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By J. A. Herbst, A. L. Mular

Digital simulation is defined and simulation techniques are re- viewed. Typical methodology involves the selection of models, the adjustment of raw data, the selection of a fitting strategy, the assessment of model accuracy in a statistical sense, and the development of an executive simulation structure. Simulations serve as aids for process engineers in evaluating the feasibility of a proposed flowsheet and the effect of a modification to an existing flowsheet. In addition, simulation plays an important role in off-line optimization and in the evaluation of alternative circuit control strategies. Several examples are presented to illustrate these uses for simulation including applications in crushing circuits, grinding circuits, and flotation circuits. It is the opinion of the authors that, within the next decade, mineral processing plants will be studied routinely via digital simulation during the preliminary design stage. Simulation will constitute an important component of the design decision making process.

Jan 1, 1978

By C. F. Kaiser, T. J. Roberts, I. A. Thomson

The Broken Hill Pty. Co. Ltd. grate-kiln pelletizing plant located at Whyalla, South Australia, produced a total of 250,000 tons of fluxed pellets during 1970. More than 180,000 tons were exported to Japan, while the remainder was used in B.H.P. Co. blast furnaces. The pellet plant treats high grade hematite ore fines and has a nominal capacity of 1.5 million tpy. The induration equipment includes a grate 12-ft 2-in. wide by 164-ft 1-in. long, a kiln 18-ft 6-in. diam by 118-ft 8-in. long, and a rotary cooler 50-ft mean diam by 7 ft wide. Operating problems encountered in the production of fluxed pellets are detailed. The most significant aspect of the trial was the increased production, from about 5100 tpd up to a maximum of 7100, brought about by the addition of artificial magnetite to the plant feed. Laboratory evaluation of fluxed pellets showed that pellets having a basicity ratio (CaO to SiO2) in excess of 1.2 have excellent physical qualities. Reducibility and compressive strength after reduction were both higher for these fluxed pellets than for normal acid pellets. Although it was not possible to publish blast furnace operating data, blast furnace trials on fluxed pellets indicated that production was higher and dust losses substantially lower, compared with similar operations on acid pellets.

Jan 1, 1973

By John V. Beall

During the last quarter of 1948, two new machines, which may revolutionize the coal mining industry, made their first public appearance within two months of each other. Both are designed to mine and load coal continuously. On Oct. 27, the "Colmol," invented by C. H. Snyder and A. E. Lamm, president and executive vice-president, respectively, of the Sunnyhill Coal Co., was demonstrated at the No. 8 mine of that Company at New Lexington, Ohio. The "Joy Continuous Miner," invented by H. F. Silver, president of the Silver Engineering Works, Denver, and developed and manufactured by the Joy Manufacturing Co., was demonstrated at the Mathies mine, near Finleyville, Pa., in the Pittsburgh coal seam.

Jan 1, 1949

By James Park

The principal gold-bearing formation is of volcanic origin, consisting of a great accumulation of andesitic lavas, tuffs, breccias and agglomerates of lower Tertiary age. These rocks everywhere bear evidence of having been subjected to the prolonged leaching-action of thermal waters, doubtless accompanied by steam and acid vapors. They are found in all stages of decomposition or alteration; and in many mines the hard blue andesite can be seen to pass by a series of almost insensible gradations into a soft, or fairly hard, greyish yellow or blue

Jan 1, 1900

By A. W. Gauger

WITHOUT QUESTION the Commonwealth of Pennsylvania contains the most remarkable coal deposits of the whole world. Within its borders ,are to be found excellent coals ranging in rank from the high volatile bituminous of the western part of 'the state through the low volatile or semi-bituminous of central Pennsylvania to that aristocrat of solid fuels, anthracite, found in the East. . . . But while other states and even the Federa1 Government have recognized the needs of the coal industry, Pennsylvania has not. Though bituminous coal represents one of the most important industries in the state, far more important in annual productive wealth than agriculture, for example, hundreds, of thousands of dollars have been spent on agricultural research whereas little or nothing has been spent on coal investigation.

Jan 1, 1932

By C. A. Schempp

STUDY of the adaptability of Tintic Standard ores to concentration dates back to somewhat before January, 1921, when the chloridizing mill at Harold, Utah, was put into operation. The operation of this mill has been fully covered in the TRANSACTIONS (Vol. 73). The process consisted essentially of a chloridizing roast followed by a percolating leach with a nearly saturated solution of common salt, acidified with sulfuric acid; precipitation of silver on sponge copper, and of copper and lead on tin-plate cuttings. This mill was built to treat the low grade siliceous ores having an average content of

Jan 1, 1933

By J. E. Forciea, O. E. Palasvirta, L. G. Hendrickson

All pilot and commercial plants working with Mesabi Range taconite employ wet magnetic separation. Progress is being made with a dry magnetic process,9-11 but this has not yet been applied to taconite except in the laboratory and pilot plants. Flowsheets in all five plants are similar, including multiple stages of grinding, each followed by magnetic separation, which rejects a finished tailing. The flowsheet in Fig. 1 is used in the preliminary and commercial plants of the Erie and Reserve mining companies and in Unit C of Oliver's Pilotac plant. At Erie the desliming operation is omitted. In the Reserve plants two ball mills are used with each rod mill. Pilotac uses flowsheet 2 in Unit A-B and has also tested flowsheet 3. Principal differences in the three flowsheets are the number of grinding stages and the type of roughing. The terms open- circuit roughing and closed-circuit roughing are best defined by the diagrams.

