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By Roland J. Lapee

A history of the progress made in copper refining in Montana is presented. The casting furnaces and the newly rebuilt electrolytic refinery are descmbed and operating details are given. Experiences with various addition agents, effects of rernoval of chlorine from the electrolyte, and effects of separan on electrolyte and on copper deposit are discussed. Observatzons are made on the effect of various impurities in anode copper and behavior of thezr salts in electrolyte and in slime, on treatment of slime for removal of copper, and on electrolyte puriification problems. The improved method for production of starting sheets is described. Attention is given to new materials for construction and to improvement in matrials handling ad quality control. COPPER refining at Great Falls, Montana, dates back to 1892. The original plant produced 65,000 lb. of cathodes per day at a current density of 16 amp per sq ft. In this plant anodes and cathodes were handled to and from the cells by means of hand-operated chain blocks and were moved about the plant by hand trucks. Cathodes were melted in coal-fired, reverbera-tory furnaces, were charged by hand, and refined copper was dipped by hand and cast in iron molds. In 1916, a new, modern plant with capacity to refine 18 million Ib. copper per month was built. Two refining furnaces were built, and each was provided with a twenty-mold Clark casting wheel. In 1922, the furnaces were converted to the use of pulverized coal: in 1923, to the use of oil; and in 1928, to the use of natural gas. In 1926, the plant was enlarged 50 pct. The use of pulverized coal for refining copper at Great Falls was discussed1 in a paper presented at the Salt Lake City meeting of the Institute in September 1925. Also, a comparison of the use of various fuels in copper refining furnaces was discussed 2 in a paper presented at the New York meeting of the Institute in February 1932. Prior to 1943 the cellroom was operated with twenty-five 720-lb. anodes and 26 cathodes per cell. Four cathodes, each weighing about 165 lb., were produced from an anode. In 1943 the weight of the anode was reduced to 460 lb., and two cathodes, each weighing about 190 lb., were produced from an anode. In 1949, a Billet Casting Wheel for the production of 3 in. diam phosphor deoxidized billets was built. A paper, presented at the New York Meeting of the Institute in February 1956, describes3 this plant and operation. In the electrolytic refinery, production is controlled by variation of the current density. In 1956, germanium rectifiers on a separate electrical circuit were provided for the starting sheet section so that current density could be maintained at any desired figure. Also in 1956, a program of modernization and enlargement of the Electrolytic Copper Refinery was started. This program, when completed, will raise the capacity of the Great Falls Electrolytic Copper Refinery approximately 33 pct, to 33 million lb. of cathodes per month. Furnace capacity for melting cathodes and anode scrap is ample to take care of the increased production from the electrolytic refinery. This fortunate condition came about primarily as the result of the three following changes: 1) The furnaces were lengthened 10 ft in 1922 when the fireboxes were found unnecessary for burning powdered coal. 2) Furnace life, and hence furnace capacity, was increased by the successful efforts of the Copper Refinery staff to develop a method for sanding furnace side walls and roof. 3) The natural gas being used has a very low sulfur content. As a result, it is possible to reduce time spent rabbling and poling and thus greatly increase tons per furnace charge. TANKHOUSE AND TANKS The Great Falls Electrolytic Refinery is 535 ft long by 252 ft wide. The cells are arranged in four crane bays in which are operated seven 10 ton Whiting Cranes. The old cells are in groups of ten, with circulation of electrolyte through five cells in cascade and with aisles between the groups of ten cells. The new cells are nested in groups of sixteen with no aisles, are all on one level, and have individual circulation to each cell. Present plans call for 1792 commercial cells and 128 stripper cells. To reduce confusion during the construction period, and to use the cranes, cars, and other equipment already on hand, the cells in the rebuilt section were designed to have approximately the same inside dimensions as the cells in the old part of the

