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By Dorsey A. Lyon, Robert M. Keeney

The utilization of hydro-electriic power in electro-metallurgical industries, aside from purely mechanical operations, may be of two kinds. The electric energy may be used to supply the heat necessary for the performance of the chemical reactions of a metallurgical process, or the electrolytic action of a direct current may be employed for extraction of metals, either in a reduction process or a refining process. In discussing this subject, it is well to distinguish between established industries, which are producing metals and alloys at a, profit by use of the electric current, and the many processes which are either still in the experimental stage or have not even passed the paper stage of development of a patent. That is, we consider electro-metallurgical industries as commercial operations which are now consuming large blocks of electric energy, while processes which are not in commercial operation are only prospective consumers. Also, owing to the difliculty and risk of any attempt to foresee the effect of the European war upon electro-metallurgical industries, we have felt obliged to disregard the war entirely, and state our opinions regardless of its existence. Application of Electric Energy to Metallurgy Disregarding electrolytic refining processes, the applications of electric energy to metallurgy, when considered from a commercial viewpoint, may be classified as follows: Industries Experimental Processes Manufacture of aluminum Electric-furnace smelting of: Electric-furnace manufacture of: Ferro-alloys Copper ore Pig iron Zinc ore Steel In this paper only the above industries and experimental processes will be considered as possible consumers of hydro-electric power in large quan-

Jan 1, 1916

By W. M. Weigel

WHILE electric lamps both of the cap and hand type are being introduced into many mines requiring the use of safety lamps, the oil-burning safety lamp is still used in the great majority of cases, and even where the former are used the latter must continue to be employed when testing for gas. It is not the intention to discuss here the relative merits of the two types, but simply to give a comparison of the illuminating effect or candlepower of several kinds of ordinary safety lamps used for general work and for testing. Few data have been published in recent years on this subject and because of this it is hoped that the following information may be of some interest and value. The lamps tested were in all cases. of standard size and in good condition, all practically new, and were selected from a collection of about 100 with a view to obtaining results on as many different common types as possible. With the exception of the gasoline-burning lamps, five different oils were used in each lamp to determine whether -particular oils were suited to particular lamps and whether there was any great difference in the illuminating power of the different oils, or whether some oils would maintain their illuminating power better than others throughout a working period of 8 hr. No attempt was made to determine the amount or cost of oil burned by each lamp, but the condition of the lamp, wick, glass, and gauzes was noted after each test.

Jan 8, 1916

By Clarence E. Sims

DURING the past several years the steel casting industry has made studies of heavy castings in which the test bar has been taken from heavy sections rather than from attached or separately cast coupons. It has been noted that the ductility properties of these heavy sections are often lower than those normally expected. Such lowered ductility is usually accompanied by a spotty test bar fracture and the ductility values often can be greatly improved if a low-temperature aging treatment is given to the casting. A loss of ductility of this type is considered "abnormal," since it is not accompanied by an increase of tensile strength or hardness, and "temporary" when the ductility can be restored by aging. The cure of such an abnormal condition represents a real improvement in the quality of the steel. Some hundreds of previous investigations, largely qualitative in nature, have established beyond reasonable doubt that hydrogen is normally present in newly manufactured steel and that this gas, in small amounts, can cause a temporary abnormal loss of ductility. The commonly observed association of high gas content and low ductility has given strong evidence for the presumption that hydrogen, possibly assisted by other gases, is the primary cause of the low ductility observed. Accordingly, the Steel Founders' Society of America has, since Nov. 1, 1944, sponsored investigations at Battelle Memorial Institute whose primary objective is to obtain quantitative information on the relation of the amount of hydrogen and nitrogen in steel, together with associated methods of steelmaking and treatment, to low-ductility effects and porosity.

