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By C. T. Eddy

The refining of native copper in the reverberatory furnace, as practiced in the Lake Superior district of Michigan, is very similar to the reverberatory melting and refining of cathodes, but the presence of arsenic in some of the copper concentrates renders the operation somewhat more difficult. Though the copper occurs as the native metal, which is often excep tionally pure—purer, in fact, than after it has undergone refining—its intimate association with the gangue minerals necessitates the cumbersome reverberatory treatment. The gangue consists chiefly of complex silicates of calcium, magnesium, iron, aluminum and sodium, but in certain ore deposits other minerals are often found, among them the native copper arsenides—mohawkite, whitneyite, algodonite and the like. These latter minerals, when present, because of their relatively high specific gravity (7.5 to 8.5), find their way into the concentrates through the gravity concentration processes employed in the recovery of the copper. When such concentrates are melted, the silicates are removed as slag, but, because of the great affinity of molten copper for arsenic, the arsenides dissolve more or less completely in the copper bath. Because of the stability of the resulting melt, the arsenic is tenaciously held in solution. The influence of arsenic on the properties of copper, especially on its electrical conductivity, is generally recognized. For certain uses it is beneficial, and in many instances its presence in limited amounts is not objectionable, but if the metal is to be used for electrical purposes, the almost complete removal of the arsenic is of prime importance. Considerable research has been done on the subject of the influence of arsenic on the electrical conductivity of copperll but the conclusions presented in the literature dealing with the problem show some disagreement. The methods now in use for the removal of arsenic have not

Jan 1, 1931

By Stuart E. Buckley

The application of hydrocarbon equilibrium data to various problems encountered in refining and in natural gasoline recovery is an old and well established practice. Both generalized data and data on specific hydrocarbon systems have been made available by a number of investigators. More recently such data have been applied to the relations governing the separation of oil and gas both in the reservoir and at the surface. Most of the applications to production problems, however, have been based upon examinations of surface samples of oil and gas. This paper describes a technique that has been used satisfactorily in a number of cases to calculate directly from the hydrocarbon analysis of and auxiliary laboratory data on a subsurface sample of the reservoir fluid the behavior of the oil and gas during the various stages of separation at the surface incident to production. Types of Information Calculated The system of calculations is not designed to supplant field data, but rather to correlate with them laboratory data obtained under controlled conditions in order to obtain a more complete and exact picture than usually is possible through the use of field data alone. The chief advantage of the calculations is the possibility of their use at a minimum of both time and expense to determine completely the effect of any possible operating technique upon each of the following: (1) The gas-oil ratio resulting from liberation of the dissolved gas; (2) the composition and gasoline content of the liberated gas; (3) the composition and gravity of the residual oil; (4) the amount and composition of the gas liberated upon flashing the oil from the separator to the stock tank; (5) the shrinkage of the oil in passing from the reservoir to the stock tank. This information is frequently essential to the correct determination of the advisability of installing a natural gasoline plant, to design such a plant to take care of seasonal production, and to determine the optimum separator pressures to carry in various parts of a field.

Jan 1, 1938

By W. G. Fischer

Basic laboratory tests on trona and the surrounding shales initiated the Rock Mechanics program. The stress-strain curve, modulus of elasticity, Poisson's ratio, the uniaxial rock strength, Mohr's envelope, the biaxial stresses at failure, and creep were investigated. A series of underground problems were then approached using this information and various field measuring devices, most of which were developed by the Bureau of Mines. Initially, stress concentrations near mine openings were evaluated using the stress relief technique. This required an accurate determination of the pre-mining stress field. Later, stress concentrations associated with the cave line were studied. After about 30 stress reliefs over an appropriate time interval the effects of one type of mining could be compared against another. The microseismic technique was used to investi- gate a possible application of warning devices near the cave line. A study of mine reorientation was made. Problems related to the shape and size of pillars and barriers were studied. The effectiveness of roof bolting patterns was examined. Control of roof stresses was attempted. A new system of mining in heavy ground has been developed using the information secured in the Rock Mechanics program. Without this system, mining in more than one instance would have been next to impossible. Indeed, from this one discovery alone, the Rock Mechanics program has paid off in improved safety as well as in dollars. The Westvaco trona* mine is located near the town of Green River in the southwestern corner of Wyoming. It is owned and operated by FMC Corp. on land leased from the US Government, the State of Wyoming, and the Union Pacific Railroad. A conventional room and pillar system is being used, (Fig. 1) with complete removal of the pillars during final mining. Return air bleeders surround