Jan 1, 1962

By Wilbur Nelson

ALL of our accounts of the discovery of copper ore at Ducktown, Tenn., state that the discovery was made in August, 1843, yet it would appear that samples of copper from this district were found by the Spanish explorer, DeSoto, when he wandered into Southern Tennessee, in 1539, in his four years of exploration through the Southern States. The following quotation is taken from his diary: "Towards the north there was a province named Chisca; and that there was a melting of copper, and of another metall of the same colour, save that it was finer, and of a farre more perfect colour, and farre better to the sight, and that they used it not so much, because it was softer. And the selfe same thing was told the governor in Cutifa-Chiqui, where we saw some little hatchets of copper, which were said to have a mixture of gold. But in that part of the country it was not well peopled; and they said there were mountains, which the horses could not passe; and for that cause, the governor would not goe from Cutifa-Chiqui directly quicker." DeSoto sent two of his company to try to find these mines, but after five days' wandering through the mountains they returned, stating that their guides had become lost. Although the Ducktown area may have been known to the ancient Indians, it was not until August, 1843, when a Mr. Lemmons, who was panning for gold on Potato Creek, in the Ducktown basin, found some reddish-brown decomposed rock, which he supposed to be gold, that the copper deposits were actually discovered. His disgust on finding that this yellow metal. was not gold was so great that he did not. try to develop his find. In March, 1847, B. C. Dugger erected an iron forge at this same place, but was unable to work the iron as it contained so much copper that on cooling it would break to pieces. The finding of copper in the iron ore by Mr. Dugger led to further explorations; and in April, of the same year, A. J. Weaver, who was passing through that country, told the people that the black rocks they had dug out were rich copper ore. Mr. Weaver began the first mining in this district.

Jan 10, 1924

By C. S. Yust, Lida K. Barrett

The change in shape of the void in a sirzterir~g copper mass has been investigated as a juntction of' density. A serial sectioning' technique was used to eoaltrate the irregular shape of the void at two levels qf density. A measure of the void size and configuration, the proximity number, is defined and used to describe the progress of void removal. The process of. void removal deduced front the observations of this study contrasts with current sintering models in that it takes into account the irregularity of structure of a sintering mass and demonstrates that isolated Porosity does not occur first as spherical pores, but as large, definitely nonspherical sections of the void void volume. The process of sintering, about which there is much practical and theoretical knowledge, has evaded a direct and thorough analysis despite the intensity with which it has been studied for 60 years or so. This is due, of course, to the complex structure of a sintering mass and the inability to observe directly the development of a fully dense solid from the initial particulate arrangement. Extensive theoretical analyses have been based on the adoption of one or another of several model systems, that is, by visualization and analysis of some sort of regular assembly or arrangement of geometric "particles" approximating the conditions of a sintering mass. It seems appropriate at this time to try to examine experimentally in some detail the extent to which a sintering mass of irregular particles dlffers from these models. Many models deal with neck growth and the initial stage of sintering and follow the direction established by ~ucz~nski' in 1949 for the sintering of spheres to flat plates. Recently Johnson and cutler2 have adapted these models to sintering of powder masses. coble3 has presented a mathematical model for sintering that applies to the middle and final stages of the process. These papers, without exception, assume a regular geometry, generally spheres in contact in a regular array. Rhines~ and coworkers, however, are studying the sintering process by applying a model based on the topological concept of genus which permits them to consider an irregular structure. whites has described the various models with the exception of that of Rhines et al., and the assumptions on which they are based and their shortcomings. The present paper examines the geometric changes that occur in the powder mass during sintering by examination of the void. The method is to analyze a series of partially sintered structures and to propose from this analysis the sequence of events which occur in the removal of the void space as a sintering mass progresses from a collection of individual particles to a solid body. The irregular nature of the stacking of particles and of the particles themselves will be taken into account. The significant points derived from this study are: first, accurate reconstructions of the irregular void shapes are presented; second, it is clearly established that closed porosity occurs first as widespread volumes of interconnected porosity, definitely nonspherical in shape; and third, a new factor, the proximity number, is defined, which serves in this paper as a tool for describing the void shape changes observed, and which will be used in a later paper as part of the basis of a mathematical model for sintering. While the specific material studied is copper, the observations are thought to be relatively general as indicated by comparison of the results with partially sintered structures in other materials presented in the literature, both metallic and nonmetallic. EXPERIMENTAL PROCEDURE Four series of specimens representing progressive stages of the sintering process were prepared by sintering high-purity copper powder for various time periods. A relatively large particle size was used so that the void-solid interface could be readily distinguished at low magnification. In three series of specimens a loose stacking of particles was obtained by pouring powder into an alumina mold and lightly tapping the mold. The green density of such compacts was approximately 40 pct of theoretical density. Two of these three series utilized irregularly shaped particles in the size range -230 +325 mesh, one series sintered in vacuum and one in hydrogen at 950°C. The third series of loosely stacked particles consisted of spherical particles in the size range -270 +325 mesh, sintered in hydrogen at 950°C. A fourth series was prepared from compacted irregular particles sintered in hydrogen at 950°C. The specimens for this series were formed by lightly pressing the irregularly shaped particles in a steel die; the green density of the pressed pellets was approximately 60 pct. The irregularly shaped particles used in this study are shown in Fig. 1. The density of these particles, measured by a toluene picnometer technique, is 98.2 pct of theoretical density. Each particle is highly convoluted, and in some instances appears in cross section to contain internal porosity. The density measurement, however, indicates that completely enclosed porosity is very small so that the individual particles have a highly irregular surface but are essentially fully dense copper. Therefore, most of the void space that appears in two dimensions to be isolated within the particle is actually at the particle surface and connected to the external void in the dimension not included in the plane of the cross section. The void space that appears as void surrounded by the par -ticle or within folds in the particle w~ll be r~fc\r?

