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By H. Rosenthal, A. L. Jamieson

The action of mercury on stressed brass to produce cracks was known before Moore, Beckinsale and Mallinson1 showed that actual season cracking did not occur spontaneously but could be induced by ammonia. These investigators studied other substances, including diphenylamine, without finding that anything other than ammonia could cause season cracking Grimston2 reported season cracking in cartridge cases stored in wooden boxes wetted with dilute sulphuric acid pickling solution. Season cracking associated with sulphur dioxide, water vapor and air has been reported by Johnston,3 although he reported that trimethylamine and pyridine did not cause cracking. Jevons4 has ascribed season cracking of brass in certain instances to trimethylamine, "aldehyde amine," "ketone amine" and pyridine, but no experimental work was done evidently to prove this definitely. Pyridine was investigated by Morris,5 who found it to have considerable cracking power. In the present investigation, the object was a qualitative evaluation of a number of representative amines with respect to their ability to cause season cracking. Thus it was desired only that an appreciable vapor pressure of each amine be obtained in order to make the test as severe as possible, without attempting to test equivalent concentrations for comparative purposes. MEthods Specimens TWO types of specimen were used: 1. Unannealed 70-30 brass CUPs formed from 0.040-in. thick sheet. Height of cup Was 13/8 in. and diameter was 17/8 inches. 2. First draw pieces of caliber .50 cartridge cases in the unannealed condition (70-30 brass)- The cups were representative of a thin wall and thin base specimen, whereas the draw pieces have a thick base (1/4 in.) and a thick wall (approximately 3/32 in.). Both types of specimens contained high residual stress and cracked in less than one minute in a solution of I per cent mercurous nitrate and I per cent nitric acid provided that this was receded by a 30-sec. pickle in 40 per cent nitric acid. Specimens were prepared as follows: (1) degreased in trichlorethylene, (2) rinsed in H2O, (3) pickled 5 min. in 10 per cent by volume H2SO4 (1.84 SP. gr.), (4) rinsed in H2O, and (5) dried. Amirtes Tested In selecting the amines, representatives of the three series of amines, and one series of substituted amines were chosen. The aliphatic series was represented by the methyl and ethyl primary, secondary and tertiary amines. These are the simplest aliphatic amines. For the aromatic series, the phenyl primary, secondary and tertiary amines were selected as being the simplest. The heterocyclic series was represented by pyridine, which is a simple heterocyclic base (tertiary amine).

Jan 1, 1944

By J. H. Keeler

The tensile characteristics of Zr-Fe binary alloys containing up to 5 atomic pet Fe are reported for the temperature range —195o to 500°C. A linear relation between stress at constant strain and volume fraction ZrFe2 was found. The coincidence of data from unalloyed zirconium with zero volume fraction ZrFe2 indicated little or no solid solution in IL-zirconium, in agreement with Hayes, Roberson, and O'Brien.' The absolute increase in strength due to particle strengthening, although decreasing with increasing temperature, was a greater percentage at high temperature. ZIRCONIUM is of interest for use in nuclear reactors because of its low neutron absorption, good corrosion resistance, and high melting temperature. The alloying of zirconium with iron has been considered as a means of increasing the mechanical strength of zirconium without seriously increasing the neutron absorption " over that of unalloyed zirconium. The Zr-Fe system has a eutectic at 934°C and 23.7 atomic pet Fe and a eutectoid at 800°C and 4.0 atomic pet Fe. The zirconium-rich end of this system determined by Hayes, Roberson, and O'Brien' is shown in Fig. 1. The intermetallic phase coexisting with a and ß-zirconium has been reported as Zr2Fe3,1 with a,, - 7.04A, and as ZrFe2,2 face-centered-cubic, the phase being of the MgCu, type (C-15). It was more recently agreed to be ZrFe33 and face-centered-cubic. This intermetallic phase is essentially insoluble in a-zirconium, the hexagonal-close-packed modification; and the lack of solubility makes the system particularly interesting metallurgically. The system is strengthened almost exclusively by particles of in-termetallic phase, and there is very little solid solution strengthening to complicate the analysis. The Bureau of Mines, in its survey of zirconium-base alloys,' reported the tensile properties of Zr-Fe alloys made from chloride process zirconium, induction melted in graphite crucibles, and swaged at 850°C in iron sheaths. Additional data on these ZrFe alloys were given by Hayes, Roberson, and O'Brien.' Chubb and Muehlenkamp% have recently reported the strength of Zr-Fe alloys containing up to about 1.25 atomic pet Fe. These alloys were made from crystal bar zirconium, hot worked at 820°C, annealed at 700°C, and tested both at room temperature and at 316°C. Experimental Procedure The materials used in this investigation were high purity zirconium made by the iodide process and electrolytic iron. The composition of the zirconium as obtained by spectrographic analysis and the nominal composition of the iron are given in Table I. Alloy ingots weighing 100 g were made by are-melting under argon in water-cooled copper crucibles in a multihearth furnace."