Jan 1, 1964

By W. M. Peirce

THE PROCESSES USED FOR THE rolling of zinc are not novel or unique in a mechanical sense. There has not been so widespread a tendency toward heavy slabs and mechanical handling, and toward 3-high and continuous mills as has taken place with steel and with some of the other nonferrous metals. Those respects in which the rolling of zinc differs from the rolling of other metals center around two facts. First, the hexagonal zinc crystal has only one plane of easy slip: namely, the basal plane. Fortunately, however, the crystal twins readily on any of the pyramidal planes, thereby creating new basal planes favorably oriented for relief of the stress which has caused twinning. Second, the recrystallization temperature of zinc is little above room temperature and for very pure grades of zinc may in fact, be at room temperature for severely strained material. The practical effect of these two characteristics of zinc will become evident in the later discussion. First, it is necessary to give some attention to the melting and casting of billets for rolling. Reverberatory furnaces are commonly used for melting. These vary over a wide range of capacity from as low as 5 tons to 100 tons or over. Low-frequency electric furnaces have also been used with satisfactory results. Arc Furnaces are, of course unsuited to a low-melting and lute-boiling metal, such as zinc. To minimize oxidation and volatilization losses in the furnace, the temperature should be kept below 500°C. With this temperature in the melting furnace, a suitable pouring temperature in the neighborhood of 460°C can he maintained at the mold when a transfer ladle is used for pouring.

Jan 1, 1948

By R. G. Hall

AN article on the subject of electrolytic zinc no longer needs to be preceded by an apology. The production of zinc by electrolysis is past the laboratory stage and has become an economic factor of considerable importance in the total production of zinc in the United States. The various methods of procedure to be, followed for the greatest economy of manufacture are fairly well known, consequently a detailed description of any method is no longer necessary or desirable. In this paper I shall endeavor to lay down some of the governing conditions in this industry, the relation of methods to ore deposits, freight rates, and sources of power supply. POWER POINTS Assuming for a moment that, for the present at least, the electrolytic production of zinc will be confined too those localities having developed water power, a glance at these powers so developed in the United States, with their relation to known zinc orebodies of economic size, will not be without interest. Northwest In the Northwest we have water powers, developed and undeveloped, in Washington and Montana. These must, of course, bear a close relation to the rapidly growing zinc production of the Coeur d'Alenes and of the Butte districts. In general, the power of the territory in question is relatively low-priced, at least as compared with the cost of developing power from coal, and the near neighborhood of large bodies of more or less complex zinc ores makes these water powers of more than usual interest. The same remarks may be applied equally to the developed water powers of the Canadian side of the line in the Northwest, where we have again commercially available complex ore deposits such as are being exploited today at and near Trail.

Jan 9, 1917

By G. R. Mansfield

THE third year of Government exploration f or potash by the U. S. Geological Survey and-the U. S. Bureau of Mines under the authorization of the act approved June 25, 1926 (Public 424-69th Cong.) is drawing to a close. The results thus far obtained are thought to be sufficiently interesting and satisfactory to justify the presentation of a brief preliminary account of the work. REVIEW OF EARLIER EXPLORATION The general geologic similarity of the Permian basin of Texas and New Mexico to the potash field of Germany had long ago suggested the possibility of the presence of potash salts somewhere in that basin, but petroleum exploration was then making little headway there and the necessary data could not be obtained. The discovery by Udden in 1912 of potash in brine from the Spur well in Dickens County, Texas, was the first direct evidence of its presence. In 1915-17 the U. S. Geological Survey drilled a test well with standard tools at Cliff side near Amarillo, but failed to find potash. Nevertheless, an observer has been kept in the field, at first in cooperation with the Texas Bureau of Economic Geology but since 1922 by the Survey alone, to `secure data and samples from oil and gas tests. Since the discovery of oil in Reagan County in 1923 exploration by drilling has been rapidly extended to many parts of western Texas and southeastern New Mexico. The identification of the potash-bearing mineral polyhalite was first announced by the Geological Survey in June, 1921, the material having come from cuttings from the Bryant well in Midland County and the Burns well in Dawson County, Texas. Successive discoveries and announcements of similar purport aroused widespread interest in potash exploration, which culminated in the action by Congress already noted.

Jan 1, 1929

By A. M. Gaudin

Of the various reagents employed in the flotation of zinc-bearing ores none have attained the wide popularity that is enjoyed at present by xanthates, copper sulfate and cyanides. This situation suggests the existence of an unusual dependence in the reactions of these chemicals and of sphalerite. A study of the flotative characteristics of sphalerite when using xanthates as collectors, as related to the chemical properties of copper salts and cyanides, has therefore been conducted at the University of Utah by the writer and his associates1 during the period of 1926 to 1929. In perusing the technical literature concerning the flotation of zinc ores and of zinc-bearing lead and copper ores, a striking and general lack of agreement as to the floatability of sphalerite was observed. The underlying cause for the erratic behavior of sphalerite has not been definitely ascertained but the presence in various proportions of iron sulfide in solid solution in the sphalerite has frequently been implicitly regarded as a major factor in this respect. Although the effect of iron sulfide in solid solution in sphalerite has not been investigated in relation to the behavior of sphalerite in flotation, it is likely that it is not as important a factor as was thought at one time. The variable float-ability of sphalerite has led to the use of fairly large amounts of cyanide to prevent its flotation in the case of certain ores, whereas mere fractions of that amount of cyanide, or even none at all, have been sufficient to achieve the same result for other ores2 Similarly, the amount of copper sulfate used to promote the flotation of sphalerite has been found to vary widely. Effect of Copper Salts in Distilled Water on Sphalerite In the work at the University of Utah, over a year was spent in futile attempts at duplicating experiments until it was discovered that the