Jan 1, 1968

By John Philip Zannaras

John Philip Zannaras (Registered Professional Engineer, Congress, Ariz.)- The authors show in their [Fig. 4] the cumulative results of grinding with two sizes of bails, one 30 mm and the other 20 mm. The Gaudin-Meloy probability for breakage for a single fall used by the authors in their paper is given by their [Eq. 6]. Another form of [Eq. 6] is given by Gaudin-Meloy in their paper as follows: [ ] From the definition of A given by Gaudin-Meloy it is obvious that A30 is greater than A., it therefore follows from the foregoing equation that according to the Gaudin-Meloy formula the probability of breakage for a single fall of all the balls in the 20-mm experiment was more than 2.25 times the probability of breakage in a single fall of all the 30-mm balls which is contradicted by the authors' experimental evidence in [Fig. 4] in which is shown that much more grinding took place with the 30-mm balls. In fact the authors present convincing evidence that the Gaudin-Meloy work is erroneous because their work is based only on a geometric configuration and on ambiguous and uncertain definition of A and disregards the fact that the distribution of fracture depends on other important and indispensable factors including the intensity of stress caused on the feed grain by the balls. That there is an immense and chaotic variation of stresses caused on the feed grains by the balls is shown by a formula, derived by this writer and published in 1955. The derivation of this formula is given in the Appendix of this discussion; it contains the variables in the operation of ball mills and is based on the science of mechanics-not on probabilities. [ ] where T is the unit stress in pounds per square inch produced by the moving load, h is the height in feet through which P has fallen, E is the modulus of elasticity of the rock, P is weight of one ball, and L is the size of the grain (assumed to be a cube of side L). It will be shown by this writer's formula that when a 30-mm ball strikes any size of feed grain it will cause 1.837 times higher stress than the 20-mm ball when striking the same size grain. It will be shown that when the 30-mm ball or the 20-mm ball strikes a feed grain of 0.1 mm it will cause 90 times more stress on the grain than when it strikes a 2-mm grain.

Jan 1, 1974

By D. R. Snow

The year 1930 stands out in the petroleum industry as an exceptional one in many ways. It is one of the few years in its history during which crude oil production declined from that of the previous year in nearly every important producing district in the United States and in the world as a whole. World production of crude oil declined approximately 81,000,000 bbl., from 1,484,451,000 bbl. in 1929 to 1,403,500,000 bbl. in 1930. Production of crude oil in the United States declined approximately 111,000,000 bbl., from 1,007,323,000 bbl. in 1929 to a production of 896,265,000 bbl. in 1930. World production outside of the United States increased approximately 30,000,000 bbl., due principally to the increased production in Russia. This, together with the decided decrease of production in the United States, resulted in a smaller percentage of world production in the United States than in any other year since 1921. This declining production occurred in the face of the greatest visible supply in the form of potential production that the industry has ever known and was clearly the result of the great efforts put forward to restrict production, both by proration and by unitization. Throughout the year, developments along the lines of proration and unitization have overshadowed all other developments in the minds of those interested in the oil industry and will, no doubt, continue to do so more and more in the future, as it is quite evident that the industry cannot hope to maintain itself in a profitable position, without some rational plan of bringing about a better balance between supply and demand than has existed in the past. The successful operation of the Van field unitization agreement and the recently completed Kettleman Hills plan are indicative of what mag be expected in the future along this line. That real progress has been made in this direction is shown by the fact that total crude oil stocks in the United States were decreased by approximately 28,000,000 bbl. during the year 1930. This is the only year on record during which such a decrease of crude oil stocks was accompanied by a severely declining price structure. This reduction of crude stocks is apparently continuing even after the price has reached its present low level, indicating that there is no

Jan 1, 1931

By C. M. Marquardt

Tramp iron and steel moving on a conveyor belt cause small currents to be generated in a coil situated in a strong magnetic field, which are converted to an alternating current and are amplified. The output voltage from the amplifier fires a thyratron with a relay in its anode circuit, which actuates a howler and simultaneously drops a spot of marker material on the belt.

