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By John B. Baker, Bernard B. Betty, H. F. Moore

For several years there has been in progress in the Materials Testing Laboratory of the University of Illinois an investigation of creep and fracture of lead and lead alloys. In the course of this investigation it has been shown that the phenomenon of creep occurs in part at the grain boundaries of lead and lead alloys. To study the occurrence of creep and the development of fracture within crystalline grains, two series of tests of single crystals of lead have been carried out. The first of these, a preliminary series, by Mr. Betty, has been described.l,2 The second, pursued by Mr. Baker for his doctoral dissertation, was carried out under the direction of Professor Moore, with the assistance of Prof. G. L. Clark in the X-ray work, and the cooperation and advice of Mr. Betty. This paper is based on the test data obtained in this second series. Single crystals of a very pure commercial lead have been prepared, some of them tested to measure creep, others tested to fracture under long-continued steady load, and still others tested under cycles of repeated tension. An interpretation of the test data of these single-crystal tests is offered, which is a combination of parts of several well-known theories. Specimens The single-crystal specimens were made from a piece of very pure commercial lead sheathing. A spectroscopic analysis of one of the single crystals showed the presence of 0.005 per cent Bi, 0.0001 per cent Cu and 0.0003 per cent Ag. Preparation.—The Bridgman method of casting single-crystal specimens was used.3 The specimens were cast to the shape and size shown in Fig. 1 (dimensions in Fig. 4c) in a duralumin mold. Molten lead does not stick to duralumin. Fig. 1 shows the mold and the blast flames for heating. After the mold had been heated to the temperature of molten

Jan 1, 1938

By John B. Baker, Bernard B. Betty, H. F. Moore

Fox several years there has been in progress in the Materials Testing Laboratory of the University of Illinois an investigation of creep and fracture of lead and lead alloys. In the course of this investigation it has been shown that the phenomenon of creep occurs in part at the grain boundaries of lead and lead alloys. To study the occurrence of creep and the development of fracture within crystalline grains, two series of tests of single crystals of lead have been carried out. The first of these, a preliminary series, by Mr. Betty, has been described.1,2 The second, pursued by Mr. Baker for his doctoral dissertation, was carried out under the direction of Professor Moore, with the assistance of Prof. G. L. Clark in the X-ray work, and the cooperation and advice of Mr. Betty. This paper is based on the test data obtained in this second series. Single crystals of a very pure commercial lead have been prepared, some of them tested to measure creep, others tested to fracture under long-continued steady load, and still others tested under cycles of repeated tension. An interpretation of the test data of these single-crystal tests is offered, which is a combination of parts of several well-known theories. SPECIMENS The single-crystal specimens were made from a piece of very pure commercial lead sheathing. A spectroscopic analysis of one of the single crystals showed the presence of 0.005 per cent Bi, 0.0001 per cent Cu and 0.0003 per cent Ag. Preparation.-The Bridgman method of casting single-crystal speci¬mens was used.3 The specimens were cast to the shape and size shown in Fig. I (dimensions in Fig. 4c) in a duralumin mold. Molten lead does not stick to duralumin. Fig. 1 shows the mold and the blast flames for heating. After the mold had been heated to the temperature of molten

Jan 1, 1938

THE SECRETARY The year 1917 has been a notable one in Institute affairs. The usual activities, including meetings, publications, local section interests, library service, and so-forth, have been continued on at least the same scale as previously, and in addition the resources of the Institute have been placed without stint at the service of the Nation, not only for the active prosecution of the military side of the war, but even more especially in the industrial operations which form the very basis of modern warfare. The officers and directors of the Institute have labored both officially and individually, while the Institute as a body, through committees of, prominent members, and through many individual members, has given freely. Finally, Institute funds have been appropriated to an amount exceeding $5000 to accomplish the cooperation with Government bureaus, and provide committee expenses necessary for performing the services that have been given. The President of the Institute had a very large personal share in many of these activities, which will be described in the following pages, as well as in the President's own report. Many of the Institute's members are giving their whole time for. $1 a year, or less, and especial mention should be made of Herbert C. Hoover, Food Administrator, W. L. Honnold, Head of the Commission for Relief in Belgium, Mark L. Requa, Petroleum Administrator, Edgar Rickard and Charles W. Merrill of the Food Administration, S. A. Taylor of the Fuel Administration, W. L. Saunders, B. B. Thayer and Joseph W. Richards who .are giving a. large share of their time to the Naval Consulting Board, W. Y. Westervelt, W.0. Hotchkiss and Harvey S. Mud of the War Minerals Committee, David W. Brunton of the War Committee of Technical Societies, and hundreds of others whose names are mentioned in the Honor Roll of Members. It has also been a notable year in cooperation with sister-societies. The most important event under this head was the accession of the American Society of Civil Engineers into the fraternity of Founder Societies.