Jan 1, 1947

By James Douglas

American metallurgical inventions have not always been absolute metallurgical improvements, if accurate work be the standard of comparison; but when we review the new methods and machinery which have been generally accepted, we find that some have become essential to the metallurgist the world over, while all are so admirably adapted to the peculiar requirements of our local conditions that they have entirely supplanted foreign processes and appliances. The necessity of diminishing to the utmost the employment of labor (owing to its great cost), and the inexorable requirements of our modern joint-stock corporate system, which demands that large quantities be worked up in order to secure large returns, regardless betimes of waste, have been the impelling motives to invention, and indicate the special directions in which originality has been exercised. As might be anticipated, the West has been the most fertile field of inventions by miners and metallurgists, by reason of its great and varied mineral wealth, locked up in ores sometimes lean and often of intricate composition, which must be profitably handled, at a great distance from fuel and from building-materials, by workmen who are paid wages very much higher than those received by their fellow-workmen of like craft in Europe, and in some localities twice as high as those paid for like services even in the eastern States. Moreover, paradoxical as it may seem, the technical inexperience of many of those engaged in mining and metallurgy has helped rather than hindered the progress of invention; fop while there may have been ignorance, there has been radical freedom from

Jan 1, 1894

By G. L. Oldright, Henry de Rycker, S. F. Ravitz

The upper limit of richness of concentrates that can be smelted by means of the blast furnace without added diluents is fixed by the operation of sintering. A sinter feed with normal gangue constituents, containing more than about 50 per cent of lead, tends to fuse; as a result, air does not come sufficiently into contact with the sulphides at roasting temperatures, and sulphur elimination is poor. Since most lead concentrates now contain 55 to 80 per cent lead, it is necessary to add diluents to lower the grade of such sinter feed to about 50 per cent or less. This not only entails the expense of providing barren diluents when adequate diluents containing precious metals are not available but also appreciably lowers the capacity of the blast furnace to produce lead and increases slag losses. Attempts to desulphurize rich lead concentrates by methods other than sintering have not proved successful. Flash roasting, for example, converts much of the lead sulphide to lead sulphate rather than to oxide. However, this suggested the possibility that deliberate flash roasting of the concentrates to sulphate, followed by sinter roasting of the resulting product, might prove promising, particularly inasmuch as the elimination of sulphur from lead sulphate requires heat alone and not contact with atmospheric oxygen. The sintering of lead sulphate products has additional interest because important amounts of such products are now treated by lead smelters. Considerable quantities of lead sulphate are present in rich lead flue dusts and other by-products; lead-chamber sulphuric acid plants and other

Jan 1, 1944

By C. A. Czako

INTRODUCTION In recent decades sintering and pelletizing of finely divided materials have become the primary tonnage producing modes of agglomeration. This statement is especially true in the iron and steel industry and, to a lesser degree, in the nonferrous, chemical and non-metallic minerals processing industries. In every industry the main objectives in agglomerating fines are essentially the same, namely to convert ores, minerals and chemicals of undesirable fineness into agglomerates characterized by a size consistency desirable for subsequent use or processing. Depending on the type of agglomeration process selected and the conditions maintained during agglomeration, the physical process of increasing size is complemented by a number of other unit processes. These processes can occur simultaneously, consecutively or in an overlapping manner. Some of these additional unit processes are incidental to the agglomeration operation, but at the same time can be critical, depending upon the subsequent use of the product. Accordingly, during processing, conditions have to be controlled to either suppress or enhance the extent of completion of these unit processes. The purpose of this report is to review laboratory testing as the basis for engineering modern sintering and pelletizing plants. Considering that most typical applications are for the iron and steel industry, agglomeration of ferrous materials is reviewed and discussed. When these total processes are adapted to suit non- ferrous materials, chemicals, or non-metallic substances, the over- all approach remains the same; only the processing parameters are affected as necessitated by the different nature of the materials.

Jan 1, 1977

By Frederick Laist

Introduction IN a leaching process, having obtained the copper in solution, the choice of the precipitation method is influenced y the following factors: 1. Availability of precipitant. 2. Adaptability to the leaching process. 3. Final product desired. 4. Regeneration of leaching solutions. 5. Fouling of solutions. There are three general classes of precipitation methods: 1. The use of iron, scrap or sponge. 2. Electrolytic deposition. 3. The use of some gas or reagent y which the copper is obtained, usually in the form of an intermediate precipitate which requires further treatment. For example, the precipitation of the copper as Cu2Cl2 from chloride solutions, with SO2 gas. The use of iron is adapted to almost any process. It has the great advantage of extreme simplicity, and the recovery of the copper and any values present in a highly concentrated, easily treatable form. The disadvantages are the cost in isolated places, the uncertainty of the scrap-iron market, and the fouling of the leaching solutions. The latter is a serious factor, When a reagent such as salt is used in them, which makes necessary their re-use. Where applicable, electrolytic deposition is very attractive. The copper is obtained in a form directly marketable, there is a regeneration of acid amid no fouling of solutions. Unfortunately, chloride solutions do not lend themselves to electrolysis. An entirely satisfactory anode material has not yet been discovered, although magnetite, apart from being rather brittle, seems to answer the requirements fairly Well.