Jan 6, 1950

Records of coal in Colorado begin only a few years before the Civil War. In 1859 Macomb reported beds of lignite on both sides of Galisteo Creek, and in the foothills of the Placer Mountains, a place where an outburst and overflow-of trap had changed the lignite into bright, hard anthracite.1 The Union Pacific Railroad sent Joseph T. Hodge to investigate the coal deposits in the Rocky Mountains, close to the projected line, in the fall of 1863. He was told of coal on South Boulder and Rock Creeks, and that somewhere on Lodge Pole Creek it was being worked for supplying fuel for stage stations; a bed was also reported seven miles north of the stage road between Laporte and Latham. It was only in the vicinity of Denver that coal mines were being worked to any extent; these openings were on Coal Creek about 22 miles north of the town, said to have been opened in. 1860. The coal was used by the smiths with ,difficulty and slacked badly on exposure., Some coke was made from one of the seams, the coke being preferred to the raw coal by smiths. Another district was opened along South Boulder Creek, about two and a half miles from the base of the Rocky Mountains, two mines being worked to supply the Denver market.2 Hayden reported a large bed of coal at Golden in 1861 and of having seen a similar one in 1862 about 65 miles east of Pikes Peak, and in 1866, he saw large beds on Rock Creek 16 to 19 miles from Golden. In 1867 he saw the Belmont or Marshall's mines opened in 1863 on South Boulder Creek, which he said was the finest exhibition of coal in the state. The next one was the Murphy mine, on Ralston Creek, five miles north of Golden. A mine was also being worked near Canon City at that time.3 The coal at Golden was being worked in 1864.4 In 1867 the coal mined at Golden was being used in a firebrick' works. At Canon City and other places on the waters of Arkansas River, coal was being mined for use in the valley towns, bringing $5.00 per ton at the mines.5

Jan 1, 1942

By V. Patarini, D. Kuehl, F. Galasso, M. Salkind

In recent years, a great deal of research has been directed toward the production of continuous low-density, high-strength, high-modulus boron fibers for aerospace applications. A technique which has proven to be quite successful for forming these fibers involves the reaction of boron trichloride and hydrogen on a hot tungsten wire. In this process, a boron fiber is produced which consists of a tungsten boride core covered with amorphous or crystalline boron depending on the temperature of the preparation.2,3 The purpose of this paper is to present the properties which have been obtained to date from measurements and observations on these fibers. Selected samples of boron filament produced by reacting boron trichloride and hydrogen on a 0.5 by 10-3 in. diam tungsten wire substrate using different reacting temperatures were cross-sectioned, polished, and photomicrographed with cross-polarized light. The temperature of the wire was measured using a two-color optical pyrometer. Photomicrographs of these samples are shown in Fig. 1. Three general types of boron, in addition to the tungsten borides, have been identified by means of X-ray powder diffraction techniques: a) at low temperatures (below 1400°C) the boron is deposited in the amorphous form; b) at temperatures between 1400° and 1500°C the boron is deposited in the ß tetragonal form; and, c) above 1500°C the boron is deposited in the B rhom-bohedral form. In the depositing range of 1400" to 1500°C the boron initially deposits as amorphous and becomes crystalline as evidenced by the large equi-axed grains which then merge into columnar grains in later stages of boron deposition. This can be seen in Fig. 1 and has been observed in the X-ray patterns of these fibers, which contain both halos from the amorphous boron and lines from the ß tetragonal form. Above 1500°C the only boron reflections observed in the X-ray patterns were those of the ß rhombohedral form and only columnar grains are seen in the photomicrographs. Photomicrographs of the surface in Fig. 2 show the smooth-surface kernal-type deposition which corresponds to the amorphous form and the rougher surfaces which correspond to the crystalline form. Mechanical measurements were made on amorphous boron produced at 1300°C rather than the crystalline boron because the strengths of these filaments were greater and were more consistent. A tensile tester consisting of a fixed crosshead containing a double

