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By Gerald Edmunds

THE liquidus line on the phase diagram for temperature versus composition of a binary alloy system, representing the boundary between the homogeneous melt and the heterogeneous melt plus solid, besides showing the minimum casting temperature, is useful in determining eutectic compositions and the presence of phase changes such as peritectic transformations and intermetallic compound formation. The liquidus often is determined by the cooling curves of thermal analysis, but supercooling frequently occurs, so that the temperature values are low. An alternative method, the one employed here, consists of determining the com- position of samples of the melts from heterogeneous alloys that are at equilibrium. With meticulous attention to fundamentals, this method is capable of yielding values limited in precision only by the temperature control and measurement and analyses. APPARATUS By starting, on the one hand, with a supersaturated solution and allowing the excess solute to precipitate, and on the other hand with an undersaturated solution and allowing more of the solute to be dissolved, both processes being carried out at the same temperature, equilibrium may be said to have been approached from both directions; that is, from above and from below. If the analyses show the solutions to contain the same fraction of solute when equilibrium has been approached from above and from below, one is assured that equilibrium has been reached in both determinations. In order to carry out such determinations, it is necessary to have equipment for obtaining and maintaining the proper temperatures; for holding the melt, measuring its temperature, and stirring, sampling and analyzing it. The present work required temperatures from 420° to 900°C. The equipment consisted of: A furnace, which was a vertical alundum tube, 1 ¾ in. diameter inside and 18 in. long, wound with Nichrome resistance wire, surrounded by a 3-in. i.d. alundum tube wound for 5 in. of length near each end, for compensation of end losses. This muffle was contained in an iron shell with Transite end plates, the intervening space being packed with Sil-O-Cel. The outside dimensions of the furnace were 12 in. in diameter by 18 ½ in. in height. Heating current was supplied by three independent variable-voltage transformers (Variac), one connected to each end compensator winding and manually controlled, and one connected to the main winding through a series resistance of 5 ohms. This resistance was short-circuited for

Jan 1, 1944

By Reed W. Hyde

Some information has been published on the sulphur dioxide concentration of gases from D wight-Lloyd machines sintering lead ores but most of this relates to the customary practice in which the charge is relatively high in lead and is sintered in two passes Over the machine. It is thought, therefore, that the following observations on sintering in one pass a low-lead, low-sulphur charge may be of interest. The data were obtained in sintering lead sulphide notation concentrates mixed with minus 20.mesh oxide ore, the mixture carrying 16,8 per cent Pb and 5.3 per cent S. No returns were used because of the limited amount of sulphur available as fuel, but the mixture pelletized readily. to make a satisfactorily permeable bed on the sintering machine. As there was a possibility that the SO z might be utilized, a series of runs was made to determine the concentration ofSO2 in the gases at different points along the wind box, and the effect on this concentration of changes in the wind-box vacuum. Several runs each were made with vacuums (as measured in inches of water at the wind box) of (1 2 to 1 in., ('1 4 to 3% in. and (3) 6 to 5% in. The averages of the determinations from each series are platted On the graph (Fig, 1). The vertical scale shows the percentage by volume of SOz (as determined by the Reich method), and the horizontal scale shows the time e~pressed as percentage of the total sintering time. Sintering was considered to be complete when no SOz could be detected in the gases. In all cases the depth of bed was 4 1/2 in. and the weight of dry charge per square foot of hearth area was 45.2 lb. Other data are given in the table. The volume of gases corresponding to the several points along the wind box at which SO2 determinations were made could not be measured, but has been calculated from the SO2 Content and sulphur elimination on the assumption that the volume is uniform throughout the sintering period. This is not strictly true, as with a given vacuum the volume usually will drop slightly toward the middle of the period and increase toward the end. However, this made is a reasonable approximation. several interesting features are brought out by these data. In general, the published data on SO 2 concentration in sintering under ordinary conditions show a high SO2 concentration in the early stages followed by a rapid decrease in concentration and with relatively little SOz in the gases from the last half or third of the operation. In other words, the greater part of the sulphur elimination is obtained in the first third or half of the period. In these runs, the 6-in. vacuum, which approximates the usual operating condition, gives a curve that follows this customary pattern. Maximum SO2 concentration is obtained 234 min. after

