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By C. F. Willis

The time is no longer when a man can act as an independent unit; the appreciation of the interdependence of one man upon another has emphasized the importance of the social unit. Epidemics have made us recognize that even a man's health is not distinctly his own to control as he pleases. The physical examination of workmen previous to employment started with an effort to prevent the spread of tuberculosis, for tuberculosis may be detected in its early stages and cured. But it was soon found that many other diseases were detected and the saving of lives made possible. The physical examination does not mean the elimination of the unfit—on that basis it would utterly fail—but rather the measuring of a man's physical fitness and placing the man where he can do the best for himself, his fellow worker, and the company. Industry as a whole cannot expect to live up to the standard of physical examination set for the army, nor should it expect to do so, for in all branches of industry there are types of work that do not require the same amount of endurance as does army work, and the lacing of men with physical limitations in the work for which they are capable permits a higher average of physical fitness for the work requiring physical excellence. Objects of Physical Examination The objects of physical examination are: The early detection of illness, particularly at a time when a full restoration of health is possible; the protection of employees from infection caused by working in contact with contagious diseases; the discovery of a man's physical limitations, in so far as his possibility for rendering good service is concerned; assistance to the safety movement by eliminating association in hazardous occupations with men whose physical condition renders them likely to accident to themselves and others; and the lessening of time lost by sickness. Statistics issued by the United States Department of Labor show that 22.54 per cent. of idleness is caused by sickness, with an average number of 7.71 weeks idle; whereas only 1.66 per cent. is caused by acci-

Jan 1, 1920

By J. C. Trantham, J. W. Marx

From 1955 to 1958 the Phillips Petroleum Co. conducted a series of small scale counterflow combustion field tests in a tar sand about 60-ft deep and 6 to 12-ft thick near Bellamy, Mo. A total of seven different well patterns, including conventional five-spots and seven-spots plus a 15-well line drive pattern and a 10-well radial pattern, were employed. Electric heaters, gas burners and wellbore fuel packs were tested as counterflow ignition devices. Direct drive ignition followed by reversal to counterflow operation was not possible in this case because of formation plugging by the semi-solid tar during the direct drive phase. Sustained counterflow burning was achieved with wellbore fuel packs under conirolled conditions which permitted close correlation of fire front velocity, air velocity, air-oil ratios and yields for a wide variation in process parameters. The tar in place was about 10' APl with a reservoir viscosity greater than 500,000 cp. The composite oil prodlcct was 26' API with a viscosity in the range of 5 to 15 cp. Vertical sweep efficiency in the line drive pattern was essentially 100 per cent, with no evidence of gravity segregation. Original tar in place ranged between 800 and 1,000 bbllacre-ft, specific rock permeability averaged about 800 md before burning and effective air pemeability with residual oil and water in place (at the time of ignition) averaged 250 md. The volume of oil recovered during stabilized line drive counterflow burning represented about 67 per cent of the volume of tar originally in place in the burned out zones. A minimum was found when air-oil ratios were plotted against formation air velocities, and a limiting air velocity existed below which the counterflow fire front reversed and burned back over its own trajectory, using the residual coke left behind. INTRODUCTION Early in 1955 the Phillips Petroleum Co. began preparations to field test counterflow underground combustion as a method for producing oil from high viscosity hydrocarbon deposits, such as bituminous (tar) sands. At that time all published information on the use of underground burning io increase oil recovery was based on the direct drive process, in which the fire front moved through the formatim in the same direction as the injected air stream. Such direct burning is not applicable to many heavy oil sands or to most tar sands because the heat-thinned native hydrocarbon congeals in the cold rock ahead of the fire front forming a gas permeability block which smothers the combustion. Laboratory experiments first demonstrated that this permeability blocking would not occur if the fire front and the air stream moved in opposite directions. In this counterflow (reverse) burning process the heated heavy oil or tar is driven back through the combustion zone. Here thermal cracking produces relatively light hydrocarbon products which pass through the heated rock behind the fire front (largely in the vapor phase) and are incapable of causing a gas permeability block.' Exploratory wring revealed that consolidated bituminous sandstones with a combination of tar saturation, permeability, thickness and depth favorable for experimental field testing existed at several points in western Missouri. By the fall of 1955, a test site for determining technical feasibility of the counterflow process under field conditions had been selected near Bellamy, Vernon County, Mo. — about fifty miles north of Joplin. The pay zone was too thin and too shallow to constitute a commercial prospect, but these same factors permitted controlled experimental operation with a small compressor installation and with a large number of monitor wells. These were needed for adequate observation of the underground phenomena at reasonable cost. RESERVOIR CHARACTERISTICS The reservoir chosen for the experimental field tests was a 124 thick section of tar sand extending from 49 to 61 ft subsurface, with shale and siltstone laminations sealing the top and bottom. This section was part of a larger 30-ft thick tar sand deposit which extended both above and below the test zone. Core analyses showed that the 12-ft sand was effectively subdivided into two approximately equal sections, with the lower zone being consistently more permeable than the upper zone. The most significant laboratory core data are summarized in Table 1. The line drive test which is the principal subject of this report utilized only the lower 6-ft thick zone, with the upper zone regarded as part of the 55-ft overburden. WELL PATTERNS The over-all field test program involved a total of seven different well patterns, including conventional five-spots and seven-spots plus a 15-well line drive pattern and a 10-well radial pattern. In some of the tests the full 12-ft zone was employed; in other cases only the more perme-

