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By Walter B. Lenhart

Introduction and Importance of the Industry Sand, as described in this chapter, is a crude product used for ballast on railroads and highways, and as the fine aggregate in concrete, mortar, plaster and in asphalt paving materials. The sand used in glass, as a molding sand, and as a source of silica is described in Chapter 43. Sand and gravel together constitute the mineral raw materials of largest volume produced from the earth. In 1958, as reported by the U.S. Bureau of Mines,21 680,080,000 tons of sand and gravel (including industrial sand) were produced in the United States. The nearest competitor was crushed rock of which 532,818,000 tons were produced. Coal, both bituminous and anthracite accounted for only 431,616,689 tons in the same year. In dollar value, sand and gravel were exceeded only by cement, crushed rock and fuels. Hence it is a major unit of the mineral-producing industry. As an example, one plant in California operates around the clock at an average rate of 1,500 tons per hour, and at peak intervals has shipped over 4,000 tons per hour, all by trucks. Nevertheless, it is controlled by one man through a panel of push buttons that control the crushing, screening, washing, grading, stock piling, and reclaiming of the products. Because sand and gravel are low-valued commodities, but are used in every construction undertaking in every city, village, farm, dam and highway, they are produced in almost every county in the United States and southern Canada, by thousands of individual operators, very few of whom operate in more than one community. Many operations, particularly those established to supply the needs of major dams that are under construction, or of major segments of new highways, are temporary in nature, and the equipment installed is more or less portable. Because of the bulky nature of sand and gravel, there is very little interstate movement, and almost no exports or imports, except a little movement back and forth across the border of the United States and Canada. First, the material needs definition. Definitions Sand and gravel have been defined as continuously graded unconsolidated materials that appear in the earth's surface as a result of the natural disintegration of rocks. Both normally appear together, but in a wide variety of sizes, types and range of size classification. The American Society for Testing Materials has tentatively revised its definition of "sand" as: granular material passing the 3/8-in. sieve and almost entirely passing the No. 4 (4760-micron) sieve and predominantly retained on the No. 200 (74-micron) sieve, and resulting from natural disintegration and abrasion of rock or processing of completely friable sandstone (ASTM Designation C 58-55T). The Society's tentative revision of its definition of "gravel" is: granular material predominantly retained on the No. 4 (4760-micron) sieve and resulting from natural disintegration and abrasion of rock or processing of weakly bound conglomerate (ASTM 125-55T). Sand and gravel deposits contain materials from the finest silt to the largest boulders. Chemical definition of the two materials is nearly impossible. Sand and gravel always are

Jan 1, 1960

By John R. Don

This paper, under the title of "The Genesis of Auriferous Lodes from a Chemical Point of View, Illustrated by Analyses of Samples Taken from the Chief Auriferous Area of New Zealand, Victoria and Queensland, by John R. Don, D.Sc., M.A., Lecturer on Geology in the University of Otago, N. Z.," was submitted by the author with the frank confession that its length, covering several hundred printed pages of the Transactions of the Institute, would preclude its acceptance for publication in full. But the great value of the original work which it records rendered its rejection on that ground highly undesirable ; and, after correspondence with Dr. Don, it was agreed that the Secretary should condense the paper, subject to the author's approval, omitting what was not essentially connected with the original work reported. In the discharge of this laborious and difficult duty, the Secretary's chief trouble has been his regret to cut out the acute criticisms and admirable theoretical and historical summaries of Dr. Don on the general subject of the science of ore-deposits. It should be added, that the original paper has been returned to the author, with full permission to publish it through any other medium (due mention being made of the first publication by the Institute of portions thereof), and a cordial expression of the hope that the treatise, as a whole, may be thus published, to the advantage of science. The Secretary begs to add, that many of the portions necessarily omitted from this condensed version would constitute, in his judgment, interesting and valuable separate contributions. In attempting to condense this paper, it was necessary at the outset to cut out the tint three chapters, of which the following brief outline is therefore given. Chapter I., introductory in character, indicates the importance of chemical analysis in the investigation of the genesis of ore-deposits, emphasizing the value of Prof. Posepny's Institute paper, and especially of the discussion which it aroused, and stating in general terms the theories of "lateral secretion" and "ascension." Chapter 11. describes the scope of the investigation undertaken by the author, the chief purpose of which was to determine which of the above-named theories was favored by the evidence obtained. This evidence consists chiefly (though not wholly) of analyses of the country-rock taken at various distances from the auriferous "reefs," (a) on deep mine-levels; (b) in the surface or "vadose" region : and also (c) of underlying, neighboring or connected crystallines (granite, gneiss, etc.). In addition to these investigations, there is a separate inquiry into the question of the deposition of gold in marine basins, suggested by the fact that most of the gold in the lodes of Australasia occurs in stratified deposits. Chapter 111. discusses the principles and methods followed by the author in the examination of country-rock for the purpose described. After giving his reasons for believing that careful tests of carefully-chosen samples of country-rock taken at varying distances from the ore-deposit might throw light upon the question

Jan 1, 1898

By E. W. Davis

About a year ago several carloads of magnetite ore from New York state were sent to the Mines Experiment Station at the University of Minnesota for grinding and concentration tests. The flowsheet used minus ½-in. ore as feed to a 3 by 3-ft. overflow cylindrical ball mill operating at 37 r.p.m. in closed ciruit with a vibrating screen. The screen oversize was returned to the mill for further grinding and the screen undersize was concentrated magnetically. Several different screens, between 8 and 35 mesh, were used and it was desired to determine the capacity of the ball mill operating in closed circuit with each screen. From earlier tests using this flowsheet and equipment, it was known that when comparatively coarse screens were used it was necessary to increase the grinding dilution in the mill beyond that ordinarily used when grinding in closed circuit with classifiers. It was also known that after the circulating load had passed about 100 per cent of the original feed it tended to increase rapidly in amount, and grinding conditions appeared to become unstable. These conditions may be peculiar to this small ball mill but they were very marked in this series of tests. If conditions were not right, the mill would suddenly "go dead," and it was found desirable to operate so that the occasional rattle of balls against the lining of the mill could be detected. As the test proceeded, it was found that the cure for almost any difficulty that developed in the grinding circuit was to add more water to the mill feed. To begin with, the mill was operated at pulp densities of from 60 to 65 per cent solids but gradually it was found that with higher dilutions grinding conditions were more stable and the ball-mill power per ton of screen undersize decreased. Actually, the most satisfactory operating conditions were secured with a pulp density of about 40 per cent solids. The ore was hard but it was possible to grind ½-in. feed so that all would pass an 8-mesh screen with a power expenditure in the ball mill of less than 2½ kw-hr. per ton and with a circulating load of less than 50 per cent. With so high a dilution in the feed to the mill, it was feared that steel wear would be very high. However, the mill was not noisy, and in order to find exactly the grinding conditions, a special test was made at the end of the main series of tests. After the mill had been in operation for several hours and grinding conditions had become balanced, the power to all the equipment was shut off at a given signal. The ball mill made about one revolution after the power was turned off, and just as soon as the mill stopped, a spout was placed at the discharge trunnion and all of the pulp that flowed out of the mill was caught in tanks. The manhole in the mill was then opened and the whole mill charge dumped into other tanks. Both of these products were weighed, dried, and weighed again. The balls were screened out and weighed, and the dry solids were sized. In this way it was possible to determine the nature of the pulp and the ore within the mill under actual grinding conditions.