Jan 1, 1944

By Harold W. Scott

Geological Engineering is now a recognized curriculum in most of the mining schools in United States. Graduates of these schools are scattered over the face of the earth, participating in exploration and mining enterprises of diverse character. They are engaged in the mapping of new mineral deposits, in the extension of old deposits, the estimation of reserves, microscopic analysis, and in the direction of exploitation and conservation of man's natural resources. The training of men qualified to carry out these technical phases of modern industry has fallen essentially to the mining schools. For the most part they have met the demand for technically trained men in the mineral industries. Schools Offering Geological Engineering Degree The mining schools have passed through the early stages of their development and at the present offer varied curricula covering the fields of geological engineering, mining engineering, and metallurgical engineering. Usually a B.S. degree is offered in any of these three fields. However, .there has been some tendency of recent date on the part of the Engineers Council for Professional Development to question the validity of a B.S. degree in Geological Engineering. The of this paper is to examine the curricula as offered in the mining schools, to evaluate their engineering content, and to propose minimum requirements for the degree of Geological Engineering in the mining industry. The curricula of eight institutions that offer the degree of B.S. in Geological Engineering or Mining Geology have been studied (Table 1). All except one of these schools are in or near mining districts and occur west of the Mississippi River. They are all state-supported institutions that have come into existence because of the state's need for technically trained men. A graduate from .a mining school is called upon to perform many duties of a technical nature. His initial task may be to make a geological map of a mine or the surface above, but before the map is finished he may be asked to take over the responsibility of getting the ore "on top." And finally, he might find it essential to know how to mill the ore. Certainly this requires technically trained men and the mining schools are essentially the organizations to do the job. The departments of geology in these schools are training geological engineers. Field Of Geology If we were to accept the opinions of some writers, we would be forced to conclude that all geology departments offer only a "dilettante" variety of subjects.

Jan 1, 1944

By E. C. Skinner

Cardox, which consists essentially of a steel tube containing carbon dioxide compressed to the liquid state, is a trade name designating a device used principally in coal mines to break down coal. The use of Cardox to break down coal was developed in the Middle Western coal fields around 1927 or 1928. At first, a large, heavy tube was used, requiring many parts. Through experimentation and technologic improvement, the weight of the tube has been brought down from 88 lb. to 20 lb. and the new, light tube makes use of larger volumes of CO2 at lower pressures than formerly was thought possible. This blasting method is extensively used today in coal mines and probably one tenth of the bituminous coal produced in the United States is prepared with Cardox. Construction and Application As used in the coal mine, Cardox looks like a piece of steel pipe 2 to 3 in. in diameter and 3 to 5 ft. long. When it is necessary to fire a shot, the tube is wired with two leg wires that are long enough so that when the tube is pushed the desired distance into the hole the wires will protrude 5 to 6 in. It has been found that No. 18 insulated copper annunciator wire is the best material for leg wires. A two-conductor rubber-covered shot-firing cable of sufficient length is then attached to the leg wires. A 2 to 6-volt current is applied, either by means of shot-firing batteries or the standard type of shot-firing generator. Upon the application of the current, the charge in the cartridge is set off. Because the breaking action upon the coal is supplied by the relatively slow physical expansion of the carbon dioxide gas rather than by the rapid chemical formation of gases as in more familiar explosives, the result is a slow heaving action, somewhat similar to that produced by black powder, rather than a shap detonating effect. Permissible powder does its work at roughly ten times the pressures in use with Cardox. The escaped gas from a Cardox shot apparently works along the planes of weakness in the coal face, such as the coal cleats, the edges of the cut, and along the top of the seam, breaking off the coal toward the free faces and heaving the mass of coal outward. Cardox tubes are manufactured in various sizes to take care of variable conditions of seam size, undercut depth, cleatage, coal hardness, and so forth. The tubes range in diameter from 2 to 3 in. (Table I) and the normal CO2 charge is from 24 to 96 oz. For any one tube size, several sizes of shear disks are available, thus excellent control of the type of shooting desired is possible. In general, local experience and experimentation dictate the size of tube chosen for any particular job. For high coal, and deeper or wider cuts, a larger size is chosen to start with, and the opposite is true for low coal, softer coal, or small cuts. After the tube size has been experimentally selected, tests are run in the mine to determine how many shot holes are needed and where the holes should be placed. The size of the disk,

