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By Nathaniel Arbiter

INTRODUCTION Almost seventy-five years ago problems in the recovery of sulfides from then designated slime fractions were the impetus for the development of flotation. The fall-off in recovery by gravity methods below about 200-mesh, and the shift from coarser vein deposits to more disseminated ores, particularly for copper, provided the background for flotation's rapid advances. Although the ensuing years have witnessed major improvments both in flotation reagents and in flotation machines, many problems are still with us. And since, with the exception of the unique leaching of chalcocite ores at Inspiration, flotation is still the exclusive mainstay for primary recovery of all base metal sulfides, the solution of these problems as they arise is vital to the well-being of the mining industry. Before considering the problems themselves, it will be useful to review the current status of sulfide flotation in the United States. The last comprehensive survey by the Bureau of Mines in 1975 (1) showed sulfide ore tonnages treated from 1960 to 1975 as summarized in Table 1; Table 2 gives similar data for the flotation of all non-sulfide ores. Noteworthy is the leveling off in sulfide ore tonnages in 1970-1975, with a probable further decline in the past three years, and the sharp drop in the number of plants floating sulfide ores. In contrast, the tonnages of non-sulfide ores floated, as well as the number of individual plants, has continued to increase. In spite of these trends, two-thirds of the total tonnage of the ores to which flotation is applied is still represented by sulfides. Average grades of sulfide ores in 1975 were: about 0.6 percent for copper; near 5 percent for lead; and near 3 percent for zinc. Recoveries averaged in the low 80's for copper; about 95 percent for

Jan 1, 1979

By Halbert Powers Gillette

In every chemical reaction heat is either developed or absorbed, and this plus or minus heat of formation is as definite in quantity as the weights of the reacting elements. In this paper I shall show that each chemical element and each chemical radical has its own definite heat-valency,—a fact which, so far as I know, has hitherto escaped the attention of investigators, but, I feel sure, will be admitted after the demonstration here given, and may lead to some practical conclusions of value. When Berthelotys " law of maximum work " was found to have so many inexplicable exceptions, the pendulum of a scientific theory swung away from a recognition of the truth underlying that proposition; and this reaction went so far that not only has thermal chemistry been relatively neglected by recent investigators, but it is not uncommon now to find textbooks on physical chemistry which practically ignore all that Thomsen, Berthelot and others have done. To this temporary tendency of thought I attribute the failure to recognize the principles herein announced and explained. Not long ago, while studying tables of the formation-heat of various salts, I noticed that in this respect all potassium salts in solution differ from the corresponding sodium salts by 9.3 cal.1 I found also that similar differences exist between other salts, not only when the basic radical is varied, while the acid radical remains constant, but also when the acid radical is the variable. Thus chlorine salts in solution differ from bromine salts in this respect by 10.9 cal. Upon further study, I found that Thomsen had noted similar constant differences, but, so far as I can ascertain, he appears to have attached no great significance thereto.

Jan 1, 1904

By Arthur Taggart

FOREWORD THE tests herein described are part of an extended series of experiments, performed by the authors together with J. F. McClelland and L. W. Bahney, on the reclamation of metallics from foundry and manufacturing-plant scrap. The most obstinate problem encountered was the proper cleaning of the metal. INTRODUCTION In the manufacture of brass and brass products the weight of the finished product leaving the plant is much less than the total weight of copper and zinc entering. A small part of this discrepancy is due to the unavoidable oxidation of the metals in melting, but by far the largest part of the loss is in the form of metallic particles of copper, zinc, and brass. These losses occur principally at three points in the process: (a) in the casting-shop ashes; (b) in the slags from furnaces melting scrap brass; (c) in material spilled on the floor throughout the manufacturing process. The amount of these products in some plants is nearly 100 tons per 24 hours. Casting-shop ashes contain the metal spilled from the crucibles during melting and pouring, and the metal included in the slags formed in the melting process. The ashes also contain pieces of broken crucibles with adhering metal; 20 to 30 per cent. of unburned coal is also present. The metal in casting-shop ashes contains clean pieces of zinc or copper ingots weighing 1 to 2 lb., jagged pieces of metal of all shapes ranging in size from several inches down to the finest dust, and shot and botryoidal shapes ranging in size from 2 or 3 in. down to 0.01 mm. or less in diameter. Slags from furnaces melting scrap brass contain metal in the form of small shot.