Jan 1, 1967

By George M. Enos, Robert J. Anderson

An impoRtant factor affecting the rate and nature of corrosion of metals and alloys is the film, or coating, formed on the surface; and this may accelerate or retard corrosive action once started. The formation of films and coatings is intimately associated with the chemical composition and physical constitution of both the metal and the corroding medium. A film or coating may be either the corrosion product resulting from oxidation; that is, an oxide or salt, or a deposition of suspended matter from the corroding media upon the surface of the metal, or a mixture of both. The coating may adhere tightly or loosely to the surface of the corroded metal. In short, a film or coating is the reaction product of the corroding medium and the metal, which adheres to the surface of the metal and with which may be intermingled material from the attacking media not concerned in the chemical reactions. As the terms film and coating are used by different writers for very different things, distinction is made between the two, by the present writers, on the basis of thickness. Thus, a film is defined as a corrosion product or deposition, on the surface of a corroded metal, that is of such thickness that it cannot be measured by the metallurgical microscope. A coating, on the other hand, is of such thickness that it can be measured. If the resolving power of the 2-mm. (equivalent focal length) apochro-matic oil immersion objective (N.A. 1.4) is taken as the limit of the microscope, the limiting resolution is two lines that are 0.0002 to 0.0004 mm. apart. It is thus possible to measure coatings that are greater than 0.0002 to 0.0004 mm. thick. This thickness is equivalent to 50,000-

Jan 1, 1925

By William Glenn

That basic slag will rapidly destroy ordinary (i.e., siliceous) fire-bricks is known to every smelter; and the smelter of copper-ores in particular knows that any kind of slag occurring in his practice is destructive. From this fact arises the chief distress of those who attempt to smelt copper-ores in any manner of furnace constructed of bricks or stone, or other similar material. We have passed the fire-brick stage of our experience; and now, having entered upon the period of the water-jacketed cupola, we will employ no furnace other than that having steel walls, kept cool by water. But,, unfortunately, the bottom of a water-jacketed cupola, kept cool by another water-jacket, fails of its purpose, being thereby made so cold as to chill both slag and regulus to a degree not bearable. The situation is more or less ameliorated when the upper surface of the water-jacketed bottom is covered with fire-bricks, since, so long as they last, they prevent the molten material from contact with the cold bottom. My own observation leads me to suppose that most smelters construct cupola-bottoms of iron slabs, which are covered, to a greater or less depth, with fire-bricks. There are cupola-bottoms which

Jan 1, 1902

By L. C. De Jong, J. F. Shirley, M. L. Campbell

The Toquepala concentrator of the Southern Peru Copper Corp., located approximately 720 miles southeast of Lima near the Chilean border, processes 36,500 tons of ore daily containing between 0.50% and 3.00% copper. The molybdenite content in the ore also varies greatly, ranging from essentially nothing to as high as 0.15%. The 1966 yearly averages were approximately 1.20% copper and 0.03 % molybdenite. The three basic problems that plague the opera- tion of any molybdenite recovery plant are all present at Toquepala in large measures. Both the quantity of plant feed and the quantity of molybdenite contained in the plant feed are continuously changing. Even more detrimental to an efficient operation is the fact that the copper mineralization in the feed frequently changes once in every 24 hours and occasionally once a shift. From the point of view of the molybdenite plant metallurgist, there are four distinctive chalcopyrite concentrates and, at least, an equal number of chalcocite concentrates treated in the molybdenite recovery circuit. The various types of concentrates are distinguished mainly by their mineral content and how effectively the copper minerals are depressed by the different reagents used in the circuit.