Jan 1, 1957

By T. L. Joseph

S. T. Killian (Johnstown, Pa.)—This is one of the finest papers I have read. Tying in stoichiometric calculations with furnace performance and practice is a step which had to be taken sooner or later. The noteworthy difference between Dr. Joseph's type of calculations and regular blast furnace calculations is that the Ib mol system is used as a basis. With the Ib mol system, weights, volumes, and chemical reactions can all be expressed in the same equation. In the paper, wind, ore, flux, and fuel are all expressed as lb or lb mols. Probably Dr. Joseph does not realize it, but the vague word coke appears only twice in the entire paper. Lb of C and Ib mols of C are followed through reactions but the word coke appears only as 1560 lb coke per ton of pig and 1700 lb of coke per ton of iron. Obviously in order to understand furnace reactions, the coke should be expressed as lb or lb mols of C. Furnaces can also be compared more easily. In some respects the paper is too thorough and too complete. The effects of the metalloids reduced into the iron upon the top gases represents a difference of less than 3 pct of the CO formed in the bosh. Due to the completeness of the calculations in relation to the CO/CO2 ratio, this was included and was necessary. However, the exclusion might have enabled more furnace men to follow the lb mol system of calculations through the blast furnace to a better degree. By considering only irons of similar analysis, this part of the calculations might have been omitted. However, if this had been done, total rewriting of the paper later would have been necessary in order to make the work complete as it is now. It also would not have been nearly as authoritative. In the paper, there appears the reaction: H2O + CO ? CO2 + H2 [I] Dr. Joseph states that he did not take this reaction into consideration in any calculations pertaining directly to the paper. The piobable reason- for this is that although it contains all the main reacting top gases except N2, it is rather inflexible since it is monomolecular in relation to each of the reacting gases and does not tie in with the gasification of C. Actually the reactions: H2O + C ? CO + H2 [2] 2H2O + C ? CO2 + H2 [31 and the solution loss reaction: CO2 + c ? 2c0 [41 tend to assume an equilibrium through the reaction: H2O + CO ? CO2 + H2 [I] which should be considered a balancing or equilibrium reaction. Reactions 2, 3 and 4 permit furnace conditions to balance with the CO/CO2 ratio and H2 formation. They tie in with the solution loss. Reaction 1 unites them chemically. Probably the best calculation to make at this time would be to try to find the relative importance of the CO2 from the flux and the H2 in the dilution on an actual furnace gas analysis. For this purpose the Dob-scha-Carnegie-Illinois paper—"Effect of Sized and Sintered Mesabi Iron Ores On Blast Furnace Performance" is chosen. This paper was presented before the blast furnace section of the AIME in 1948. This represents the best large scale furnace operation available to me. Unfortunately the changes were brought about by beneficiation of the burden and not by changes on one burden. In choosing the basis for the calculation in relation to the furnace, 100 mols of dry top sgas is chosen. This leaves something to be desired inasmuch as the nitrogen basis is changing but I believe it will be better understood than any other type and it is the easiest to use.

Jan 1, 1952

By J. E. Gould, H. J. Hand

MANY independent studies are being made on slag-metal relationships in the open-hearth furnace, and these studies cannot help but result in an ultimate improvement in the quality of open-hearth steel of both the open and killed types In maintaining quality control at the National Tube Company's plant, emphasis has been placed on an evaluation of the iron oxide content of the steel in as quantitative a manner as possible, in order that the most desirable level of oxidation might be obtained for a given type of steel, and to secure a more precise basis for final deoxidation In the past, various methods were used for estimating FeO content of the metal at tap to ensure uniform and thorough deoxidation of killed steel, avoiding over-deoxidation to minimize the amount of inclusions present and to make as sound a steel as possible For the open-type steels, such control involves obtaining the necessary level of oxidation for the most suitable action of the steel in the molds to provide good surface quality and cross section for the specific grade involved While rapid analytical methods are available for determination of FeO in the liquid metal, such methods are still not sufficiently rapid for routine control on the open-hearth floor, nor do such analyses provide information as to what causes high or long FeO values The method of sampling can still be considered a problem in view of the variability encountered in taking simultaneous duplicate tests With the accurate rapid methods now available for determining carbon in the metal, estimating slag basicity and obtaining temperatures of liquid metal, it was believed possible to determine the influence of the various furnace reactions in establishing the state of oxidation at a given time Simultaneous slag and metal tests were used in this analysis, aided by statistical methods, to determine the factors that affect the metal FeO, and also to make a quantitative evaluation of these factors Data obtained are from actual furnace operations, the metal test being of the spoon, Herty type, and taken in duplicate. Metal temperatures were taken with the open-tube bath pyrometer developed by the Research Laboratory of the United States Steel Corporation This method of taking open-hearth metal temperature was invented by Collins and Oseland,1 and was developed into its present form by L 0 Sordahl,2 of the Research Laboratory The instrument and its mode of operation have been fully described by Sordahl and Sosman in three publications 3,4,5 Slag components were obtained by chemical analysis Data were taken from four 165-net-ton furnaces during the working period of the heat Recognizing that additions of ore affect the