Jan 7, 1914

By Roy Moore

THE Tom Reed Extension and Big Jim mines of United Eastern Mining Co. are situated in the Oatman district, Mohave County, Ariz., about 28 miles southwest of Kingman, the nearest railway point. Articles descriptive of the mine surface plant, mill construction, and plant operations have been written by Otto Wartenweiler1, the designing engineer; Wheeler 0. North,2 when he was assistant general manager for the company, and Earle M. Bagley, mill superintendent.3 The last article covers average costs for the full time the mill was operated. The geology of the mines is described by F. L. Ransome4 of the United States Geological Survey. Production was started in January,. 1917, and the known orebodies were exhausted in May, 1925, showing a life of seven years and five months. On account of the comparatively short life and the fact that stoping operations were confined to two orebodies, little experimenting was done with mining methods. The two orebodies were in what is generally called the Tom Reed-United Eastern vein, which occupies a fault fissure having a normal displacement of several hundred feet. Seven or eight very productive ore shoots were mined along this vein in a distance of 1 ½ miles, the two worked by the United Eastern being 1 mile apart. The maximum dimensions of the Tom Reed Extension ore shoot were height, 750. ft.; length, 950 ft.; thickness, 48 ft. The vein structure varied from a solid quartz-calcite filling to a series of parallel stringers separated by andesite. From this body, 511,976 tons of ore were mined. (Fig. 1.)

Jan 1, 1928

By W. Francis

OF THE methods that have been used for studying the chemical composition of coal, attack by reagents has not, in general, yielded much information. Most of the reagents used have been strong oxidants such as nitric acid or Schulze's solution. The use of a milder oxidizing agent, such as air at low temperatures, enables progressive changes in the character of the coal substance to be studied and thus helps toward an understanding of its constitution. British bituminous coals frequently have a banded structure. These bands (of four types) can be separated one from another and have been found to possess markedly different chemical characteristics, even when taken from contiguous portions of the same lump coal. It has been found convenient to give each of the ingredients of banded coal a distinctive name, more or less descriptive of its appearance, and the study of the chemistry of bituminous "coal" in England has resolved itself into a study of each ingredient separately. . The coal chosen for this work was taken from the Top Hard seam at East Kirkby colliery, Nottinghamshire, a detailed chemical analysis of which has been recorded by Baranov and Francis.1 The banded structure was well marked and the bands could readily be separated. The research was confined to the brilliant vitreous bands (vitrain), the dull hard bands (durain) and the "sooty partings" (fusain); for previous work had shown that the fourth type, to which the name clarain has been given, is intermediate in character, chemically, between vitrain and durain.

Jan 3, 1925

By J. Lyndon Rosenblad

This chapter describes the development of a rocklike model material for use in tests with a rock-blocks model to investigate the failure mechanism of a discontinuum. In order to provide reliable results, the model material must be characteristic of natural rock and obey the laws of similitude. Initially, the development of such a material does not appear to be a difficult problem. Only when one undertakes such a task does he realize how little is actually known, and that there is considerable work yet to be done. A material that simulates rock in all of its physical properties probably will never be developed. There is now and probably always will be room for improvement. Improvement is needed not only in the component materials but also in the technique of preparation. The material developed and subsequently described in this chapter simulates rock in general and a schistose gneiss rock in particular. The material possesses many rocklike physical properties not found in previously used model materials. One of the most significant improvements of this material is that there is an increase of Young's modulus with an increase in confining pressure as determined by triaxial compression tests. A change in the usual procedure of material preparation was used to develop this material and is also described. MODEL MATERIALS USED IN THE PAST Intact Materials Numerous materials have been used by investigators in models in the past to simulate a wide range of prototype materials. Some of the materials used include cork, plastic, concrete, plaster of Paris, portland