Jan 2, 1918

By J. A. Kitchener, J. P. Anfruns

Measurements have been made of the rate of capture of single particles of strongly hydrophobic, surface-methylated, quartz, of sizes ranging from 12 to 40 µm diam., by single rising bubbles of diam. 0.5 to 1.1mm. The results agree closely with the theoretically calculated hydrodynamic collision rates, indicating that, in this system, every collision results in capture and retention of a particle.

Jan 1, 1976

By F. W. Bloecher, A. M. Gaudin

THIS paper describes the results of a series of tests carried out to determine the partition of dodecylamine between distilled water and the surface of quartz at various concentrations of dodecylamine acetate in solution. An adsorption-column technique was utilized for this purpose. Ralston and Harwood, of Armour and Co., had synthesized marked dodecylamine acetate for us.' In their preparation which we employed, 0.0007 pct of the total carbon was the radioactive isotope, carbon fourteen. Unmarked dodecylamine acetate of high purity was also prepared by them for our use. The presence of carbon fourteen in the dodecylamine enabled us to analyze quantitatively for dodecylamine on the surface of quartz, using a radioactive-tracer technique. The method used was that known as internal gas counting of carbon dioxide, formed by oxidation of the amine. This method has already been described, "3 ' and the reader is referred to these papers for details of the analytical method and procedures. and surrounding liquor, a technique analogous to chromatographic columns was utilized. The experimental setup is shown in fig. 1. The dodecylamine-acetate solution was made up in a volumetric flask and poured into the glass funnel shown. It was allowed to drip slowly onto the quartz bed, the rate of flow from the funnel reser- voir being controlled by a hose clamp. The quartz column was contained in a small, fritted-glass filter (size 20 mm, C). The beaded top edge of the filter was cut off to enable the holder and contents to fit into the open end of the 30/45 joint on the combustion tube. This combustion tube is used in the analytical train described in a previous paper.' A piece of gum-rubber tubing joins the bottom of the fritted-glass filter to a filter flask, which in turn is connected to a vacuum line, or water aspirator. The rate of flow of amine solution through the bed was

Jan 1, 1951

By F. W. Bloecher, A. M. Gaudin

THIS paper describes the results of a series of tests carried out to determine the partition of dodecylamine between distilled water and the surface of quartz at various concentrations of dodecylamine acetate in solution. An adsorption-column technique was utilized for this purpose. Ralston and Harwood, of Armour and Co., had synthesized marked dodecylamine acetate for us.' In their preparation which we employed, 0.0007 pct of the total carbon was the radioactive isotope, carbon fourteen. Unmarked dodecylamine acetate of high purity was also prepared by them for our use. The presence of carbon fourteen in the dodecylamine enabled us to analyze quantitatively for dodecylamine on the surface of quartz, using a radioactive-tracer technique. The method used was that known as internal gas counting of carbon dioxide, formed by oxidation of the amine. This method has already been described, "3 ' and the reader is referred to these papers for details of the analytical method and procedures. and surrounding liquor, a technique analogous to chromatographic columns was utilized. The experimental setup is shown in fig. 1. The dodecylamine-acetate solution was made up in a volumetric flask and poured into the glass funnel shown. It was allowed to drip slowly onto the quartz bed, the rate of flow from the funnel reser- voir being controlled by a hose clamp. The quartz column was contained in a small, fritted-glass filter (size 20 mm, C). The beaded top edge of the filter was cut off to enable the holder and contents to fit into the open end of the 30/45 joint on the combustion tube. This combustion tube is used in the analytical train described in a previous paper.' A piece of gum-rubber tubing joins the bottom of the fritted-glass filter to a filter flask, which in turn is connected to a vacuum line, or water aspirator. The rate of flow of amine solution through the bed was