Jan 1, 1947

By E. W. Davis

ABOUT a year ago several carloads of magnetite ore from New York state were sent to the Mines Experiment Station at the University of Minnesota for grinding and concentration tests. The flowsheet used minus ½ -in. ore as feed to a 3 by 3-ft. overflow cylindrical ball mill operating at 37 r.p.m. in closed ciruit with a vibrating screen. The screen oversize was returned to the mill for further grinding and the screen undersize was concentrated magnetically. Several different screens, between 8 and 35 mesh, were used and it was desired to determine the capacity of the ball mill operating in closed circuit with each screen. From earlier tests using this flowsheet and equipment, it was known that when comparatively coarse screens were used it was necessary to increase the grinding dilution in the mill beyond that ordinarily used when grinding in closed circuit with classifiers. It was also known that after the circulating load had passed about zoo per cent of the original feed it tended to increase rapidly in amount, and grinding conditions appeared to become unstable. These conditions may be peculiar to this small ball mill but they were very marked in this series of tests. If conditions were not right, the mill would suddenly "go dead," and it was found desirable to operate so that the occasional rattle of balls against the lining of the mill could be detected. As the test proceeded, it was found that the cure for almost any difficulty that developed in the grinding circuit was to add more water to the mill feed. To begin with, the mill was operated at pulp densities of from 60 to 65 per cent solids but gradually it was found that with higher dilutions grinding conditions were more stable and the ball-mill power per ton of screen undersize decreased. Actually, the most satisfactory operating conditions were secured with a pulp density of about 40 per cent solids. The ore was hard but it was possible to grind ½ in. feed so that all would pass an 8-mesh screen with a power expenditure in the ball mill of less than 2 1/2 kw-hr. per ton and with a circulating load of less than 50 per cent. With so high a dilution in the feed to the mill, it was feared that steel wear would be very high. However, the mill was not noisy, and in order to find exactly the grinding conditions, a special test was made at the end of the main series of tests. After the mill had been in operation for several hours and grinding conditions had become balanced, the power to all the equipment was shut off at a given signal. The ball mill made about one revolution after the power was turned off, and just as soon as the mill stopped, a spout was placed at the discharge trunnion and all of the pulp that flowed out of the mill was caught in tanks. The manhole in the mill was then opened and the whole mill charge dumped into other tanks. Both of these products were weighed, dried, and weighed again. The balls were screened out and weighed, and the dry solids were sized. In this way it was possible to determine the nature of the pulp and the ore within the mill under actual grinding conditions.

Jan 1, 1945

LIBERIAN ore has been called the richest iron ore mined in the world, and thus far, the output from the Liberian Mining Co.'s Bomi Hills mine has lived up to its reputation. Iron content has been variously given as 68.47 pct to 68.825 pct. A recent United Nations survey gave it first place, surplanting the previously top-rated Swedish product. The first shipment of Liberian ore to the United States reached Baltimore in June, 1952 and went into blast furnaces at Republic Steel's Cleveland plant, where excellent results were reported. The physical make-up of the ore was hard, dense lumps, free of fines and with ideal size distribution. The Bomi hills mines were scheduled to be in full operation by the end of 1952. At the close of 1951, 200,000 tons of ore had been delivered to Baltimore. Liberian Mining Co. states that production is about 90,000 tons of ore per month at present. Between 1200 and 1500 men are employed at the mine site, with about 25 pct of them Americans. The Bomi Hill project was financed with the aid of the Export Import bank, which loaned Liberia Mining part of the sum needed to initiate and put the development into production. No definite expansion plans are in the making but extensive diamond drilling is being pursued. Original estimates of annual production for Bomi Hills ran in the neighborhood of 1.5 million tons, but the figure is no longer applicable. Liberia's potential as an iron producing country has been known for a long time, but the physical obstacles in the way of large scale production were such as to prohibit even contemplation of the project. Until recent years, the only route from the mine site to Monrovia was a foot trail. Once to the coast, over swamps and unbridged rivers, the ore was still useless because of the lack of loading facilities. Transportation Solved One problem was solved with the completion of the artificial harbor at Monrovia. Harbor construction was well under way when the mine project began in 1948. The island location of Monrovia also made the building of a bridge across the St. Paul River necessary. The 980 ft reinforced concrete structure, accommodating railroad and vehicular traffic, was opened in 1949. Meanwhile, preliminary work on railroad construction started. Grading was completed quickly. In April, 1951, the first train made the trip from Monrovia to the Bomi Hills. About half of the cost of the entire project went into railroad construction. More than 2200 men, often forced to resort to primitive methods, were engaged in clearing a path through the heavy forests between the mine and port. Swamps were drained and filled, and bridges, including the William V. S. Tubman, named for the Liberian President, were constructed. At the port, a Robbins Conveyor Belt Co., orehandling plant was installed. Ships can be loaded from the stockpile at the rate of 3000 tons per hr and vessels need spend only one day in port. Liberian Mining is operating under an 80 year lease, giving the company exclusive mining rights to all minerals, except gold, platinum, and diamonds, within a 40 mile radius of Bomi Hills. The contract provides a fixed royalty to the Liberian Government of five cents per ton of ore extracted, and a premium -based on the New York market price for Bessemer-grade pig iron. The entire project started because an American,