Jan 1, 1930

By Nicholas J. Grant, Italo S. Servi

THE creep and stress rupture properties of three grades of aluminum have been reported in a previous paper.' It was found that the stress coefficient of the creep rate and of the rupture time changes at the transition from low temperature-type to high temperature-type deformation. The transition corresponds to the equicohesion for grains and grain boundaries. In order to support the conclusions obtained from the examination of creep and stress rupture data, the deformed specimens were observed metallographically and a few special tests were conducted. The results of these qualitative observations are given in the present paper. Experimental Procedure and Results Table I gives the types of aluminum specimens.' The creep and stress rupture tests were conducted in simple tension at constant stress. Further details on the experimental techniques have been given.' The test bars were electropolished in a perchloric-acetic mixture before testing and were observed after testing without any further preparation unless otherwise specified. Observations of specimen cross-sections were made after electrolytic polishing and etching. The samples were extended along a direction parallel to the longer side of the micrographs of Figs. 12 through 27. The log-log plots of stress vs. minimum creep rate for the three grades of aluminum appear in Figs. 1 and 2. The reference numbers on each curve help relate the photographs to the conditions of testing, indicating where high temperature-type deformation and failure prevailed and where low temperature behavior prevailed. Deformation of Single Crystals at Very High Temperature: An annealed, high purity aluminum specimen was slightly strained at one end and re-annealed. A large single crystal was formed at the strained end of the specimen during re-annealing; the other end remained polycrystalline (see Fig. 3). A stress of 50 psi was applied to the cold specimen to avoid loading at 1100°F. The temperature was then raised to 1100°F, kept at 1100°F for 3 hr, and lowered again to room temperature. Fig. 4 shows the appearance of the specimen after testing. The single crystal deformed by gliding along parallel planes, while the polycrystalline part deformed mainly by grain boundary flow. Some grain growth occurred in the polycrystalline part. Another high purity specimen, which had two large single crystals at the two ends and a polycrystalline zone in the middle portion, was tested at 1000 °F under a stress of 100 psi. The appearance of the sample after test is shown in Fig. 5. Even though considerable slip occurred in the single crystals, the fracture occurred in the weaker polycrystalline portion. Evidence of Grain Boundary Migration during Creep Testing: A high purity, coarse grained specimen, which had a large crystal in the middle portion (see Fig. 6) was tested at 700°F under a constant stress of 175 psi for 30 hr. The appearance of the specimen after testing (Fig. 7) indicates that the large crystal deformed by gliding along parallel planes, while the rest of the specimen deformed mainly by grain boundary flow. Microscopic examination showed clear evidence of grain boundary flow and grain boundary migration, an example of

Jan 1, 1952

By Gilbert Doan

AN extensive program of investigation is being carried out at Lehigh University in the study of arcs and arc welds of high-purity iron1, spon-sored by the Engineering Foundation. The part of that program reported in the present paper deals with welds made of high-purity iron in an argon atmosphere and for comparison with them welds made of the same iron in ordinary air. Welds of commercial steel also were made in argon and in air. The primary purpose of the study is to discover the basic physical constants of iron welds when not contaminated either by impurities in the iron or by the action of oxygen and nitrogen of the air during welding. Upon these constants can be founded such future studies as will determine what effects the various impurities and alloy elements present in steel have upon its welding characteristics, and what influence is exerted by the action of oxygen and nitrogen. The welding of steel involves such a multitude of variables, both of composition and of procedure, that development in the fabrication of this most important metal has necessarily been slow, wasteful, and in many instances discouraging. In the present investigation, the simplest possible condition has been selected; namely, iron practically free from contamination and a nonparticipating atmosphere, the inert gas argon. This simplification reduces the number of variables to a point where more rigid control of the system is possible. Although this study is significant for the contributions it makes to the science of steel fabrication, yet it is hoped that it will not be without value also in increasing knowledge of the nature and behavior of iron and steel in general. From the standpoint of open-hearth practice, and to