Jan 1, 1951

By H. C. Kenny

The annealing or softening temperature of cold-worked copper is appreciably increased by almost unbelievably small amounts of silver. As indicated by some data in this paper, the softening temperature of high-conductivity, tough-pitch copper may be increased from 200" to 350" C. by the addition of only 15 oz. per ton (0.052 per cent) of that element. Because it has this higher annealing temperature as compared with the silver-free metal, silver-bearing copper finds considerable use in industry. For example, when hard-rolled copper is used in operations that involve soldering or tinning, silver-bearing copper insures against loss of strength, whereas silver-free copper becomes "dead soft." Yet—though several investigators, beginning with Caesar and Gernerl in 1916, have shown that small amounts of silver do definitely raise the softening temperature of copper—data are lacking on the problem: What is the specific influence of different amounts of silver on this temperature? It was to help in filling this gap in the knowledge of what might be termed "alloy coppers" that the data given herein were obtained. The softening of cold-worked copper depends, of course, on a number of factors, of which the composition of the material is only one. Other highly important factors are the degree to which the material is cold-worked and the time it is held at the annealing temperature. The method of cold working and the grain size of the metal produced are also significant. All these variables were taken into account in the investigation reported here, and the influence of silver on the electrical conductivity and on the working was also considered. The coppers used in the softening tests were Lake coppers melted and cast by the Calumet and Hecla Consolidated Copper Co. The ires were fabricated by the Roebling Wire Co. and the sheets were rolled at the Battelle Memorial Institute. Partial analyses of some of the coppers are listed in Table 1, with their electrical conductivities.

Jan 1, 1934

By F. M. Lewis, J. F. Myers

The selection of the proper type of flotation machine involves the consideration of a wide variety of factors. Under any condition, all types of machines will promote some kind of separation. Obviously, the correct way of deciding which type of machine is best suited for a particular problem would be to set up all types of machines and test them out in a competitive manner, but the vast number of small concentrating plants are unable to make such complete and exhaustive tests. The experience of the authors of this paper indicates that if all the factors involved in any particular problem can be determined, and if all the flotation-machine characteristics are understood, some basis for selection could be arrived at other than actual comparison. This paper is presented to show how the process factors and machine characteristics have been combined at the mills of the Tennessee Copper Co. from studies of several types of flotation machines. At the two mills of the Tennessee Copper Co. in the Ducktown Basin of Tennessee, four distinct flotation separations are made on the complex sulphide ore. Three different concentrates are produced from the ore—in the order of their importance: iron concentrate, copper concentrate, and zinc concentrate. Four different types of flotation machines are used. The selection of these four machines, for the plant operation, was based upon the study and operating experience of the machine units shown in the following list: Fagergren machine; square cell, size 56 inches Fagergren machine; level type, size 56 inches Denver machine; conical disk impeller, size 24 inches Denver machine; receded disk impeller, size 24 inches Minerals Separation Sub-A, size 24 inches Munro-Pearse deep cell, pneumatic Southwestern air machine, Hunt principle To date the study of flotation machines has been confined almost entirely to the rougher circuits. The various cleaning operations, being relatively a much simpler matter, have not been investigated so thoroughly. Table I shows a typical analysis of the two ores as well as of the mineral content.

Jan 1, 1947

By J. F. Myers, F. M. Lewis

The selection of the proper type of flotation machine involves the consideration of a wide variety of factors. Under any condition, all types of machines will promote some kind of separation. Obviously, the correct way of deciding which type of machine is best suited for a particular problem would be to set up all types of machines and test them out in a competitive manner, but the vast number of small concentrating plants are unable to make such complete and exhaustive tests. The experience of the authors of this paper indicates that if all the factors involved in any particular problem can be determined, and if all the flotation-machine characteristics are understood, some basis for selection could be arrived at other than actual comparison. This paper is presented to show how the process factors and machine characteristics have been combined at the mills of the Tennessee Copper Co. from studies of several types of flotation machines. At the two mills of the Tennessee Copper Co. in the Ducktown Basin of Tennessee, four distinct flotation separations are made on the complex sulphide ore. Three different concentrates are produced from the ore—in the order of their importance: iron concentrate, copper concentrate, and zinc concentrate. Four different types of flotation machines are used. The selection of these four machines, for the plant operation, was based upon the study and operating experience of the machine units shown in the following list: Fagergren machine; square cell, size 56 inches Fagergren machine; level type, size 56 inches Denver machine; conical disk impeller, size 24 inches Denver machine; receded disk impeller, size 24 inches Minerals Separation Sub-A, size 24 inches Munro-Pearse deep cell, pneumatic Southwestern air machine, Hunt principle To date the study of flotation machines has been confined almost entirely to the rougher circuits. The various cleaning operations, being relatively a much simpler matter, have not been investigated so thoroughly. Table I shows a typical analysis of the two ores as well as of the mineral content.