Jan 1, 1944

By Parke A. Dickey

Potential differences between strata of shale and sandstone have been recognized for about years, and they form the basis of the electrical logging of oil wells. Hitherto these potentials have been ascribed solely to electrochemical reactions caused by the disturbing effects of the water in the drill hole through which they are generally measured. Observations by the author in wells empty of water and in a mine shaft suggest that potential differences between sandstones and shales are natural and specific properties of the rocks, although they are modified in measurement by the disturbing effects of the water in the drill hole. The cause of these potentials probably is to be sought in the relative polar adsorptive capacities of quartz and clay particles. Introduction The existence of potential differences in the surface of the earth has been known for some time, and their measurement has facilitated the discovery of geological discontinuities such as ore bodies. The technique of measurement has been well established.'-a In measurements in oil wells, it has been found that the potential of shales with respect to some arbitrary reference is very nearly constant in any one well, at least below the zone to which meteoric water has gained access. Sandstones and some other types of sedimentary rocks have a difference of potential with respect to shale that is negative and may attain a value of 200 millivolts or more. The difference of potential, as usually measured commercially with water in the hole, is distributed over about one foot vertically at the top and bottom contacts of the sandstones. The sharpness of the curve at the formation contacts can be improved by using a short electrode that is close to the wall of the hole. These potentials generally have been ascribed to the disturbing effects of the water in the drill hole. Potentials have been found, however, in wells in which no water was present. In the course of experiments in electrical logging in Pennsylvania, carried out by the Pennsylvania Geological Survey, observations were made of several phenomena that hitherto have not been described, to the author's knowledge, in the published literature. The potential differences across the contacts of sandstone and shale are called in this paper "natural potentials," as distinguished from the potentials caused by electroendosmosis (electrofiltration) and concentration differences, which will be discussed subsequently. Potentials in Cored Well In the spring of 1942, the author measured the potentials in an exploratory well (Day 13, near Grand Valley, Pa.) which had been cored with diamond tools. The potentials were first measured with fresh water in the hole. A null balance potentiometer was used in this and all the other measurements described in this paper. One nonpolarizing porous pot electrode, containing copper sulphate solution and crystals surrounding a pure copper elec-

Jan 1, 1944

By M. M. Neale

The pottery department has been aptly described as the "heart of the zinc plant," md every operator of a horizontal-retort plant is acquainted with the fact that good retort practice is the keystone of the smelting process. Since retorts and condensers are clay products, it is obvious that improvements in other branches of the ceramic industry should be observed for possible adoption in the pottery process for zinc smelting. Deaeration of clay bodies is one of the improvements that have become fully, established in many brick and pottery plants. Our investigation of a number of these installations always yielded the same answer—improved practice. Improvement in workability, elimination of laminations, less porosity, greater wet and dry strength, were among the claims put forth for this process. All of these features are exceedingly desirable characteristics in the manufacture of a zinc retort. A preliminary test, which involved truck transportation of deaired slugs over a relatively long distance, did show the value of many of these characteristics in forming the retort. Results from the standpoint of , longer retort life in the smelting furnace were not outstanding. The idea lay dormant for several years but was revived again in 1940, when it was decided to make whatever changes were necessary in the equipment for pottery manufacture to fully demonstrate the process. A number of the manu- facturers of machinery for clay work were asked to submit proposals, and the plan finally adopted was extremely simple and economical. Machine FOR DeaeRRATING Selection of the ''Straight-line'' principle for conversion of the "Wettengel" pug mill to a ''vacuum-extrusion" machine preserved some usable parts of the original equipment, such as the drive mechanism, and main shaft. The converted machine consists of a feed hopper, a compression and shredding zone, a vacuum chamber, and an extrusion barrel, as shown in Fig. I. In operation the clay mix travels from the feed hopper into the compression zone, where it is compressed and finally forced around the tapered cone into the vacuum chamber. As it enters this chamber the clay body is shredded into thin plates, for exFosure to the vacuum. The shredder consists of a hub mounted on the main shaft, to which are bolted segmental sections, each of which carries shredder knives. The compression zone and extrusion barrel function as seals for the vacuum chamber and the shredded clay mix is agitated thoroughly during its exposure to the vacuum. A vacuum pump, equipped with a 3-hp. motor, is attached to this chamber, and maintains 25 to 26 in. vacuum during operation of the mill. Changes in Practice Prior to the adoption of the deaeration process, our standard pottery practice called for double mixing in the combination 7

Jan 1, 1944

By G. W. Jones

One of the major activities of the Bureau of Mines is the promotion of safety in mining and other industries, In this connection, the Bureau determines the explosion hazards' of combustible gases, vapors, and solids and investigates means of controlling and preventing explosions. Many dangers are likely to confront men who must enter a building immediately after it has been damaged. Rescue workers must watch constantly for common gases and vapors that may be present in dangerous concentrations in and about demolished, buildings. Fuel gas is the most common source of danger, although refrigerants, gases from furnaces, flues, fires, sewers, and industrial processes, and gas from bomb, explosions in confined places also constitute definite hazards. To rescuers and trapped casualties, these gases offer the hazards of (1) explosion, (2) toxic effects, including asphyxiation and death, and (3) displacement of air so that the oxygen content of the atmosphere is reduced to or below the danger level.