Jan 9, 1967

By Donald L. Katz, Leslie J. Noaker

Experimental data are presented for hydrate formation conditions for mixtures of hydrogen sulfide and methane. Vapor-solid equilibrium constants for hydrogen sulfide are also presented. Equilibrium constants, defined here as the ratio of the mole fraction of hydrogen sulfide in the vapor phase (dry basis) to the mole fraction of hydrogen sulfide in the solid phase (dry basis), were calculated using the vapor-solid equilibrium constants for methane presented in an earlier paper. The conditions at which a natural gas will form gas hydrates with water may be computed from its composition, when hydrogen sulfide is present in addition to carbon dioxide and the paraffin hydrocarbons. INTRODUCTION Many gases are known to form solid hydrates in the presence of liquid water at temperatures above 32°F. This hydrate formation is of importance to the natural gas industry inasmuch as most of the constituents found in natural gases will form hydrates. The attention of the industry was called to hydrates by Hammer-schmidtl0 in 1934. A number of papers have been written giving the temperatures and pressures at which these hydrates will form3,4,5,6,7,8,9,10,13,14,15,18,19 and a bibliography on the subject has been compiled13. Deaton and Frost4,5,6,7,8 report work for various pure gases and for some natural gases. Katz and co-workers3,4,13,14,18,19 have reported data for various gases at high pressure. They developed a method of predicting conditions for hydrate formation from equilibrium constants3,19 and from gab gravity." The effects of anti-freeze agents on the formation of hydrogen sulfide hydrate were reported by Bond and Nelson.' The hydrogen sulfide-water system, including hydrate, has been the subject of recent investigation by Sage and co-workers." Mixtures of hydrates behave as solid solutions and an equilibrium exists between the vapor phase and the solid phase that appears to be comparable to the equilibrium between vapor and liquid phases.3,10 By means of the vapor-solid equilibrium constants which have been published for methane, ethane, propane, iso-butane, and carbon dioxidel6 it is possible to determine the temperature and pressure at which hydrates will form for a specific gas mixture when water is present. Hydrogen sulfide which is frequently found in natural gases has a very strong tendency to form hydrate and must enter the solid solution when present in a natural gas forming a hydrate. To determine the effect of hydrogen sulfide when computing the conditions for gas hydrate formation, it is necessary to have the equilibrium constant giving the ratio of the concentration of hydrogen sulfide in the gas phase to the concentration in the solid phase. This paper presents data on hydrate formation for mixtures of hydrogen sulfide and methane and presents the equilibrium constants which were calculated from these data. EXPERIMENTAL PROCEDURE The apparatus used to determine the conditions of hydrate formation for the methane-hydrogen sulfide system was similar to that employed by previous investigators.3,18,19 A charge gas cylinder was used to supply the hydrogen sulfide-methane mixtures, called the charge gas, and to supply the pressure up to 1.000 psia. This

Jan 1, 1955

By J. B. Austin

IN considering so complex a process as the smelting of iron in the blast furnace, there is obviously no single method of calculating efficiency that gives a complete appraisal of the performance of the furnace in all its several functions; such a comprehensive view as is required to evaluate producing ability and manufacturing costs for a given furnace is obtained only by considering a group of efficiencies, each of which measures the performance of the furnace from a specific point of view. For instance, there is the rate of consumption of coke per ton of iron produced, which is probably the most frequently considered, and is certainly one of the most important of the group; there is the efficiency of recovery of iron charged; and there is the efficiency of utilization of energy, both chemical and thermal, in some respects related to the former two yet in other ways independent of either. In each of these cases, the calculation can be made on the basis of the actual input of material or energy, or it may be based . upon a comparison with the minimum amount of material or energy that would be required by a "perfect" furnace; that is, an imaginary ideal furnace analogous to the perfect steam engine used in thermodynamic calculations, when this furnace is operating under optimum conditions. Moreover, the furnace itself can be considered either as an apparatus for smelting iron or, taking a somewhat less common point of view, as a gas producer yielding iron and slag as by-products. Some of these effi-ciencies are more useful than others, yet all are instructive; for a knowl-edge of them not only leads to good engineering practice from the standpoint of control but also discloses limits to possible improvement in performance and indicates the lines along which improvement is most likely to be profitable. Estimates of some of these efficiencies have appeared from time to time in the literature, but many of them are open to objection because they are based on data of uncertain accuracy or because they have been calculated without due regard to the thermo-dynamic principles involved. Moreover, so far as the author is aware, no general survey of the blast furnace comparing its performance in all the aspects mentioned has been made.

Jan 1, 1938

By J. B. Austin

In considering so complex a process as the smelting of iron in the blast furnace, there is obviously no single method of calculating efficiency that gives a complete appraisal of the performance of the furnace in all its several functions; such a comprehensive view as is required to evaluate producing ability and manufacturing costs for a given furnace is obtained only by considering a group of efficiencies, each of which measures the performance of the furnace from a specific point of view. For instance, there is the rate of consumption of coke per ton of iron produced, which is probably the most frequently considered, and is certainly one of the most important of the group; there is the efficiency of recovery of iron charged; and there is the efficiency of utilization of energy, both chemical and thermal, in some respects related to the former two yet in other ways independent of either. In each of these cases, the calculation can be made on the basis of the actual input of material or energy, or it may be based upon a comparison with the minimum amount of material or energy that would be required by a "perfect" furnace; that is, an imaginary ideal furnace analogous to the perfect steam engine used in thermodynamic calculations, when this furnace is operating under optimum conditions. Moreover, the furnace itself can be considered either as an apparatus for smelting iron or, taking a somewhat less common point of view, as a gas producer yielding iron and slag as by-products. Some of these efficiencies are more useful than others, yet all are instructive; for a knowledge of them not only leads to good engineering practice from the standpoint of control but also discloses limits to possible improvement in performance and indicates the lines along which improvement is most likely to be profitable. Estimates of some of these efficiencies have appeared from time to time in the literature, but many of them are open to objection because they are based on data of uncertain accuracy or because they have been caleulated without due regard to the thermodynamic principles involved. Moreover, so far as the author is aware. no general survey of the blast furnace comparing its performance in all the aspects mentioned has been made.