Jan 1, 1947

By Newell G. Alford

Forecasts of future timber consumption in soft-coal mining are handicapped by the lack of adequate experience records for estimating properly the timber requirements of the industry. Data were obtained from plants where records are kept or from operators who collected the information and to these were added composite figures for the continental United States in 1905 and 19191 and for central and western Pennsylvania and for Illinois in 1922.2 The result, representing slightly over 928,000,000 net tons, is shown in Table 1. Some of the companies furnishing data were unable to segregate the timber into classes of use but for those who did, Table 2 shows the board feet of posts and cross ban used per ton of coal mined and the percentage of the total timber consumed that was used in roof support. The wide variation in amounts of timber per ton of coal mined is the result of

Jan 1, 1924

By John T. Ryan

DEFINITE improvement in its accident fatality rate in the coal-mining industry was recorded during 1941, based on preliminary figures for the period from January through October. Total production during this ten-month period was approximately 91 percent of the total production in all of 1940. The ten-month accident rate for both bituminous and anthracite mining in 1941 was 2.15 killed per million tons of coal mined, compared with a rate of 2.66 for the full year of 1940. The bituminous rate decreased from 2.55 in 1940 to 1.99 in ten months of 1941, and the anthracite rate from 3.62 to 3.53 in similar periods. The decrease is more apparent for the bituminous branch of the industry, as the high figure in 1940 was due to seven major disasters which brought death to 276 men. The same number of major explosions during ten months of 1941 caused only 64 lives to be lost. The severity of the explosions has been lower this year but a definite need still exists for reduction in this type of accident.

Jan 1, 1942

By Robert Keeney

THE electric smelting of manganese ore and the production of ferro- manganese did not exist as an industry, in the United States or elsewhere, previous to the outbreak of war in 1914. Ferromanganese had been produced, electrically, during times of high prices by two companies at Niagara Falls and by several European companies, but the production. was spasmodic, and none was electrically produced when ferromanganese sold at from $35 to $40 per ton. Thus the electric smelting of manganese ore must be considered as a development caused by the high prices prevailing during the years 1916, 1917 and 1918, and the necessity of smelting domestic ore in order to fill the ferromanganese requirements of the steel industry of the United States, which increased from 189,088 tons in 1914 to 356,356 tons in 1918. The electric furnace is well adapted to smelting domestic-ore because it can be located in small units near the source of ore supply. In 1918, the ferromanganese production of the United States was 333,027 tons, of which about 7 per cent., or 23,000 tons, was produced in the electric furnace. The electric furnace not only assisted materially in the development of a domestic-ore supply but made a considerable saving of coke, as it requires about 1,4 tons of bituminous or lignite coal per ton of ferromanganese compared with a blast-furnace consumption of 2.9 tons of coke per ton of ferromanganese. Some of the plants in the United States that smelted manganese ore in the electric furnace during the war and in 1920 are listed in Tabled. From early in 1919 to about February, 1920, little ferromanganese was produced in the electric furnace. During this period the price of ferro-manganese (78 to 82 per cent. manganese) was about $100 per ton. During the first half of 1920, several plants resumed operation when the, price of. ferromanganese (76 to 80 per cent. grade) gradually increased to $200 per ton, delivered.

Jan 2, 1921

By James Aston

THREE years ago the writer presented a paper on the trend of development in the wrought iron industry,1 wherein was described a process in the development of which he has been a factor, which at that time had passed through several years of progressive experimental development but which had not then been put upon a commercial scale of operation. The present paper deals with two years of observation and experience in the commercial operation of a plant by the A. A Byers Co. at Warren, Ohio. It will not enter into the controversial field of the relative merit of wrought iron and steel in various classes of service, nor will it elaborate upon the characteristic services or fields of utility to which wrought iron is particularly adapted. It is sufficient to state that the wrought iron industry is upon a substantial basis and that the material finds service in pipe, where its advantages are in superior corrosion, fatigue, welding and threading qualities; in bar iron for staybolts, engine bolts, and rivets, demanding maximum service against corrosion and fatigue; in plates for corrosion service; and in chains, because of welding and shock-resisting characteristics. In short, ability to withstand the stresses of shock and vibration, or the ravages of corrosion, to hold protective coatings, and to give maximum efficiency in welding, are its features of relative superiority. If these features were not well recognized, the wrought iron industry would have shrunk to insignificance in the face of high costs and acknowledged limitations in manufacture. To charge that this industry is built upon a structure of assumption, psychology, and improperly weighed evidence is an impeachment of the integrity or belittling of the powers of observation of users through many centuries of service experiences.