Jan 1, 1967

By AIME AIME

IN RESPONSE to a request from the president- elect of the Institution of Civil Engineers of Great Britain, Mr. Calvin W. Rice, secretary of the American Society of Mechanical Engineers, prepared a brief history of the joint activities of engineering societies in the United States, from which we have taken the following facts. National Societies Our first joint activities were in collection with the celebration of the eightieth birthday of "Uncle John" Fritz in 1902, and it is of interest to note that two of the members of the original celebration committee, Messrk. . Ambrose Swasey and Jesse Merrick Smith, will be members of the official deputation to England in June. Mr. Rice, also,' was .a member, of the original committee.

Jan 1, 1921

By JAMES SCULLY

For the last 4 years political leaders have found a new subject on which they can safely generalize wihout creating opposition. That subject is commodity prices. Since the four-fold increase in OPEC crude oil prices, public attention has focussed as never before on the subject of commodity prices. To advocate stabilizing commodity prices is akin to supporting motherhood or peace or better schooling. Everyone gives lip service to the concept that stable commodity prices are desirable. It is easier to state the principle than to achieve it. Prices that are stable in terms of one currency may be clearly unstable in terms of a different currency. This has become a troublesome matter since 1971, when the world's leading trading currencies were set free to float in relation to each other. To illustrate: consider copper prices in the interval between the end of 1974 and the end of 1977. During those 3 years, the copper price in pounds sterling on the London Metal Exchange rose by 25 per cent. During that period, however, in terms of the USA dollar equivalent, the price was unchanged. And during that period, in terms of the German mark equivalent the price shrank by 13 per cent while the Japanese yen equivalent fell by 20 per cent. Thus a price that appears stable in dollars, rose in terms of pounds sterling and fell in terms of marks and yen. Had this result been achieved as a consequence of an international effort to stabilize prices, an American would have said the effort was successful. An Englishman would have said it had failed to prevent a price rise. And a German or a Japanese consumer would have been happy to have covered his copper needs at a lower cost in terms of his own currency.

Jan 1, 1978

By F. L. Toy, C. E. Sims

I. A. Sirel—I would like to ask Mr. Sims what would the preferred hot metal analysis be as far as manganese and silicon are concerned if you used specially made iron for this process instead of basic iron. C. E. Sims (authors' reply)—A preferred composition would contain somewhat less silicon than the basic pig iron used in these experiments. High silicon requires a large lime addition. Lime must be added in sufficient quantity to neutralize the silica formed and to leave an excess for dephosphorization. Manganese presents almost no problem in operation. It is almost completely oxidized and, in burning, develops considerable heat. The evidence indicates, however, that, in continuous commercial operation, there will be an excess of heat produced, and the bath will need to be cooled in some manner as by the addition of scrap or by utilizing the energy for the direct reduction of ore. There do not seem to be any serious limitations on composition of pig iron. One heat was made with an iron containing 2.27 pct silicon and the phosphorus finished at 0.007 pct. In another, the iron contained 0.45 pct phosphorus which was lowered to 0.019 pct. This indicates considerable leeway in composition. D. R. Loughrey—We are all very much interested in the recent discovery of very large deposits of iron ore both in Labrador and in Venezuela. I would like to ask Mr. Sims if the iron ore at either or both of these places is such that it would lend itself to the manufacture of iron suitable for use in the turbohearth. C. E. Sims-—According to my information, those ores are not essentially different from ores now used in this country for making basic pig. They should, therefore, be adaptable to this process. D. I. Brown—You have spoken about the leeway, or spread in analysis of the various irons you can use in the vessel. I would like to have you tell us, if you can, about the different kinds of steels which can be made in such a vessel. The turbohearth process, or it might more aptly be called pneumatic openhearth, is a little different from that used in most Bessemer shops and in the one in which I worked. If we had a blow in the air over 10 min, the boss was in the pulpit in a hurry