Jan 1, 1936

By John C. Calhoun, Alfred Chatenever

An exploratory study wap made to examine the possibilities of a visual approach in investigations into microscopic mechanisms of fluid behavior in porous media. Appropriate apparatus and techniques were developed so that microscopic phenomena could be recorded on color movie film as well as be observed visually. The observation flow cells in which tlie fluid behavior studies were made were essentially single-layered matrices of spheres between plates. sometimes all-glass, sometimes all-Lucite and sometimes a combination of the two. The fluids were limited to water and a filtered crude oil. Two flow regimes were observed during the flow of the immiscible liquids: channel flow and slug flow. In the former, transport was effected through stable networks of interconnecting channels; and in the latter, part of the movement took place in the form of slugs. Under certain conditions, flood-front patterns were found to be different depending upon which liquids were the displacing and displaced phases and not depending upon whether the matrix was water-wet glass or oil-wet Lucite. Residual formations of oil and water were observed and are described. Some of the ramifications and significance of the ohservetl phenomena are discussed. INTRODUCTION In recent years considerations of microscopic mechanisms of fluid flow in porous media have taken on greater significance. Much needs to be learned before the fundamentals of petroleum technology are completely established. For example, many unanswered questions exist in connection with relative permeability, displacement phenomena, residua! fluid formations. flow structure, etc.; and further analytical mathematical formulations are seriously indicated. It is hoped that systematic investigations into the microscopic mechanisms connected with the behavior of fluids in porous media will shed some light on some of the problems extant. Until recently microscopic mechanisms have been considered almost exclusively as speculative hypotheses. Within the past few years, however, the problem has been submitted to a limited number of experimental investigations. Nuss and Whiting' made some studies on the pore-space geometry of sandstones and limestones by impregnating cores with an inert plastic and leaching the solid matrices to leave behind plastic models of the pore spaces. SchaeferZ traced pore spaces microscopically through lengths of limestone cores by cutting away thin sections from the exposed faces normal to the line of view. In 1949 two projects were organized in which dynamic flow phenomena were examined microscopically to uncover microscopic mechanisms. One was set up at the Pennsylvania State College where Lowmanb bserved heterogeneous fluid flow phenomena in capillaries. The second was the American Petroleum Institute Research Project 47B at the University of Oklahoma where microscopic studies of dynamic fluid phenomena in synthetic porous matrices have been made by visual observation and cinephotomicrography.' It is with the latter that this paper is concerned. treating the techniques involved and the observations made. TECHNIQUES Observation Flow Cells The observation flow cells formed a focal point in the techniques employed. Essentially, these were matrices composed of a single layer of spheres sandwiched between two flat plates. This design was arrived at after a series of pre-

Jan 1, 1952

By M. B. Bever, A. K. Jena

Equations for the heat effects of additions of mixtures of multicomponent phases to a solution have been derived in terms of the enthalpy interaction coefficients. By these equations and the measured composition dependence of the heat effects on addition of mixtures of Ag-Cd solid solutions and elemental gold to liquid tin-rich solutions, values of the enthalpy in-teraction coefficients in tin-rich solutions at 541°K have been obtained. Analysis of these results in terms of the regular solution theory and the quasichemical theory suggests that near the melting point of the solvent association in the solution becomes important. SEVERAL recent papers have discussed the nature of dilute solutions on the basis of measured enthalpy interaction coefficients. l-3 These coefficients contribute to the understanding of the constitution of solutions and can be used for the evaluation of thermo-dynamic data of multicomponent systems. Their experimental determination, however, is laborious. This communication reports values of the enthalpy interaction coefficients of silver, cadmium, and gold in liquid tin-rich solutions obtained from the measured heat effects of additions of mixtures of Ag-Cd solid solutions and elemental gold to liquid tin-rich solutions. These measurements were made in the course of the determination of the heats of formation of Ag-Cd solid solutions reported in a concurrent publication.4 THE HEAT EFFECT OF AN ADDITION TO A SOLVENT This analysis is concerned with the addition of a mixture of multicomponent phases from the temperature To to a solvent of known composition at temperature T. If Nmixture << Nsolvent, where N designates the gram-atoms involved, the heat effect per g-atom of mixture added can be expressed as (HT - HT )i = difference in heat contents of component element i in the mixture at T and To Q = heat effect on solution of the mixture at temperature T Also1 Q = S Xi [2] where ?Hi ,T,x = relative partial enthalpy per g-atom of i in solution at temperature T and composition of the solution x x = average of the atom fractions of the added material in solution before and after the addition The relative partial enthalpy ?Hi per g-atom of an element i in a dilute solution composed of a solvent 1 and the solutes j = 2, ... m is related to the interaction coefficients by the following equation5 ?Hi - ?Hi-?Hi,x1-1 + S n1ixj+ . . . +S...S...S nrixn2... Xnji...Xnmm+... [3] vhere Xj = atom fraction of solute j in the solution nri = the rth order enthalpy interaction coefficients, which can also be represented by the more general designation5 L(i)n2,n3...nm and nj may have any positive integral value or zero. For identification of various rth order interaction coefficients, nri is written as nn2i2,...nij,...nmm. Eqs. [1], [2], and [3] combine to give the following general equation for the heat effect on addition of a small quantity of a mixture to a large quantity of a dilute solution n = _?ga ?Ha,To + ? Xi(HT - HT o)i a. i + ?xi?Hi,X,i?1 + ??xnjixj + . . . + ???. . .?. . .?xinrix2n2. . . xnji. . . xnmm+ . . . [4] The first term on the right-hand side of this equation is the heat of decomposition at the addition temperature of the phases present in the mixture, the second term is the heat required to raise the temperature of