Jan 1, 1944

By J. R. Long, T. R. Graham

This report is concerned with part of a series of investigations carried on by the Federal Bureau of Mines on alloys, particularly nonferrous alloys, made with electrolytic manganese. A broad general program instituted after commercial quantities of electrolytic manganese became available was necessary in order to compare the effects of electrolytic manganese with those of the ordinary commercial grades. Representative analyses of these two materials show the commercial manganese metal to contain up to 2 per cent iron, a maximum of I per cent silicon and 0.06 per cent carbon, while the electrolytic manganese rarely exceeds 0.01 iron, 0.02 sulphur, with no silicon or aluminum. In the literature, the emphasis has been largely on high-strength casting alloys containing up to 5 per cent manganese, and few data are available on wrought manganese alloys. These factors, coupled with the strategic position of copper and zinc, have given impetus to the Bureau's War Research Program for the development of alloys containing nonstrategic manganese for the purpose of supplementing or providing alternates for the more strategic metals. The alloy reported here was studied, along with several other ferrous and nonferrous alloys, as possible cartridge-case material, and was chosen after a review of the properties of the ternary alloys of copper-manganese-zinc. Preliminary Work In a cursory survey of this system, alloys ranging from 60 to 95 per cent copper, o to 50 per cent manganese, and 5 to 40 per cent zinc were investigated. The alloys containing 60 per cent copper were found to fall into the two-phase alpha plus beta region of the system, and since those containing 70 per cent would not permit a saving, only alloys containing 65 per cent copper were considered. The tensile properties of these 65 per cent alloys are plotted in Fig. I as a function of manganese content for annealed material and for four conditions of cold-work In the annealed condition the increases in strength and decreases in elongation are minor up to 15 per cent manganese; beyond this, the changes become more significant. In the cold-worked condition, the first 5 to 10 per cent of manganese appears to have the greatest strengthening effect, the rate of increase dropping off as the manganese increases beyond this amount. These effects are more pronounced with moderate than with severe cold reduction. It is also interesting to note that while the elongation of annealed material drops regularly with increasing manganese, the elongation in the cold-worked state is relatively little affected by increasing manganese content, particu-

Jan 1, 1944

By J. J. Forbes

The rapid increase in the quantity of coal being mined by stripping methods is one reason for the increased interest evinced by safety and other agencies in the hazards that are inherent in this Method of mining. The coal-mining laws of some States contain general provisions governing the mining of coal by open-cut methods, but none contains a complete list of specific safety regulations or laws for-the safe operation of such mines. The cool-mining laws of one State empower the head of the coal-mining inspection organization to proscribe regulations for coal-stripping operations and gave him the authority and power to enforce the rules and regulations promulgated by him.

Jan 1, 1944

By Sidney A. Swensrud

The 24-in. crude-oil line. and- the 20-in. petroleum-products line, built as a war emergency by the United States Government and running from points in Texas to the New York-New Jersey-Philadelphia area, were constructed only because of the inability during the war to continue nor-inal ocean tanker movements from the Gulf Coast to the East Coast. The postwar disposition of these lines may be considered as one of the important problems of the postwar readjustments in the oil industry, if not the most important one. In the first place there appear to be many complications in keeping the lines in crude-oil or petroleum-products service. This conclusion was reached also in a study by T. E. Swigart, President of Shell Pipeline Corporation.' Since the lines are too largc for any one company to utilize, and since it appears likely that a surplus rather than a deficiency of tankers will exist after the war, most companies probably will feel that they can achieve lower costs and more satisfactoiy results from the resumption of tanker movements to the East Coast rather than by endeavoring to take over or utilize the capacity in the large pipe lines under some tariff-rate structure. As for using the lines for making deliveries to the middle west or central eastern areas, it would appear that when the war is over and normal transportation arrangements can be resumed, there will be no need of any extra capacity for such deliveries. Therefore, the War Emergency lines could be utilized for this purpose only if privately owned pipe lines and other transportation facilities were to be displaced. Against this rather unprepossessing prospect for use in petroleum or product service is the fact that at or near the source of the lines lie the greatest developed gas reserves in the world, for much of which there is at present no satisfactory market outlet; and at the other end of the lines lies one of the greatest concentrations of population in the world, which is not now served by natural gas. These who have been fortunate enough to use natural gas can have little doubt of its desirability as a domestic fuel. An analysis of the market potentialities and comparison with other areas where natural gas is being distributed, and where it has displaced manufactured gas, makes it seem clear beyond question that the full capacity of both of the large-diameter lines could be fully utilized in this service, and this without creating any undue drain upon the gas reserves of the nation. On the basis of an estimated capacity of roo to 120 billion cubic feet per year, the gas that might be marketed through these lines would amount to only 3 to 4 per cent of the total con-