Jan 1, 1942

By Fred C. Bond

THEM is acute need for a method that will measure the size distribution of finely divided materials, particularly when the particle sizes are smaller than the openings of the finest screen cloth regularly available for testing. Several methods and types of apparatus are in common use, but none are entirely satisfactory for all purposes. The commonest methods are microscopic grain counts, elutriation by liquids or air, and sedimentation. Valuable results have been secured by air elutriating devices, typified by the Haultain Infra-Sizer and the Pearson Air Analyzer. These are especially useful in obtaining sized fractions that can be examined and analyzed separately. They are particularly advantageous because the sizes of the samples produced are adequate for a considerable amount of subsequent manipulation and testing. The sedimentation methods, such as the Wagner and Klein turbidimeters, and the sedimentation balance, do not deliver sized fractions, but they do provide a means for reasonably rapid comparative determinations of fineness and surface area, which are important in many industries. The sedimentation balance consists essentially of a balance pan suspended in a liquid that contains falling particles. These are weighed as they settle onto the pan, and the time rate of settling is determined. The size distribution is computed from the settling rate. The balance appears to be inherently more accurate than any of the other methods, and it has served a useful purpose in the study of numerous problems, but there have been limitations which have restricted its scope of application. Because of the essential simplicity of the method, it was felt that intensive investigation might lead to modifications that would make it a valuable tool for the operators in industries that require precise information regarding the results secured from grinding equipment. A large number of size-distribution determinations below 200 mesh were required in connection with a particular research problem in fine grinding. The sedimentation balance was used in this investigation, and a technique was gradually developed that ultimately gave good results. A serious difficulty appeared early in the work. It was discovered that less material always settled on the sedimentation pan and more on the bottom of the containing jar than could be accounted for by calculation, and also that the material that settled to the bottom of the jar outside the edges of the pan was considerably finer than that on the pan. This segregation was so great that the distribution obtained for the finer sizes was obviously very much in error; material ground to about the degree of comminution of cement might have only 60 per cent of the calculated weight actually settling on the pan, and the error increased with the fine-

Jan 1, 1939

By Herbert H. Kellogg, Nathaniel Arbiter, Arthur F. Taggart

THE experimental work herein described is presented in support of the following broad hypothesis: Conditioning of metals and metallic sulphides by amine collectors involves metathetic reaction at the solid surface between the collector and an oxidized metallic compound, to produce a coating comprising an amine-bearing compound of low solubility in the system. The type of reaction is different in acid and in basic solutions; both types may occur simultaneously in near-neutral pulps. EXPERIMENTAL The experiments comprise contact-angle tests with a variety of metals and metallic sulphides and extraction tests on ground chalcocite. Contact-angle tests were made principally on metals. Covellite paralleled metallic copper in amine solution at pH 8.8 (Table 3) and in alkaline water, but maintained an angle of about 70° in 10-3 HCl solution, where metallic copper lost its angle. The tests with anionic collectors (Table I) indicate that the behavior of metals in general is parallel to that of their minerals in anionic solutions. It is believed that this is generally true with cationic collectors also, but the covellite test is a warning against a broad assumption to this effect. All test specimens were mounted in Transoptic.* All tests in conditioning solution were preceded by a test in distilled water; cleaning and polishing were continued in every case until the angle in water was zero. Subsequent transfers into and out of solutions and test cells were made in such a way as to prevent exposure of the surface to air.1 The amine used was primary laurylamine, Armour and Co., AM-1120. It was used in the form of the hydrochloride, obtained by precipitation with gaseous hydrochloric acid from an ether solution of the amine, and purified by two recrystallizations from ether-alcohol.2 Inorganic and other test reagents were standard laboratory grades. [ ] Temperatures were not controlled; the probable range of test-solution temperatures is 65° t0 80°F.