Jan 12, 1958

By Oliver Bowles

AUTOMOTIVE TRANSPORT by highway, which has become indispensable to modern life either in peace or war, involves the use of powerful machines, many of which travel at high speed. To start, accelerate, and stop each motor vehicle demands the use of clutch and brake. Friction is applied intensively to both these mechanisms, and their linings must therefore be of materials that will resist wear and that will not ignite with the heat of friction. Asbestos, that curious fire-resisting: natural fiber that may be woven into unburnable cloth, is eminently suitable for this special' use, and no satisfactory substitute for it has yet been found Because- asbestos is regarded as absolutely essential to all types of motor transport on land, and in addition is indispensable to. many .other kinds of machines and equipment, the situation of the- United State's with respect to supplies of-raw-material-is of special interest: From the standpoint of national self-sufficiency, conditions are far, from satisfactory, for United States mines furnish only three to four percent of the total domestic require-

Jan 1, 1938

By A. F. Colombo, R. T. Sorensen, D. W. Frommer

An analytical method has been developed and used in batch and continuous tests to provide initial insights into the effect of soluble calcium ion in anionic flotation of silica from iron ores. A deficiency or excess of calcium ion in pulps subjected to this type of flotation produces an impairment in flotation efficiency. Data developed in the investigation are from a single ore, but show that total calcium requirement is met from water, ore and reagent sources. In batch studies, starch additions were shown to exert no influence on the calcium level, but fatty acid and sodium hydroxide had subtractive effects. The investigation was next extended to continuous flotation testing where the general observations from batch testing were confirmed. Factorially designed experiments were performed showing that the relationship of calcium additions to flotation response was not a simple one, but tended to shift to higher additions with increased fatty acid. Nevertheless, the range of soluble calcium levels measured remained fairly constant in areas of good flotation response. It is concluded that techniques developed should be useful in removing empiricism from flotation operations in this and other systems requiring activation for success. Further development should aid in process control both through methods outlined and through investigations aimed at studying the effects of other soluble reagents. Of the major mineral commodities, iron ore was one of the last to succumb to flotation processing. Commenting on this fact, one of the speakers 1 at the convention celebrating the 50th Anniversary of flotation in the U.S.A., said ". . . in 1951 froth flotation as a means of beneficiating nonferrous minerals was a might giant and could be characterized by 'you name it, we float' - but not iron ore". This tardiness in applying flotation to iron ores was the result of a number of factors, including economics and ready availability of direct shipping ores. Even now, when the need for beneficiation can no longer be denied, proposals for flotation of iron ores are apt to be viewed with some misgivings. This disquiet results from knowledge that wide variability, which would necessitate corresponding adjustments in reagents, often exist within even a single ore deposit. Coupled with ore variability is the fact that, at present, there is no way of quickly and precisely anticipating the direction and magnitude of reagent changes required for uninterrupted production of acceptable concentrates. Despite the long delay, iron ore flotation is now practiced commercially, although the chief applications2-4 are to specular hematites having relatively coarse liberation and low slime content. In addition, the application of flotation in upgrading magnetic concentrates seems assured. However, these flotation methods do not appear applicable to substantial tonnages of fine grained, earthy, and frequently more complex semitaconites and nonmagnetic taconites. The U.S. Bureau of Mines, in devoting its attention to the semitaconite and nonmagnetic taconite class of materials, has demonstrated that anionic flotation of calcium-activated silica can be utilized with an expected high frequency of success.' Even so, it has been recognized that the flotation method is a complex one, and that the reagent suite must be carefully tailored to the feed. These conditions would be expected to offer difficulties in treating ores with the wide range of variability previously discussed. Accordingly, research was initiated to develop methods to remove much of the empiricism from the flotation operation by measuring the reagent variables within the pulp for a correlation with flotation response. A simple illustration of the technique sought would be in the well established use of pH meters to provide feedback control to reagent feeders and thereby limit acidity or alkalinity to a range producing optimum results. The first efforts in this area have been concerned with measurements of soluble calcium ion. Bureau experience in both laboratory and pilot plant over the past five years has proved that the amount of calcium