Jan 1, 1952

By James B. Macelwane

THE Mineral Industry Education Division of AIME has long been interested in geophysical education. Organized in 1938, a Committee on Geophysical Education presented a number of reports in succeeding years. The AIME is an engineering society; hence it might be expected that the interest of the Mineral Industry Education Division would have centered about the relation of courses in geophysics to engineering education. However, this was not the case. The burden of the discussion held under the auspices of the Committee on Geophysical Education bore on geophysics in general and particularly on its relation to geology. In the decade that has passed since those meetings much water has flowed under the bridge. Not only have the geophysical sciences developed at an extraordinarily rapid rate but the practical importance and the range of their applications have spread in ever widening circles and have even assumed a very prominent place in research programs of the military, the Army, the Navy and, particularly, the Geophysical Research Directorate of the Air Force at Cambridge, Mass. So enormously have the geophysical sciences as such grown in scope and in degree of specialization that no one man in a lifetime of study can hope to master the theoretical and experimental complexities or even to follow intelligently in the published literature all the varied accomplishments of basic research in these 'fields. As in the other sciences, most of the results of geophysical research have potential economic value and are being applied to a wider and wider range of human needs. Here we see a parallel with the older sciences and their relation to engineering. Whenever the applications of scientific results required the special experimental background, the economic outlook, and the practical knowledge characteristic of the engineer, a curriculum in that type of engineering grew up in the colleges and universities. In the words of the "Report of the Committee on Adequacy and Standards of Engineering Education" in the. January 1952 number of the Journal of Engineering Education: "Engineering education in America was not developed after a preconceived plan. It evolved in parallel with the needs of a growing country, a country engaged in the development of a vast industrialization. From the first it filled a practical need, and its design emanated largely from an evaluation of the professional requirement." The advent of the railroad created a need for scientifically trained engineers and the response was the curriculum in civil engineering. The development of steam power created the demand for a curriculum in mechanical engineering. Neither of these types of engineers was trained to cope with the requirements of electrical power, and so there came to be a curriculum in electrical engineering. The advent of radio communication and of electronics during the first World War and in the years that followed resulted in the establishment of electronics engineering, sometimes within the curriculum in electrical engineering and sometimes independent of it. The complexities of industrial management have created an ever increasing demand for industrial engineers and the consequent building up of a curriculum in industrial engineering. The wide industrial application of chemical processes required a type of engineer whose background was training in chemistry but who was able to design processes and plants on an industrial scale; hence we have the curriculum in chemical engineering. The advent of the airplane created an entirely new set of problems which were solved by the training of aeronautical engineers. Many of these have called for more and more science and mathematics. Such was the history of the older engineer-

Jan 1, 1952

By E. W. Davis

About a year ago several carloads of magnetite ore from New York state were sent to the Mines Experiment Station at the University of Minnesota for grinding and concentration tests. The flowsheet used minus ½-in. ore as feed to a 3 by 3-ft. overflow cylindrical ball mill operating at 37 r.p.m. in closed ciruit with a vibrating screen. The screen oversize was returned to the mill for further grinding and the screen undersize was concentrated magnetically. Several different screens, between 8 and 35 mesh, were used and it was desired to determine the capacity of the ball mill operating in closed circuit with each screen. From earlier tests using this flowsheet and equipment, it was known that when comparatively coarse screens were used it was necessary to increase the grinding dilution in the mill beyond that ordinarily used when grinding in closed circuit with classifiers. It was also known that after the circulating load had passed about 100 per cent of the original feed it tended to increase rapidly in amount, and grinding conditions appeared to become unstable. These conditions may be peculiar to this small ball mill but they were very marked in this series of tests. If conditions were not right, the mill would suddenly "go dead," and it was found desirable to operate so that the occasional rattle of balls against the lining of the mill could be detected. As the test proceeded, it was found that the cure for almost any difficulty that developed in the grinding circuit was to add more water to the mill feed. To begin with, the mill was operated at pulp densities of from 60 to 65 per cent solids but gradually it was found that with higher dilutions grinding conditions were more stable and the ball-mill power per ton of screen undersize decreased. Actually, the most satisfactory operating conditions were secured with a pulp density of about 40 per cent solids. The ore was hard but it was possible to grind ½-in. feed so that all would pass an 8-mesh screen with a power expenditure in the ball mill of less than 2½ kw-hr. per ton and with a circulating load of less than 50 per cent. With so high a dilution in the feed to the mill, it was feared that steel wear would be very high. However, the mill was not noisy, and in order to find exactly the grinding conditions, a special test was made at the end of the main series of tests. After the mill had been in operation for several hours and grinding conditions had become balanced, the power to all the equipment was shut off at a given signal. The ball mill made about one revolution after the power was turned off, and just as soon as the mill stopped, a spout was placed at the discharge trunnion and all of the pulp that flowed out of the mill was caught in tanks. The manhole in the mill was then opened and the whole mill charge dumped into other tanks. Both of these products were weighed, dried, and weighed again. The balls were screened out and weighed, and the dry solids were sized. In this way it was possible to determine the nature of the pulp and the ore within the mill under actual grinding conditions.

Jan 1, 1947

By Ö. Valla, A. Muan, K. Grjotheim

The solid miscibility gap between CaO and "FeO" in the system CaO-"FeO" in contact with metallic iron gradually closes as MnO is added as a third component. On the liquidus surface of the system CaO-"FeO"-MnO, this situation gives rise to a boundary curve which originates in the bounding system CaO-''FeO", proceeds a short distance into the composition triangle of the ternary system, and then vanishes. A new approach has been used to follow the course of this boundary curve. It is shown that the curve vanishes at a much lower temperature and at much lower MnO contents than has been inferred previously. The oxides CaO, "FeO", and MnO together with SiO2 are the major components of the slag phase formed in the basic oxygen process. Hence, the system CaO-"Fe0"-MnO is of considerable technological interest. In addition, the system is theoretically interesting. The three oxides above all have sodium chloride structure. The size differences among the cations are such that in the bounding "binary"* systems CaO-MnO and "FeO"-MnO complete solid-solution series are formed,1,2 whereas in the system CaO-"FeO" there is only limited mutual solubility in the solid state,3 see Fig. 1. Hence, a solid miscibility gap exists in a part of the "ternary"* system Ca0-"Fe0"-Mn0, and a liquidus boundary curve originates at the peritectic point, point a in the insert in Fig. 1, in the system CaO-"FeO", extends a certain distance into the ternary system, and then vanishes. Very little quantitative information on the system Ca0-"Fe0"-Mn0 is available in previous literature. Fischer and Feischer4 sketched isothermal sections at 1600° and 1700°C, and estimated that the vanishing boundary curve extends to approximately 1650°C and a composition of 42 wt pct MnO. The work to be described in the following was aimed at locating experimentally the "vanishing" liquidus boundary curve, determining its end point, and deriving representative isothermal sections below and above the temperature of the end point of this curve. EXPERIMENTAL METHODS The phase relations were determined by the well-known quenching method. (For a description of this method as applied to oxide systems, see the original paper of Shepherd, Rankin, and wright.5) Prereacted oxide mixtures of desired compositions were contained in iron crucibles and heated in a vertical tube furnace in an atmosphere of purified nitrogen. After equilibrium was judged to have been attained, the samples were quenched to room temperature, the phases present were identified by microscopic and X-ray examination, and total iron oxide contents were determined by chemical analysis. "Fisher Certified" reagents (MnCO3, CaCO3, Fe2O3, and Fe) served as starting materials. The calcium carbonate and ferric oxide were heated in air at 400° and 800°C, respectively, for 24 hr prior to use. Manganese oxide was prepared by decomposing the carbonate in a graphite crucible in hydrogen atmosphere at 1000°C. The product was ground under acetone to -100 mesh. The iron powder was used directly without any preparation. Dicalcium ferrite was used as a starting material for some mixtures. It was made by mixing some of the above prepared CaCO3 and Fe2O3 in proportions corresponding to the formula 2CaO. Fe2O3. This mixture was then fired in air for