Jan 1, 1943

By J. H. Brophy, J. Wulff, H. W. Hayden

The mickel-activated sintering of tungsten occurs in two stages of densification. A kinetic analysis of the second stage has been based on an appropriate model of the process. As in the first stage, the rate-controlling mechanism for the second stage is also the solution of tungsten in the nickel carrier phase. The transition from the relatively rapid first-stage results from the spherozdization of pores and the initiation of grain growth. Finer grain size due to higher-nickel content leads to more rapid and higher degrees of densification 1 HE sintering of tungsten is accelerated by small additions of nickel, cobalt, and iron.' Experimental evidence in detail has shown that nickel-coated, hydrogen-reduced tungsten powder may be sintered to more than 90 pet of theoretical density at l100o C.2, 3 Simultaneously, a kinetic analysis of the process showed that it took place in two distinct stages. In the first stage, nickel evidently served as a carrier phase through which tungsten atoms could move. This stage was kinetically similar to the "solution-precipitation" step postulated when the carrier phase is a liquid,4 although in the Ni-W case, there is no evidence of the existence of a liquid phase either in equilibrium phase relationships or in microstruc-tures at the temperatures under consideration. It has been shown that this stage corresponds to a process which is rate controlled by a phase boundary reaction.3 More recent evidence has been presented5 showing that after the initial rapid stage of sintering, densification continues in the final stage but at a slower rate, although no mechanism for this stage of densification was defined. An analysis of later stages of densification in solid state sintering has been presented,6 but it is not directly applicable in the present case of activated or carrier phase sintering. It is the purpose of this investigation to study the final stage of nickel activated tungsten sintering in greater detail The effect of varying nickel content has been examined, and a possible kinetic mechanism defined. EXPERIMENTAL PROCEDURE AND RESULTS Commercial hydrogen-reduced tungsten powder from Wah-Chmg Corp., having a nominal particle size of1 µ and a B.E.T. specific surface area of 5500 sq. cm per g was mixed with aqueous solutions of hydrated nickel nitrate in proportions sufficient to produce nominal compositions of 0.25, 1, 3, and 5 wt pet Ni. This solution was then evaporated to dry-ness at approximately 150" C for 15 hr. Following evaporation, the resulting powder cake was broken with a mortar and pestle and reduced in hydrogen at 800oC for 1 hr. Following reduction, the powder

Jan 1, 1962

By C. S. Smith

It is the policy of The Metallurgical Society to provide, in the TRANSACTIONS OF THE METALLURGICAL SOCIETY OF AIME, a prompt and accurate medium for publication of reports of significant new research in both the scientific and engineering aspects of metallurgy. Papers submitted to the Society are judged by competent reviewers according to established criteria for technical merit, accuracy, originality, and presentation. STAFF: Editor, Dr. Gerhard Derge; Editorial Assistant, M. A. Redmyrski; Staff Coordinator, James J. Burke. THE METALLURGICAL SOCIETY: W. R. Hibbard, Jr., President; J. C. Kinnear, Jr., Post-President; John Chipman, Vice President; T. D. Jones, Treasurer; R. W. Shearman, Secretory. PUBLICATIONS COMMITTEE OF THE METALLURGICAL SOCIETY: A. W. Thornton, Chairman- Dennis Carney John Chipman J. C. Fulton J. H. Hollomon H. H. Kellogg, A. E. Lee, R. Moddin, J. D. sullivan, and D.' Swan. Review and selection of manuscripts is under the supervision of the following Publications Committees: Extractive Metallurgy Division: T. B. King, Chairman; S. J. Dickenson, R. P. Hermsdorf, R. Schuhmann, Jr., and P. T. Stroup. lnstitute of Metals DM lion: Robert Maddin, Chairman. F. Lincoln Vogel, Jr.. Vice chairman. W. A. Backofen R. W. Boliuffi J. H. Bechtold' M. B. Bever R: S. Busk C 6. Goetzel poul Gordon C. D. Grobom, Jr., Robert F. Hehe-mann R. I. Joffee F. i. Joumot Jr. lrvin R. Kromer, A. J. Leno. Horold Morgolfn, C. J. McHargue, Russell A. Meussner, J. B. Newkirk, H. W. Paxton, G. E. Pellissier, I. S. Servi, Alon U. Seybolt, A. J. Shaler, and Jack Washburn. Iron and Steel Division: J. C. Fulton, Chairman. T. B. King, F. C. Laogenberg, W. O. Philbrook, and T. 0. Winkler. Publishod bimonthl by the American Institute of Mining Metollurgicol and Petroleum Engineers Inc., 29 West 39th Street, New York 16, N. Y. Telephone: PEonylvanie 6-9220. Subscription $20 par yew for non-AIME members in United States and North, South and Control Americo $25 foreign; $5 for AIME members. Single copies, $4.00, single copios foreign $5,00. The AIME is 1958 by the Amarican mode or opinion axpressed in it* publications ... Copyright by the Amarican lnstitute of Mining, MataIlurgicol, and Petrolum Engineers, Inc,. . . Reg. istered cable address AIME New Yark ... Indexed in Engineering Inderx, Industrial Arts ...Index and Chemicol Number5. Absrtracis . . . Second class postage paid at New York,Indor. N. Y., Industrialond Ann Arbor, Mich.

Jan 1, 1959

By T. M. Anderson

From the start of production in 1915 until 1948, underground block caving operations accounted for all of the ore production of Inspiration Consolidated Copper Co. Open pit development work began in 1947, and ore production from the open pit commenced in March 1948. Thus began the transition from underground to open pit mining which continued until August 1954. Since then, open pit mining has accounted for all ore production which presently averages 105,000 tons of ore and 75,000 tons of waste rock each week. Open pit mining operations at Inspiration is carried on in two separate pits-the Live Oak Pit and the Thornton Pit. The Live Oak Pit covers an area of approximately 1500x3000 ft and the Thornton Pit, 2500x2000 ft. The geographic centers of the two pits are 4000 ft apart and, at their nearest point, the surface slopes are 500 ft apart.