Jan 2, 1916

By Morris M. Fine, Norwood B. Melcher

As a raw material, prereduced pellets can be considered symptomatic of the quiet revolution taking place in the quality and grade of blast furnace burdens for the past decade. In 1954, the average analysis of ores from U.S. ranges in the Great Lakes area was 50.86% Fe (natural), 10.22% SiO2, and 10.90% moisture; ten years later, the average was 56.67% Fe (natural), 8.13% SiO2, and 6.17% moisture. The advance in Canada was even more pronounced in a lesser number of years. In 1957 the average product of Canadian ore-producing areas was 51.62% Fe (natural), 8.59% Si02, and 8.02% moisture; in 1964, the average grade was 59.59% Fe (natural), 6.27% SiO2, and 3.94% moisture.2 These dramatic data are testimony to the giant strides made in iron ore improvement, and the next logical step is prereduction. Prereduction can well be considered as a beneficiation step in which oxygen is the gangue. Since the ultimate objective of milling and smelting is iron metal, non-metallic constitutents in general, whether oxygen or silica, are contaminants. The past and continuing attack aimed at lowering the silica content of concentrates is succeeding. One need only thumb through the Grade Name listings of the American Iron Ore AssociationVo note that virtually all commercial pellets contain less than 8% silica, many are lower than 6%, and a few below 45%. With natural technical evolution, it is expected "many" rather than "few" will ultimately be in the last category and further mechanical concentration will have reached the point of diminishing returns. At this level, oxygen would constitute the only major diluent worthy of attack.

Jan 7, 1966

By B. H. Sage, W. N. Lacey

Variations in the composition of the liquid phase of natural reservoirs which are continuous through significant ranges in elevation have been noted by petroleum technologists. In general, there is a greater gas-oil ratio and the gravity of the oil is higher in production from the upper parts of the formation. In the present paper the possible changes in composition with elevation which would result from the attainment of thermodynamic equilibrium in a uniform gravitational field have been evaluated for a naturally occurring hydrocarbon liquid, a binary hydrocarbon liquid phase and a binary hydrocarbon gas. The results indicate a progressive decrease in the mole fraction of the components from methane through the butanes with increasing depth, accompanied by a corresponding increase in the amount of the heavier components making up the system. The magnitude of these variations is perhaps insufficient to explain completely the variations in the properties of the liquid phase that are encountered at various elevations within a particular producing horizon. However, the changes are significant and the treatment presents an example of the application of thermodynamic data to the evaluation of the properties of hydrocarbon fluids under the conditions approaching those encountered in natural reservoirs. Theoretical Considerations Muskat1 has discussed the work of earlier authors relating to the equilibrium relationships of multicomponent systems in a gravitational field. He also presented explicit solutions for several cases and discussed the physical significance of gravitational concentration gradients. In engineering work it is customary to consider the pressure, the temperature and the composition of a phase to be the independent variables sufficient to establish its state. This procedure neglects the effect of gravitational or other types of fields upon the energy associated with the system and assumes, among other things, that the pressure is uniform in

Jan 1, 1939

By W. N. Lacey, B. H. Sage

Variations in the composition of the liquid phase of natural reservoirs which are continuous through significant ranges in elevation have been noted by petroleum technologists. In general, there is a greater gas-oil ratio and the gravity of the oil is higher in production from the upper parts of the formation. In the present paper the possible changes in composition with elevation which would result from the attainment of thermodynamic equilibrium in a uniform gravitational field have been evaluated for a naturally occurring hydrocarbon liquid, a binary hydrocarbon liquid phase and a binary hydrocarbon gas. The results indicate a progressive decrease in the mole fraction of the components from methane through the butanes with increasing depth, accompanied by a corresponding increase in the amount of the heavier components making up the system. The magnitude of these variations is perhaps insufficient to explain completely the variations in the properties of the liquid phase that are encountered at various elevations within a particular producing horizon. However, the changes are significant and the treatment presents an example of the application of thermodynamic data to the evaluation of the properties of hydrocarbon fluids under the conditions approaching those encountered in natural reservoirs. Theoretical Considerations Muskat1 has discussed the work of earlier authors relating to the equilibrium relationships of multicomponent systems in a gravitational field. He also presented explicit solutions for several cases and discussed the physical significance of gravitational concentration gradients. In engineering work it is customary to consider the pressure, the temperature and the composition of a phase to be the independent variables sufficient to establish its state. This procedure neglects the effect of gravitational or other types of fields upon the energy associated with the system and assumes, among other things, that the pressure is uniform in