Jan 1, 1972

By C. S. Duncan, S. Scuro, D. R. Muss

Work is vepurted which was aimed at accentuating the pec14liar attributes of the GaAs laser diode, namely its sutzull size and its high efficiency. This has been done by reducing- transport losses in the bulk p and n regions of the diode and combining many of. these diodes into series stacks with common optical cazlities. The result of this effort is a nearly monochromati source at about 8450A With a luminous areu 0.05 by The GaAs laser diode is an attractive pulsed light source in the near ir because of its ability to emit very large pulse powers and its small size. In addition to this, the device is efficient; and the higher the 0.05 cm emitting peak pulse po we rs at greater than 300 LC at repetition rates below 200 pps into a cone about 0.01 steradians when operated at 77°K. The results of nzeasuvetnents of peak optical power and spectra frorr~ these stacks are reported and some conclusions are drawn about the vole the individual diodes play in the stacked operation. peak output power, the more efficient it is. The limit for the amount of power that these diodes can emit is the transient and average dissipation associated with the pumping pulse. This power dissipation arises primarily from transport across the bulk regions of the diode; this fact, along with the relatively low thermal conductivity of the GaAs, led us to the conclusion that higher power

Jan 1, 1968

By Clinton M. Young

The experiments herein described were carried on in 1908-9 by- the State Geological Survey of Kansas. Some months before taking up work on black powder the Survey had resumed work on an interrupted investigation of explosions in coalmines, a subject which is engaging the attention of numerous investigators. An unusual number of serious disasters has directed to the subject a study which discloses the disquieting fact that, in the United States, the ratio of lives lost per ton of coal mined has been 011 the increase. Methods of coal-mining have changed to some extent with the great increase of output, attained in comparatively recent years. These changes involve the working of very extensive mines, with increased difficulty of ventilation, increased accumulation of coal-dust, and a very great increase in the amount of explosive used. This last point assumes truly startling proportions when it is carefully observed. In the fields of the Middle West it is not now uncommon for a miner to use six kegs (150 lb.) of black powder in a " pay" of two weeks, while within the memory of men still active, one keg (25 Ib.) would last two men for a " pay." So great has the use of explosives become in some fields that the skilled coal-miner is hard to find, and the coal is not mined, but blasted. A preliminary study of the subject of explosions in coalmines has led to the belief that the use of large quantities of explosives, in some cases by slightly-trained men, had riot been

Jan 1, 1911

By Norman J. Sather

LOCATION AND HISTORY The Bunker Hill Mine is situated on the south side of the Coeur d’Alene River in Shoshone County of Northern Idaho near the City of Kellogg. Kellogg, the largest in the Coeur d’Alene District cities, is at an elevation of 2,300 feet and has a population of approximately 7,000 people. It can be reached by air, railway or highway. The history of the Bunker Hill Mine dates back to August 26, 1885, when Noah S . Kellogg found the outcrop of the Bunker Hill ore body on the hillside above the present town of Wardner, Idaho, in Milo Gulch. A small concentrator was erected in 1886. Before the railroad came, the mine output was transported by mule teams to the head of navigation on Coeur d’Alene Lake. After ten years of production, an interest was purchased in the Tacoma Smelter at Tacoma, Washington, to which the entire output was shipped. In 1916 and 1917 a modern lead smelting plant and refinery was erected and in 1927 and 1928, a modern Electrolytic Zinc Reduction Plant was built and put into operation by the Sullivan Mining Company which was 50% owned and now totally owned by The Bunker Hill Company. GEOLOGY AND MINERALOGY The Bunker Hill ore bodies are found in gray and greenish gray quartzite and argillaceous quartzite of Precambrian age and are known as the Revett and St. Regis formations. Most of the ore bodies are found in the St. Regis formation.