Jan 1, 1970

By Oscar Johnson

The industry has been canvassed for information on methods of handling grinding steel at milling plants, an important subject overlooked in most descriptive articles on milling plant arrangements. The data collected are offered in this paper as a guide to designers and planners who have loading and storage problems to solve. WITH capacities of milling plants expanding from a few hundred tons per day to many thousand, replenishment of grinding media is an important phase of mill operation. Information on this aspect of milling procedure, solicited from several mining companies, is summarized here. At International Nickel&apos;s Copper Cliff concentrator the normally strenuous job of changing rods is considerably simplified by the use of the Garrow rod charging machine, Fig. 1. The overhead crane, Fig. 2, brings a bundle of rods, weighing four to a ton, to the loading platform of the machine, positioned in front of the mill. The rods roll one by one down the slight incline of the platform onto a conveyor which sends them into the mill. A modified version of the Garrow machine, Fig. 3, is used at the Federal mill of St. Joseph Lead Co. An overhead crane places the portable steel structure in position in front of the discharge end of any one of the five 9x12-ft rod mills. It then raises a bundle of about twenty 3-in. rods to the discharge platform of the charging machine. The rods are 11 ft 7 in. long and weigh about 278 lb. By tripping a lever the operator allows one rod at a time to roll onto the inclined rollers. A slight push by the operator sends the rod smoothly into the mill. The Union Miniére du Haut Katanga rod charging machine, Fig. 4, is mounted on a pair of wheels at the forward end with swiveling castors at the back for steering it to position for use or storage. Wheels are equipped with locking brakes to maintain the machine in position while it delivers rods to the mill. The device is made in two parts. The first consists of the base, which carries the supporting wheels, grooved rollers, and drive. The other part serves as the rod deck, which can carry up to six 3-in. x 12-ft rods. A short boom built integral with the base reaches through the mill trunnion and delivers the rods into the mill barrel. Three grooved guide rollers ,are provided to receive the rods from the sloping charging deck. One rod at a time is fed to the rollers and thus delivered into the mill. Two of the rollers are driven by 11/2-hp motor through a V-belt drive. The third roller is driven off the first by a single V belt in a groove below the rod groove and on the same center line. Rods are delivered to the charger by an overhead crane in bundles of three to six as needed. The power is supplied by cables plugged into power outlets, suitably located near the rod mill discharge end. The Oliver Iron Mining Co. uses a rod charger, Fig. 5, suspended from a monorail by cables. It is constructed .of structural steel and has two decks, each capable of carrying five rods of 4-in. maximum diameter. The rods ride in grooved free-turning rollers. Legs extending down from the mill end of the mechanism act as supports when the unit is ex-

Jan 1, 1955

By H. H. Stout

IN the early fall of 1025, the writer was conducting, in the Ledoux and Co. labora-tory, New York, experiments directed to-ward ascertaining the effect on its impurity content when cathode copper was subjected to a current of various gases at an elevated temperature below the melting point. The apparatus consisted of a vertical I-in. dia. silica tube about 12 in. long, heated on the outside. The cathodes were broken to pass 3/8-in. mesh, and a current of various differ-ent gases was passed up through a 4-in. long column of these loose cathode particles in the vertical tube furnace. Temperature was maintained to 1500° to 1600°F. and the gas treatments lasted from 3 to 6 hr. The writer observed that whenever reducing gas (H2 or CO) was used, these cathode par-ticles stuck together at points of contact with each other. The cohesion was so marked and tenacious that an examination was made of the fractured surfaces, when cathode particles were broken from the cluster. Crystal growth was always found to have taken place across the surfaces where separate particles were in contact, but only after all oxides, sulphates, etc., had been completely removed. The idea of a possible new process was then conceived and was disclosed to A. M. Smoot (V. P. Ledoux and Co.) with intent to obtain his views. The first conception as given Smoot was "to gas-clean broken cathodes, put them in an extrusion press, solidify and extrude them at around 1500°F." Smoot&apos;s reaction, after a few moments considera-tion, was, "It looks perfectly all right to me." The writer and his assistants, W. H. Osborn and H. H. Stout, Jr., after confer-ring as to ways and means, decided to go ahead with preliminary laboratory experi-ments, which, it was thought, would move the new process from the possible to the probable. This program followed a course indicated by three basic considerations: I. Since brittle cathodes were often unin-tentionally produced, it seemed probable that the laws controlling this type of deposi-tion could be ascertained. 2. We had already proved the gas-clean-ing feature. 3. There remained to prove: whether a sound, homogeneous metal billet could be produced with crystal growth established over the entire surface of each individual particle in the billet; and, if so, what would be the physical properties? Osborn arranged with Columbia Uni-versity for conducting experiments in its research laboratory to prove or disprove the third item; Columbia assigned C. A. Phillipi, Jr. to assist in the project. A press with a cylinder 2 in. high and of I-in. dia. was used. It was surrounded and heated by a resistance coil of Nichrome wire. Broken tough cathodes were used.