Jan 1, 1965

By O. U. Bradley

The methods of handling the oil output of the Mid-Continent fields are not unlike those practised in other oil fields of the United States, and it is not expected that this paper will present any entirely novel ideas. Some features of the practice of handling this oil may be of interest, however. Wooden Gaging Tanks Practically all of the oil sold to pipe line? and other purchasing agencies throughout the Mid-Continent field is gaged from wooden tanks. Steel gaging tanks are slowly coming into use, and are preferable in many ways—leakage and evaporation are reduced, and the strapping and recalculation of capacities are unnecessary. The wooden tanks are slightly coned to facilitate tightening the hoops. The sizes in common use are 250, 500, 800 and 1600 bbl. The number and the capacity of the gaging tanks upon any producing oil property depend upon its production, and the facilities for disposing of the output. The 1600-bbl. size was the most common in the Cushing field, particularly during the period of flush production. The tanks are distributed over the leased premises in groups of two, three, and four tanks each, and these are filled from flow tanks, or through direct pipe connections with the heads of the wells. Flow tanks are merely temporary reservoirs to facilitate the transfer of oil from the wells to the gaging tanks. They diminish fire risk, and are considered indispensable on small producing properties where water is pumped with the oil, as they permit the refuse and water to 'settle out before the production is run to the gaging tanks. strapping and Calculations After a gaging tank has been strapped (measured) and its contents computed, a deduction of 3 per cent. is made from its computed volume. The strapping of a tank requires four steps: (1) The outer circumferences

Jan 1, 1920

By R. L. Wiegel

The generation of operating information for mineral beneficiation processes has become more sophisticated as a result of the use of improved laboratory analytical techniques, some of which provide multiple component assays, as well as the introduction and gradual industrial acceptance of process sensors for the measurement of flow, density, size, and chemical composition. In general, however, the mineral processing engineer's ability to tie together this wealth of information has not kept pace with these developments. In fact, in almost all existing plants, the metallurgical inflow-output balance, wed to indicate current process performance, is still being calculated from only a small portion of the information routinely available. There is substantial activity in the development of techniques for using all available process information to significantly improve the reliability of the metallurgical balance. While the use of these improved techniques does require access to computing facilities and a slight change in perspective on the part of the mineral processing engineer regarding the inviolability of process information, there are numerous practical benefits to be derived from their application. In addition to summarizing some of the concepts basic to these techniques, this paper describes the experience of the author in applying one of these advanced metallurgical balance techniques to a variety of pilot plant and commercial plant flowsheets during the past eight years.

Jan 1, 1983

By Frank A. Hill

A visitor to the Northern anthracite coal-field in 1844 wrote: " History and song have hallowed the valley of Wyoming, and everything pertaining to it seems wrapped in an atmosphere of romance." Song and history have since been almost forgotten in the rush of enterprise and business energy, while the invested capital which has built 160 colliery plants, producing last year 17,031,826 tons of coal and giving employment to 50,000 men and boys, lends an atmosphere the inspiration of which is the very sustenance of prosperity and progress. The fundamental cause of this great valley's financial strength, however, rests on the fulness of its mineral wealth. Its mountains surround and its cities are built upon anthracite coal. Its foundation, physically, financially and socially, is coal. Its geology has governed its growth and developed its greatness. In 1768, ten years, prior to the celebrated Wyoming massacre, two Connecticut Yankees, named Gore, settled near Wilkesbarre, Luzerne County, and, burning Pennsylvania anthracite in their blacksmith's forges, were the first to utilize it as a fuel. Its first use in the household was also at Wilkesbarre, where, in 1808, Judge Fell burned it in an open grate. Carbondale, Wilkesbarre, and Scranton were early recognized as the coal centers of the field.