Jan 1, 1970

By Albert J. Phillips

As early as 1824, Haidinger' described crystals of native copper that were, according to Dana,2 " probably twinned parallel to the octahedral plane and normal to this axis." In 1837, Rose3 very clearly demonstrated that native copper crystals were commonly twinned on the octahedral plane. Lasaulx,4 in 1882, described polysynthetic octahedral twins and stated that enclosed twinning lamellae were observed. Even on crystals formed artificially by electrolysis, twinning was observed as early as 1886, by Brown.5 Many other descriptions of twinning in native copper and in gold and silver are to be found in the literature, and in every case with which we are acquainted the twinning is conformable to the spinel law; i. e., the octahedral plane is both twinning and composition plane. Metallurgists have long been familiar with the straight-sided bars or bands that commonly occur within the irregularly outlined grains of metallic crystalline aggregates. They are certainly found in nearly all metals of the face-centered cubic type after cold working and annealing. If a specimen showing these bands is rotated, keeping the angle of incidence of the illuminating beam constant, they usually exchange color contrast periodically with their respective matrix crystals. Also slip lines, when produced in these specimens, nearly always show a change in direction upon passing through the bands, giving rise to the "stairway" effect often illustrated in metallurgical textbooks. Apparently the only quantitative observations on bands of this sort were made by Osmond and Cartaud6 on austenitic steel. They selected,

By Ben L. Seegmiller

Introduction The profitability of an open pit operation depends to a large extent on the use of the steepest pit slopes possible, provided they do not fail during the life of the mine Optimum pit slopes can be designed by using rock mechanics technology. Such technology includes gathering and analyzing pertinent data prior to pit design, rigorous application of rock mechanics principles during the design process, remedial actions to improve slope stability, and monitoring slopes during the life of the mine. Ignoring rock mechanics technology in pit design may place the entire mining enter- prise in jeopardy Disruption of mining operations and safety hazards caused by slope instability can be severe. A classic case in point is the major slope failure (Seegmiller, 1972) that occurred at a southwestern US copper mining operation in 1970-1971 Minor slope stability problems initially amounted to no more than a nuisance, but in time, the unstable zones became larger, causing greater disruption of production and threatening safety Mining at or near the slide toe had continued throughout the period of slope failure, aggravating the already unstable condition The original plan for this pit called for mining the overall pit slope to 37.5" Mine operators were forced to lessen the back- slope angle in the hope that the failing rock mass would stabilize. However, stabilization did not take place, and when mining in the area of failure was completed, the overall slope had been reduced to approximately 27" Mining had been successful in removing only a small portion of the ore body at a high stripping ratio.

Jan 1, 1979

By L. H. Marshall

MALLEABLE-IRON castings frequently are made brittle by hot-dip galvanizing. The castings may be and usually are perfectly normal before the hot-dip treatment, in that they will stand a remarkable amount of distortion and punishment before fracturing, yet, after galvanizing, a single blow with a hammer will often cause a break. One such casting broke when accidentally dropped on a concrete floor. Such weakness causes galvanizers to view malleable cast iron with misgivings, and, in turn, is a source of worry to the manufacturer of the castings. It is felt, therefore, that a practical method of overcoming this embrittlement, a method that has already been used on several thousand tons of castings, will be of general interest. The purpose of this paper is to describe this immunizing process. DEVELOPMENT OF THE PROBLEM In the early days the trade was not much concerned with the finish of the castings and in most cases the only protection given to the parts placed in service was a coat of paint. It was soon found that this form of protection was inadequate and the user demanded a better type of rustproofing. In compliance with this demand, the use of zinc for coating gradually spread until it became general practice. More than half of all the zinc produced today is used for coating iron and steel, and, in spite of the recent use of cadmium and chromium, zinc coatings are still recognized as among the best general rust inhibitors for atmospheric exposure.

Jan 2, 1926

By F. F. Frick, Frederick Laist

In a leaching process, having obtained the copper in solution, the choice of the precipitation method is influenced by the following factors: 1. Availability of precipitant. 2. Adaptability to the leaching process. 3. Final product desired. 4. Regeneration of leaching solutions. 5. Fouling of solutions. There are three general classes of precipitation methods: 1. The use of iron, scrap or sponge. 2. Electrolytic deposition. 3. The use of some gas or reagent by which the copper is obtained, usually in the form of an intermediate precipitate which requires further treatment. For example, the precipitation of, the copper as Cu2Cl2 from chloride solutions; with SO2 gas. The use of iron is adapted to almost any process. It has the great advantage of extreme simplicity, and the recovery of the copper and any values present in a highly concentrated, easily treatable form. The disadvantages are the cost in isolated places, the uncertainty of the scrap-iron market, and the fouling of the leaching solutions. The latter is a serious factor, when a reagent such as salt is used in them, which makes necessary their re-use. Where applicable, electrolytic deposition is very attractive. The copper is obtained in a form directly marketable, there is a regeneration of acid and no fouling of solutions. Unfortunately, chloride solutions do not lend themselves to electrolysis. An entirely satisfactory anode material has not yet been discovered, although magnetite, apart from being rather brittle, seems to answer the requirements fairly well. The use of a method of the. third class is involved in many special