Jan 1, 1938

By J. B. Austin

In considering so complex a process as the smelting of iron in the blast furnace, there is obviously no single method of calculating efficiency that gives a complete appraisal of the performance of the furnace in all its several functions; such a comprehensive view as is required to evaluate producing ability and manufacturing costs for a given furnace is obtained only by considering a group of efficiencies, each of which measures the performance of the furnace from a specific point of view. For instance, there is the rate of consumption of coke per ton of iron produced, which is probably the most frequently considered, and is certainly one of the most important of the group; there is the efficiency of recovery of iron charged; and there is the efficiency of utilization of energy, both chemical and thermal, in some respects related to the former two yet in other ways independent of either. In each of these cases, the calculation can be made on the basis of the actual input of material or energy, or it may be based upon a comparison with the minimum amount of material or energy that would be required by a "perfect" furnace; that is, an imaginary ideal furnace analogous to the perfect steam engine used in thermodynamic calculations, when this furnace is operating under optimum conditions. Moreover, the furnace itself can be considered either as an apparatus for smelting iron or, taking a somewhat less common point of view, as a gas producer yielding iron and slag as by-products. Some of these efficiencies are more useful than others, yet all are instructive; for a knowledge of them not only leads to good engineering practice from the standpoint of control but also discloses limits to possible improvement in performance and indicates the lines along which improvement is most likely to be profitable. Estimates of some of these efficiencies have appeared from time to time in the literature, but many of them are open to objection because they are based on data of uncertain accuracy or because they have been caleulated without due regard to the thermodynamic principles involved. Moreover, so far as the author is aware. no general survey of the blast furnace comparing its performance in all the aspects mentioned has been made.

Jan 1, 1938

By W. A. Ver Wiebe

It is becoming increasingly apparent that the State of Kansas contains one of the largest reserve areas for oil exploration in the United States. During the year 1936 no less than 54 new oil pools were discovered by drilling. In addition, seven gas pools were found, which may develop into oil pools when deeper horizons are tested. Several old pools increased their reserves when production was found in lower strata. The data presented in Table 2 indicate that nearly 2000 wells were drilled in the state during 1936. Of these more than 1214 found commercial quantities of oil and at least 61 found marketable quantities of gas. The data are conservative because complete results on drilling are not available for the eastern part of the state. Ellis, Rice and Russell Counties share honors with a total of 10 new pools in each. Barton County is prominent with six pools; while those counties claiming fewer new pools are Clark, Ellsworth, Harvey, McPherson, Ness, Pawnee, Rooks, Stafford and Trego. Important additions to our gas reserves were found in Finney and Haskell Counties, which are north of the extensive Hugoton gas area and may some day be part of it. At the close of the year there were 17,317 wells in the state rating as producers. By far the larger share (14,000) were classed as strippers and allowed to flow 100 per cent of their potential capacity, thus accounting for 33,500 bbl. a day. The remaining wells, capable of producing from 15 up to over 6000 bbl. per day, were limited in output according to these amounts. The largest wells having a potential of from 3000 to 7000 were allowed to flow from 2 to 3½ per cent of their official potential capacity. The percentage rises until wells of 15 to 20-bbl. capacity have a rating of slightly over 83. On the basis of these calculations the total potential capacity of all wells was 1,667,814 bbl., and the daily amount allowed was 175,851. Nine of the pools most recently opened were still unable to market their oil and were classified as "shut-in" pools. Total production for the state for 1936 was somewhat over 58 million barrels. Striking Geological Data Some interesting geological data were uncovered by deep drilling during the year. The most remarkable bit of information is the discovery