Jan 1, 1961

By Lillian Erskine

While brass and other copper alloys have long been listed as offering health hazards to their workers, it is questionable if the metals involved are alone responsible for the trades' records of morbidity. The entire science of foundry sanitation is the product of the past two decades; and the best standards now operative would have been regarded as little short of revolutionary prior to 1910. The special handicap to the conservation of the health of the brass founder's employees has been the fact that, unlike the iron founder, his business could be profitably carried on in almost any small and unsanitary quarters. As a result, writers on occupational disease have accepted brass chills or brass founders' ague as an inevitable feature of the trade; and respiratory disabilities, as well as phthisis and disturbances of the nervous system, are also included as prevalent among those employed. While there can be no question as to the basic accuracy of past investigations, there is every reason to doubt the necessity for an undue percentage of ill health among brass molders and casters who are safeguarded by scientific ventilating standards and by improving personal habits of sobriety. There is, however, need for a campaign of education as to the most approved practices and equipment whereby the employer may safeguard the health of his workers, and thereby reduce his labor turnover and increase his productive efficiency. Broadly speaking, copper, tin, and aluminum carry negligible health hazards. The toxic qualities of lead, however, are a menace; especially if scrap lead is recovered or bought for foundry processes. The rapid volatilization of zinc renders its fumes and flocculent condensation the chief problems in conserving the health of the brass worker. The frequent presence in the foundry air of traces of arsenic compounds, lead

Jan 1, 1919

By P. R. Swann, R. M. Fisher, W. R. Duff

Observations by transmission electron microscoPy of the microstructures in quenched Fe-A1 alloys provide the basis for revision of the Fe-A1 phase diagram. The diagram is characterized by first-order transitions between the disordered ferromagnetic a! solid solution and the two ordered phases FeAl and Fe3Al. However, second-order transitions showing corre-luted fluctuations in the degree of order near the critical temperature occur between the paramagnetic a! and FeAl and the FeAl and FeAl phases. ELUCIDATION of the true nature of the Fe-A1 equilibrium diagram has proven to be an extremely challenging problem as evidenced by the fact that six quite different versions of the iron-rich portions have been published since 1958.&apos;-6 The most recent diagram shown in Fig. 1 was proposed by Rimlinger6 based on X-ray diffraction analysis and dilatometry. He shows the single-phase fields of the ordered phases of the types FeAl(L20) and Fe3A1(D03) and the disordered bcc Fe-A1 solid solution, a, separated from one another in every case by large two-phase regions. Thus, he implies that in Fe-A1 alloys ordering always occurs via a classical phase transition. In contrast to this view, theoretical studies3&apos;" have concluded that the transitions a — FeAl and FeAl — Fe3A1 should be second- or higher-order in character. A further revision of the Fe-A1 diagram of state is presented in Fig. 2 based on our previous8,9 and current observations by transmission electron microscopy of the microstructures found in quenched specimens. The average quenching rate was 50,000°C per sec and although this was sufficiently rapid to prevent Fe3A1-type ordering below -550°C it was not sufficient to suppress ordering of the type FeAl in the temperature range -650" to 800°C. However, ordering during the quench is easily recognized since the FeAl phase formed during holding at temperature rapidly develops large antiphase domains whereas FeAl formed during quenching has a very fine domain size, -50Å diam. Each symbol in Fig. 2 indicates the result of a micro-structural examination of specimens heat-treated (-1 hr) until equilibrium was established. The results will be discussed in the order of the points, A - Dl marked on both diagrams with reference to the phase fields, critical temperature, and "transition" ranges, respectively. The dark-field micrograph corresponding to point A is shown in Fig. 3 and was obtained using a 111 reflection of the Fe3A1 structure which reveals both a&apos;/4<111> and a&apos;/2<100> antiphase domain boundaries.10 The structure observed in this specimen is typical of single-phase Fe3A1 and shows no evidence for FeAl or any other additional phase. The dark-field micrograph shown in Fig. 4 corresponds to point B on the two diagrams. It was taken with a 100 FeAl reflection which reveals a/2(111) domains and exhibits the typical structure of single-

Jan 1, 1970

By E. A. Moulder

The mining industry is continually faced with problems involving dewatering, pollution, water supply, leaching and hydrochemical mining and prospecting. Greater application of the principles of ground-water hydrology to solution of these problems promises improved operating efficiency, increased safety and better public relations. Estimating the magnitude of dewatering for a proposed mine may be a major factor in determining the feasibility of proceeding with mine development. Diverting the source of ground water to an abandoned mine may save costly treatment of acid-mine drainage. Development of a large ground-water supply near an ore deposit may enhance the possibilities of a leaching operation. Detection of certain dissolved minerals in water from springs or wells may lead to hitherto unknown mineral deposits. Current efforts of industry, educational institutions and government are making these kind of events more commonplace. Dewatering of Mines The magnitude of dewatering problems was dramatized by a flooding that occurred last year in a gold mine in South Africa. During drilling operations at the West Driefortein mine, a major fracture was encountered from which large volumes of water issued necessitating evacuation of 1350 men from the mine. Dewatering required an increase in pumping of more than 80 million gpd. Models of ground-water systems are being used to test alternate plans for dewatering mines. Using the models in conjunction with computer optimization programs may lead to minimizing costs of operation. In addition to computer simulation of aquifers associated with phosphate deposits in North Carolina mentioned in last year&apos;s report, two USGS employees developed a model to estimate the amount of pumping required to dewater a mine site in Colorado.