Jan 1, 1939

By Arthur Lake

Within the past few months I have had occasion to visit and examine the area of country in Gunnison county locally called the Gold Belt and extending from the Cebolla river on the west to the head of Taylor Park and the Sawatch range on the east. The region including the "belt" may be hided topographically into two parts, a northern and a southern one. The former is characterized by lofty mountains and deep canons, with occasional parks and wide valleys. Most of it is included in the granitic system of the Sawatch range, with local patches of the Palaeozoic sedimentary rocks, more or less traversed by great bodies of porphyry and other eruptive rocks. The southern portion, on the other hand, is characterized by comparatively low, rounded hills of schist and sahistose gneisses, underlain by coarse, massive granite, which outcrops locally in small, and sometimes in large, patches. These hills also sometimes form table-lands by reason of overflows of lavas, such as andesitic breccia, rhyolite, trachyte and basalt. The leading geological feature is that of a schistose area of width and extent unusual for Colorado. These schists and gneisses are of pre-Cambrian age; but whether assignable to the Algonkian or to some older system has not been determined. The granite which occasionally outcrops from beneath these schists is, I think, of true eruptive character, since its mode of occurrence indicates a once molten, or at least highly viscous or plastic, condition. Thus, we may observe, included in its mass, numerous fragments of schist, almost like a coarse, volcanic breccia. Again, at its immediate contact with the schists, which often stand vertically upon it, the pediments of the latter are fused into the granite, and granite tongues and veins run up amongst the schists, as only a molten or viscous

Jan 1, 1897

By A. H. Bromly

The small agricultural village of Santa Barbara, in the State of Guanajuato, has been the center of spasmodic tin-mining operations during recent years. The deposits, so far as I know, are unique, and a few brief notes may be of interest. Santa Barbara, about 12 miles west of San Felipe station on the Mexican National Railway, and at an elevation of 2,400 m. above sea-level, is situated in a flat valley extending east and west, and bounded north and south by broken rugged hills rising about 330 m. above the general level of the valley. Tin-mining operations have been conducted at the Queensland mine, near this village. A small concentrating-mill was erected and attempts were made to smelt the ore in reverbera-tory furnaces. The country-rock of the district for many miles is rhyolite of great thickness. There are some local variations due to differences in cooling, or subsequent alteration or impregnation; but throughout the whole district the principal constituents of the rocks remain the same, viz., free silica, orthoclase-feldspar and sanidine. The latter is especially marked. The crevices and joints of the rock are frequently filled with calcedonic and opalescent quartz. The ore-formation at the Queensland mine is of an unusual nature, consisting of cracks in the rhyolite which have been filled with clay. This phenomenon is largely developed over a width of from 80 to 100 m., in which the principal fissuring follows an approximate direction of north and south. The average dip ranges between 70 and 80 degrees. Some of the fissures hold sufficiently true for a time to afford the impression that they are due to dynamic causes, or earth-movement. This may be true of some of the north by south fissures; but considering

Jan 1, 1906

By George F. Becker

Complexity of Rock-Fractures. - The strains to which rocks have been subjected are manifestly very complex, and it is entirely safe to presume that every possible node of deformation and rupture is exemplified. The most superficial inspection of any ordinary mountain region is sufficient to assure the observer that the rocks have been pressed, stretched, bent, buckled, twisted, and shorn. The study of torsional rupture cannot fail, therefore, to throw light on geological phenomena. The question is, how areas which have been broken in this manner are to be distinguished from those which have yielded to other systems of forces. Phenomena of Joints. - It is well known that a large part of the more homogeneous rocks and some very heterogeneous rocks are intersected by partings, often called joints. These partings are frequently flat surfaces, even when seen in very large exposures, but are sometimes surfaces of moderate single or double curvature. Joints usually occur in groups, in each of which the several partings are parallel to one another, and several such groups often intersect the same rock-mass. In such cases the different systems make large angles with one another. Nearly all students of the subject of jointing have reached the conclusion that joints are faulted surfaces, the dislocations usually being of small amplitude; and this conclusion receives abundant support from the study of thin sections under the microscope. It has thus been shown that much even of what would be regarded in I hand-specimens as mere slaty cleavage consists, in reality, of innumerable microscopic faults. For this reason, Mr. Daubrée rejects the term "joint," as failing to imply the existence of relative motion, and has introduced the terms “diaclase” and “paraclase” as substitutes.1