Jan 1, 1940

By R. C. Padfield

Experience over a 3-year period in Bethlehem Steel Corporation&apos;s plants has demonstrated the reliability of open-hearth roofs of bonded sprung-arch constructzon with burned basic brick. The design principles lor constructing these roofs include a minimum hot-strength requirement for the basic brick, expansion allowances that extend the full roof thickness, structural members to control arch contour, and a specified minimum roof rise. The greater stability of bonded roofs is explained in terms of the basic stress patterns of ring constrution and bonded construction. PRIOR to the development of successful sprung-arch roofs of basic brick, the majority of open-hearth furnaces in the United States were operated with sprung-arch roofs built of silica brick. Although many silica roofs used on open-hearth furnaces were ring-arch construction, Bethlehem Steel Corp. used bonded-arch construction because of its greater stability. In ring construction, each ring of brick is separately keyed and comprises an independent arch with the straight joints between rings traverse to the longitudinal axis of the furnace. In bonded construction, the bricks are laid in rows starting from the skewbacks so that the straight joints run parallel to the longitudinal axis of the furnace. Each brick in a given row is laid so that it spans the joint between two bricks in the row beneath it. Thus, the transverse joints across the arch are broken and the arch rings are thereby interlocked or bonded. When basic roofs were first being developed, the basic brick that were available had low hot strength. Such brick could not be safely used in sprung-arch construction without some means of suspending them. With the development of higher firing techniques by brick manufacturers and the recently introduced direct bonded bricks with high hot strength, the use of burned basic brick in sprung-arch roofs became feasible. The availability of high hot strength basic brick coupled with the potentially lower cost and proven stability of bonded construction prompted Bethlehem&apos;s Research Department to study the possibility of using basic brick in bonded roofs. With the full cooperation of plant ceramic engineers and open-hearth superintendents, particularly in 3 years of fur-nace trials, we developed the design criteria for bonded roofs and the corresponding property requirements for the basic brick that are discussed in this paper. DESIGN PRINCIPLES OF SPRUNG-ARCH BRICK ROOFS Stresses in Fixed Arches. A sprung-arch open-hearth furnace roof is generally built on rigidly held skewbacks. The constraint of the fixed support at each end adds a bending moment to the horizontal and vertical reactions at the ends of the arch. Fig. 11 shows the positive direction of forces acting on an arch fixed at both ends. Fixed arches can be analyzed when the members are continuous and have elastic properties. However, brick are inelastic, and arches built with individual brick segments cannot carry tensile stresses. Therefore, for practical solution of brick arches, empirical formulas have been derived from elastic theory that place design restrictions on arch dimensions to avoid development of tensile stresses. McDowell2 cites three main conditions for stability in sprung brick arches: 1) the thrust line of the arch should be maintained in the middle third of the thickness to avoid tensile stresses and resulting open joints in inner and outer curves of the arch; 2) the angle between the line of thrust at any joint and a line perpendicular to the joint must not exceed the angle of repose between brick; and 3) the maximum pressure at any point must not exceed the strength of the arch materials at furnace operating temperatures. The first and third conditions are particularly important in designing sprung-arch basic roofs because of the comparatively low hot strength of basic brick. According to McDowell&apos;s equation, if the thrust line is maintained within the middle third of the arch thickness, the unit pressure is obtained as follows: where p = unit pressure in psi, F, = resultant thrust normal to skewback in pounds per foot, t = arch thickness in inches, and z = distance in inches of thrust line from arch axis. When the resultant thrust normal to the skewback acts along the arch axis, z equals zero and unit pressure is simply the thrust divided by the cross-sectional area. If the thrust line moves to the limits of the middle third of the arch thickness, beyond which tensile forces would develop, z then equals one-sixth of the arch thickness and the unit pressure is double that when the thrust line is acting

Jan 1, 1968

By F. M. Hamilton, H. F. Ameen

Results of a laboratory investigation of some sintering variables are presented. The effect on physical properties of mix component variation and rate of cooling of the sinter is illustrated by crush and tumbler test results and data of reducibility tests and microscopic examination of sinters are shown. The results of using solid additions in the mix to improve bed permeability are given. SOME of the variables encountered in the sintering of iron ores and their effect on sinter properties have been investigated at the Jones and Laughlin Ore Research Laboratory in Michigan. Ores requiring agglomeration before blast furnace utilization may be classed as coarse, intermediate or fine. Coarse iron ore is considered similar to a — 1/4-in. Mesabi wash ore containing some 95 pct of its particles between 94 in. and 100-mesh. Intermediate iron ore is considered similar to our New York State magnetic concentrates in which all the particles are — 20-mesh and about 60 pct are +100-mesh. Fine ores are considered as being at least 100 pct —100-mesh. This paper will deal only with the two coarser classifications. Most of the work has been done in a small experimental batch unit previously described in an AIME1 paper. Results being obtained form a basis for present and future trials in production sinter plants. It is expected that new production units that may be added in the future will benefit from laboratory studies. In general, the results reported here are obtained by laboratory study, but it is Experimental Sinter Machine: The laboratory sinter machine employed in the work consists of a chamber with 1 sq ft of grate area. It is mounted on