Jan 1, 1951

By Dick Whittington, W. R. Taylor

GENERAL In mid-1974, a representative of ARCO Petroleum Company walked into our Austin offices and asked for a permit for ARCO's first Clay West Mine site. This was the first in situ uranium mining permit issued in the United States. That initial permit, issued in January 1975, was for three acres. The four years since have been characterized by growth and change. Today there are 16 permits approved for approximately 1,540 production acres issued to five companies at eight sites in four counties. There are approximately seven additional permit applications being processed or on the verge of being submitted for an estimated 2,000 additional acres of production. As a rough gauge of the financial scope of this activity, at the typical 40 production wells per acre and an estimated $2,000/well, operators hale installed or committed $122 million for production wells. This does not account for the exploration and development wells installed to delineate the ore or the cost of processing facilities for extracting the uranium. HISTORY OF URANIUM MINING IN TEXAS Information I have concerning early in situ uranium mining activities is "sketchy" but the apparent first on-site test of in situ uranium mining was conducted between 1967 and 1971 at the Dueterstat site, north of Yorktown in Gonzales County, by City Service. Others ran tests at the Bruni site in Webb County and the Burns and Clay West sites in Live Oak County in the mid-70's. During this period, Texas Water Quality Board personnel in the central and district offices maintained a general surveillance of these various test activities. Regulation of in situ uranium mining was formalized with the issuance of a permit in January 1975 with the advent of ARCO's initial production scale (3 acre) effort in the Clay West area at the Moser mine site. Since 1975, the accelerating rate of mining and exploration activity is noticeable. There were 16 exploratory rigs operating early in 1977. This year, the rig count is averaging 46--a 287% increase. HISTORY OF LEGISLATION Paralleling this mining activity was state and federal legislation which subjected in situ mining to environmental regulation. The following is a brief chronology of the legislation that is directly or indirectly related to uranium mining. As most of you know, disposal wells are an integral part of most in situ uranium mines operating in Texas. They are used both during production and during aquifer restoration following production. The wells are regulated by the Texas Injection Well Act, enacted in 1961 by the Texas Legislature. In 1967, the Water Quality Act established the Texas Water Quality Board, and provided for the regulation of water quality by the so-called permit system. In 1969, the Solid Waste Act was enacted by the Texas Legislature. The legislation provides for control of wastes from manufacturing, mining, and agriculture. This Act regulated uranium surface mining activities until 1975 when the Texas Surface and Mining Reclamation Act placed responsibility with the Railroad Commission for uranium open-pit mining and surface mining of coal and lignite. In 1972, the Federal Water Pollution Control Act (Public Law 92-500) was passed. This legislation forms the legal base for the NPDES (National Pollutant Discharge Elimination System) and the subsequent point source effluent guidelines and standards. The November 6, 1975 issue of the Federal Register published interim final rules for Best Practical Treatment levels for effluent discharges from ore mining and dressing operations. Litigation was immediately initiated by eleven companies against these proposed rules, and they are currently being reconsidered for reissuance in 1979. In 1974, the Federal Safe Drinking Water Act (Public Law 93-523) was enacted. A part of this legislation is the Underground Injection Congrol Program. The regulations implementing this program have undergone various public hearings and it is expected that they will be published in the Federal Register before the end of 1978. In 1975, the Texas Surface Mining and Reclamation Act (Senate Bill 55), providing for the Railroad Commission's authority to require reclamation of surface mines, was passed. In 1977, an amendment to Senate Bill 55 was introduced that proposed to place regulation of in situ mining of coal, lignite, and

Jan 1, 1979

By Lewis M. Haupt

IT has given me great pleasure to read, in the papers recently published by this Society, the discussions on the subject of Technical Education, which were developed at the joint meeting held at the Franklin Institute in June, 1876; and since it was impossible for me to be present, I desire to improve this my first opportunity of adding the weight of my testimony and experience to what has been so ably presented by others. It is a subject about which the people need to be kept agitated, that their views may expand with the demands made for a higher and more thorough education. It is the public at large, the capitalist, the manufacturer, and the laborer, who are to be benefited more or less by this elevation of the standard of our professional schools, and it is but just, therefore, that the schools should look to them for the means with which to accomplish so desirable an object. It is no doubt to the interest of a metallurgist to employ a skilled laborer who will prevent waste by properly proportioning his materials ; by regulating the supplies of air and fuel ; by arranging his plant in the most economical manner, and by disposing of his products to the greatest advantage. The engineer is benefited by selecting for an assistant a person able to determine the values of his factors of safety for the same materials in different forms and positions, avoiding expensive suits for damages and cost of reconstruction; he should be able to so locate a road as best to fulfil the requirements of a through traffic, and yet develop local industries. But I need not multiply instances to show what all will readily concede, viz.: the advantages of a theoretical education ; that was fully demonstrated at the previous special meeting, but it is still an open question whether the practical instruction should precede, accompany, or follow the theory.