Jan 1, 1944

By R. S. French

The purpose of this paper is to present data that have been obtained during the past two years concerning the effects of prior cold-work and temperature and time of anneal upon the recrystallization and grain growth of 70-30 cartridge brass. It was desirable to study certain of these phases so that an accurate picture of the principles of the subject could be shown. The work is not intended to provide explicit annealing data, but to provide material examples that may help to clarify analogous problems concerning this alloy. Specifications often set limitations upon the grain size of annealed materials because of the importance of grain size upon subsequent manufacturing operations. It was, therefore, worth while to study the variables that affect the recrystallized grain size of this material. C. H. Mathewson and A. Phillips,l W. R, Webster,2 and others have presented annealing characteristic curves of this alloy. A recent typical curve presented by R. S. Pratt3 is shown in Fig. I. The tensile properties and grain sizes are shown as functions of the annealing temperature. Such curves serve as a useful guide in determining the physical properties of annealed material, but as they are made generally under carefully controlled laboratory conditions they do not indicate the performance of metal annealed in a mill muffle, where such conditions as amounts of metal, heating time and temperature may differ. Study of the effect of time and temperature upon grain growth and subscquent recrystallization was made with a coil of metal having the following analysis: 70.04 per cent copper; 0.007 lead; 0.007 iron; 0.00 tin; 0.00 silicon; 0.001 nickel; 0.000 phosphorus; balance zinc. The sample coil was obtained from metal that had been rerolled from hot-rolled mill stock, and was received at 0.228-in. gauge, soft, with a grain size of 0.125 mm. This material was then rolled 43.5 per cent to 0.129-in. gauge and annealed to a 0.053-mm. grain size. In this condition, samples were cut and used in all of the experimental work reported in this paper. Time The first study was of crystal growth at a constant temperature over a moderate length of time. Material was cut from the stock coil at 0.129-in. size and rolled 75 per , cent hard to 0.032-in. gauge. From this piece small samples were cut M by 2 in., suitable for grain-size determina.tions. Twelve samples were placed in an electric furnace uniformly across the width, approximately an inch from the floor. A thermocouple was wired to the center sample, so that the approximate metal temperature could be followed. At various

Jan 1, 1944

By A. M. Gaudin, R. T. Hukki

PREVIOUS work on the principles of comminution has shown: (I) that the surface produced is proportional to work input (Rittinger law, 1a-3); (2) that there is regularity to the weight distribution of the fragments according to size.4-10 In this paper it is brought out that the surface on the fragments is distributed in definite and simple relation to size. The experimental work has involved: I. Construction of an apparatus capable of measuring the surface of mineral fragments independently of the chemical composition of the fragments and independently of the site of the surface; 2. Refining the methods available for measurement of particle size; 3. Designing and building a crusher capable of operating on very small quantities of mineral, if necessary on single crystals, and in such fashion as to minimize handling losses of material. Complete experiments have been carried out with massive quartz and individual quartz crystals. Partial experiments, lacking surface measurements, have been made with glass spheres, galena, sphalerite, fluorite, salt and coal.

Jan 1, 1944

By T. K. Prentice

ABSTRACTED AND REVIEWED BY E. W. DAVIS,* MEMBER A.I.M.E. THE January-February number of the Journal of the Chemical Metallurgical and Mining Society of South Africa is made up entirely of a discussion of Ball Wear in Cylindrical Mills. Following the principal paper by T. K. Prentice are several remarkably pertinent and carefully prepared discussions. Few persons in this country would be likely to see this publication, and since the information presented is new and of current interest, it seems desirable to abstract and review this publication for the benefit of the members of the A.I.M.E. The purpose of the investigation is stated in the first two paragraphs of Prentice's paper, as follows: Early in 1941, The Chamber of Mines Steel Products, Limited, initiated a series of tests under semi-working scale conditions to determine, if possible, those physical and chemical properties of a ball which make it resistant to wear when used in a cylindrical mill as a grinding medium, with the primary object of incorporating those beneficial qualities in the balls being produced at their works. This paper describes the tests carried out and discusses the results obtained. From these results it was possible to formulate a new theory relating to ball wear in cylindrical mills. This theory is presented in the second portion of this paper. PRACTICAL BALL-MILL TESTS IN A CYLINDRICAL MILL Part I of the paper begins with a discussion of the methods used for the manufacture of grinding balls in South Africa. The following paragraph is of particular interest. The cast steel ingots, 4 ¼ - in. square by 3 ft. 6 in. long, are re-heated in a gas-fired sloping stationary-hearth furnace and then rolled in a six-pass continuous mill into 2 5/8 in. round billets. Some of these billets are then removed and cut into suitable lengths for forging into 4 in., 3 ½ in., 3 in. or 2 ½ in. balls by means of three Drop and two Beché hammers, but the greater number, whilst still at about 1,000 ºC., pass directly into a set of scroll rolls which produce, in an ingenious manner, finished 3 in. balls direct from the 2 5/8 in. billets. Except in special cases, all balls are allowed to cool in the atmosphere and are not water quenched. Details of the Tests In order to enable the reader to evaluate properly the results and conclusions in the rest of the paper and in the discussions following the paper, most of the information presented by the author under this heading is quoted: ….. The testing unit was a nominal 30 in. diameter and 18 in. long centre discharge Denver Ball Mill. The ore pulp to the ball mill comprised a small portion of the normal feed to one of the fourteen City Deep 5 ft. 6 in. X 22 ft. tube mills, and the grinding media consisted of the balls under test plus other balls to give the desired load. The running time of the test-mill was divided into approximately equal periods of five days 13 ½ hours each. The usual procedure was to examine and make up the load