Jan 1, 1970

By J. F. Shirley, H. K. Burke

In January, 1964, three years of laboratory and pilot plant test work reached its culmination. The San Manuel Div. of the Magma Copper Co. switched its molybdenite extraction circuit from the sodium hypochlorite-ferrocyanide process to the new process described in this paper. The San Manuel Div. Concentrator of the Magma Copper Co. is located near San Manuel, Ariz., approximately 45 miles northeast of Tucson. The concentrator treats approximately 35,000 tons of ore per day containing about 0.85% copper and 0.025% molybdenite. The San Manuel ore body is a disseminated copper deposit in quartz monzonite and quartz monzonite porphyry. The primary copper mineral is chalcopyrite; minor amounts of chalcocite, bornite and covellite are also present in varying degrees. Pyrite makes up somewhat more than half the sulfide content of the rock. The molybdenite is nearly always found on fracture faces or associated with quartz veinlets.&apos; On January 9, 1964, the sodium hypochlorite-ferrocyanide process that had been used for molybdenite recovery was replaced by the following process: 1) A conditioning step with hydrogen peroxide, sulfuric acid, sodium cyanide and zinc sulfate. 2) A two stage rougher flotation step with stove oil and sodium ferrocyanide. 3) One cleaning step with sodium ferrocyanide. 4) One cleaning step with sodium hypochlorite and potassium ferricyanide. 5) Four cleaning steps with an anti-foam Exfoam 636 and potassium ferricyanide. COPPER CONCENTRATOR Since molybdenite recovery is closely allied with previous steps in the operation, the copper concentrator will be briefly described first. The ore is ground to approximately 5% plus 65-mesh and 65% minus 200-mesh in a two-step grinding circuit consisting of rod mills in open circuit and ball mills in closed circuit with rake classifiers. A straight forward rougher circuit producing only one concentrate is used. The rougher concentrate is combined with the discharge from the regrind ball mills and is then cycloned, with the overflow going directly to the cleaner circuit and the underflow going to the regrind mills. The feed to the cleaner circuit is approximately 90% to 94% minus 325 mesh. The cleaner circuit consists of two stages in which the tailing from the final cleaner stage is returned to the primary cleaner and the primary cleaner tailing is returned to the rod mill discharge at the head of the circuit. Approximately 0.013 lb of the allyl ester of amyl xanthate (S-3302) per ton of ore is added to the rod mills and approximately 0.006 lb of sodium isopropyl xanthate (2-11) per ton of ore is stage added down the rougher banks. The frother used is methyl iso-butyl carbinol (MIBC) and it is added at various points in the grinding and the rougher flotation circuits. Lime is added to the ball mills and/or to the rod mills to maintain the desired pH in the rougher flotation. The rougher flotation has been operated at various pH levels between 10.5 and 11.5. Fuel oil is added in the regrind mills at a loading of approximately 0.01 lb per ton of ore. Factors Which Directly Affect Molybdenite Recovery: It has been found at San Manuel that, to obtain maximum molybdenite recovery, an oily type flotation collector must be added in the grinding circuit. When molybdenite is crystallized in the characteristic platy form, which appears to be the case almost all of the time at San Manuel, its surface has a greater tendency to adhere to oils than water. 2 Of the several oily type collectors available on the market, the allyl ester of amyl xanthate seems to be the best molybdenite promoter. The floatability of San Manuel&apos;s molybdenite does not appear to be affected, at least up to a pH of 11.5, by lime. It has been reported that at several plant operations high lime alkaline circuits have adversely affected the molybdenite recovery.3,4 It has been found through microscopic studies that the bulk of the chalcopyrite will float before the molybdenite in both the rougher and cleaner circuits. It is necessary to add fuel oil to the regrind mills to enhance the