Jan 1, 1877

By W. C. Lilliendahl, H. W. Highriter

The method developed and used in this laboratory for the production of metallic uranium of such purity that it is ductile and can be cold-worked to fine wire or thin sheet by rolling has already been described1. It consists, briefly, in the electrolysis of potassium uranous fluoride (KUF5) in a molten bath composed of equal parts of sodium and calcium chlorides. The bath is contained in a graphite crucible, electrically heated to about 775° C., the crucible serving as the anode for electrolysis. The uranium deposits in finely divided form mixed with salts upon a molybdenum cathode suspended axially in the crucible. Upon completion of the electrolysis the cathode is removed and cooled, the deposit broken and leached to remove salts. The metal powder is washed with water and dilute acetic acid and dried in vacuo to reduce oxidation. Suitable amounts are then prcssed into pellets and heated in vacuo by high-frequency induction, using a thoria crucible. The uranium melts and flows away from the pellet, leaving a shell, which is largely oxide. In general, this method produced a satisfactory metal, although at times tile uranium was not ductile. The investigations recorded here were made to find the cause of this embrittlement. It was known that the metal generally contained carbon, derived from disintegration of the graphitc crucible in which electrolysis is conducted, in amounts dependent upon the thoroughness of washing the metal powder. Accordingly, analyses of several samples, both ductile and brittle, were made by combustion and absorption of CO² in Ascarite, using air instead of oxygen to reduce the temperaturc and rate of oxidation. Several of these metals were made with special precautions to reduce carbon content. The results show no relationship between ductility and carbon content in the range investigated (Table 1). Microscopic examination of ductile and brittle metals disclosed the presence in the latter of an intergranular constituent, harder than the matrix and less easily oxidizable, which was absent from the ductile material. Rough estimates of the volume of the hard constituent

Jan 1, 1935

By W. C. Lilliendahl, H. W. Highriter

The method developed and used in this laboratory for the production of metallic uranium of such purity that it is ductile and can be cold-worked to fine wire or thin sheet by rolling has already been described1. It consists, briefly, in the electrolysis of potassium uranous fluoride (KUF5) in a molten bath composed of equal parts of sodium and calcium chlorides. The bath is contained in a graphite crucible, electrically heated to about 775° C., the crucible serving as the anode for electrolysis. The uranium deposits in finely divided form mixed with salts upon a molybdenum cathode suspended axially in the crucible. Upon completion of the electrolysis the cathode is removed and cooled, the deposit broken and leached to remove salts. The metal powder is washed with water and dilute acetic acid and dried in vacuo to reduce oxidation. Suitable amounts are then prcssed into pellets and heated in vacuo by high-frequency induction, using a thoria crucible. The uranium melts and flows away from the pellet, leaving a shell, which is largely oxide. In general, this method produced a satisfactory metal, although at times tile uranium was not ductile. The investigations recorded here were made to find the cause of this embrittlement. It was known that the metal generally contained carbon, derived from disintegration of the graphitc crucible in which electrolysis is conducted, in amounts dependent upon the thoroughness of washing the metal powder. Accordingly, analyses of several samples, both ductile and brittle, were made by combustion and absorption of CO² in Ascarite, using air instead of oxygen to reduce the temperaturc and rate of oxidation. Several of these metals were made with special precautions to reduce carbon content. The results show no relationship between ductility and carbon content in the range investigated (Table 1). Microscopic examination of ductile and brittle metals disclosed the presence in the latter of an intergranular constituent, harder than the matrix and less easily oxidizable, which was absent from the ductile material. Rough estimates of the volume of the hard constituent