Jan 1, 1913

By Leo Dana

As a part of an investigation conducted by the Cement Section of the Bureau of Standards, at the plant of the Security Cement & Lime Co., Security, Md., the High-temperature Measurements Section was called upon to measure temperatures in a dry-process, coal-burning kiln. Although the measurements were made only under the conditions existing in one plant, the methods employed and the conclusions drawn apply, in a general way, to those existing in most plants. As far as we have been able to learn, no sufficiently thorough methods of making accurate pyrometric measurements in the sintering zone and in the rear end of rotary cement kilns have been described. It is believed that in this investigation, data were obtained that can serve as a foundation for further study of the problems of pyrometry in cement kilns. IMPORTANCE OF TEMPERATURE MEASUREMENTS IN ROTARY CEMENT KILNS The manufacture of Portland cement is today fairly well standardized. The various steps in the manufacture have been developed to such an extent that the process is almost automatic. In spite of these strides the efficiency of utilization of heat in the kiln is very low and an undue proportion is wasted; for example, about 50 per cent; ordinarily goes up the stack. In order to prevent these losses, not only should means be provided to utilize the waste heat but instruments, such as pyrometers, should be installed to study and control the operation with the view of minimizing the losses. At the same time, such control will produce a more uniform product. The saving in-fuel that may be effected by the proper use of pyrometers would be much more than their cost. Where these pyrometers should be installed and what they can show are very briefly indicated in the following paragraphs and discussed in greater detail later.

Jan 9, 1919

By Will Coghill

FLOTATION has been so closely allied with the sulfide minerals and their early and associated oily reagents that the term "oil flotation" has erroneously been applied to the entire flotation process. Today, the term "chemical flotation" might be used to advantage. Flotation literature has dealt primarily with the removal of sulfides from non-sulfide gangues, and the separation of one sulfide from another. Now, the application of the process to the separation of nonsulfide minerals is coming to the fore; and from the standpoint of the number of commercial minerals involved, the flotation of nonsulfides offers the larger field. Here, soap or soap-forming substances, such as the fatty acids and their derivatives, are used; hence there may well be a subdivision of the chemical flotation process called "soap flotation." Early experimenters learned that it was easy to form a froth or foam that would carry a part or all of the ore charge over the lip of the flotation machine; but this could not be regarded as flotation because of the lack of selectivity. Doubtless soap was one of the first reagents tried, and doubtless it was rejected on account of its gangue-carrying properties. Now this same gangue-carrying ability makes soap an acceptable reagent, for we are dealing with that, which among sulfides, is considered "gan-gue." As in the flotation of sulfides, so in the flotation of nonsulfides, the selective flocculation of the mineral and the dispersion of the gangue are the first objectives. In fact, these two phenomena epitomize flotation. They depend upon the unlike surface properties of the respective miner-als; and as long as the components of an ore have unlike surface proper-ties, a separation is possible, at least in theory. Often in nonsulfide flotation it makes little difference which mineral floats and which is depressed; generally only a separation is sought.

Jan 1, 1932

By Charles Mitke

THE United Verde Extension mine is located in the Jerome mining district, on the eastern slope of the Black Hills, approximately northeast of the town 'of Jerome, Yavapai County, Arizona. The ore deposit may be termed a replacement in Yavapai schist. This schist is one of the oldest formations in the district, being probably of volcanic origin, and has been folded and faulted and contains intrusions of diorite and quartz porphyry. It is believed that the mineralization followed the porphyry intrusions and replaced the country rock; this was followed by erosion and a period of secondary enrichment, all completed in pre-Cambrian time. Later sediments of sandstones and limestones, to the depth of approximately 600 ft. (182 m.), were laid down, followed by volcanic flows. Faulting and erosion again took place, resulting in the present complicated arrangement of the strata. Prospecting, therefore, is very difficult, because the sediments practically cover the mineralized areas. This necessitates the sinking of deep shafts, cross-cutting, and, in some instances, diamond drilling to learn something of the various relations of the different formations and the occurrences of intrusions associated with ore deposition. The locating of new orebodies, therefore, is beset with innumerable difficulties. EARLY MINING METHODS The two orebodies constituting the principal resources of the company are known as the- small orebody and the Bonanza, or large orebody. These are about 150 ft. (45 m.) apart, and while they appear to be distinct orebodies may later prove to be connected. The character of the ore, the general associations of the porphyries adjoining the orebodies, and other characteristics, both in the ore-and general environment, are very similar. The small orebody was the first to be discovered and was mined for some time before the Bonanza was found.