Jan 1, 1944

By R. G. Knickerbocker, W. H. Yarroll, P. E. Churchward, J. W. Hunter, J. H. Jacobs

THE present paper records a chapter in the history of the development of an electrolytic manganese industry in the United States.1 A relatively large pilot plant at Boulder City, Nev., for the production of electrolytic manganese was conceived as part of the national defense program to make this country independent of foreign importation of manganese ore. The first authorization, in November 1940, however, was for a plant of only several hundred pounds capacity. Improvements in process and subsequent additions to some sections authorized by subsequent appropriations have enabled the plant to produce as much as 2000 lb. of manganese a day for substantial periods of time. Since in pilot-plant operation frequent changes are made in the flowsheet, the electrolytic manganese plant was constructed so that equipment could be rearranged with a minimum of expense and time. Several different kinds of the various types of equipment were installed for many of the operations, so that the one most suitable for the process might be chosen. Pilot-plant operations were begun in November 1941 and have been continuous except for brief shutdowns for installation of new equipment. More than one-half million pounds of manganese have been produced. The improvements in process, selection of equipment, and operational procedure developed are recorded here. DEVELOPMENT OF THE PROCESS The work of early investigators on the electrolysis of manganese solutions has been reviewed by Shelton.2 Until the method of continuous production of manganese by electrolysis was perfected by Shelton2-4 and coworkers, no practical procedure had been devised. The method as originally developed by the Bureau of Mines will be described here only briefly. The manganese dioxide ore was reduced in a rotating kiln-type furnace at 650°C. in an atmosphere of "city" gas. The calcine was leached with spent electrolyte and enough sulphuric acid to produce a neutral leach solution containing 25 grams manganese per liter as manganese sulphate and 200 grams per liter of ammonium sulphate. Arsenic was removed from the solution by the addition of 0.05 gram iron per liter as ferrous sulphate followed by oxidation

Jan 1, 1944

Jan 1, 1944

By Marie L. V. Gayler

WITHOUT diffusion taking place in liquid metals and alloys, no castings could be made; it is therefore the most important factor affecting the structure of metals. Diffusion involves the interchange of atoms, a process which takes place during the life history of an ingot. In the liquid, atoms are in a state of high thermal agitation, but this thermal vibration is reduced in amplitude with falling temperature. When solidification sets in, the atoms arrange themselves on an ordered space lattice and the changes in structure which take place in the solid are due to the interchange of atoms on this space lattice. The rate of atomic interchange-e.g., of diffusion-is most rapid at temperatures close to the melting point and decelerates as the temperature is lowered. At room temperature, the rate of diffusion is practically negligible in most alloys, and any change in structure can only be brought about by using methods which will accelerate the rate of diffusion. The rate of diffusion depends on three factors (I) temperature; (2) concentration gradient and (3) activation energy. The growth of grains and particles in the solid alloy also depend on these factors and are therefore intimately associated with diffusion. The rate of homogenization in a cast alloy depends on several factors, such as: (I) rate of solidification, which involves grain and particle size which, in their turn, depend on diffusion: (2) the nature of the constituents; (3) the temperature interval between the melting point of the metal or alloy and the temperature at which it is being heat-treated. It is well known that coarse, cast structures are extremely difficult-if possible to homogenize, and the finer the grain size and particle size, the more readily solid solution will take place. The rate of diffusion depends, also, largely on the nature of the constituents; for instance, copper and magnesium form solid solutions with aluminum quite readily but nickel and iron do not; neither do certain intermetallic compounds, such as alpha and beta FeSi. Furthermore, the actual formation of intermetallic compounds may be a very slow process, particularly when they are formed in the solid state as equilibrium products. For example, ßFeSi is formed in the solid as the result of the reaction aFeSi + Al?ß FeSi. The particles of aFeSi become sur¬rounded with a reaction ring of ßßFeSi. This layer is formed as the result of diffusion of atoms taking place between the aluminum matrix and aFeSi. As the amount of ßFeSi surrounding the core of aFeSi increases the concentration gradient becomes low and so the rate of diffusion of atoms also decreases until it practically ceases. This occurs after a comparatively thin layer of ßFeSi has been formed. It follows that when intermetallic compounds of this type are formed in the solid, as the result of diffusion, it is generally impossible ever to attain equilibrium, since the forma-