Jan 1, 1951

By G. R. Brophy, A. J. Miller

The Grossmann principle1 for the calculation of hardenability of steel from composition is attractive because of its simplicity. It postulates that the hardenability of a steel for any particular grain size may be expressed in terms of an ideal critical diameter, which is the product of an ideal critical diameter for a "pure" iron-carbon base multiplied by a succession of factors for each element of composition contained, including the incidentals. It infers that the multiplying factor for a given quantity of an element is constant for all combinations of composition. Gross-mann has stated that in the great majority of cases the experimental values of hardenability are found to be well within 10 per cent of the calculated values. The validity of the scheme has been confirmed in principle by Crafts and Lamont2,3 and by Kramer et al.4 Their results differ from the original in the magnitude of the effect of some elements but, since they accepted the product concept and followed its direction, it is to be ex~ected that similar results would be obtained. Crafts and Lamont, in their second Paper, recognized that the factor relations for manganese and nickel were not continuously linear, but beyond certain critical amounts increase sharply. Austin, Van Note and Prater6 demonstrated nonlinear relations between hardenability and alloy contents. Their curves for chromium, silicon, manganese and nickel were all convex upward to show decreasing incremental effects. They concluded that Grossmann&apos;s factors under-evaluate the hardening effect of low percentage additions of these elements, and overevaluate the larger additions. More recently W. Stevens has found that the factor method fails when applied to complex steels containing two or three principal alloying elements other than carbon. Multiplying factors derived from his results bear a complex relation to composition and are not constant for a given amount of an element as the base composition varies. C. A. Liedholm7 found that, using either the Grossmann or the Crafts-Lamont multiplying factor values, not only were the relative hardenabilities of two heats of S.A.E. 6130 chromium-vanadium steel

Jan 1, 1947

By R. E. Rick-Secker, W. M. Baldwin, R. McC. Baker

The development of residual stress in strip during rolling has not been systematically studied. A few scattered papers1 -3 mention the existence of residual stresses in rolled strip or touch upon some of their consequences,4 but there is no report of experimental studies in the literature describing the effect of roll diameter, strip thickness, reduction per pass, metal or metal temper on the magnitude of residual stresses developed in strip. A knowledge of the effect of these factors is of utmost importance since the present trend in some mills to roll thicker castings brings the rolling operation directly into that set of conditions which, as will be brought out in the present paper, can develop residual stresses of a high order of magnitude. Fundamentally, residual stresses are developed when a metal is inhomogeneously unloaded from a plastic stress state. A quantitative treatment of the problem requires a reasonably complete understanding of both the plastic stress state existing in the metal during deformation and the elastic stress state that would exist in the metal if the metal deformed as a perfectly elastic body. Our knowledge of either state during rolling is so meager that we can make no more than certain limited predictions. The external stress state* operating between the roll and the metal consists of Fig i—External stress state operating on metal being rolled (after siebel and LUEG5) compressive stresses acting almost perpendicularly to the strip surface but varying in intensity both across the width of the strip and along the length of contact between the roll and the strip. An example of such a stress distribution is shown in Fig I. The nature of the internal stress state, produced by this distribution, is not known. Various investigators,5-7 however, have felt that a qualitative similarity must exist between the internal stress state so produced and that produced in a wide strip that is compressed between two flat-nosed punches. In the latter case the external stress state is represented by a uniformly distributed compressive stress acting per-pendicularly over the face of the tool. The