Jan 1, 1965

By R. Schuhmann

PROBLEMS in expressing, interpreting, and using size-distribution data recur in many phases of mineral dressing; therefore it is desirable that size analyses be expressed in such a form, either numerically or graphically, that comparisons can be made readily. The size distribution of comminuted material is a result of a specific physical operation on the material and therefore should be governed by some definite physical principle, or cause-effect relation. Although this principle has not been discovered, it has been found that the size distribution of comminuted, homogeneous solids may be expressed by relatively simple mathematical equations. Two equations in particular, proposed by Gaudin1 and by Rosin and Rammler,2 respectively, have stood out, both having wide demonstrated ranges of application. The form and the method of application of the two appear almost irreconcilably different on the surface, but, as will be shown, they are asymptotic in the fine sizes when expressed in the same units. This paper gives the results of a further study of the Gaudin and Rosin-Rammler relations, made with the object of developing a form of size-distribution equation that will be more usable and more significant-particularly in comminution studies, both for interpreting the nature of size distribution and for evaluating surface. The work is summarized in the following: I. An equation relating cumulative per cent finer to particle size in the fine sizes is derived from Gaudin&apos;s original equation. That equation relates weight per cent retained on one size and through the next larger size in a geometric series of sizes to size (of the retaining screen, for example). 2. Comparisons with Gaudin&apos;s equation and with the Rosin-Rammler equation show that the cumulative equation applies to the fine sizes of all size distributions that fit either of these earlier relations, and, furthermore, has some advantages over each. 3. A simple graphical method of surface calculation based on the cumulative-equation plot is evolved and illustrated. 4. Additional confirmation of the cumulative equation was obtained in the more severe test of sizing down to the limit of a sedimentation balance a sample of jaw-crushed quartz. The equation was closely followed over a 20o-fold range in size, from approximately 0.4 mm. (35 mesh) down to 0.0023 mm. (2.3 microns), the lower limit of the size analysis made. There is no indication that the equation will not hold further to well below 2.3 microns. 5. Calculations of the surface produced in the jaw-crushing test mentioned above showed that at least 8o per cent of the total new surface was on particles finer than 35 mesh (about ½ 5 of the crusher setting). The minus 35-mesh portion was only

Jan 1, 1940

By William M. Bowron

THIRTY years ago, when I stood on the cliff of red fossil iron-ore, on Red mountain, Jefferson county, Ala., I asked what were the geological relations of this remarkable deposit. In reply I was told that it was a limestone colored and saturated by some unknown but wholly external influences, and that at a reasonable distance from the surface the color would disappear. I could find no satisfactory explanation either of the nature of this wonderful external permeating influence, or of the cause of such a ferrous impregnation selecting this one particular bed of limestone, to the exclusion of the higher and lower beds of the same material which are not even stained. I. THE PRESENT THEORY. Referring to this subject, Dana says:&apos; "The clays, clayey sandstones and limestones of the Clinton epoch, through New York and the Appalachians, show that the mud-flats and sand-banks, and hence the shallow seas of the coast region, still continued. . . The beds of argillaceous iron-ore, which spread so widely through New York and some of the other States, south and west, could not have formed in an open sea, for clayey iron-deposits do not form under such circumstances. They are proof of extensive marshes, and, therefore, of land near the sea-level. The fragments of crinoids and shells found in these beds are evidence that they were, in part at least, salt-water marshes, and that the tides sometimes reached them." At first, this explanation seemed satisfactory, but the more I studied the ore the less satisfying the explanation became. 1. In the ore itself I found associated with the small particles of rounded matter (now consisting of iron oxide in which organic structure, if ever present, has become lost, though the

Nov 1, 1905

By T. L. Joseph

A study is made of the amount of solution loss necessary to maintain the reducing power of the gas stream in the blast furnace. Curves are presented to show the effect of solution loss, moisture in the blast, and carbon dioxide from the flux on the nitrogen in the THE blast furnace process is based upon the counter flow of gases and solids. As CO, N, and H, flow upward from the combustion zones, oxygen is acquired from the descending charge. In the reduction of iron ore, a portion of CO is converted to CO, and similarly a portion of H, is converted to water vapor. The inert N,, from the air used in combustion, passes through the furnace with little change. Its concentration is, however, decreased by reactions such as direct reduction and solution loss which increase the volume of CO in the gas stream; Similarly the evolution of C02 from the limestone also dilutes the nitrogen. he purpose of this paper is to illustrate an idealized and simplified method of studying furnace processes by following changes in the gas phase between the tuyeres and the stock line. A more specific objective is to evaluate the effect of solution loss upon the CO/CO, ratio in that region of the furnace in which FeO is reduced to metallic iron. This last stage of reduction requires relatively high CO/CO, ratios to exceed the equilibrium requirements. Solution loss or the reaction of COZ with C to produce CO has a pronounced effect upon the ratio of the carbon gases and is necessary to maintain the reducing power of the gas stream if the consumption of coke is low. It will be explained later that indirect reduction followed by solution loss is stoichiometri-cally equivalent to direct reduction. Calculations will be made to show how the composition of the gas in the region of the mantle varies with coke consumption and with different amounts of solution loss. Such calculations show the condi- tions under which gasification of C with oxygen in the charge is needed to maintain the reducing power of the gas. Equilibrium conditions for FeO and the carbon gases will be used to establish a minimum CO/CO, ratio below which reduction will not proceed. The manner in which carbon is gasified in the furnace, at the tuyeres with oxygen in the air or above the tuyeres with oxygen from the charge, will be a basic feature of all calculations. It is hoped that greater interest in the use of top gas as a means of following furnace reactions will be aroused by the calculations and generalized curves which are presented. Bosh Gas Equations Subject to some alteration by the amount of moisture in the blast and by direct reduction, the gas leaving the combustion zones of a blast furnace has a definite composition. Because a relatively small amount of oxygen is acquired from the charge in the bosh and in the crucible, the products of combustion undergo little change until they enter the shaft. Bosh gas is, therefore, essentially the products of combustion of carbon in a deep fuel bed with air. The relative weights and volumes of reacting materials are expressed by the equation: 2~ + 0? + 3.76N, = 2C0 $ 3.76NZ [I] Air Bosh Gas -air = 79% N? = 3.76) 21% 02 Starting with a known mass of C consumed largely by air, Eq 1, but partly by water vapor, Eq 2, the volume and C + H2O = CO $ H? [21 composition of the bosh gas can be calculated and subsequent changes followed as reactions take place at various elevations in the furnace. As shown in