Jan 1, 1887

By T. M. Morris

G. L. Simard and D. J. Salley—The authors and ourselves" independently came to similar conclusions both as to the value of tracer methods for the study of flotation and the general nature of collector-mineral interaction. The dodecylamine-quartz system appears to be simpler than the dithiophosphate-galena one, and the results therefore appear clearer. It is evident from a comparison of the two papers, however, that care must be used in extending the results to other more complicated systems. In the case of dodecylamine-quartz, the possible influence of micelle formation is of interest. There is no a priori reason why complete monolayer formation should necessarily occur at the concentration for micelle formation, since sorption depends on the nature of the substrate as well as on the properties of the solute in solution which alone determine micelle formation. Indeed, the fact that the onset of increased adsorption, point B in fig. 2, occurs at a concentration one tenth the critical value for micelles might imply that micelle formation does not have an influence. Interestingly enough, the data may be handled by the methods used for multilayer adsorption of gases on surfaces. Thus, if the amount adsorbed is plotted versus concentration, a sigmoid type curve is obtained, similar in form to a so-called Type I1 isotherm13 generally attributed to multimolecular adsorption. A monolayer value of about 0.12 mg per g may be estimated from the knee of this isotherm. On the other hand, if a plot is made according to the multilayer gas equation for adsorption to an unrestricted number of layers, eq 38,13 assuming the critical micelle concentration as the saturation concentration, the data above 120 mg per liter fall on a straight line from which a monolayer adsorption of 0.3 mg per g results. These considerations suggest that the monolayer may occupy an area somewhat less than the geometric value of 0.4 mg per g, and that micelle formation may indeed be a factor in the adsorption. the angle between the solid-liquid and liquid-gas interfaces, measured through the liquid. The value of the equilibrium contact-angle is uniquely determined by the value of the interfacial energies of the three intersecting interfaces and is independent of other forces in the system. When the liquid-gas interface intersects the solid at an edge—as was the case for all the experiments reported in this paper—the orientation of the solid-liquid interface is indeterminate or varies through 90" for a right-angle edge. Mr. Morris has called the angle between the horizontal and the liquid-gas interface for this edge condition a "static contact-angle." I feel that this term is unnecessarily misleading. In the first place, "static contact-angle" sounds too much like "equilibrium contact-angle." In the second place, the magnitude of the "static contact-angle," which I would prefer to call the "supporting angle," is determined by the forces in the system other than those derived from the interfacial energies, hence "contact angle" is misleading. If Mr. Morris had said that the "supporting-angle" is variable and depends on the weight of the particle and size of the bubble and that it has a maximum possible value equal to the equilibrium contact-angle, his discussion would have been more accurate. T. M. Morris (author's reply)—Mr. Kellogg puts forth a reasonable criticism of some of the terminology used in the paper. I agree that the term "static contact angle" may be misleading. Substitution of the term "supporting angle" or "vector angle" may be more suitable. F. X. Tartaron—In this paper the author presents a very interesting mathematical development of the forces present when a mineral particle adheres to an air bubble. Excellent concordance is obtained between mathematical formulation and experimental results. It is the writer's understanding that when the mineral surface presented to an air bubble is greater than the area of contact, the maximum contact angle is obtained. However, this contact angle represents distortion of the bubble, the normal shape of which is spherical or in cross-section, circular. This distortion produces a force that acts in opposition to the force of adhesion between the bubble and particle. Hence, at maximum contact angle, the force of adhesion between bubble and particle is at a minimum for static conditions. However, when the size of bubble is increased, the size of particle remaining the same (and all other conditions remaining the same), the contact angle decreases, the distortion of the bubble decreases and the force in opposition to adherence of bubble and particle also decreases. Thus, there is stronger attachment between bubble and particle. When this situation is applied to actual flotation conditions, it is doubtful that it has any significance. The reason is that the bubbles are normally so much larger than the particles, that in substantially all cases, it is probable that negligible distortion of the bubble takes place. In table IV, the author makes computations for bubbles from 0.50 to 2 mm diam. This is from 0.02 in. to 0.08 in. Certainly the bubbles generated in a flotation machine are far larger than this. The surfaces of the author's bubbles range from 0.79 to 12.6 sq mm. The area of contact of the glass rod (0.15 mm diam) is 0.017 sq mm. Thus, ratio of bubble surface to mineral area of contact ranges from 47 to 741 in round numbers. If we take a %-in. diam bubble and a 65-mesh (0.208 mm) particle of cubical shape, the ratio of bubble surface to mineral area of contact is 2931. Mineral particles do not readily become attached to air bubbles. Taggart has shown that in pneumatic flotation machines collector-coated particles are only temporarily attached to bubbles. They keep falling off and down in the froth but at a delayed rate as compared with gangue. Spedden and Hannan's motion pictures confirm the difficulty of attaching particles to air bubbles. In the agitation froth process, according to Taggart, air is precipitated from the water selectively on to the collector-coated particles and these