Jan 1, 1969

By E. H. Edwards, J. Washburn, E. R. Parker

The mechanism of strain hardening was discussed in connection with some recent observations on the stress-induced motion of dislocation boundaries and on the simple shear deformation of zinc, cadmium, and copper crystals. THE nature of work hardening accompanying plastic deformation of metals has long been the subject of speculation. As early as 1925, Becker' suggested a thermodynamic process to explain slip based on the statistical probability for the occurrence of local glide steps. The theory that plastic glide was due to the presence of lattice defects known as dislocations was first introduced in 1934 by Taylor: and Orowan, and Polanyi.4 Taylor presented a rather complete analysis of the behavior and interaction of dislocations. He assumed a certain type of stress field to be associated with a single dislocation, and postulated that work hardening would result from plastic flow in two ways. First, dislocations following one another across a slip plane might encounter a barrier which would impede their movement, thereby gradually diminishing and eventually stopping plastic flow on that plane. The second mechanism involved the concept of dislocations traveling in opposite directions on nearby planes attracting one another to form a meta-stable lattice. The interaction of dislocations in such an array was shown to be large enough to require an increase in stress before plastic flow would continue. Kochendorfer5,6 extended the concept of work hardening involving a back stress due to an accumulation of like dislocations on a slip plane. He suggested that the formation of a new dislocation is hindered by those dislocations already present. The hardening resulting from the interaction of newly forming dislocations with bound dislocations was designated as "formative hardening," and indicated to be the only type of hardening necessarily connected with the slip process. In another detailed picture of work hardening, Mott and Nabarro7 assumed that sufficient dislocations are primarily present in the crystal as a consequence of growth irregularities (mosaic structure) to initiate slip. Work hardening resulted from the interaction of migrating dislocations with localized internal stresses produced during deformation. More recently, however, Mott8 as modified his treatment to include the generation of dislocations at Frank-Read sources and he accounts for the hardening by the formation of sessile dislocations. It has been widely accepted that metals of hexagonal structure, usually possessing only one set of glide planes, exhibit mechanical behavior markedly different from those having cubic structures. However, the differences in behavior of the two classes may be less fundamental than suggested. Rohm and Kochendorfer9 have shown that a single crystal of aluminum subjected to approximately simple shear gives the type of stress-strain curve associated with the hexagonal metals. Similar behavior has been demonstrated for gold and silver crystals by Andrade and Henderson.'" Thus when glide in cubic metals is restricted to one plane, the strain hardening characteristics closely resemble those of the hexagonal metals. It would appear, therefore, that an investigation of some of the strain hardening properties of single crystals sheared in simple glide might provide a more complete understanding of the phenomenon of work hardening. This report relates a number of recent observations made on single crystals of copper, zinc, and cadmium tested in simple shear. In addition, pertinent observations of effects accompanying stress-induced movement of dislocation boundaries are reported. Experimental Procedure and Results Details of the production and advantages of the type of single-crystal shear specimen employed for the following tests have been presented in a previous publication.n The method of testing makes

Jan 1, 1954

By J. J. Cosgrove, J. E. Warren

A general model which approximates the effect of cross- flow has been developed to give a practical method for predicting the waterflood behavior of a stratified reservoir. The model is based on a modification of Dietz's theory and allows for variations in both the permeability and hydrocarbon pore volume. In the particular cases considered, it is assumed that the permeability can be characterized by a log-normal distribution and the hydrocarbon pore volume by a normal distribution. A simple graphical method which enables the practicing engineer to predict the behavior of a stratified system is presented The results obtained by the proposed method are compared with those obtained by the Dykstra-Parsons method. As a result of this study the following conclusions have been drawn: (1) The effect of cross-flow in a stratified system can be appreciable, particularly at very favorable or very unfavorable mobility ratios; (2) Under normal conditions, the effect of variations in the hydrocarbon pore volume can be neglected; and (3) The failure to use all of the available permeability data can lead to large errors in the prediction of the behavior of a stratified reservoir. INTRODUCTION Various methodshavebeenproposedto characterize and to predict the waterflood behavior of a stratified reservoir. Most of the methods assume that the reservoir is composed of discrete homogeneous continuous layers. With this model, the degree of stratification can be measured by several parameters based on core-analysis data. Among these are the Lorenz coefficient1 and the variation of a log-normal permeability distribution? The behavior of stratified systems is usually predicted by the Stiles, Dykstra-Parsons method or some modification of these. In both of these methods the reservoir is divided into discrete homogeneous layers with no cross-flow between layers. In the Stiles method the mobility ratio is assumed to be equal to unity while in the Dykstra-Parsons method it is allowed to take on any value. Other predictive methods have been proposed; method allows for cross-flow between the beds and a method by Schmalz and Rahme6 correlate.s the recovery directly with the Lorenz coefficient. In this new approach, which is essentially a continuous analog of Hiatt's method, the effects of both mobility ratio and cross-flow between the beds have been included. It is assumed that the permeability can be represented by a log-normal distribution and the hydrocarbon pore volume or porosity by a normal distribution. These types of distributions have been observed by several authors, 1,2,4 and most field data seem to confirm their observations; e.g., if these distributions are assumed and there is a 1:l correspondence between porosity and permeability samples, the commonly encountered linear relationship between porosity and the log of permeability is obtained. Since, in many field cases the permeability and poro sity data are truncated or cut-off at predetermined upper and/or lower values, the effect of discarding part of the data was investigated with the proposed method. A better technique for truncating the data is suggested. THEORY In the derivation of the method to be described in this paper the following assumptions are made: 1. Capillary forces are negligible per se; their effects are only manifest in the relative permeability curves. 2. The fluids are immiscible, incompressible and homogeneous. 3. The reservoir is horizontal and uniformly thick; it is initially liquid saturated i.e., connate water and oil. 4. The reservoir is composed of discrete layers, each having its own permeability, porosity and connate water saturation; each layer is homogeneous,