Jan 1, 1937

By J. B. Austin

In considering so complex a process as the smelting of iron in the blast furnace, there is obviously no single method of calculating efficiency that gives a complete appraisal of the performance of the furnace in all its several functions; such a comprehensive view as is required to evaluate producing ability and manufacturing costs for a given furnace is obtained only by considering a group of efficiencies, each of which measures the performance of the furnace from a specific point of view. For instance, there is the rate of consumption of coke per ton of iron produced, which is probably the most frequently considered, and is certainly one of the most important of the group; there is the efficiency of recovery of iron charged; and there is the efficiency of utilization of energy, both chemical and thermal, in some respects related to the former two yet in other ways independent of either. In each of these cases, the calculation can be made on the basis of the actual input of material or energy, or it may be based upon a comparison with the minimum amount of material or energy that would be required by a "perfect" furnace; that is, an imaginary ideal furnace analogous to the perfect steam engine used in thermodynamic calculations, when this furnace is operating under optimum conditions. Moreover, the furnace itself can be considered either as an apparatus for smelting iron or, taking a somewhat less common point of view, as a gas producer yielding iron and slag as by-products. Some of these efficiencies are more useful than others, yet all are instructive; for a knowledge of them not only leads to good engineering practice from the standpoint of control but also discloses limits to possible improvement in performance and indicates the lines along which improvement is most likely to be profitable. Estimates of some of these efficiencies have appeared from time to time in the literature, but many of them are open to objection because they are based on data of uncertain accuracy or because they have been calculated without due regard to the thermodynamic principles involved. Moreover, so far as the author is aware, no general survey of the blast furnace comparing its performance in all the aspects mentioned has been made.

Jan 1, 1938

By Charles E. Lees

The Globe Mining District is in the southeast central part of Arizona, in Gila County. Globe, with a population of about 7000, is the terminus of the Arizona Eastern R.R., a branch line 130 miles long that connects with the Southern Pacific R.R. at Bowie. In 1874, prospectors crossing the Pinal Mountains from the west located what is generally known as the Old Dominion mine. For several years, it attracted little attention, because of the greater interest aroused by the discovery of high-grade silver ores in some of the foothills northeast of Globe. About six years later, the prospector turned his attention to the abundant copper ore revealed by surface workings along the Old Dominion vein, and, in 1884, the Old Dominion company erected two 30-ton furnaces. From 1888 to 1893, the Old Dominion company is said to have maintained an average annual production of about 8,000,000 Ib. of copper. Until Dec. 1, 1898, all supplies had to be freighted into Globe by wagons and the mines of the district operated intermittently because of high expenses, but with the advent of the railroad the Old Dominion company continued to be a large and steady producer. In the Globe district, the production of copper far exceeds in importance that of any other metal. There are four operating companies along the Old Dominion vein and the total annual product of these properties for 1923 was about 45,000,000 lb. of copper. The unit size of the mineral tracts in the district is the regulation mining claim, 600 ft. wide by 1500 ft. long, and all ownerships are held in fee. Globe is 3600 ft. above sea level, and lies between the Apache MOUntains to the east and the Pinal Mountains to the west. The principal drainage of the district is northward through Pinal creek into the Salt River. The general slope from the high point along the vein, where the Superior & Boston mine is, to Pinal creek, where the Old Dominion mines are, is about 250 ft. to the mile. Geology The oldest rocks in the district are pre-Cambrian crystalline schists known as the Pinal schist, which are the basement upon which all the later rocks were deposited. These latter rocks comprise shale, con-

Jan 1, 1925

By Dirk van Zyl

The paper describes the construction of a clay pad in Southern California. The pad consisted of a mixture of in situ soil and imported clay products. The paper summarizes design considerations. Laboratory permeability tests performed on samples removed from the pad formed part of the quality control requirement of the State of California Water Quality Control Board. The paper presents statistical analysis of the data (about 70 permeability tests in total) and their significance in controlling seepage losses. The results obtained from an investigation of the first pad-area after completion of the leach cycle are presented and discussed. Results from visual observations and laboratory tests are presented.

Jan 1, 1984

By J. R. Thoenen

THE preper classification of mining methods has received the earnest study of many mining engineers and has resulted in much technical controversy, depending no doubt upon the point from which classification is viewed or the use to which it is put. So far as the writer is aware, the discussion has invariably centered around the classification of underground mining methods, and only superficial attention has been directed to surface methods. Volume 72, page 10, of the Institute Transactions, presents such a classification, sponsored by the Mining Methods Committee of the Institute. A similar classification by Prof. Hugh P. Nicholson appeared in Mining and Metallurgy in October, 1934. The two classifications are quite different in their treatment of underground methods but are identical in classifying surface methods, although Professor Nicholson does suggest possible further divisions for surface mining and admits that such subdivision is more difficult than appears at first. Surface subdivisions as given by these two authorities are as follows, showing that in spite of rearrangement the two classifications are identical: From his experience of many years in the study and operation of both underground and surface metal and nonmetallic mines, the writer does

Jan 1, 1942