Jan 1, 1944

By W. T. Isbell, Carleton C. Long

Zinc recovery from lead blast-furnace slags has heretofore been an indirect process, involving, first, the fuming off and collecting of an impure zinc oxide, and second, the reduction of the zinc portion of this oxide to metal either by electrolytic or pyrolytic means. (In a variation of this process, blue powder is the intermediate product rather than zinc oxide fume.) In 1940, W. T. Isbell proposed that molten slag from the lead blast furnace or stock-pile slag melted down in a blast or cupola-type furnace be charged directly into an airtight container (i.e., furnace) provided with means to heat further the slag by passage of electric current and means to introduce the carbon (coke) necessary to reduce the ZnO constituent of the slag to zinc as a zinc vapor and CO. He also proposed that the zinc vapors so obtained be condensed in a Weaton-Najariant internal condenser directly connected to the proposed furnace. It was thought that the Weaton-Najarian condenser could liquefy zinc vapor from lean mixtures of vapor and noncondensable gases. Such condensers have been in commercial use! since 1936 at Josephtown smelter, where the source of zinc vapor is a column of coke and zinc-bearing sinter electrically heated (charge resistor). Condenser output when supplied with vapor-gas mixtures containing approximately 45 per cent zinc and 55 per cent noncondensable gases, varies from 18 to 30 tons of slab zinc per day per condenser, depending upon the heat-transfer area (length) of the condenser and the volume of vapor (furnace size) fed to it. Lead-smelting operations at the St. Joseph Lead Company's plant at Hercu-laneum, Mo., produce a slag containing 12 to 16 per cent zinc. For several years this slag has been stock-piled with the object of recovering the zinc values if and when a commercial method was invented. Evaluation of the possibilities of the proposed method was made by pilot-plant operation at Josephtown. The first plant, designed in 1940 and operated in early 1941, consisted of a single-phase, two-electrode furnace. The evolved vapors were burned. Electrical characteiistics of the molten slag, power requirements, coke requirements, and extent of zinc elimination indicated the feasibility of the proposed method. In the latter part of 1941 a second pilot furnace was constructed, to which "was attached a small (6 ft. long) Weaton-Najarian condenser in order to develop an over-all picture of zinc-in-slag to zinc-in-slabs. This furnace was operated in the early part of 1942 and yielded such promising results that a decision was made to design- and construct a commercial furnace. Feed for the pilot-plant furnaces was granulated slag. A suitable deduction (300 to 350 kw-hr. per ton slag) was calculated in estimating power require-

Jan 1, 1944

By Parke A. Dickey, Robert B. Bossler

The presence of connate water in oil sands is of far greater practical significance in secondary oil-recovery operations than it is in primary operations. The percentage saturations of oil, water, and gas in a depleted field determine whether it will be economically possible to recover oil by secondary methods, and whether water-flooding or gas-driving, or either, will be successful. It is suggested that economic recovery of oil by secondary water-flooding can occur only when a rich bank of oil is formed by the encroachingm water. If the sand has a greater effective permeability to water than it has to oil before flooding, a bank will not be formed, and water-flooding will not be successful, although gas-driving may be. Published results of laboratory work indicate that the effective permeability of a sand to oil and water depends primarily on the saturation of the sand by these phases. They also indicate that a small difference in relative saturation produces a large difference in effective permeability to the phase in question. There thus exists a critical range of saturations, wherein a small change in oil and water content of the sands will make water-flooding possible or impossible. In gas-drive operations the water saturation is less critical but no less important. The presence of connate water in a sand increases the proportion of the residual oil that may be recovered by gas drive. Sands containing oil saturations too low and water saturations too high to make water-flooding possible can often be subjected to gas drive with economic recovery of oil. The results of laboratory work on test samples that do not contain water cannot be applied to normal field operations. More tests on cores containing water as well as oil are desirable, and the improvement of coring technique is necessary. However, sufficient data are already available to enable an operator to use core data intelligently in estimating the chances of a secondary oil-recovery program. Introduction In recent years laboratory work has led to a much better understanding of the principles of oil-reservoir performance. The general principles of the expulsion of oil from sandstone by gas or water were developed by geologists of the Second Geological Survey of Pennsylvania in the 1870lsl but only recently has the mechanism of gas or water drive been intensively investigated. Most published articles have large the facts established in the labora tory to the primary production of oil from flush fields- This Paper is not based on any new observations, but is an attempt to apply some of the conclusions obtained in the laboratory and described in the literature to the recovery of oil from depleted pools by secondary methods. One of the most important factors that determine whether or not a secondary-recovery operation is economically successful is the ratio of injected fluid to oil recovered. This ratio may be expressed as the over-all or cumulative gas-oil ratio if gas is the driving medium, or water-oil ratio if water is the driving medium. Recent theoretical and experimental work has shown that the relative amounts of