Jan 1, 1965

By F. A. Veer, W. G. Burgers, B. H. Kolster

Starting-- from Cu-Si diffusion couples a study of diffusion in the intermetallic compound Cu3Si of the Cu-Si system has been made. Mmker experiments showed copper to be the diffusing element. From the rate of growth of the Cu3Si phase diffusion coefficients were derived. The activation energy for diffusion is 18.6 kcal per mole. The couples show some interesting microscopic features, for which a tentative explanation is given. THE synthesis of dimethyldichlorosilane, (CH3)2SiC12, an important compound in the manufacture of methyl-silicones, takes place at the surface of a thin Cu3Si layer deposited on a mass of silicon particles."' By passing CH3C1 vapor at about 350°C, silicon atoms are consumed from Cu3Si in forming the volatile silane molecules, thus leaving copper atoms at the surface. It is well-known that copper acts as a poison for the above-mentioned reaction by catalyzing the dissociation of methylchloride.' However, no poisonous effect is observed, at least not before most of the silicon from the particles is converted into silane.3 This would be understandable, if either the copper atoms diffuse through the Cu3Si deposit to the underlying silicon or silicon atoms diffuse in the reverse direction to the copper, both processes resulting in the formation of new Cu3Si and so ensuring the proceeding of the reaction. In this paper experiments are described, demonstrating copper to be the diffusing element. Also a very low activation energy for the diffusion is observed. EXPERIMENTAL The silicon used contained 1 ppm Mg and 1 ppm Cu; the copper was spectroscopically pure (Fe: 2 ppm; Ag, Mg, Si: 1 ppm). The copper and silicon samples were prepared in the form of blocks of approximately 10 by 10 by 5 mm with two parallel sides by spark-machining. The blocks were ground on emery paper (grit 600), etched (copper with nitric acid, silicon with a 4:l nitric acid:hydrofluoric acid mixture), and cleaned with alcohol. As the brittleness of the silicon did not allow a welding procedure to prepare the diffusion couples, the copper and silicon blocks were pressed together in a steel clamp. The pressure exerted by the clamp brought about contact between the parts of the couple and so ensured proceeding of the diffusion. The couples were heated in a vacuum furnace (about 10"5 Torr). The temperature was stabilized within 1 pct. After a heat treatment a section parallel to the direction of diffusion was examined in the microscope and in the X-ray scanning microanalyzer. To determine whether copper or silicon is the diffusing element marker experiments were carried out using tungsten wires with a 20-p diam. EXPERIMENTAL RESULTS Figs. 1, 2, 3, and 4 give micrographs of diffusion zones of Cu/Si couples. Analysis by the electron mi-croprobe of the Cu/Si samples after a definite heat treatment revealed the existence of only one intermetallic phase as can be seen from the line scan shown in Fig. 5. From the X-ray diffraction pattern it could be deduced that this phase was CU 3 Si.4 Even when diffusion zones of considerable width (up to 600 p) were obtained, no other phases occurring in the Cu-Si system could be detected, neither by the electron microprobe nor by X-ray diffraction analysis. The optical anisotropy of the Cu3Si phase made it possible to observe the columnar shape of the crystal-

Jan 1, 1969

By G. R. Fitterer

Trends in slag composition in acid open hearth practice, particularly the variation in iron and manganese oxides during refining, are reviewed. A procedure which is currently being used to control the refining reactions is described and partially explained through slag phase diagram considerations. In addition, the ionic nature of these slags is considered and it is proposed that silica combines with the oxide ion and forms a series of complex silicate ions. The effect of basic oxides such as FeO, MnO, and CaO is apparently additive in furnishing the oxide ion for this purpose. IT is now possible to control192 the refining of steel in an acid open hearth furnace to a surprising degree. This control has been brought about through the knowledge and use of several facts and tests. These are: 1—A planned charge analysis based on a knowledge of the type of fuel, the bath depth, etc. 2—Knowledge and control of rate of fuel input as well as its method of atomization, if any. 3—Determination of the slag fluidity. 4—Bath temperatures (use of the Pt-Pt-Rh thermocouple). 5—Periodic determination of carbon content (use of the Carb-analyzer or Carbometer). Through the use of these control methods, a heat may be made to "melt-in" with or without residual manganese and silicon. The rate of refining or carbon elimination may be controlled accurately, and the desired tapping (or "go-ahead") carbon may be approached at a rapid or slow rate according to preference and type of steel being made. Thus operating time may be predetermined and greatly reduced. Further, all of the refining can be done without any ore or other oxidizing additions, and the heat may be brought to the desired tapping temperature simultaneously with the attainment of the desired carbon analysis. This control procedure is being used in most acid plants in the United States today and has been de- scribed.', ' Although the slag metal relations are sufficiently well known to control the heat as stated, yet it is possible to account for only about two-thirds' of the 0, which must have been used for the elimination of the carbon and other metalloids. Phase diagram studies' of the slags, slag weights, the metal particle theory,' ore additions, limestone additions, etc., may all be taken into consideration; yet, the mechanism of oxidation and source of all the oxygen remain to be explained. This paper reviews some of the principles upon which the control methods were based and proposes other possibilities regarding the unexplained phenomena. Old and New Acid Open Hearth Practice Some of the recent statements in the literature regarding acid open hearth operation are based on old heat data which are not typical of modern American practice. These old heat logs have been responsible for many misconceptions regarding the acid hearth practice and represent heats which do not coincide with modern methods. In recent years, American practice has been altered materially and these changes will be briefly described. Modern American Practice: A typical log of a modern American acid open hearth heat' is shown in Fig. 1 which indicates that the refining time was only two hours, during which the carbon was eliminated rapidly and the bath temperature increased at a fast rate. The manganese and silicon contents of the metal were essentially eliminated and their oxides had become constituent parts of the slag at the "melt-down" period. During the course of the heat, the MnO content of the slag remained practi-

Jan 1, 1954

By Tell Ertl

The term oil shale is defined. Foreign oil-shale developments are outlined briefly. The richest and most extensive oil-shale deposits in the United States lie in western Colorado. The Bureau of Mines is opening two adjacent areas for underground mining. in western Colorado. From the first area the oil shale is mined selectively as required by the retorting plant. The second area is being developed as a unit of a full scale oil-shale mine to ascertain the most practical methods of mining oil shale and to determine costs. In both of these mining areas, research will be carried on to develop new and improved practices for mining oil shale. Introduction Oil shale is a sedimentary rock containing a solid mineraloid of indefinite composition known as kerogen. On heating oil shale, the kerogen undergoes thermal decomposition and some of the vapor products of the decomposition can be condensed as shale oil. Oil from shale can be a major source of liquid fuels since extensive deposits of oil shale are known to exist throughout the world. The United States considers the establishment of an oil-shale industry only when doubt exists of the adequacy of the domestic supply of crude petroleum. On the other hand, oil shale is not strange to foreign oil men. The industry is an old one in other parts of the world. The French industry has been in existence since 1838, the Scottish since 1859, the Australian since 1860, the Estonian and Swedish The since World War 1, and the Manchurian industry since 1929. The most highly exploited oil-shale deposits are the Carboniferous shales of Scotland. About 20 seams ranging from 4 to I2 ft in thickness are worked. The yield during recent years in scotland has been 18 to 25 gal of shale oil per ton, from 3&"30'000 tons per year' The French and Swedish oil-shale deposits are of lower grade than the Scottish. The Estonian oil-shale deposits are 7 ft thick, and the oil yield averages 50 gal per ton. Over 1,000,-ooo tons are mined each year, half of which is used directly as fuel to substitute for coal and the other half is used for the production of oil. Immense deposits of oil shale that will yield 10 to 15 gal per ton exist in Germany. Because of the impending loss of the Rumanian and Polish oil fields and the bombing of synthetic liquid fuel plants, the Nazis in 1943 started a large-scale oil-shale program in Germany. By V-E Day, it is said, oil-shale production had reached the rate of 2500 tons per day and rapid expansion of the industry was imminent. Australian oil shale, known as torbanite, occurs in beds 2 to 6 ft thick. It is of a very high grade and on retorting yields 80 to 160 gal per ton. The oil-shale industry of Manchuria was the largest in the world during the past decade. The well-known Fushun coal deposit in Manchuria has an overburden of 500 million tons of oil shale about 450 ft thick that will yield 10 to 15 gal of shale oil per ton. The oil shale is