Jan 1, 1919

By Lillian Erskine

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

Jan 2, 1919

E. L. BLOSSOM, New. York, N. Y.-That this paper deals with a real problem is illustrated by a statement made to the speaker a few months ago by the manager of a silver-lead property: "Our ore contains 60 per cent. silica on which the smelters are penalizing us heavily, and they are not able to take all our stuff even then. We have simply got to find some method other than smelting for getting the silver and lead out of our ores. We have had experts down here and have investigated flotation, leaching and volatilization, of which processes the latter is by far the most promising. We are continuing investigation." I was somewhat concerned in certain chloride volatilization experiments which we carried on in Denver in 1903, working on a carload of ore from Butte. Now being connected with the Cottrell process, by which method the fumes will undoubtedly he recovered if they solve the volatilization problem, I have looked into the matter again, and believe it can be developed into a commercial process. On a laboratory scale, working With silver-lead ores, experimenters have obtained a volatilization of over 90 per cent. of the total values in 30 to 60 min, on quantities of 1 to 5 lb., using a roasting dish and a muffle. That looks very good, and would be entirely commercial. On attempting to duplicate these results in a reverberatory furnace, they found that it is more likely to take 8 hr. firing to yield 75 per cent. extraction, which is not commercial at all, as it requires too much time, labor, and fuel, and the whole process is too slow. Of course it can be done, because we have done it in the laboratory.

Jan 1, 1918

By C. W. Jr. Gennet

ANNOUNCEMENT was made in the spring of 1926 that the Boston & Maine R. R. Co. had contracted with the well known German steelmakers, Messrs. Fried Krupp, for the manufacture of 15,000 tons of basic open-hearth steel rails at the Rheinhausen Works, for delivery to Boston, Mass. The manufacture of rails in the United States has for many years been almost a national pride, and as this feeling is chiefly the result of a long-time liberal and consistent patronage of, American rails by American railroads, it is not strange that this somewhat unusual announcement should arouse more than ordinary interest. Since the end of the World War, the importation of foreign rail has been fairly large, principally because the newly created economic conditions have rendered some American competition more difficult, but the tonnage imported, for the most part, has been made up of small orders for miscellaneous use; and the contract referred to constitutes the largest single importation of foreign rail in over ten years. In 1915, the Algoma Steel Co. of Sault Ste. Marie, Canada; supplied the Illinois Central R. R. with 30,000 tons of rails,1 and various other American roads with smaller amounts. In 1902, 1903 and 1904, large tonnages of rail from abroad were purchased, the Louisville & Nashville R. R. alone obtaining 30;000 tons from German mills. It is the object of this paper, to present, in what is believed to be a new and concise form, figures showing the production and consumption of rails in the United States, and to record some of the testing and inspection results of the recent Krupp rails; also, to direct attention to two quite unique departures from American practice that were regular features of the Krupp process and which are worthy, it is thought, of careful study.

Jan 1, 1928

By C. H. Herty

During the past few years frequent reference has been made to a certain type of iron known generally as "bad iron," "dirty iron," etc., both by steelmakers and producers of iron castings.' Open-hearth operators have claimed that such iron was entirely within the specified limits as to ordinary analysis but it was difficult to make good steel from it. It has been suggested that unreduced material in the iron is responsible, also that most trouble is experienced with the iron when the blast furnace is delivering a product whose analysis is more or less variable. Other reasons suggested are the use of scrap or borings, unsintered flue dust in the burden, a cold hearth, too high a proportion of unsuitable grade of ore, or the form of the carbon in the iron. Accordingly, a subcommittee was appoint at the fall meeting of the Open-hearth Committee of the Americ m Institute of Mining and Metallurgical Engineers held in Pittsburgh in October, 1926, to investigate the reasons for the occurrence of this bad iron and suggest methods for preventing its appearance. This committee enlisted the cooperation of the U. S. Bureau of Mines Experiment Station at Pittsburgh in undertaking a study of pig-iron quality as affecting the open hearth. The following is a report of the findings to date: Method of Testing Inasmuch as a "spell" of dirty iron occurs without warning and may be of short duration, it was deemed advisable to attempt to simulate the conditions existing before and during such a period and compare the quality of the steel made with the normal and with the dirty iron. The Bourne-Fuller Co., of Cleveland, which has a single furnace that supplies

