polarizing-analyzing vertical illuminator. The light source was a tungsten-mercury vapor arc lamp.

Jan 1, 1943

By W. E. Bearce

The recent concern for the recovery of even the finest fractions of coal preparation plant feeds has created needs for new equipment. Thermal dryers currently available have difficulty reducing the filter cake moisture on down to the desired point. This difficulty involves 1) the physical problem of handling this wet, sticky material and making each particle accessible to the hot gases, and 2) removing the extremely fine dried particles from the cooled gases. The dryer described in this paper handles the first of these problems, and eliminates the second by the substitution of steel balls for air as the heat transfer medium. As a general statement, the cost of preparing coal for market is inversely proportional to the size of the lumps or particles. In the not too distant past the finer sizes were discarded as being uneconomical to treat and this practice might be still continuing if it were not for the insistence of the public that this material be kept out of our streams. This being the only cost-free outlet, the disposal of fine refuse became a significant item of expense in every preparation plant. When this happened it was only reasonable to look to the recovery of the values in this material, not only to defray this expense, but to reduce the tonnage which had to be wasted. There seemed to be no device available suited to reducing the moisture in this material to what the market requires. All of the fine coal dryers commonly employed make use of air to bring the heat of combustion into contact with the coal particles. Any device employing air as a heat transfer medium, has the following two strikes against it in attempting to handle 28 mesh by 0 filter cake: 1) It is practically impossible to bring the hot air into intimate contact with the enormous number of fine particles stuck together in the cake. 2) Even if this can be effected, it is impossible to remove the dried coal from the air. A wet scrubber must be employed, the discharge of which must go back to the filter and dryer as a circulating load of the most objectionable sort, being the extreme fines. Various compromises have been used to cope with the problem of drying this relatively small tonnage of high moisture coal. Often some of the dried coal is mixed back with the feed to the dryer in an attempt to make the mixture more handleable and more available to contact with the hot air than the filter cake alone would be. This may help to some extent with the first problem but it does nothing about the second and a dryer operated in this way has to be oversized. Sometimes the filter cake is mixed with a coarser fraction for the same reason. Here again, while this may make a mixture (the particles of which are more readily brought into contact with the hot air), the problem of getting the fine coal out of the air remains and a larger percentage of the total coal to be dried is handled by the most expensive means. Mechanical dewatering has accounted for more and more of total coal drying lately and in many cases would satisfactorily handle the whole load, down to 28 mesh, if there were a means available for doing a good job on the —28 mesh by itself. The dryer which is the subject of this paper was designed expressly for doing this job — drying fine material by itself regardless of how wet it may be to start with, how fine it may be, or how gummy and sticky these properties in combination may make it. The essential features are depicted in Fig. 1. A rotating cylinder is supported on a frame in such a way that one end may be raised or lowered by hy-

Jan 1, 1968

By J. Gurland

The effect of four different second-phase additions on the strength of composite alloys with a common matrix was investigated. The four compositions each consisted of 85 pct by volume of silver with additions of 15 pct of either tungsten, molybdenum, tungsten carbide, or nickel. These particular additives were chosen because of their low mutual solid solubilities with silver at room temperature, the alloys consisting essentially of a dispersion strengthened silver matrix in which the second phase is distributed randomly. Test specimens were prepared by a powder metallurgy procedure consisting of ball milling the mixed powders, compacting, and sintering at 920°C for 1 hr in hydrogen. The constituent powders were of CP quality and of particle size between 2 and 10 ?. The compacts were subsequently hot pressed at 1000 psi and 1400° in an Inconel die, coined at room temperature at 60,000 psi and finally annealed and outgassed in vacuum at 800°F. The microstructures of the alloys are shown in Fig. 1, and the microscopically observed porosity grade was A-2 or better as evaluated by ASTM Recommended Practice B 276-54. The properties of the sintered compacts are listed in Table I, and the load-deformation curves in bending are shown in Fig. 2. The samples, of rectangular cross section, were loaded at the center of 58 in. span, and the reported stress was calculated on the basis of linearly elastic behavior in order to allow the comparison of specimens of slightly different dimensions. It is apparent that the tungsten, molybdenum, and tungsten carbide alloys exhibit very similar deformation curves. The moduli of elasticity were determined from the slopes of the stress-deflection curves at small loads. The measured values agree quite well with those calculated by the strength of materials approximation proposed by Paul1 for the elastic constants of mixtures, the calculated values being 15.0, 15.0, 17.4, and 13.4 million psi, respectively, for the tungsten, molybdenum, tungsten carbide, and nickel combinations with silver. The strength of the Ag-Ni composition is appreciably lower than that of the other three alloys. The discrepancy between the two groups is accounted for by the following characteristics of deformation and failure which were observed microscopically during the tests: A) The deformation of the W, Mo, and WC alloys did not involve the second phase particles to any appreciable extent. Slip and fracture took place in the silver-rich matrix alone, although the fracture path generally skirted the particles by favoring the phase boundaries. The deformation proceeded according to the following sequence: 1) formation of small, discontinuous microcracks in areas of the matrix adjacent to a particle, 2) general slip in the matrix and extension of cracks, 3) failure of specimens by propagation of cracks through matrix. The near coincidence of the 3 load-deflection curves suggests that the nature of the second phase particles does not decisively influence the plastic behavior of composite alloys of this composition as long as the particles do not undergo any considerable deformation themselves. B) A markedly different behavior was exhibited by the Ag-Ni composition where the relatively low flow strength is associated with the low yield strength of the nickel grains. Slip in the nickel grains was first observed at a stress of approximately 10,000 psi, although failure, at a later stage, took place by the propagation of cracks through the matrix. The ductility of this aggregate, in which both components deform plastically, is appreciably greater than that of the elastic-plastic composites. In summary: 1) The measured values of the moduli of elasticity of the composite alloys under discussion are in good agreement with the "strength of materials" approximation proposed by Paul.' 2) The overall plastic behavior of these particle-strengthened alloys is unaffected by the nature of the second phase particles, if the latter remain elastic. This work was supported by the Office of Naval Research. The experimental results are presented