Jan 1, 1949

By J. D. Forrester, Erich Sarapuu, T. C. Cheasley

Electrocarbonization of coal will produce cheap fuel for electric power plants. The complete electrification of industry and domestic power consumption of gas generated as fuel in situ is a worthwhile goal for the coal industry. Production of synthetic oils, gasoline, and coal chemicals from coal gas will create additional new markets for the coal industry. RANKING high in the nation's wealth of natural resources, readily available liquid and gaseous hydrocarbons are nevertheless falling steadily in supply, while industrial requirements for hydrocarbon compounds are greater today than during the peak period of World War 11. Theoretically, several processes will increase the future supply of liquid and gaseous fuels, but the practical application of these methods depends on two controlling factors: 1—that enough carbon-bearing material be available to warrant industrial exploitation, and 2—that the given process be physically, chemically, and economically applicable. With regard to the first factor, the Western Hemisphere is fortunately well supplied, see Table I. Table I not only shows the extensive occurrence of many fuel sources, but also the wide discrepancy among quantities of fuel substances in various materials. Great quantities of potentially available fuel have not been recovered. Many coal seams and other hydrocarbon-bearing deposits are so situated that production is uneconomical by present-day mining or oilwell pumping methods, and even in many exploitable deposits where the most efficient production methods are used a large proportion of material is never recovered. Industrial production of hydrocarbon liquids and gases must be better balanced, and processes must be developed which will convert coals, oil sand, and oil shales into fabricated commodities. Among the techniques employed by scientists and engineers to secure fuel masses not economically available at present are several processes of underground gasification. These are all concerned with converting raw materials into gaseous products by thermal treatment of source substances while they are still in the ground and therefore require that a subsurface heat (fire) zone be induced to affect pervasively the buried raw fuel deposit. This is possible only where sufficiently high temperature exists and where the fuel material is satisfactorily opened or channelized. Also, to compete successfully with common mining or oilfield practices, a given method must be controllable and must not involve greater operational expense than regular methods. Preferably, it should be less expensive. Since the close of World War 11, England has continued field studies of underground gasification methods. Experiments have also been conducted in Sweden, Estonia, France, Belgium, Italy, and Germany. The U. S. Government has sponsored field studies at Gorgas, Ala., and because gasification in situ is vitally important to establishment of the nation's fuel resources, the mining engineering department at the Missouri School of Mines has been actively interested in developing the process of underground electrocarbonization. Research was conceived by Erich Sarapuu, and preliminary experiments in treating bituminous coal were begun at the school in September 1947. The work consisted of laboratory experimentation until June 1948, at which time, through a cooperative agreement with the Sinclair Coal Co. of Missouri, pilot plant studies were instituted at the Tiger mine of the Hume-Sinclair Coal Co. near Hume, Mo., to test the encouraging laboratory findings. This comprehensive field program was pursued continuously until the beginning of 1952."'" The broad term underground electrocarbonization describes a unique gasification process that releases by electricity the desired economic constituents from a raw carbon-bearing material, converting the substance of such deposits into deliverable form and greatly reducing the cost-of-mining factor. Underground electrocarbonization is not subject to the major limitations of many other underground gasifi-

Jan 1, 1955

By Nicholas J. Grant, Hanna Ibach, Bill C. Giessen

The system Ta-Rh was investigated over the entire comnposition range using metallogvaphic and X-ray techniques as well as thermal analysis. Terminal solubility limits, solidus temperatures, and the crystal structures of two new intermediate phases were determined. There are five intermediate phases: o, tetragonal, isostructural with o(Fe-Cr); a1, orthorhomnbic : a2, orthorhombic, isostructural with CozSi; 0 3, a high -temperature phase of unknozun structure; and a TaRh3, cubic, AuCu3 structure. a, aL, a,, and a melt peritectically; and a TaRh, has a maximum melting point. Five peritectic and one eutectic reactions occur. THE Ta-Rh phase diagram has not been fully treated in the literature; however, two inter metallic phases have been described.&apos;-&apos; This study attempts to work out the diagram covering the details of phase boundaries as well as the crystallography of the intermediate phases. EXPERIMENTAL METHODS Starting materials were tantalum powder of 99.8 pct purity, supplied by National Research Corp., Cambridge, Mass., and rhodium powder of 99.9 pct purity, supplied by Bishop Co., Malvern, Pa. Analyses as given by the manufacturers are presented in Table I. In addition to the spectroscopic analysis, an oxygen analysis has been made of the tantalum powder. After preliminary trials, the standard procedure employed in making the alloys was as follows (see Ref. 4 for further details). The powders were weighed, mixed manually, compacted under 16,000 psi, and arc-melted at not more than 500 amp under thoroughly titanium gettered welding-grade argon of 400 mm Hg pressure. The gettering process was repeated after each melt. It had been shown previously5 that under these conditions no oxygen pick-up exceeding 0.001 pct in a hafnium button could be detected. The buttons, ranging from 5 to 10 g in weight, were inverted or, if possible, crushed and remelted three times. Melting presented no difficulty, except for tantalum-rich al- loys, which showed considerable spashing during melting. The average weight loss of 1 wt pct rose to 2.5 wt pct in these cases. Subsequent melting, however, resulted in losses of less than 0.1 wt pct. The melts obtained frequently showed small in-homogeneities, mostly in the tantalum-rich part of the system below 25 at. pct Rh. This was not due to insufficient blending of the elements, but to crystallization taking place from the cooled bottom. This condition was not improved by further re-melting; therefore the following precautions were taken. Cross sections of as-cast buttons were made. For the investigation only buttons were used where these inhomogeneities did not exceed 1 at. pct (estimated from the amounts of haSeS resent). In addition, only the center portions of such buttdns were utilized to minimize errors. Smaller buttons showed smaller concentration gradients and were used as a check. Finally, all alloys were homogenized to eliminate coring (see below). After this, the error in alloy composition due to inhomogeneity was cl at. pct. In order to confirm the concentrations of the alloys and to provide an impurity check, wet-chemical analyses and oxygen-fusion analyses of four key alloys were carried out. The results, together with the concentrations as calculated with the weight balance method, are presented in Table 11. It was found that for three alloys the agreement is very good (< 0.2