Jan 1, 1935

By G. E. Johnson

E. D. HYMAN*—How much sorting of scrap is done ? G. E. JOHNSON (author's reply)—We do practically no sorting. We charge "run of mine" scrap to the furnace. The unmeltables, mostly iron, are in such demand today that there is no difficulty in disposing of them. It may soon be desirable to sort out from the unmeltables as much of the brass as possible. J. J. BRUGMAN†—We have somewhat similar problems in the secondary aluminum business. What is your method of removing the unmelted material from the furnaces? Why have you such an apparently small space in which to charge your materials? Do you find that you have to seal that opening, or can you have it open and continuously charge at one end and pull out the other ? G. E. JOHNSON—Our means of melting scrap is efficient only to the extent that we use the waste heat from the vaporizing chamber to do the job. It is a batch process. We open the charge door and place the scrap on the hearth by hand shoveling. The door is then closed during the melting down period. After the melting is complete, the opposite door is opened and the unmeltables are raked out. The doors are approximately 3½ X 4½ ft and are not sealed during the process only closed. They are nominally tight. Some metal is oxidized in the process. We have visualized a means of conveying the materials through this melting unit with the metals that are melted trickling out during its travel. T. H. WELDON‡—Mr. Johnson, in line with the last question, is it necessary to seal the furnace between the melting down and the vaporizing unit, or have you got an inverted syphon in the bottom of the chamber? G. E. JOHNSON—That was one of the first things we encountered. We had to have a sealed opening, and it is a molten metal seal. You have indirectly asked me another question, which was: "Do you have to seal up the melting unit?" I would say we should exclude as much air as possible, although we are not too efficient in doing that. We allow the melting unit doors to be open when we charge and when we remove unmeltables. You can readily see that that would lead to the idea of having a controlled atmosphere in the melting unit, and I think this would do a more efficient job of melting the scrap. T. H. WELDON—How often do you charge the furnace? G. E. JOHNSON—We charge the melting unit, and rake out the unmeltables, about every hour. H. R. HANLEY*—Are any provisions made for controlling the rate of oxidation for the production of various size particles for certain characteristics of the zinc oxide product? G. E. JOHNSON—Yes, there are many. You are getting pretty much into the fine points of zinc oxide manufacture. Some of us still think we have something to learn about that. In general, this muffle furnace as I have described it to you produces a rounded particle of zinc oxide which is generally formed by a rapid oxidation of the zinc vapor, followed by rapid cooling. We have gone to the other extreme in some of our experiments. We have changed the furnace to produce a type of zinc oxide, such as we thought was peculiar to American process zinc oxide, by controlling the temperature at the point of oxidation and maintaining that temperature for a much longer period of time than we do when we make the rounded shape. There are other relationships that this furnace readily provides. One of the important factors is the ratio of air to zinc vapors. We can vary that by varying the air supply to the baghouse, or vary the rate at which we are vaporizing the zinc by the simple expedient of regulating the temperature over the carborundum arch. We have a number of variables that permit us to produce all of the grades of French process zinc oxide from lead-free up through the highest grades of seal oxides. There are many controls that we can apply to the operation. What I have said is but a brief condensation. K. MORGAN*—Can Mr. Johnson give us some idea of the fuel consumption of the furnace ? How much oil does he use per ton of zinc distilled? I am also interested to know what sort of heat transmission he gets through the arch? What is the thickness of the tiles used to construct the arch? Some time ago we built a small furnace for a different purpose, using a carborundum arch, and we found that the reflectivity of the molten zinc surface was so great we had to use a very high arch temperature. We found we made an improvement by having a layer of carbon on the surface of the zinc. Has Mr. Johnson had any experience on these points ? Does he make any sort of insolu-bles which he leaves in the furnace which he cannot tap out ? G. E. JOHNSON—I believe your first question was the fuel consumption. If I recall, somewhere in this paper there is a test that I quote. I believe we used 800 gal in a given period of time. Offhand I cannot translate that into tons of metal. I might also state that we have this understanding; that the carborundum arch, as the temperature becomes higher, becomes more efficient in heat transmission. As a matter of fact, I believe it is at about 2600°F or higher that the highest efficiency of heat transmission becomes available. We have calculations that I cannot quote from memory which indicate that the carborundum arch does a really very fine job for this type of furnace. Another point that we had considered was the fact that this furnace could be readily constructed so as to furnish an ideal source of heat for waste heat boilers. If a carborundum arch was used over the melting unit, we would have no zinc vapors in the gases at all— just clean combustion gases from which we would have removed some of the heat. L. P. DAVIDSON†— The insolubles

Jan 1, 1950

By O. J. C. Runnalls, L. M. Pidgeon

Some observations on the kinetics of the iodide process are reported. The deposition rate is geometry-sensitive in a system containing a finely divided titanium charge. Further, results indicate that the iodine diffusion rate influences the velocity of the process. The nonvolatile iodide, Til,, forms in the hot filament zone, thus removing iodine from the cycle. TITANIUM metal of 99.9 pct purity may be prepared using a refining technique originated by Van Arkel and de Boer.' The purity of this metal, commonly called iodide titanium, exceeds that produced by any known process. In a recent application, the method was employed by Gonser et al.² to prepare titanium rods up to 2 to 3 cm in diam. In the Van Arkel-de Boer system, the relative influence of the fundamental mechanisms: l—production of titanium iodides, 2—gaseous countercurrent diffusion, and 3—decomposition, on the deposition rate have not been clearly established. Blocher and Campbell" have indicated that the controlling step in the process under practical conditions of operation may be the reaction rate of iodine with the crude metal. Fast' reported that crude titanium metal reacted with iodine rapidly, even at room temperature, in his apparatus. Little has been reported on the effect of gaseous diffusion or decomposition on the deposition rate. It is these aspects of the process about which this investigation is centered. An attempt has been made to separate these latter effects from those due to the formation of the iodides at the crude metal surface by a division of the experimental program. Reaction of Iodine with Titanium Apparatus: In the investigation of gas-metal reactions of this type, the chemical reactivity of the halogen and halide vapors dictates the use of all-glass apparatus. In such a system standard techniques for measuring reaction rates are difficult to employ. Here, a simple apparatus was devised (Fig. 1) so that some indication of the reactivity of titanium powder with iodine vapor could be obtained. A stream of iodine gas was evolved from a bulb of controlled temperature and passed over a sample of titanium powder heated in a horizontal tube furnace. The product of the reaction, TiI4, volatilized and was condensed outside the furnace in a series of four glass bulbs, each cooled to room temperature in turn. Preliminary experiments indicated that distillation was retarded in a sealed evacuated system due to a pressure build-up in the condensing end of the apparatus. Hence, the system was pumped continuously using a mechanical pump and two oil diffusion pumps in series, through a liquid air trap. The iodine bulb was made large and a capillary restriction was inserted between the titanium bulb and the condensers so that the iodine pressure over the metal would approach the equilibrium pressure over solid iodine crystals. The effect of this restriction on the evaporation rate of TiI4, was determined separately. The iodine bulb was heated in an oil bath controlled to ±2°C. The titanium bulb temperature was automatically controlled to ±5°C. Procedure: About 200 mg of —30 mesh titanium powder, weighed to 0.1 mg, was placed in the reaction bulb after part B had been joined to part A. The powder was tapped into a long (5 cm) shallow mass along the bottom of the tube. Two chromel-alumel thermocouples were inserted into the magnesium radiator which was clamped to the reaction