Jan 1, 1949

By David R. Hargis, John W. Harshbarger

The Upper Santa Cruz Basin lies in the drainage area of the Santa Cruz River in Arizona, and extends upstream from the community of Rillito to the international boundary [(Fig. 1)]. The principal water use area lies between, and includes, the cities of Tucson and Nogales. A subsurface geologic barrier near Rillito provides a reasonable dividing line between the ground waters of the upper and lower Santa Cruz basins. The upper basin contains the Tucson and Sahuarita-Continental critical ground water areas. The Tucson water use area encompasses the Tucson metropolitan area and extends from the northern boundary of the basin south to the boundary between the Tucson and Sahuarita-Continental critical ground water areas near San Xavier. The San Xavier use area is the San Xavier Indian Reservation. The north and south boundaries of the Continental use area coincide with the limits of the Sahuarita-Continental critical ground water area. The first study of ground water in this valley was initiated by Dr. G. E. P. Smith in 1905, and the results were published in 1910, followed by a series of bulletins of the Arizona Agricultural Experiment Station, University of Arizona, covering the general field of ground water development and utilization. Beginning in 1939, the ground water branch of the US Geologic Survey, in cooperation with the Arizona State Land Department and the Arizona Water Commission (AWC), published a series of bulletins concerning ground water occurrence and utilization in various areas of the state. In 1975 and 1977, the AWC published the Arizona State Water Plan (Arizona Water Commission, 1975) comprising a detailed inventory of water availability and use in Arizona and a study of alternative futures. The importance of ground water supplies in the Upper Santa Cruz Valley cannot be overemphasized. Metropolitan Tucson, surrounding agricultural areas, and the mineral industry are completely dependent upon ground water. Agriculture has been the largest user of ground water. The land distribution of the Upper Santa Cruz Basin is rural in character with large tracts of land included in national monuments and national forests. The Upper Santa Cruz is one of several state basins that does not depend upon one single industry as its major economic activity. Agriculture, mining, tourism, international commerce, and manufacturing all contribute to a viable economy. The city of Nogales, on the Mexican border, and the city of Tucson, to the North, are the centers of commerce in the basin.

Jan 1, 1982

By R. S. Archibald

The subject of this paper is particularly appropriate, since Daniel C. Jackling was active in early exploitation of taconites on the Mesabi Range and contributed greatly to their later economic development. After his success in developing the low grade porphyries in the West he looked for more worlds to conquer, and so undertook the concentration of low grade taconites, from which he hoped to produce commercial ore. Mesabi Iron Co., organized in 1919, actually did produce merchantable sinter from taconites in 1922. The enterprise did not prove commercial at the time, as cost of production was high and the surplus of iron ore in the Lake Superior District already contributed to a low market price, but this same property has since been developed by Reserve Mining Co. The work done by Jackling had much to do with the success of this later venture. Iron ore was first discovered on the Marquette Range in Michigan in 1845. The first ore from this range came from the old Jackson mine in Negaunee in 1848. During these early years this property and others on the Marquette produced limited tonnages for transportation to Lower Lakes and for consumption by charcoal furnaces in the area, where a plentiful supply of hardwoods furnished the charcoal for iron smelting. The Marquette and other ranges tributary to Lake Superior did not produce much ore for transportation to Lower Lakes until the locks at Sault Ste. Marie were constructed, but from the time the first lock at the "Soo" was completed in 1855 these ores were transported through the locks to consumer centers in the East. The Marquette Range has a history of continuous production from 1848 to the present day. In 1877 the Menominee Range was discovered at the location of the old Penn Mines near Vulcan, Mich. There were further discoveries of ore on the old Menominee Range and at Florence, Wis., in 1880 and at Iron River and Crystal Falls, Mich., in 1882. Penn Mines continued in operation from the date of their discovery until they were finally exhausted by Pickands-Mather in 1945, but operations still continue on the Menominee in the Crystal Falls and Iron River districts. Ore is shipped to a lake port at Escanaba, Mich.

Jan 1, 1960

By Franklin Moeller

Considering the really short time that has elapsed since hydro-metallurgical processes of extracting copper from ores have been extensively developed, and the large scale on which this method is practised at Ajo, the successful operation of the plant must excite the admiration of every visitor. The application of the mechanical unloader to the purpose for which it is employed at Ajo is but an extension of the use for which it was originally designed, some 20 years ago, for unloading iron-ore vessels at the lower lake ports. At a time when the maximum output of a single machine, with men shoveling the ore into buckets, did not exceed 40 tons per hour, G. H. Hulett invented and constructed a mechanical unloader with a bucket of 10-ton capacity. This machine was of the steam hydrauIic type, and it is still in operation after nearly 20 years of service. Several more machines of the same type were built, but the difficulties of power transmission, and the rapid development of electrical machinery, soon led to the adoption of electrically operated machines, and practically all of the later installations have been thus equipped. This electrically operated unloader has proved so well fitted for the work that the design of the lake boats has been practically revolutionized, with special view to the ease and rapidity of unloading. It is now possible to unload a 12,000-ton vessel with four machines in a little over 2 hr. This has necessitated an increase in the capacity of the machine, and the largest yet built handles an average load of 17 tons, with a possible maximum of 20 to 21 tons. The Ajo excavator is somewhat simpler in design than the iron-ore unloader, in that it is not provided with a larry. In the unloader, the iron ore, picked up by the bucket, is delivered to a larry or transfer car which runs in the lower chord of the bridge; the larry then delivers the ore either into railroad cars, standing on several parallel tracks, or into the stock pile, thereby saving the time that would be required for the bucket to make the trip. At Ajo, the bucket delivers the tailing

Jan 1, 1920