Jan 1, 1964

By D. A. Flanagan, B. L. Landrum, P. B. Crawford, B. C. Norwood

Herern is described a heat conduction model which has been developed to predict the pressure distribution within a reservoir being subjected to rrnsteady-state depletion. Although potentiometric models have been widely used to study reservoir pressure distribution, their application is limited to the study of steady-state cases. Electrical analyzers may be used to study unsteady-state phenomena, but their application and simulation have certain limitations. Much of the now accepted theory of unsteady-state fluid flow in porous media has evolved from previous heat conduction knowledge. An analogy between the flow of fluid in an unsymmetrical reservoir and con-duct ion of heat in a similarly shaped unsymmetrical metal plate is made to show adaptability of the hear conduction principle to transient reservoir cases. A description of the model and necessary instrumenrarion is included. Data show influence of well location on pressure distribution during unsteady-state deple[ion. Application of results is made to a hypothetical reservoir and to a reservoir located in an irregular aquifer. INTRODUCTION Development of methods for predicting behavior of petroleum reservoirs has resulted partially from adaptation of electrical and thermal flow concepts to the flow of fluids through porous media. Extensive investigation of electrical and thermal flow problems has resulted in mathematical solutions applicable to many reservoir problems. The relative ease of measuring electrical flow has brought wide acceptance of the use of the potentiometric model to study certain field problems. Potentiometric models are restricted to the study of steady-state conditions because of the instantaneous response of electrical flow to changes in the applied potential. The electrical reservoir analyzer has been one of our most useful instruments for studying certain phases of unsteady-state behavior1. Other than approximation techniques, no method exists for determining pressure distribution in an irregular reservoir during primary depletion. Heat flow, like fluid flow, is inherently transient. The model described here was developed to use this transient nature of heat flow, measurable in the laboratory, to simulate transient flow of fluids in the porous medium of the reservoir above the bubble point. A metal plate shaped like the reservoir to be studied was heated by a "well" source. Temperature increase in the plate is analogous to pressure decline in the field if the field is being depleted, or pressure increase if fluid is being injected. This study is intended to determine the feasibility of using the transient nature of the heat flow to study the transient behavior of fluid flow. It is hoped that this new technique will aid in the understanding of one of the more complex phases of reservoir engineering. THE FLUID FLOW-HEAT CONDUCTION ANALOGY The similarity of the equations which describe the flow of fluids through a porous medium and the conduction of heat through a solid is well known2. Rate of flow of fluids is given by Darcy&apos;s law3. while the rate of flow of heat is given by Fourier&apos;, (I,, - KA 4T........(2) Combining Eq. 1 with the equation of continuity for a compressible liquid", i.e.,results in Expressing y in terms of the compressibility, i.e., pr = peey ,..........(5) and by expanding the exponential and neglecting higher orders of cp one can obtain

By J. C. Rengel

Why and how the nuclear industry entered the electric power generation business is discussed in terms that nuclear energy was an undoubtedly additional energy resource and that it had promise of becoming a virtually inexhaustible generating power if breeder reactors could be devised. The growth of nuclear power, its total generation capacity, are related to the need of increasing energy requirements. The use of atomic energy for power generation will grow if it can compete economically with other fuels. The rate of growth, the time scale and direction of technical development is dependent on ore supplies. It is predicted that by 1980, 50% of all new power installations will be nuclear stations. INTRODUCTION Ten years ago, the nuclear industry was virtually unborn, the Atomic Energy Act of 1954 had just been signed, and peaceful applications of atomic power was little more than a phrase. Serious discussion of the practical application of nuclear energy to electric utility installations in the West was highly unlikely. The questions: Why and how did the nuclear industry enter the electric power generation business at all?; What is the predicted growth of nuclear power?; What technological changes do we predict?; How will the above changes affect the utilities? will in part be answered by this paper. WHY NUCLEAR POWER? The only justification for the West as for any other section of the country for atomic power is economics. Whatever energy source will provide the lowest generation cost will prevail; the only electric utilities which have shown an interest in nuclear power are those to whom it means lower generation costs. It is true that the Government sponsored the development of this technology long before there was any evidence of better economics; but a Government must take a very long-range view and it is the only type of organization that can afford to look more than twenty or thirty years into the future. The Government looked at projections such as shown in Fig. 1, which shows various rates of energy consumption, and matched these against estimates of fossil fuel resources. This showed that we will exhaust our low-cost fossil fuel supplies within 75 to 100 years and our total known fuel supplies within 150 to 200 years. The decision to invest in nuclear energy rested, therefore, on two arguments: a) It was undoubtedly an additional energy resource; and b) It has promise of becoming a virtually inex-haustable resource if breeder reactors could be devised if, while generating power, the reactors would produce more fissile materials than they consumed. This decision produced an unexpected bonus: nuclear power became competitive with fossil power much earlier than had been expected and, as shown in Fig. 2, forced the coal industry to take a hard look at its own position. I believe that the drop of coal prices shown here is the direct result of the entry of nuclear power into the energy supply business. At this point, it ought to be explained why and under what conditions nuclear power can be cheaper than fossil power. Fossil fuel cost to the utility is composed of two factors: a) Mining; and b) Transportation. As a result, the cost of fossil fuel to the utilities varies from 126, 106 Btu to 306, 106 Btu and higher. Nuclear energy is highly concentrated and the transportation factor becomes insignificant. Today the cost of nuclear fuel to the utility ranges between 156

Jan 1, 1967

By U. N. Bhrany, J. H. Brown

The specifications of particle size and the size analyses of fine particulate materials are commonly presented without reference to the method of analysis. A review of the various sizing methods showed that not only numerous sources of error but also different definitions of size are inherent in the different methods of analysis. To demonstrate the magnitude of the differences, the size distribution of finely crushed quartz was determined by several methods and a critical comparison of the data was made. The experimental results show that appreciably different sizes may be indicated for one material depending on the method of analysis used. However, because the shape of the size-distribution curves determined by almost all methods was constant, a simple method of correlating the data can be adopted. Conversion factors, by which size measurements obtained by the various methods can be expressed in terms of screen sizes, are presented as one method of correlating the results. The size analysis and size specification for lump rock and particulate materials are commonly determined with sieves. With this technique, a readily reproducible measure of size can be obtained merely by duplicating the sieve and the method of sizing. For coarse materials, such as lumps of rock, this technique is simple and effective; and the effects of properties of the material such as shape can be readily understood. When very small particles are measured, however, problems arise. Small sieves are difficult to construct and maintain, and size separations become sensitive to the analytical procedure. For these difficult sieve sizes and for still smaller particles, other sizing techniques employing, for example, sedimentation, light extinction, and microscopy are available. Because these various techniques employ different size-dependent responses to establish size, it is appropriate to examine them and the results they yield to determine their relationships and their limitations. The &apos;size&apos; of a lump of rock is not an absolute quantity, but rather a defined one. With sieves, for example, the size is defined by the screen aperture and no reference is made to the actual shape of the particle, yet only in the case of a regular body, such as a sphere, can the sieve size be related to the shape. With sieves only two dimensions of a particle can be suggested, for the sieve makes no allowance for the length of the particle passing through an aperture. Similarly, the size of a particle as measured by a microscopic technique need bear no relationship to the size as measured by sieves, although the two measurements may be related statistically. In fact, all size measurements are not only defined quantities, but the measurement actually used is an average that is controlled by the technique employed and, hopefully, reflects the property in question of the material of interest. Many papers have been presented that illustrate the accuracy of the various sizing methods, present the advantages of certain methods for certain applications, and describe the principles and technical backgrounds of the various methods. No attempt will be made in the present paper to review this work in detail. The purpose of the present paper is to examine the limitations of the various sizing methods, and to demonstrate experimentally the relationships between the sizes as determined by the various methods of analysis. It is hoped that by recognition of these limitations and relationships, errors in size specification and size interpretation will be avoided. REVIEW OF SIZING METHODS In specifying the size of a material, not only the data but also the method of measurement must be stated. For example, the size of the lump might be specified as its total volume, as its weight, as its maximum dimension, or as its minimum cross section; any one definition might be completely satisfactory for one problem, but not for another. In practice, size analyses follow four basic approaches and fortunately, the conditions that restrict each approach are known. These major methods include: 1) screen analysis, 2) direct measurement of particle dimensions, 3) determination of equivalent spherical size in response to fluid flow, and 4) specific surface determination. Each of these techniques has several variations and some new techniques are also available, but the limitations of the basic techniques are sufficient to permit at least a preliminary