Jan 1, 1953

By C. E. Sims, F. W. Boulger, H. A. Saller

Most of the data on equilibrium constant and the deoxidations potentialities of those elements, considered to be stronger deoxidizers for steel than is silicon, have been calculated from thermodynamic data. The reason for this is, primarily, the obvious difficulty of obtaining direct experimental evidence of equivalent accuracy. This is an excellent use of the principles of thermodynamics and has given valuable data not otherwise available. Such results, of course, can be no more accurate than the physical constants used in the calculations, and one can never be sure that the basic data are either complete or accurate. In fact, as in the case with silicon,1 there are not only discrepancies among the calculated theoretical values of the equilibrium constant for deoxidation of steel but also between the theoretical and experimental values. It is highly desirable, therefore, to obtain experimental values for checks on calculated results whenever possible. If they disagree, both cannot be right, but if there is good agreement, their value is enhanced. The present work was done in an effort to obtain experimental evidence in regard to some of the common alloying additions but more particularly the so-called "strong" deoxidizers for steel. The method used was to determine the minimum concentration of the deoxidizer that would effect a certain definite degree of deoxidation in steel. The criterion of deoxidation was the change from the large globular Type I sulphide to the eutectic Type II as described by Sims and Dahle.2 This change is sharp and definite, and inasmuch as it can be produced with equal facility by aluminum, zirconium, and titanium, it is considered a manifestation of a certain degree of deoxidation and not an alloying effect. Ostensibly such a procedure could give only a comparison of deoxidizing powers and no absolute values. Nevertheless, repeated observations have shown that, when increasing increments of aluminum are added to a steel, the residual aluminum content begins to increase simultaneously with the appearance of Type II inclusions. Thus it seems warranted to postulate that the Type II inclusions appear coincident with the virtual elimination of FeO as an active constituent of the steel. Experimental Procedure The data obtained were primarily from the microexamination of polished and unetched specimens and from chemical analysis. Experimental heats weighing 200 to 250 lb were made in a basic-lined high-frequency induction furnace. The base composition was nominally that of a medium-carbon casting steel to which the appropriate additions were made. Specimens were poured into sand-cast ingots 3 in. in diam as shown in Fig 1. Sand-cast ingots were used to prevent chilling and to allow sufficient time in freezing for normal inclusions to form of a size large enough to be studied readily. In the first few heats, the tapered wall ingot was used, but in the majority, the extra large riser was used to prevent piping in heavily deoxidized steels. Specimens for microexamination were taken from the location shown in Fig 1, and drillings for chemical analysis were taken from a similar location. The procedure was to melt the base composition and deoxidize with the usual manganese and silicon additions and then to pour an ingot. The furnace was then tilted back, and the first increment of strong deoxidizer or special alloy was added and allowed to disseminate through the melt, with enough power on to hold the temperature constant, for 45 sec. Then a second ingot was poured. After this, another increment was added, and after the same holding time another ingot was poured. In this way from 9 to 12 ingots were poured from each heat, each successive ingot having progressively larger total additions of alloy. Eighteen heats were made altogether, and the range of alloys used and additions made are outlined in Table 1. The three principal types of sulphide inclusions found are illustrated in Fig 2. The globular Type I sulphides are characteristic of silicon-killed steels, the eutectic Type II are characteristic of steels deoxidized with a small amount of aluminum, while the larger, angular Type III are usually found in steels with a residual aluminum content above about 0.02 pct. In all specimens studied, the transition from Type I to II either did not occur at all or was very abrupt and clear cut. There never was any doubt as to just which increment produced the change, although the individual additions were small, in the order of 0.01 pct. The change from Type II to Type III was considerably less sharp, and, in some cases, both types were found together. Inasmuch as the formation of Type III sulphides is apparently not a deoxidation phenomenon, they will not be discussed here.