Jan 1, 1951

By T. M. Morris

G. L. Simard and D. J. Salley—The authors and ourselves" independently came to similar conclusions both as to the value of tracer methods for the study of flotation and the general nature of collector-mineral interaction. The dodecylamine-quartz system appears to be simpler than the dithiophosphate-galena one, and the results therefore appear clearer. It is evident from a comparison of the two papers, however, that care must be used in extending the results to other more complicated systems. In the case of dodecylamine-quartz, the possible influence of micelle formation is of interest. There is no a priori reason why complete monolayer formation should necessarily occur at the concentration for micelle formation, since sorption depends on the nature of the substrate as well as on the properties of the solute in solution which alone determine micelle formation. Indeed, the fact that the onset of increased adsorption, point B in fig. 2, occurs at a concentration one tenth the critical value for micelles might imply that micelle formation does not have an influence. Interestingly enough, the data may be handled by the methods used for multilayer adsorption of gases on surfaces. Thus, if the amount adsorbed is plotted versus concentration, a sigmoid type curve is obtained, similar in form to a so-called Type I1 isotherm13 generally attributed to multimolecular adsorption. A monolayer value of about 0.12 mg per g may be estimated from the knee of this isotherm. On the other hand, if a plot is made according to the multilayer gas equation for adsorption to an unrestricted number of layers, eq 38,13 assuming the critical micelle concentration as the saturation concentration, the data above 120 mg per liter fall on a straight line from which a monolayer adsorption of 0.3 mg per g results. These considerations suggest that the monolayer may occupy an area somewhat less than the geometric value of 0.4 mg per g, and that micelle formation may indeed be a factor in the adsorption. the angle between the solid-liquid and liquid-gas interfaces, measured through the liquid. The value of the equilibrium contact-angle is uniquely determined by the value of the interfacial energies of the three intersecting interfaces and is independent of other forces in the system. When the liquid-gas interface intersects the solid at an edge—as was the case for all the experiments reported in this paper—the orientation of the solid-liquid interface is indeterminate or varies through 90" for a right-angle edge. Mr. Morris has called the angle between the horizontal and the liquid-gas interface for this edge condition a "static contact-angle." I feel that this term is unnecessarily misleading. In the first place, "static contact-angle" sounds too much like "equilibrium contact-angle." In the second place, the magnitude of the "static contact-angle," which I would prefer to call the "supporting angle," is determined by the forces in the system other than those derived from the interfacial energies, hence "contact angle" is misleading. If Mr. Morris had said that the "supporting-angle" is variable and depends on the weight of the particle and size of the bubble and that it has a maximum possible value equal to the equilibrium contact-angle, his discussion would have been more accurate. T. M. Morris (author's reply)—Mr. Kellogg puts forth a reasonable criticism of some of the terminology used in the paper. I agree that the term "static contact angle" may be misleading. Substitution of the term "supporting angle" or "vector angle" may be more suitable. F. X. Tartaron—In this paper the author presents a very interesting mathematical development of the forces present when a mineral particle adheres to an air bubble. Excellent concordance is obtained between mathematical formulation and experimental results. It is the writer's understanding that when the mineral surface presented to an air bubble is greater than the area of contact, the maximum contact angle is obtained. However, this contact angle represents distortion of the bubble, the normal shape of which is spherical or in cross-section, circular. This distortion produces a force that acts in opposition to the force of adhesion between the bubble and particle. Hence, at maximum contact angle, the force of adhesion between bubble and particle is at a minimum for static conditions. However, when the size of bubble is increased, the size of particle remaining the same (and all other conditions remaining the same), the contact angle decreases, the distortion of the bubble decreases and the force in opposition to adherence of bubble and particle also decreases. Thus, there is stronger attachment between bubble and particle. When this situation is applied to actual flotation conditions, it is doubtful that it has any significance. The reason is that the bubbles are normally so much larger than the particles, that in substantially all cases, it is probable that negligible distortion of the bubble takes place. In table IV, the author makes computations for bubbles from 0.50 to 2 mm diam. This is from 0.02 in. to 0.08 in. Certainly the bubbles generated in a flotation machine are far larger than this. The surfaces of the author's bubbles range from 0.79 to 12.6 sq mm. The area of contact of the glass rod (0.15 mm diam) is 0.017 sq mm. Thus, ratio of bubble surface to mineral area of contact ranges from 47 to 741 in round numbers. If we take a %-in. diam bubble and a 65-mesh (0.208 mm) particle of cubical shape, the ratio of bubble surface to mineral area of contact is 2931. Mineral particles do not readily become attached to air bubbles. Taggart has shown that in pneumatic flotation machines collector-coated particles are only temporarily attached to bubbles. They keep falling off and down in the froth but at a delayed rate as compared with gangue. Spedden and Hannan's motion pictures confirm the difficulty of attaching particles to air bubbles. In the agitation froth process, according to Taggart, air is precipitated from the water selectively on to the collector-coated particles and these