Jan 1, 1929

By G. L. Oldright, Virgil Miller

It is well known, in metallurgical circles, though less recognized in the technical press, that there have been remarkable increases in the capacity of the blast furnace in the last five .years. In places this capacity has been almost doubled. This paper will brief the experimental work carried on during more than five years with the direct assistance of the technical staffs of three lead smelters treating three distinctive types of feed. The first is the custom smelter of the International Smelting and Refining Co. at Tooele, Utah1, with a multiplicity of ores; the second, the Kellogg, Idaho, smelter of the Bunker Hill and Sullivan Mining and Concentrating CO.2, treating an exceedingly rich lead charge, such as is now being made more and more as the practice of concentration is improved; and the third, the smelter at Trail, B. C., owned by the Consolidated Mining and Smelting Company of Canada, Limited3, which treats highly zinciferous charges and later recovers zinc from the slag. In comparing operations at these three smelters it must be clearly recognized that the objectives in smelting differ through differences in economics. Many operations are not, then, strictly comparable. There have also been decided improvements in operation since all of the smelters were examined, though this was but a relatively short time ago. The general factors that govern speed in smelting and the loss of metals in the smelters examined will be stressed. (For details of operation the reader is referred to the original papers.) This paper will then be an examination of the fundamentals of operating units in a search for improvements, and not a description of three great lead smelters. Capacity of Blast Furnace Assuming a well prepared and self-fluxing charge to start with, enough coke must be added: (1) to melt the charge, particularly the slag-forming

Jan 1, 1937

By W. J. Slatosky

W. 0. Philbrook (Cairiegie Institute of Technologyogv—Mr. Slatosky has presented an interesting and constructive paper that represents another step along the way of converting steelmaking from an art to a science. I am confident that his computer will be practical and successful and that with a very few months of experience it will provide a significantly better degree of control than his record of 65 pct of heats within range obtained with the slide-rule calculator . A paper such as this, with a lot of symbols and condensed mathematics, is difficult to comprehend quickly. Since I have had an opportunity to study it carefully, perhaps my evaluation of its validity and accomplishments will save time for others. Mr. Slatosky has correctly used standard principles of stoichiometry and heat balances, which are available to anybody, but he has also brought to them two original contributions: 1) He has developed from operating data some empirical relations for predicting the final FeO content of the slag (at 0.5 pct C end-point) as a function of slag basicity, lance height, and scrap, ore, and scale in the charge. This improves the accuracy of prediction of temperature or scrap requirement compared with assuming an arbitrary, constant FeO content at the end of each heat. There is no assurance yet that exactly the same relations will hold for other furnaces or practices, but similar correlations can be expected. 2) He has combined calculations that are ordinarily carried out laboriously as a number of individual steps into a single, simple linear equation that can readily be fed into a machine. This involved a tremendous amount of painstaking detail work as well as the imagination to see the possibility and work out the steps. While his particular Eqs. [3] and [6] are valid only for the furnace design, charge weight, and blowing time used at Aliquippa Works, only a few numerical values have to be changed to adapt it for other conditions. In order to arrive at a useable solution, Mr. Slatosky had to make some basic assumptions about the process that are similar to those used by others. He neglected variation in some process variables and assumed an arbitrary average value for waste gas analysis and temperature for want of more exact information at the present time. All of these judgments are clearly stated. In addition, some thermody-namic data presently available are not adequate for the job, notably in relation to heats of formation and sensible heat in slag, and some expedient has to be adopted to get around the difficulty. Other people might prefer slightly different judgments about these details and hence obtain somewhat different numerical solutions. This is not of serious importance, however, because the errors accumulate in the "heat loss" term and are largely self-compensating for a constant heat time. Although the extended Eq. l(a) in Appendix I was set up as a rate equation originally, for convenience in using an analogue computer as stated in the paper, the time dependence was removed by later mathematical manipulations and assumptions about the process. The final result is an integration of element and energy balances from initial to final states; this procedure is as legitimate here as in any other form of heat-balance calculation. The formal handling of stoichiometry and thermochemistry appears to be correct, and it is assumed that any arithmetical errors would have come to light in applying the calculations to furnace practice. Mr. Slatosky's approach is not necessarily unique, in that other people might start with apparently different equations or prefer another form of final equation for another type of computer. However, he has presented an accomplished result that appears to be a theoretically sound and practically useful way of applying scientific principles and rapid computation for better control of steelmaking. His success will undoubtedly encourage himself and others to improve on the mathematical model and its use as better informatioq becomes available. John F. Elliott (Massachusetts Institute of Teck-t2ology)-The last comment by Mr. Richards that a calculator is quite unnecessary for an L-D operation ?-equi??es a rebuttal. The L-D furnace is a very high capacity process which places a premium on close control. When one is making steel at rates between 100 and 200 tons per hr, one cannot afford the luxury of an extra 5 or 10 min at the end of a heat correcting for an error that should never have been made in the first place. Mr. Slatosky's paper is a very sound application of the simple principles of stoichiometry and the energy balance. It is a satisfactory and valuable start, but only the start of the development of methods of control for this process. An analysis of the process shows that it should be very suitable to control by a computer. This is especially the case when various grades of steel are to be made. In fact, it would seem that the organizations who are planning new and bigger installations of L-D vessels should consider carefully the advantages that would stem from computer control of a vessel with the operator present to do little more