Jan 1, 1929

By George S. Rice

IN other countries, research involving testing in various phases of ground movement and lessening its damaging effects, as by roof control, is going on more intensively than in this country, as evidenced by official mining papers and general articles appearing- in .Great Britain, Germany, France, and South Africa. One most important bulletin, "Some Aspects of Deep Level Mining on the Witwatersrand Gold Mines with Special Reference to Rock Bursts,"' was published by the Association of Mine Managers of the Transvaal, Johannesburg, under date of June, 1933, though not received in this country until 1.934. Since the deepest mining in the world is being done on the Rand-several mines over 7000 ft. deep and the Robinson mine 8000 ft.-the studies made are of intense interest to all mining men who have to deal with heavy ground pressure. In the discussion following the papers differences of opinions are shown on a number of problems; for example, on the ade¬quacy of sand-filling to prevent rock bursts and whether compressible or rigid artificial supports are best; also whether pressure bursts are due to the doming of strata and collapse of a lag of the dome or to induced shear cracks in the hanging wall. The problem of obtaining some means of warning of an impending rock burst led to testing with height indicators to find whether warning might be obtained by the lessening of distance between hanging wall and footwall. The indicators used are similar in idea but not in detail to the "convergence recorders" developed by the Safety in Mines Research Board of Great Britain for their roof-control studies in coal mines. Success at several Rand mines is claimed in that indicator records give some degree of warning when the lessening of height is rapid, although, on the other hand, when this happens bursts do not always occur.

Jan 1, 1935

By D. Foster Hewett

The scope of this paper is the description of two districts in Peru in which deposits of vanadium have been found, and the consideration of much laboratory-work that I and others have done to determine the nature of these deposits. It is with regret that I present some of the data in a state of evident incompletion, particularly the analyses of a few of the minerals, which leaves some doubt as to whether the true nature of the migerals is understood. I make no apology, however, since in this case, as in many others referring to ore-deposits, conclusive opinions cannot be stated until a great amount of work has been done, and the deposit has been thoroughly exploited. I believe that the data and the tentative conclusions here presented indicate a unique and interesting condition which may assist others in work along similar lines; arid further, what is of more practical importance, stimulate a search for a metal which, though long considered rare, is probably so merely because proper care has not been taken to recognize it. An excellent bibliography on the occurrence of vanadium in nature is given by I?. W. Clarke in his paper, Data of Geochemistry;' and in the preparation of this paper 1 have consulted many of the references contained in the Bibliography of the Chemistry of Vanadium, by M. Moisan.2 A brief review of the subject having special reference to the metallurgy of vanadium is contained in the small book by P. Nicolardot.3 One of these vanadium-deposits has already been briefly. 1 Bulletin No. 330, U. S. Geological Survey (1908). 2 Chimie Minerale, vol. iii. (1905). 3 Le Vanadium (1905).

Jan 1, 1910

By C. Baldwin Sawyer

During the last half century, much time has been devoted to investigations of the effect of nitrogen on the physical properties of steel, but in all discussions of results there is considerable doubt as to the accuracy and interpretation of analyses. No conclusions concerning the effects of nitrogen on the physical properties of steel can be more reliable than the methods used for determining the quantities of nitrogen present. The work described in this paper endeavors to establish some additional conditions required by the customary distillation method for reliable and nccurate determinations. Results by a combustion method of analysis for total nitrogen content are presented; these indicate that all of the nitrogen in steel, exclusive of that contained in blowholes, may be determined by the distillation method. Based on these more sound and more reliable analyses, results havc been obtained that bear on the following divisions of the general subject, nitrogen in steel: Nitrification of steel by melting in nitrogen, nitrification of steel by heating in ammonia, decomposition of nitrified steel by heating, and thermal analysis of nitrified steel. Consideration of Two Methods of Analysis and Some Results The details of the distillation and combustion methods are chemical in character and of little interest to most readers. They are therefore described in an appendix. The distillation method is essentially that described by Hurum and Fay1 and was generally used throughout this work. It is capable of the greatest accuracy and all results given are significant to the last, figure. Where analyses do not check, the samples