Jan 1, 1950

By William P. Shinn

Jan 1, 1881

By H. R. Hanley, Charles Y. Clayton

One of the most important contributions to the art of electrolytic zinc production has been the aluminum cathode. This has been used in all major production since its commercial development in 1916. The literature is replete with important contributions, some of which may have been replaced by better ones, but thus far there appears no other metal to take the place of aluminum as cathode material. Credit for this innovation goes to Sherard Cowper Coles, of England. When experimenting on the extraction of zinc from Broken Hill ore at Hayle, Cornwall, in 1893, he introduced the aluminum cathode, and in 1895 obtained British Patent No. 20073. The reason for this dominant position of aluminum as cathode material in zinc sulphate electrolytes is its unique surface, to which electro-deposited metals usually do not tightly adhere. The metal must, be of high purity for best results. It is possible to develop a starting-sheet method by which thin electro-deposited sheets of cathode zinc are made and stripped from a smooth aluminum plate. Such thin sheets of cathode zinc may be used as are the copper sheets in standard electrolytic copper-refinery practice. However, complications arise because of extreme warping of the zinc starting sheet after a few hours of deposition, and thus special arrangements must be made to compensate for this abnormality. Reasons advanced for the ease with which deposits may be stripped from the aluminum surface are: (1) presence of a permanent oxide coating on the metal, (2) failure of aluminum to alloy with the deposit, (3) differences in coefficient of expansion, (4) high position of aluminum in the electromotive scries of metals. Of these reasons for nonadherence, which may have some application in general deposition, probably the oxide coating has the greatest bearing on the subject of zinc deposition. Adherence of zinc deposits has occasionally had serious effect on tonnage and production costs. Opinions have differed as to the specific

Jan 1, 1943

By H. R. Hanley, Charles Y. Clayton

One of the most important contributions to the art of electrolytic zinc production has been the aluminum cathode. This has been used in all major production since its commercial development in 1916. The literature is replete with important contributions, some of which may have been replaced by better ones, but thus far there appears no other metal to take the place of aluminum as cathode material. Credit for this innovation goes to Sherard Cowper Coles, of England. When experimenting on the extraction of zinc from Broken Hill ore at Hayle, Cornwall, in 1893, he introduced the aluminum cathode, and in 1895 obtained British Patent No. 20073. The reason for this dominant position of aluminum as cathode material in zinc sulphate electrolytes is its unique surface, to which electro-deposited metals usually do not tightly adhere. The metal must, be of high purity for best results. It is possible to develop a starting-sheet method by which thin electro-deposited sheets of cathode zinc are made and stripped from a smooth aluminum plate. Such thin sheets of cathode zinc may be used as are the copper sheets in standard electrolytic copper-refinery practice. However, complications arise because of extreme warping of the zinc starting sheet after a few hours of deposition, and thus special arrangements must be made to compensate for this abnormality. Reasons advanced for the ease with which deposits may be stripped from the aluminum surface are: (1) presence of a permanent oxide coating on the metal, (2) failure of aluminum to alloy with the deposit, (3) differences in coefficient of expansion, (4) high position of aluminum in the electromotive scries of metals. Of these reasons for nonadherence, which may have some application in general deposition, probably the oxide coating has the greatest bearing on the subject of zinc deposition. Adherence of zinc deposits has occasionally had serious effect on tonnage and production costs. Opinions have differed as to the specific

Jan 1, 1943

By H. R. Hanley, Charles Y. Clayton

ONE of the most important contributions to the art of electrolytic zinc production has been the aluminum cathode. This has been used in all major production since its commercial development in 1916. The literature is replete with important contributions, some of which may have been replaced by better ones, but thus far there appears no other metal to take the place of aluminum as cathode material. Credit for this innovation goes to Sherard Cowper Coles, of England. When experi¬menting on the extraction of zinc from Broken Hill ore at Hayle, Cornwall, in 1893, he introduced the aluminum cathode, and in 1895 obtained British Patent No. 20073. The reason for this dominant position of aluminum as cathode material in zinc sulphate electrolytes is its unique surface, to which electrodeposited metals usually do not tightly adhere. The metal must be of high purity for best results. It is possible to develop a starting-sheet method by which thin electrodeposited sheets of cathode zinc are made and stripped from a smooth aluminum plate. Such thin sheets of cathode zinc may be used as are the copper sheets in standard electrolytic copper-refinery practice. However, complications arise because of extreme warping of the zinc starting sheet after a few hours of deposition, and thus special arrangements must be made to compensate for this abnormality. Reasons advanced for the ease with which deposits may be stripped from the aluminum surface are: (1) presence of a permanent oxide coating on the metal, (2) failure of aluminum to alloy with the deposit, (3) differences in coefficient of expansion, (4) high position of aluminum in the electromotive series of metals. Of these reasons for nonadherence, which may have some application in general deposition, probably the oxide coating has the greatest bearing on the subject of zinc deposition. Adherence of zinc deposits has occasionally had serious effect oil tonnage and production costs. Opinions have differed as to the specific