Jan 1, 1962

By J. Sibakin, R. D. Hindson

In order to devise a practicable soaking pit schedule for use at The Steel Co. of Canada Ltd.'s Hamilton Works, soaking pit heating temperatures, sooking times, pit capacity, and safe maximum mill drafts were correlated with fluctuations in the current or load of the bloom mill driving motor. Other variables such as total delays in the pit, rolling schedules, mill delays, and track times were also investigated. IN order to show an easily applied and accurate means of establishing soaking pit heating temperatures, soaking times, pit capacity, and safe maximum mill drafts, these various factors are correlated herein with fluctuations in the current or load of the bloom mill driving motor. Rolling practices have a considerable influence on the production capacity of a blooming mill. The maximum values of the torque, in particular, are of importance, since even instantaneous current peaks lead to the tripping of the motor by the overload relay and result in loss of mill time. The establishment of safe maximum drafts and accelerations for ingots of different sizes and of a soaking pit practice which would ensure a consistent and satisfactory plasticity of the metal is of considerable importance for increasing the efficiency of both the blooming mill and the soaking pits. The Bloom Mill Dept. of the Hamilton Works, The Steel Co. of Canada Ltd., is equipped with one 44 in. mill driven by a 7000 hp motor with the setting of the overload relay at 22.0 ka. The speed of rotation of the motor is regulated after the Ward-Leonard system. There are three basic speeds of 9.5, 28, and 47 rpm and a further possibility of increasing the speed by weakening the field. This last possibility is hardly ever used during practical operations. The rolling program of the blooming mill is varied, both in the size of the ingots to be handled and in the steel grades. The total tonnage handled by the mill is about 2,000,000 ingot tons per year. At the time of the investigation, the Bloom Mill Dept. was equipped with 22 soaking pits (6 regenerative, 14 bottom-fired, and 2 one-way top-fired pits) with a total bottom area of 2770 sq ft. The pits are fired with a blast furnace-coke oven gas mixture having a calorific value of 155 Btu per cu ft. The foregoing figures show that the production program was such as to impose the necessity of a most efficient usage of the available equipment. For this purpose, the operations of the 44 in. mill and of the soaking pits were investigated, and the results of the investigation were used as a basis for a revised soaking pit schedule and drafting practice. The plasticity of an ingot of a certain chemical composition when being rolled is determined mainly by the following factors: I—the ingot size, both thickness and width; 2—the length of the gas soak; and 3—the surface temperature. The first two factors determine the uniformity of the temperature distribution over the cross-section of an ingot. The third factor introduces the level of the heating of an ingot. The torque produced by an ingot being rolled is determined by the area of the metal displaced, its plasticity, and acceleration values. On the other hand, with shunt motors the torque is determined by the current. This can be assumed to be correct with only a small degree of error for compound motors with a relatively small effect of the series windings as long as the velocity is not regulated by weakening the field. Since the spread is relatively unimportant when compared to the width of an ingot and since it is also reduced several times during rolling by edging passes, the draft alone and not the area of the metal displaced may be taken into consideration with ingots of a similar size. It is therefore possible to determine the main features of the heating and drafting of an ingot by measuring the current and acceleration of the mill motor. After the acceleration has been taken into account, the amount of current will be an indication of how the motor responds to a heating and/or drafting practice and these practices can be adjusted in order to get the desired result. As peak currents are more likely when heavier ingots are rolled, the rolling of plate and slab ingots was investigated. Conditions prevailing when smaller ingots are rolled can be deduced from the results obtained on heavier ingots. All measurements were made when plain carbon grades under 0.15 pct C were rolled. The motor current, the voltage across the armature, and the rpm were recorded simultaneously on synchronized charts, Fig. 1, which moved with the speed of 6 in. per min. Each draft was recorded by a special observer. The rpm curve made it possible to establish the acceleration at any given moment. For purposes of correlation, the maximum current during a pass and the corresponding acceleration were used. The charts made it possible to establish the position of the roller's lever at any given moment as well as the total time of a pass. The slab ingots were divided into three groups (28x35, 28x45, and 27Mx53 in. ingots) and each group was investigated separately. Since they account for most of the current peaks, only flat passes were used for purposes of correlation, a total of 1373 having been investigated.