Jan 1, 1923

By C. Baldwin Sawyer

During the last half century, much time has been devoted to investigations of the effect of nitrogen on the physical properties of steel, but in all discussions of results there is considerable doubt as to the accuracy and interpretation of analyses. No conclusions concerning the effects of nitrogen on the physical properties of steel can be more reliable than the methods used for determining the quantities of nitrogen present. The work described in this paper endeavors to establish some additional conditions required by the customary distillation method for reliable and nccurate determinations. Results by a combustion method of analysis for total nitrogen content are presented; these indicate that all of the nitrogen in steel, exclusive of that contained in blowholes, may be determined by the distillation method. Based on these more sound and more reliable analyses, results havc been obtained that bear on the following divisions of the general subject, nitrogen in steel: Nitrification of steel by melting in nitrogen, nitrification of steel by heating in ammonia, decomposition of nitrified steel by heating, and thermal analysis of nitrified steel. Consideration of Two Methods of Analysis and Some Results The details of the distillation and combustion methods are chemical in character and of little interest to most readers. They are therefore described in an appendix. The distillation method is essentially that described by Hurum and Fay1 and was generally used throughout this work. It is capable of the greatest accuracy and all results given are significant to the last, figure. Where analyses do not check, the samples

Jan 1, 1923

By Kenneth C. Vincent, A. M. Gaudin

IN a study1of the action of amyl xanthate on chalcocite in water suspension, it was found that if the xanthate is added in relatively large quantity the xanthate group can be accounted for in three forms: (1) as xanthate ion remaining in water, (2) as benzene-soluble cuprous xanthate on the chalcocite, (3) as a benzene-insoluble coating on the chalcocite. Reduction in the amount of xanthate added leads to disappearance of form 1 then of form 2. With minute quantities of added xanthate, substantially all the reagent is of the "unleachable" kind. Yet this unleachable xanthate can be dissolved by pyridine to form a soluble cuprous xanthate complex, and it is sufficient in effectiveness to make chalcocite flotable even if insufficient in quantity to form a complete monomolecular film on the mineral. In that study it was also found that chalcocite abstracts cuprous xanthate from benzene solution, in what may (or may not) be a case of molecular adsorption. It seemed desirable, therefore, to study further the "unleachable" xanthate on the chalcocite, and particularly to ascertain whether it is formed as a result of the benzene leach or is actually formed during the conditioning of chalcocite in aqueous xanthate solution. A splendid tool to make such studies has recently been perfected; that is, the use of radioactive spies or tracer atoms. With this tool, it was thought possible to answer the problem stated above, but, unfortunately, this did not prove to be true. Answer to the flotation question was clouded by the existence of rapid and selective diffusion of copper atoms in the solid mineral-a phenomenon that was totally unexpected yet remains interesting and perhaps important. METHOD OF RADIOACTIVE SPIES The method of radioactive spies is discussed in many places. Two convenient references are the article by Evans2 and the book by Pollard and Davidson.3 The method was first developed by Von Hevesy and Paneth in 1913, when only natural radioactive isotopes were available. These isotopes are few in number, and so the method remained limited in scope. Recently the synthesis of over 350 active isotopes of all the known stable chemical elements4 has opened widely expanded possibilities for the method. A fundamental tenet of the method is that a radioactive atom and a nonradioactive atom are exactly alike until disintegration of the radioactive atom. Then, by its sudden death, the spy reveals its location. The relative abundance of spies at various locations makes it possible to ascertain the relative abundance of the corresponding nonradioactive atoms at the same times and locations. A second fundamental tenet of the method of radioactive tracers is that the radioactivity lies in the nucleus of the atom: transfer of radioactivity from one