Jan 1, 1944

By H. M. Kraner, E. B. Snyder

This paper shows that volume stability, low porosity and decreased pyroplasticity are desirable for blast-furnace linings, partitularly for the hearth. It shows further that a hot load test is a valuable means of testing the fusion or softening behavior of a refractory at operating temperatures. The effect of carbon monoxide on commercia1 blast-furnace refractories in their as-received condition and after refiring is reported, showing that many commercial blast-furnace refractories disintegrate badly but that refiring decreases the effect and certain special refractories are now available which are almost free of the tendency. Factors Affecting Choice of ._ Refractories If one were to depend entirely upon experience or trial in the selection of clay refractories, the solution of a problem would be a slow process. Furnace campaigns are so long and attended by so many variables that it is difficult to draw fine distinctions within a reasonable period of time in regard to the quality of refractories used. It could be said, of course, that if service results do not yield the proper information for intelligent choice, there is no difference in the quality of brick being considered, but this is not necessarily true. Conventional ceramic tests are designed to give the ceramic engineer information as to the refractoriness and firing tempera- . ture, which he in turn internrets in terms of volume stability, ability to withstand load at high temperature (pyroplasticity), permeability, chemical stability and re-. sistance to the action of slag. In most refractory applications . several of these factors are involved. In a particular instance, one requirement may be predominant, while in others some other factors may be of primary importance. In this country, clay refractories are generally made from mixtures of plastic and flint fire clays. The process of firing a clay refractory is one of slowly melting the constituents, and during this operation its porosity is gradually reduced. The process is arrested, of course, in its incipient Stages and the Progress is determined by measuring slight changes in porosity, volume, bulk gravity, etc., that have taken place. Often the temperatures to which clay refractories are exposed in service are higher than those employed in their firing. However, if the manufacturer were to fire them at such high temperatures the brick would distort. Therefore it would be difficult for the manufacturer to fire all of his clay refractories to temperatures at which they are to be used, although in many cases it would be desirable from the user's point of view if he would do so. The porosity of clay refractories decreases by firing, to a minimum limit, after which a further increase in the temperature causes expansion in certain clay constituents and bloating in others. Both may occur in the same refractory containing two such clays.

Jan 1, 1944

By T. E. Eagan, W. R. McCrackin

IN dealing with segregation in babbitt, and its effect on the final cast structure, which is a bearing, it is obviously impossible to cover all of the compositions manufactured. Each composition, of course, will exhibit certain specific types of segregation. However, as examples,, two compositions of babbitt are presented: one a tin-base of well-known analysis and the other a lead-base, which in the past few years has found wide usage. Bearings usually are cast either statically or centrifugally; therefore the effect of these two methods on segregation is presented. EXPERIMENTAL PROCEDURE A slab of babbitt 1/2 in. thick by 5 in. wide and 17 in. long was cast, using a book mold with the long edge vertical. An A.S.T.M. grade 2 babbitt was used (3.5 per cent copper, 7.5 per cent antimony, remainder tin), to which 0.10 per cent tellurium had been added. Unfortunately, no metal without tellurium was available. The mold to hold the babbitt was heated to approximately 300°F., the temperature being judged by the babbitter. The pouring temperature of the babbitt was 875°F. (470°C.). One slab was made by allowing the babbitt to cool without stirring. The other slab was stirred during the entire cooling cycle. This stirring consisted of a vigorous churning or puddling into the mold until complete solidification had taken place. Three samples were removed from these slabs. One was taken at the extreme bottom, another half way to the top, and another at the extreme top, all at the center of the width. Chemical, macroscopic and microscopic examination was made of all samples. Table I shows the chemical analyses obtained at the described positions [ ] in the slab. The analyses show no serious amount of gravity segregation. Microscopic examination from edge to edge of the slab showed little change in structure. From top to bottom there was a progressive coarsening of the grain size in the stirred slab but little change in the slab that was not stirred (Fig. I). No definite exhibit of segregation could be detected. In line with our experimental study on the tin-base babbitts, we cast an almost duplicate slab using A.S.T.M. Alloy No. 15, containing 0.9 to 1.25 per cent tin, 14.75 to 15.5. per cent antimony, 0.80 to 1.25 per cent arsenic and 0.4 per cent copper. The slab was 16 in. long and 3/8 in. thick, cast with the long side vertical. One slab was allowed to cool normally and the other was stirred continually during cooling. The pouring temperature of the babbitt was

Jan 1, 1944