Jan 1, 1956

By D. S. Gleason, D. E. Severson, D. R. Skidmore

Pittsburg and Midway Coal Co. has modified the German Pott-Broche process, on which patents date back to 1927, to produce on a bench scale liquid products by solution hydrogenation of coal. A continuing program of lignite solution-hydro gena-tion experiments is directed toward investigating coal solution reactions, determining favorable conditions for the solution refining of lignite by the Pott-Broche process, and investigating some of the uses for the de-ashed product obtained from lignite The German Pott-Broche process1" on which patents date back to 1927, has been modified by the Pittsburg and Midway Coal Co., a Gulf Oil subsidiary, to produce on a bench scale liquid products by solution -hydrogena-tion of coal." The objectives of the present effort are to investigate coal solution reactions, to determine favorable conditions for the solution refining of lignite by the Pott-Broche process, and to investigate some of the uses for the de-ashed product obtained from lignite. This paper is a summary of results to date in a continuing program of lignite solution-hydrogenation experiments. The coal solution reaction program has several principal aims. The first of these is to determine whether lignite can be successfully dissolved in solvents that might be practical for commercial development. The second object is to determine whether the solvents function after successive cycles of use, recovery, and reuse. It seems necessary to the economics of a potential commercial process that the solvent be recycled. Third, it is desired to learn something about the distribution of the ash constituents between cake and filtrate. The extent of ash removal is important. The nature and quantity of mineral matter passing through the filter may determine end-use marketability. For certain use applications, trace quantities of certain minerals can be objectionable, e.g., titanium and vanadium must be very low in electrode carbon for aluminum production. The Solution Reaction The coal solution Process involves an extremely complex system of chemical reactions. An initial solvent such as anthracene oil is a mixture of hundreds of different compounds with a boiling range of roughly 500" to 750°F at atmospheric pressure. The coal macro-molecule is broken down by thermal decomposition and solvent action into myriads of different compounds, some the same as those comprising the solvent. This similarity in structures opens up the possibility of production and subsequent recovery of solvent. Some solvent is inevitably lost by reaction. Regeneration of solvent was not a problem in the early German Pott-Broche plant. The coal refinery was an integral part of a petroleum refinery complex and replacement solvent was readily available. A coal refinery using lignite, however, might be isolated from other hydrocarbon processing facilities and the regenerability of solvent could be vital to the economic success of the venture. Several structural features of the solvent molecules have been cited as important to the coal solution process.'. The first of these is aromaticity of the material, the second, ability to transfer hydrogen to another molecule, as for example the ability of tetralin to transfer hydrogen and be converted to naphthalene. Finally, the presence of hydroxyl groups on aromatic rings within the molecule, i.e., phenolic character, seems beneficial. Mixtures of pure compounds have been tried by various investigators. Mixtures of o-cresol, a phenolic substance, and tetralin were found to dissolve bituminous coal better than either substance alone.3 This maximum solubility was not found with lignite." Hydrogen contributes to the reaction by hydro-genolysis and by combining with free radicals and molecular "loose ends" to stabilize the compounds formed in coal depolymerization. High boiling point, and correspondingly high molecular weight, seems to be a property which improves solution potential for coal with a given type of compound.' The maceral components of the coal appear to have an important bearing on its ease of solution. The fusain portion is quite inert to solvent action, but the an-thraxylon material dissolves quite readily.3 The hydrogenation reaction can be improved by the use of a catalyst; commercial hydrogenation catalysts having been found effective. Although cost is involved in the use of catalyst and catalyst recovery, the resulting saving in time and perhaps lowered temperature or pressure might justify their use in the solution refining process and decrease the total process costs. Apparatus and Procedure The coal solution runs were made in a 1-gal stainless steel stirred autoclave. The autoclave was provided with thermocouple wells and a transducer to permit continuous recording of temperature and pressure. The autoclave stirrer was magnetically driven, eliminating the leakage inherent with a rotating pressure seal. For runs in which a catalyst was used, the catalyst in the form of beads was placed in a wire mesh container mounted on the stirrer shaft. A control system programmed the heatup and reaction cycle. The permissible heating rate was 5°F per min because of the need to minimize thermal stress in the autoclave body. The temperature was raised at that rate until the reaction temperature was attained and then the temperature was held constant for the desired length of time. The maximum temperature seldom exceeded the average run temperature by more than 15°F.

Jan 1, 1971