Jan 1, 1962

By J. S. Marsh

OPPORTUNITY to pay tribute to the memory of Professor Henry Marion Howe is a strenuous assignment as well as an honor. Upon recalling Howe lecturers and lectures of the past 25 years, glancing over the list of those earlier, and rereading Howe&apos;s books, I arrive at several conclusions: 1—Many lecturers either worked under or knew Professor Howe. 2—It is virtually impossible to pick a subject on which Professor Howe did not touch. 3—There is precedent for a technical paper based upon pursuit of a single subject. 4—There have been listening lectures and reading lectures. There is solid comfort only in 2: the subject field is wide open. I did not know, nor even ever saw, Professor Howe, so can supply no fitting reminiscence. As a college student I was dimly aware that he counted among the giants. Fuller appreciation of his stature came with reading his books and papers, growing acquaintance with some of his associates, and the intrinsic dignity of the climax of the Annual Meeting, beginning at four o&apos;clock of a Thursday afternoon in the auditorium of the Engineering Societies Building in New York. As for producing the technical paper sort of thing, it is my lot to have reached an age and assignment such that to do so would be to filch information from those who did the work and whose story is theirs to tell; for this I have no enthusiasm. As for the final conclusion, Professor Howe was one of the chosen few so highly expert at expository writing that he could produce a lecture or paper that reads as though it would also have listened well. One of his tricks was the free use of words not ordinarily part of the technical vocabulary, provided that such words were likely to communicate most precisely what he had in mind. How wonderful it would be for all who must read reports by the ton if ability at exposition could be taught with the effectiveness open, say to, differential calculus! Perhaps Professor Howe should be required college reading even if for no other reason than to prove that technical writing need be neither dull nor diffuse. My assignment is clearly still strenuous. Another point to consider is the fact that metallurgy is now so tremendously diversified that hope of finding a topic of universal appeal is negligible, even if one were competent enough to be permitted free choice. That which follows is, therefore, a compromise composed of necessity and of the obligation to attempt to avoid boring to slumber those of you who are not especially interested in the general subject chosen. The Iron and Steel Div. is now essentially a process metallurgy division, heavily concerned with the smelting of iron and the making of steel. The American Iron and Steel Inst. figure for present steel capacity of this country is 125,828,310 net tons; how this is divided among processes is indicated by the production totals for 1953, shown in Table I. The glamor girls and boys make the front page and so it is with steelmaking processes. If there is an Antarctic Daily Bugle, it undoubtedly has carried stories of revolutionary development, such as oxygen processes and vacuum melting, and stories of the incomparably rosy destiny of electric arc melting. All such certainly have their place and their future; meanwhile, it is the sturdy and old reliable open hearth that accounts for the bulk of production reported back on the financial page, and it is the old reliable that is most likely to continue to account for the bulk for some perfectly sound raw material, technologic, and economic reasons. This, plus the fact that next year marks a centennial (for it was in 1856 that Frederick and William Siemens conceived the regenerative open hearth), is reason enough to talk about open hearth furnaces, but is not the real one. The real reason is that in some years of association with open hearths, I have accumulated—in addition to a genuine liking and respect for them—certain odds and ends of fact and fancy that this lecture provides a unique chance

Jan 1, 1956

By Nicholas J. Grant, Rolf Nordheim, Thomas B. King

Constant-load creep-rupture tests were conducted in an argon atmosphere at temperatures of 1600 to 2200°F on two heats of iron containing about 0.06 and 0.09 pct P in solid solution. The tests were conducted in the as-cast condition. Stresses were selected to give strain rates approaching those encountered in the hot working of steel, and within the limits of the creep-rupture test apparatus, namely. from about 0.001 to 50 pct per sec. FOR generations, rolling and forging practices have been developed largely by empirical methods, based on prior experience. While largely successful, difficulties are frequently encountered when new or different alloy compositions are tried for the first time. There is need to know the relationships which exist among temperature, strain rate, composition, and other variables on the deformation and fracture characteristics of steels. It has been shown for aluminum and several high-temperature alloys that the deformation and fracture characteristics follow rather well-defined laws and patterns which are closely related to the effects of strain rate, temperature, and composition.1"3 As the melting temperature of aluminum or its alloys was approached, it was possible to study the interplay of work-hardening factors and recovery or recrystal-lization, the latter resulting in improved ductility and increased resistance to intercrystalline fracture. In particular, the effects of composition are very poorly known. Within the meaning of "composition" should be included impurity elements, such as sulfur, phosphorous, lead, copper, and many others, as well as those elements which are added for alloying purposes in iron. The role of multiphase structures, in contrast to solid solutions, should also be studied in much greater detail. high strain rate creep-rupture tests would provide information regarding the deformation and fracture characteristics of metals at hot-working temperatures. It was also desired to establish the stresses which are necessary to accomplish the desired deformation, and to relate these to the strain rate and temperature. Secondly, it was the purpose of this particular study to determine the effects of phosphorus, within solid solution limits, on the deformation and fracture characteristics of iron at hot-working temperatures. EXPERIMENTAL PROCEDURE Two phosphorus levels were selected, one corresponding to the upper limit normally found for commercial steels, and one substantially higher than this, but within the region of solid solubility at the test temperatures chosen for this investigation. Twenty-pound heats were prepared by induction melting electrolytic iron in air in a magnesia lined furnace. After deoxidation with about 0.2 pct Al, ferro-phosphorus was added, and the heats were then poured into prefired silica molds. The purpose of using silica molds was to obtain a slow cooling rate during solidification to produce a relatively coarse grain size, producing a structure subject to some segregation and therefore more nearly characteristic of ingot structures. The major part of the casting assembly provided a large shrinkage head in order to produce sound castings and to promote slow cooling of the specimens. The primary austenitic grain size varied from ASTM No. 2 to No. 00. The composition of the heats, including a low phorphorus melt, used for comparison purposes, is shown in Table I. It will be noted that the oxygen content of the phosphorus containing heats is relatively high, in spite of the deoxidation practice, a condition which is difficult to control in small melts. Creep-rupture tests were nevertheless undertaken when it was noted that this quantity of oxygen did not appear to give results any different from those from a heat containing 0.01 pct 0, low phosphorus and comparable carbon Content;4 see Table 11.

Jan 1, 1961