Jan 1, 1915

By Ben L. Seegmiller

Artificial support of rock slopes in mining applications may consist of rock anchors with and without auxiliary support systems, but- tresses or shotcrete. The use of artificial support systems is not applicable in all cases of slope instability. Some pit slope problems simply cannot be cured with a support system. In other cases, a sup- port system which would solve the problem would be uneconomical. Rock anchor design may be undertaken using an active or tensioned system or a passive or untensioned system. Failure problems to which artificial support systems are most commonly applied include planar, wedge, rotational and toppling failures. Design of auxiliary support systems and rock anchor peripheral items may be initially estimated using analytical concepts, but field trials are commonly used to determine final requirements. Field procedures usually require a close coordination between mining personnel and the support installation team. Great care must be exercised during installation to prevent numerous potential problems including poor anchorage, excess bearing and corrosion. Displacement monitoring of the completed system is a must if the effectiveness is to be closely judged by means other than total slope and/or support system failure. The cost of a support system is relatively high when compared to other remedial measures that may be taken to solve a slope instability problem. Therefore, the system costs play a vital role in determining whether or not artificial support should be considered beyond the initial assessment stage. Case histories are few, but do include examples of each type of support system.

Jan 1, 1983

By A. R. Troiano, W. J. Barnett

IN recent years the demands of space limitations and increased loads, particularly in the aircraft industry, have accelerated the trend toward utilization of ultra-high strength steels. The increased application of such steels has focused attention on the phenomenon of delayed failure or static fatigue. Parts subjected to a static load, after successfully sustaining the load for an extended period of time, may fail in a brittle manner. Subsequent examination of such failed parts by conventional laboratory tests in many cases reveals no apparent signs of embrittle-ment. That is, the material exhibits good ductility and impact resistance. Furthermore, consideration of the service conditions (environment and temperature) under which this brittle failure occurred eliminates its classification as a stress-corrosion or creep type of failure. Recently this unique time dependent fracture process has been the subject of numerous investigations. The most significant result of these studies was the recognition of hydrogen as the source of embrittlement. While the effect of numerous variables on the occurrence of static fatigue failure has been defined, an adequate explanation of these behaviors is lacking. The occurrence of this phenomenon in steels generally has been limited to strength levels in excess of 180,000 lb per sq in. Although steels at high hardness levels have exhibited delayed failure in the absence of hydrogen introduction after heat treat-ment,'.' this behavior was most prevalent when the material in processing had been subjected to an environment conducive to the absorption of hydrogen. Delayed failures have been produced in high strength steels by the introduction of hydrogen

Jan 1, 1958

By John Sasadi, Karl Heinz Zepter, Leonard Sugin, Roger L. Hulette

Mt. Newman Mining Co. is now completing an expansion program, begun even before initial construction was complete, which will result in the ability to ship up to 35 million tpy of iron ore by early 1973. Located in the Pilbara region of Western Australia, the mine at Mt. Whaleback is about 700 road miles north of Perth and 265 railroad miles south of the port facilities at Port Hedland. Development of the tertiary crushing and screening facilities best illustrates the orderly, but rapid, sequence through which the capacity of the port loading terminal has been expanded. When the present program is completed, crushing and shiploading capability will reach - - 35 million tpy. Operations commenced in 1969 with 3 crusher lines in service; and despite the 5-million annual ton rating, 6.46 million tons of ore were shipped during the first full year of operation. With continuing increase in ore sales, expansion to an annual capacity of 12 million tons was authorized, and installation of two more crusher lines was begun. As a part of this program, provision for installation of a sixth crusher at some future date was included in the planning; but before construction was completed, new ore sales contracts demanded further expansion to an annual rate of 20 million tons, and the sixth crusher line was authorized. The distributing and collecting conveyors had been designed for extension in length and increase in capacity, therefore, conveyor service was provided for the additional crushers with additional belting and hardware only.

Jan 6, 1972