Jan 1, 1951

By G. Derge, Ling Yang, G. M. Pound

The specific conductance and its temperature dependence were measured over the entire composition range of the molten Cu2S-CuCI system. At a typical temperature of 1200°C, 10 rnol pet of the ionically conducting CuCl reduced the specific conductance from about 77 ohm-lcm-l for pure Cu2S to about 32 ohm -1cm -1, and 50 mol pet CuCl reduced the conductance to that for pure CuCI—about 5 ohm 1cm1. The nature of electrical conduction in molten Cu2S, FeS, CuCI, and mixtures was studied by measuring the current efficiency of electrolysis at about 1100°C. The Cu2S, FeS, and mattes were found to conduct exclusively by electrons, but addition of 1 5 wt pet CUS to Cu2S produces a small amount of electrolysis. Addition of CuCl to Cu2S suppresses electronic conduction, and ionic conduction reaches almost 100 pet at a CuCl concentration of about 50 mol pet. These facts are interpreted in terms of electron energy level diagrams by analogy to the situation in solids. RESULTS of electrical conductivity studies on molten Cu-FeS mattes as a function of composition and temperature have been reported.' The specific conductances ranged from about 100 ohm-' cm-' for pure Cu2S to 1500 ohm-' cm-1 for pure FeS. This is in sharp contrast with the low specific conductance of molten ionic salts for which the transfer of electricity is by migration of ions in the field. In general, these ionically conducting molten salts, such as NaC1, KC1, CuC1, etc., have a specific conductance of the order of magnitude of 5 ohm-' cm-'. It was concluded on the basis of this evidence that molten FeS and Cu,S exhibit electronic conduction. Pure molten FeS has a small negative temperature coefficient of specific conductance, resembling metallic conduction, while pure molten Cu2S has a small positive temperature coefficient, resembling semi-conduction. The molten Cu2S-FeS mattes follow a roughly additive rule of mixtures, both with respect to specific conductance and temperature coefficient. Savelsberg2 has studied the electrolysis of molten Cu2S and Cu2S + FeS. He concluded that while molten Cu2S is an electronic conductor, there is some ionic conduction in molten Cu2S + FeS3 owing to the formation of the molecular compound 2Cu2S.FeS and its dissociation into Cu1 and FeS2-1 ions. The present work does not verify his results. Chipman, Inouye, and Tomlinson" have studied the specific conductance of molten FeO and report a high specific conductance, about 200 ohm-1 cm-1 of the same order of magnitude as that found for molten mattes, and a positive temperature coefficient. They interpret these results in terms of p-type semiconduction in the ionic liquid by analogy to the situation in solid FeO.1 imnad and Derne' detected appreciable ionization in molten FeO by means of electrolytic cell efficiency measurements. In order to verify the conclusion that electrical conduction in molten Cu2S and mattes is electronic, and to gain further insight into the structure of molten sulfides, the following investigations were carried out in the present work: 1) The specific conductance, s of the molten system Cu2S-CuC1 was measured as a function of temperature over the entire composition range. As discussed later, molten CuCl is an ionic substance. It was thought that if molten Cu2S were simply ionic in nature, addition of small amounts of CuCl might not have a catastrophic effect in lowering the high conductance of the Cu2S. On the other hand, if much electronic conduction occurs, addition of the ionic CuCl should have a large effect in destroying the electronic conduction. 2) The electrolytic cell efficiency of the following molten systems was measured at about 1100°C in specially designed cells: Cu3; Cu2S + FeS, 50:50 by wt; FeS; Cu2S + CuS, 15 wt pet; Cu2S + CuC1, 5.9 to 46.4 mol pet; and CuC1. This gives a direct measure of the fraction of current carried by ions in these melts. Further, the cell efficiency, extrapolated to zero ionic current, is given by cell efficiency = (s leasile + s elexstronic). [1] s lucile for molten CulS would be expected to be no greater than that for molten CuC1, whose s lonle is about 5 ohm-' cm-1, as will be seen in the following. u,.,,.,.,.......for molten Cu,S is of the order of 100 ohm-' cm-'.' Thus, a large increase in cell efficiency from 0 to values of 10 to 100 pet upon addition of CuCl to Cu2S would indicate destruction of the electronic conductance. Conductance Measurements Experimental Procedure—The apparatus and experimental method were the same as those described in detail in connection with the study of electrical conduction in molten Cu,S-FeS mattes.' A four terminal conductivity cell and an ac poten-

Jan 1, 1957

By W. H. Caruthers

ECONOMIC utilization of all by-products has long been the goal of American industry. One of the first groups that was popularly supposed to have achieved its aim was the meat-packing industry, which reputedly found a use for everything except the squeal of the hog. To the metallurgist, slag has always been the principal wasted by-product, representing a loss not only of material, but of heat. Slag does not possess many qualities that appeal to man's imagination or suggest a romantic influence on the daily life and progress of a community or nation. It is a bulky product, and space for its disposal within reasonable hauling distance of a smelter is not always available; the iron-ore smelter especially has been wont to find space for slag disposal at a premium. Therefore, the success that has been attained in recent years in finding a use for iron blast-furnace slag is notable. It has become a vital economic factor in the construction industry in areas where it is available. Its use may suggest further possibilities of an economic outlet for the slags from nonferrous smelting as well.