Jan 1, 1962

By L. H. Levenson, Charles S. Barrett

Numerous determinations1-' of the texture of cold-rolled polycrystalline iron, steel, and ferritic alloys have been made with good agreement among the various observers as to the principal features of the texture common to all, but there has been no adequate explanation of the texture in terms of, the behavior of individual grains. This study presents an explanation of the texture based on the observed rotation of single crystals when deformed in a manner similar to a grain in the aggregate, a method we have found useful in leading to a better understanding of compression and tension textures;8,9,10 in particular, the aim has been to determine experimentally the end orientations of rolled single crystals of iron. These are discussed in connection with the point of view of Weverl and of Boas and Schmid2 that the rolling texture is a simple compression texture (compression normal to the rolling plane) superimposed on a simple tension texture (tension in the rolling direction), and the point of view of Kurdjumow and Sachs3 that three ideal end orientations exist. Experimental Method The single crystals used were in the form of disks cut from a stock of crystalst pre- pared in this laboratory by a strain-anneal method from mild steel decarburized and purified in hydrogen, the details of which have been described elsewhere.11 To ensure maximum elongation in the rolling direction and to simulate approximately the rolling of a grain in an aggregate, lateral flow was constrained by placing each crystal in a close-fitting hole in a plate of copper or iron of equal thickness and rolling the plate and crystal together. About one-third of the crystals were rolled in a "sandwich" pack by adding top and bottom cover plates. The two-high mill used had 8-in. diameter rolls and was operated at 15 r.p.m. The initial diameter of the crystals was between 1/4 and 1/2 in., while the starting thickness varied from 0.031 to 0.376 in. With a single exception, which was rolled 63 per cent, the crystals were rolled to a final reduction in thickness of 82 to 97 per cent in 20 to 40 passes, alternately changing the sense of the rolling direction. The initial orientations of the crystals were determined either by X-ray back reflection12 or by optical reflectionl3 from etch pits; the mean final orientations were determined by X-ray Laue photograms using molybdenum, silver, or tungsten radiations, by optical reflection, and in many cases by both methods. Results Twenty-six crystals were studied. It was found that there were three typical be-

Jan 1, 1941

By John Chipman, Carl F. Floe

A year ago the authors published a paper on the solubility of sulphur dioxide in molten copper.l The data in that paper agreed closely with that obtained by previous investigators, which, however, did not agree with the theoretical predictions for solubility of triatomic gases of this type. It has generally been assumed that the reaction of solution is: 6Cu(l) + SO2(g) = Cu2S (in Cu) + 2 Cu2O (in Cu) [I] _ (CU2S)(CU2O)2 K = (Cu)6(Pso2) [2] Neglecting the slight change in copper concentration and considering that the concentrations of sulphur and oxygen are both proportional to the volume of gas absorbed, it follows that this volume should be proportional to the cube root of the pressure. It was found that a plot of the volume absorbed versus the cube root of the pressure gave a straight line, but that this line did not pass through the origin. Calculations of the equilibrium constant for the reaction showed that it was fairly constant for pressures above 100 mm. but that actually it approached zero at lower pressures. The conclusion was made therefore that the solubility as determined could not be expressed by Eq. I or by any other simple equation, particularly at low pressures. Other investigators have concluded that the solubility of sulphur dioxide in copper as well as in several copper alloys is more nearly proportional to the square root of the pressure.* Such a conclusion, however, does not satisfactorily account for the results, even when rather complicated mechanisms for the solution are assumed. The highly improbable speculations of Lepp2 and of Schneider and Esch3 based upon hypothetical dissociation pressures of Cu2O and CU2S dissolved in copper illustrate the type of reasoning that has been used to account for the discrepancy. In the discussion of the previous paper, the authors pointed out that the discrepancy might possibly be due to impurities in the copper, although the purest form available was used. Further consideration of the problem suggested that the impurities likely to have the greatest effect on the solubility of so2 in copper were oxygen, sulphur and carbon. Accordingly, further experiments have been made to show the effects of these elements. Experimental Methods The apparatus used for measuring solubility was essentially the same as that shown in the previous paper. However, since it was desired to make measurements at low pressures, a McLeod gauge was added and 6-mm. glass tubing was substituted for the capillary. This increased the "hot volume" considerably but was necessary in order to obtain good vacuums in a reasonable length of time. A mercury diffusion pump was also installed.

Jan 1, 1942