Jan 1, 1938

By Lewis M. Haupt

IT has given me great pleasure to read, in the papers recently pub lished by this Society, the discussions on the subject of Technical Education, which were developed at the joint meeting held at the Franklin Institute in June, 1876; and since it was impossible for me to be present, I desire to improve this my first opportunity of adding the weight of my testimony and experience to what has been so ably presented by others. It is a subject about which the people need to be kept agitated, that their views may expand with the demands made for a higher and more thorough education. It is the public at large, the capitalist, the manufacturer, and the laborer, who are to be benefited more or less by this elevation of the standard of our professional schools, and it is but just, therefore, that the schools should look to them for the means with which to accomplish so de sirable an object. It is no doubt to the interest of a metallurgist to employ a skilled laborer who will prevent waste by properly proportioning his ma terials ; by regulating the supplies of air and fuel; by arranging his plant in the most economical manner, arid by disposing of his products to the greatest advantage. The engineer is benefited by selecting for an assistant a person able to determine the values of his factors of safety for the same materials in different forms and positions, avoiding expensive suits for damages and cost of reconsiruction; he should be able to so locate a road as best to fulfil the requirements of a through traffic, arid yet develop local industries. But I need not multiply instances to show what all will readily concede, viz.: the advantages of a theoretical education ; that was fully demonstrated at the previous special meeting, but it is still an open question whether the practical instruction should precede, accompany, or follow the theory.

By James Bowron

CONSIDERING the importance of the steel trade and the strategic position occupied in it by the Birmingham District, it may be surprising to many to realize that even the first pig iron smelted with coke was made in Alabama on Feb. 28, 1876, although merchant pig iron had been produced in Rockwood, Tenn., in 1867, a plant which is still in active operation. The heavy deposit of Clinton ore extending from Pennsylvania into Alabama, varying greatly in accessibility on account of geological changes such as erosion or anticlinal upthrow, varies equally as much in thickness and in quality. The brown ores extensively scattered through the South also vary materially in quality, some being relatively low in phosphorus and high in manganese, and vice versa. The red ore varies materially in phosphorus, but the iron produced from these ores was always considered to be too high in phosphorus for treatment by acid Bessemer or open hearth and did not contain sufficient for the basic Bessemer process. Under these conditions there remained only the basic open hearth as a possibility, and for many years it appeared impossible to use it, because, with coke smelted iron, the silicon was too high to permit its use in basic lined furnaces.

Jan 1, 1924

"The reduction works of the Boston & Montana Reduction department, near the north end of this dam is one of the reduction plants belonging to the Anaconda Copper Mining Company, the other being at Anaconda. These works employ about 1,100 men and have a capacity of about 3,800 tons of crude ore per day. This plant is now being remodeled to embody results of experiments and investigations which have been made with a view to more economic.al treatment of ores. A brief description of the plant as it will be after the remodelling is as follows:Concentrator Department: Consists of six units or sections, each section treating from 550 to 600 tons of crude ore per day. This department is not being. remodelled at the present time. A concentrating process, however, has been developed and partially installed in the old mill, and an experimental section embodying this concentration process has also been installed at the concentrator at Anaconda."

Jan 1, 1913

By K. C. Ko, D. A. Pifer

The theory of probability with respect to the failure of structures is discussed. It is shown that the probability of safety, probability of failure, and factor of safety are directly related to each other and that as standard deviation approaches zero, the probability curves approach a unit step function which can be interpreted as the conventional factor of safety. The factor of safety is numerically the ratio of the load to the strength of the material at a particular point or plane in an engineering structure. Mathematically, it can be illustrated as a unit step function undefined at the point where the factor of safety is one (Fig. 1). The uncertainty of variation of soil and rock strengths require factors of safety much higher than those used in other engineering structures. The factors of safety used are generally determined from past experiences with similar structures. However, the factors thus determined do not have any theoretical meaning or do not indicate any relationship to actual safety.' It seems, therefore, logical to develop a system with a sound theoretical basis to obtain a more suitable factor of safety for structures. An application of elementary theory of probability indicates that it is possible to relate this number to theoretical and practical engineering facts.

Jan 1, 1971