Jan 1, 1940

By R. W. Carpenter, J. C. Ogle

It is possible, by using pack-rolling instead of conventional rolling, to reduce a number of metals to thicknesses of 2µm or less. Such thinfoils are generally made at room temperature without intermediate annealing. In addition, pack-rolled foils fail by developing pinholes at thicknesses near 2µm instead of developing the shear cracks usually observed in cold-rolled ductile metals. This paper presents the results of a general investigation of the deformation substructure and texture developed in copper and iron pack -rolled from 130 to about 2µm thickness. Electron microscopy showed that in both metals a fine (0.2 to 0.5?µ m) deformation subgrain structure formed during pack-rolling; in neither case was this substructure grossly different from substructures formed during conventional rolling. The deformation texture formed in pack-rolled iron was quite similar to usual bcc textures; however, in the case of copper, the cube texture was stable during pack-rolling and the normal copper deformation texture was unstable. It is shown analytically that the constraining pack induced a large hydrostatic pressure in the foils during pack-rolling. The pinhole failure mechanism is attributed to the presence of the large hydrostatic pressure during pack-rolling; this strongly suppressed the growth of shear cracks. The stability of the cube texture in copper is also probably due to the unusuul stress distribution developed during pack-rolling. EXPERIMENTS at several laboratories have shown that very thin foils of the common structural metals and many of the rare earths can be made by "pack-rolling". 1-3 The technique was originally developed to make specimens for nuclear scattering experiments and foils for X-ray filters. It is also useful for making experimental laminar metallic composite bodies and foils thin enough for direct examination by ultra-high voltage electron microscopy without the need for special thinning techniques. Pack-rolling in the present context means a three-layer pack, with the material to be rolled into foil comprising the center layer. The outer two layers, which constrain the foil during reduction, are ordinarily austenitic stainless steel. Typically, a 130 µm (0.005 in.) metal strip can be reduced to a final thickness of 2 µm or less by this process. This is accomplished at room temperature, without intermediate annealing. It has been observed that foils produced by this process do not exhibit at any stage of their reduction the severe work-hardening found in strip rolled by conventional cold-rolling methods. Neither is the failure characteristic the same."&apos; Conventionally cold-rolled ductile metal strip fails by developing shear cracks on planes whose normals nearly bisect the angle between the rolling direction and normal to the rolling plane; these are planes of maximum shear stress. In pack-rolling this mechanism has not been observed; failure occurs by the formation of pinholes on the foil surface (penetrating the foil). If pack-rolling is continued the hole density increases. These differences in behavior imply the existence of appreciably different substructure in pack-rolled foils compared to substructure in conventionally rolled material, or perhaps that the geometry of pack-rolling has an effect on the foil behavior. This paper describes an investigation of deformation substructure and texture in some specimens of pack-rolled copper and iron, and some considerations of the stress distribution in the foils during rolling that result from the geometry of pack-rolling. EXPERIMENTAL DETAILS Three different materials were used for pack-rolling in the present work: soft copper sheet (99.8 pct Cu, 0.03 pct 0, electrolytic tough pitch) and two types of iron, Ferrovac E* and Armco iron. Each was "Crucible Stccl Co. initially in the form of 130 µm annealed strip with grain size ranges of approximately 10 to 40 µm. The initial texture of the copper (determined as noted below) was the normally observed cube type (001)[100]; there was evidence of a small amount of material in the cube-twin orientation reported by Beck and Hu.4 The initial texture of the Ferrovac E was similar to that reported for recrystallized iron by Kurdjumov and sachs,5 who list the principal orientations as {111}<112>, {001}<110> 15degfrom RD and a weak component {112}(110) 15 deg from RD. The starting texture of the Armco iron was not determined. Pack-Rolling Procedure. A four-high mill was used for all specimens. The work roll and backing roll diameters were 1.625 and 5.25 in., respectively. The peripheral roll speed of the work rolls was about 2.5 in. per sec. All foils were initially reduced from 130 to 100 µm by conventional straight rolling and then inserted into a pack, without any intermediate annealing, for further reduction. The pack consisted of an 0.033 in. (838 µm) thick 3 by 6 in. polished sheet of austenitic stainless steel, folded to make a 3 by 3 in. jacket. After folding, the jacket was given a small reduction to close the fold tightly before insertion of the foil. During pack-rolling a constant change in roll spacing was made every third pass. The roll-spacing change corresponded to a 5 pct reduction in thickness for a new pack. This approached a 10 pct reduction when the pack had decreased to about half its original thickness. At this point the deformed pack was discarded and a new one

Jan 1, 1970

By C. K. McArthur

THE subject of classification is so broad that this discussion is confined to what the author believes is of prime importance in connection with proper grinding and classification. The years passed have witnessed many noteworthy changes in fine grinding and classification, which have been accompanied by a readjustment of ore-dressing flowsheets for the preparation of better ground and/or sized products at an expenditure of less power, steel and maintenance than formerly. Nowhere in the industry is more being done in the way of experimental work to lower costs than in grinding circuits, because, at best, grinding costs are high. Recent years have indicated that, on the average, finer grinding has a real application. Without careful preparation of the process feed, no operation can be highly efficient or successful. In an earlier paper, the findings of an extensive survey at representative concentrators were presented1. Also, in the year of 1935, a technical discussion was given by Dr. J. V. N. Dorr (Some Notes on Classification Trends in America) before the Chemical, Metallurgical and Mining Society of South Africa In both papers mentioned, much has been said regarding flowsheets, grinding and classification. The author is very familiar with these papers, having had considerable to do with the actual operation of the flowsheets, as well as large mills and classifiers in the work described. Some data from the second paper have been included in the following discussion. Circulating Load In this particular paper it seems advisable to deal with the classification phases of the work that to a major extent govern the success of any closed-circuit grinding unit. The question has often been asked in connection with a closed circuit: "What circulating-load ratio should be carried?" This is really an