Jan 1, 1952

Willet G. Miller, Toronto, Canada (communication to the Secretary): In his interesting paper Mr. Lindgren says: " As to ultimate results, it would seem as if we should be justified in concluding, with Prof. Suess, that the gold-supply of the world will gradually decrease if no further important improvements are made in the processes for the extraction of this metal; but regarding events so far distant no predictions may safely be made." It seems to the writer that no very important improvements require to be made in order at least to keep up the present production for many years to come. In many parts of the world there are large deposits of auriferous material which can be worked if present conditions are slightly changed. In the territory occupied by the Archean protaxis of the Province of

Jan 1, 1903

By T. M. Anderson

Open pit mining at Inspiration began in 1947 after 32 years of underground mining. Two separate pits are included in the operations: the Thornton pit, which measures approximately 2500 x 2000 ft, and the Live Oak pit, which is 1500 x 3000 ft. The geographic centers of the two pits are approximately 4000 ft apart, and at the closest point, the two slopes are only 500 ft apart. Today, much of the open pit mining is being carried out in areas which were broken by earlier underground block caving operations; less than 50% of the total material moved has required drilling and blasting. In the solid or virgin areas, the, material ranges only from soft to medium hardness, thus simplifying drilling, blasting and loading operations. As a result, most mining costs and problems have been centered around truck haulage, truck maintenance and the ever-increasing length of the grade haul.

Jan 3, 1963

By A. G. McGregor

IN THE Southwest a number of large steel chimneys discharge the gases from the copper smelting furnaces. Some of these chimneys show no deterioration after twenty years, others show serious deterioration after tour years service. A steel stack 20 ft. 7 ½ in. (6.3 m.) in diameter by 279 ft. (85 m.) high, Fig. 1, used for roaster gases only at the Calumet & Arizona Mining Co.&apos;s plant at Douglas, Ariz., was lined to the top of the bell, 40 ft. (12 m.) from the base, with common brick placed on end, lime and cement mortar being used. Above the bell, the stack was lined with 4 by 4 by 8 in. (10 by 10 by 20 cm.) building tile, placed on end, making a lining 4 in. thick. The tiles were supported on angle-iron rings, riveted to the inside of the chimney shell about 15 ft. apart. The chimney was put into use in the latter part of 1913. Four years later, considerable of the tile lining had fallen out of place and mixed with the flue dust at the bottom of the chimney. About a year later, several . flattened and distorted sheets were noticed about 70 ft. below the top. An investigation showed that the thickness of these distorted sheets, which was originally ¼ in., had been reduced one half. One year later, or six years after the chimney went into use, several holes, a square foot and smaller in area, appeared near the flat spots mentioned. Soon afterwards, when the chimney was shut down for repairs, it was found that most of the tile lining for 125 ft. from the top had fallen out and that the steel shell was badly corroded; but where the lining remained in place the shell was undamaged. Many of the tile which had fallen out of place had become soft or flaky and crumbling, others were as hard as when placed. An analysis of the hard and soft tile is shown on p. 2. These tile were of a fireclay mixture, and were used instead of common brick on account of lower cost. The steel forming the upper 125 ft. (38 m.) was replaced, and a 4 ¼ -in. (11-cm.) lining of firebrick was laid from the bell to the top of the chimney. The brick were placed on end, wedges and keys being used. After each 8-in. course was set, keyed, and wedged tight, thin mortar -water, sodium silicate, and finely ground silica-was worked into the joints. The brick are supported on angle-iron rings, every 15 ft., in the same way as the tile.

Jan 1, 1921

By Y. C. Liu, R. H. Richman

The effects of gel,manium and tin on the deformation and 9-e-crystallization textures of copper have been explored in detail with in the copper-rich terminal solid solutions. Addition of solute to copper produces a change in deformation texture from the copper type to the 70 :30 brass type. This transition has been measured quantitatively The types mid proportions of recrystal-lization components have been determined as a function of com-position, and correlation of recrystallization components with specific deformation components is discussed. On the basis of information available in the literature, it has been suggested that the effect of solute elements on the recrystallization texture of copper

Jan 1, 1961