Jan 1, 1944

By R. M. Hardgrove

PULVERIZED coal was first used for firing cement kilns about 45 years ago, with such success that it has continued in general use. Based on cost, pulverized coal is usually the most economical fuel. In some localities natural gas or oil is cheaper, but 85.5 per cent of all cement kilns at present are fired with pulverized coal. The pulverized-coal flame is well suited to kiln conditions. Its soft, luminous nature gives it a high radiating property and the length of the flame can be readily varied to suit conditions in a kiln of any length. Ash and slag cause most of the difficulties incident to the burning of coal. In a cement kiln, however, the ash, being similar in composition to the raw mix and being deposited uniformly in the mix and clinker, occasions no difficulty as long as it remains constant in quality and quantity. Until 6 years ago almost all cement kilns using pulverized coal employed the bin system. The coal was dried and pulverized in a separate plant and delivered into a bin at the kiln. Thus the bin system requires driers, storage-type pulverizers, conveying systems, individual kiln bins, pulverized-coal feeders and primary air fans. The direct-fired system requires only a pulverizer and a blower. Fig. I shows typical plants. The first installations of direct-fired pulverizers were of the impact type but fineness of pulverization was both inadequate and variable. About 1927 a few direct-fired installations employing tube-type pulverizers were made, which were much more satisfactory. As more efficient pulverizers were developed from 1934 on, equipment for direct firing was installed at a large number of plants, until now 196 of about 900 kilns in use in the United States are direct-fired. Most of these replaced antiquated bin systems. PROCESS OF BURNING CEMENT CLINKERS The process of burning cement clinkers is fundamentally one of heat transfer. In boilers and other heat-exchange apparatus the area of the surface receiving heat from the gases is the best unit for comparing output. This seems to be equally true for kilns. The inside kiln surface is the heat-receiving surface and its area is used as the unit of kiln size in the following comparisons. Heat input is based on British thermal units in the fuel. E. G. Bailey,1 in his work on boiler-furnace heat absorption, has used the unit "B.t.u. available." This is the practical calorific power of the fuel, plus the heat in the air used for combustion. In other words, it is the heat available for useful work in the furnace or kiln. The unit of kiln output is barrels per hour. The composition of the raw mix, the percentage of water in the slurry of wet plants and hardness of burning all affect the output. These conditions, however, are hard to evaluate and probably have less effect on the output than irregularities of raw feed and clinker discharge and inexpert control of combustion. WET VS. DRY PLANTS The study presented here covers 88 plants, of which 41 are wet and 47 dry. Of

Jan 1, 1941

By S. W. Poole, J. A. Rosa

THE object of this investigation was to determine the distribution of chemical elements within a large, killed alloy-steel ingot, by sulphur printing and quantitative chemical analysis. With regard to segregation in steel ingots, the factors of melting practice, pouring temperatures, mold design, etc., and the mechanics of solidification and its attendant functions, have been the subject of intensive study over a period of years by many investigators. Notable among these is the Sub-Committee of the No. 5 Committee of the British Iron and Steel Institute. For an exposition 0f the many problems awaiting the researcher on the heterogeneity of steel ingots, the methods of attacking these problems, together with some of the answers, the reader is referred to the nine reports and numerous papers of that committee and its membership. STEELMAKING DATA Melt.-The heat was made in a 70-ton direct arc-type basic electric furnace. Furnace charge consisted of nickel-chromium-molybdenum steel, most of it in the form of heavy mill scrap. All of the scrap was charged cold. The standard double-slag method was employed, the heat being finished under a strong carbide slag. Aluminum was used as the deoxidizing agent. Tapping temperature, as observed with an optical pyrometer, was 3000°F. Detail of Mold and Ingot Size.-Details of the ingot mold and the ingot itself are given in Fig. I. Teeming.-Teeming temperature of the subject ingot as observed with an optical pyrometer was 2830°F. The ingot was top-poured directly through a 1 ½ in. nozzle and required 7 min., 44 sec. to fill up to the hot top. An additional 2 min., 30 sec. were required to fill the hot top. The ingot was stripped hot and charged with the remainder of the heat into an annealing furnace. There it was given the standard annealing cycle used for these ingots. Subsequent heat-treatments are described elsewhere in this paper. SECTIONING AND PREPARATION FOR SULPHUR PRINTING Because of previous favorable experience in sectioning ingots up to 21 ½ in. square with an oxyacetylene torch, it was decided to use this method to section the subject ingot. The ingot was preheated to 900°F. for 12 hr. It was then placed on a steel bed in a horizontal position so that the longitudinal axis was level and parallel to the track of the motor-driven torch carrier. Two cuts were made, one 2 in. above the longitudinal axis and the other 2 in. below. The time required to make each cut was approximately 75 min. The cutting operation is shown in Figs. z and 3. The 4-in. thick slab was mmediately charged into a furnace standing at 1200°F.

Jan 1, 1944