Jan 1, 1937

By Gilbert E. Doan

WHEN metallurgists and other engineers meet their college classmates or former teachers, the conversation will frequently become reminiscent and finally turn to engineering education. These graduates have tested the value of their college training in the hurly-burly of the outside world so respectful attention is due their opinions, which, strangely enough, fall into two opposite categories. A member of one group expresses a deep-seated conviction that engineers should have a fuller foundation of physical chemistry, another asks for a more thorough training in mathematics, others wish a more thorough grounding in refractories, a series of courses in petroleum engineering, or in electric welding. Each alumnus of this group

Jan 1, 1937

By C. J. Rosa, W. C. Hagel

An attempt is made to determine the diffusion coefficients of oxygen ions in hypostoichiometric zirconium oxide. A phenomenological theory is developed for three-phase, unidirectional volume diffusion of a gaseous species from a planar source. Knowledge about oxygen diffusion in a and ß zirconium and experimentally measured rates of movements of interfaces permit the evaluation of oxygen ion diffusivi-ties in ZrO2-x. The results conform to the relationship: sq cm per sec, for the temperature range of 875" to 1050° C. DIFFUSION coefficients of oxygen ions in stoichio-metric oxides have been studied by many investigators. The obtained results not only supplement the knowledge about the lattice-defect structures of oxides and conduction mechanisms but also provide information of technological importance. Rate processes such as oxide sintering, high-temperature creep deformation, and oxidation of metals and their alloys are directly dependent on diffusion phenomena. Unfortunately, diffusion coefficients obtained from studies on stoichio-metric oxides cannot be treated without restraints when applied to oxidation kinetics, if precise evaluations of oxidation rates are desired. Oxides formed on metals are usually nonstoichiometric and exhibit nonuniform distribution of either cation or anion vacancies across their thicknesses. Debuigne and Lehr1 extended Danckwerts&apos;2 mathematical analyses and furnished a semitheoretical treatment for evaluating oxygen diffusion coefficients in zirconium oxide in terms of weight gain measurements during oxidation of zirconium in the temperature range 400° to 850°C. Their calculations are based on theoretical partitioning3 of the total amount of oxygen between a zirconium and its oxide phase. An inherent discrepancy appears to continue throughout their calculations. The amount of oxygen confined to the oxide phase should be corrected by multiplying the calculated oxide thickness by the inverse of Pilling-Bedworth ratio, if expansion of zirconium dioxide is taken into account. The purpose of the present investigation is to provide a new semitheoretical treatment for evaluating diffusion coefficients of moving species in hypostoichiometric oxide. The analyses are relevant to unidirectional volume diffusion. Although the presented method is quite general, its applicability will be discussed in terms of kinetic measurements from oxidation of zirconium at temperatures above the a/ß transition, for reasons stated in the later part of this paper. EXPERIMENTAL Pure, 99.93 wt pct, zirconium samples of approximately 2 by 1 by 0.35 cm were exposed to oxygen for various times at four temperature levels: 875°, 950°, 1000°, and 1050°C. High-purity, better than 99.9 vol pct oxygen was passed through a cold trap and columns containing anhydrous CaSO4 to remove residual water vapor. Before exposing to oxygen at a pressure of 500 Torr, specimens were subjected to wet abrasion on 200- through 600-grit Sic papers and polished with 1—p diamond dust. Prior to oxidizing, all zirconium samples were vacuum-annealed at 10-6 mm Hg for about 15 min at the test temperature. The temperature variation across the uniform heat zone was ±2°C from the preset value. Final polishing, for phase thicknesses measurements, was performed by using 8- and 1-p diamond dust and followed by vibrator polishing with 0.05-µ ? Al2O3 solution. Measurements of phase thicknesses were made by projection on a metallographic viewing screen. Conventional powder X-ray analyses for the oxide were employed. RESULTS Fig. 1 is an example of the cross section of oxidized zirconium. Designations of phases given below this figure are the same as those used in the three-phase diffusion system represented by Fig. 5 in the following section. Zirconium oxidized for longer exposure times showed two types of oxides: white oxide at the surface and an underlaying layer of gray oxide. X-ray powder patterns of these oxides at room tern-

Jan 1, 1969