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By J. W. Cunningham, W. A. Tiller, D. H. Lane

The effect of ultrasonic vibrations on ingot solidification has been considered both theoretically and experimentally. The theoretical section elucidates the mechanisms by which the ultrasonic vibrations might refine the ingot structure. The experimental section describes a very efficient means of introducing the ultrasonic vibrations to the freezing interface. The application of this technique to the consumable-electrode arc melting process shows that the columnar mode of freezing may be effectively suppressed yielding an ingot structure consisting predominantly of equiaxed grains. The results support the contention that the ultrasonic vibrations increase the nucleation frequency in the layer of liquid adjacent to the freezing interface. CERTAIN structural characteristics of as-cast ingots are undesirable since they create considerable difficulty for subsequent processing and often produce defects in the finished product. These structural defects are illustrated in Fig. 1(a), and are: 1) planes of weakness where columnar grains growing from the different mold faces meet, 2) strength anisotropy due to the preferred orientation of the columnar grains and 3) inhomogeneity due to segregation at dendrite boundaries within the columnar grains and at the columnar grain boundaries. The type of ingot structure that eliminates 1) and 2) and diminishes 3) is the fine-grained equiaxed structure illustrated in Fig. 1(c). Many attempts have been made to produce the desirable ingot structure illustrated in Fig. 1(c) by inoculating, casting with varying superheats, vibrating or stirring, or by irradiation with ultrasonic vibrations. These attempts have met with various degrees of success, the ingots generally having the structure illustrated in Fig. 1(b). All four methods have been the subject of numerous investigations,1"4 the latter producing the most erratic behavior and inconsistent success. The method of ultrasonic irradiation during ingot solidification has shown considerable promise on small-scale ingots (diam 2 in.) but has not yet been successfully adapted to large-scale operation. The present paper considers the application of ultrasonic radiation to ingot solidification both theoretically and experimentally. The purpose of the paper is to elucidate the mechanism by which ultrasonic energy refines the ingot structure and to describe a method for producing the desirable ingot structure in both laboratory scale experiments and in ingots of commercial size. THEORY Conventional Casting—Before discussing the possible effects of ultrasonic radiation upon ingot structure let us first briefly review the reasons for the breakdown of columnar crystallization to equiaxed crystallization during ingot solidification. The following is a slightly oversimplified description. In the conventional method of casting, the alloy having a certain degree of superheat, T, is poured to fill a cold mold which is at room temperature, Tc,. Due to conduction of heat through the mold wall the outer rim of liquid metal cools rapidly to the liquidus temperature and begins to supercool. At some degree of supercooling, nuclei of solid form at random in this supercooled layer at the mold surface. The grains in this chill layer begin to grow inwards producing a solute build-up, thus lowering the freezing temperature at the interface as illustrated in Fig. 2. As growth proceeds, the temperature gradient in the solid conducts away not only the latent heat of fusion evolved during growth but it also conducts away some of the superheat of the melt so that the temperature

Jan 1, 1961

By C. H. Samans, G. F. Tisinai

HARDENING and embrittlement of the ferritic chromium stainless steels at temperatures near 885 °F have been known for a long time.' However, no satisfactory explanation has been given. Both ordering and precipitation hardening have been suggested. Fisher, Dulis, and Carroll2 discovered a chromium-rich body-centered-cubic precipitate in embrittled alloys. Subsequently, Williams' and Wright4 also have found evidence of this body-centered-cubic constituent. William's hardness, electrical resistance, and magnetic studies led to his proposal of a new constitutional diagram for the Fe-Cr alloys. The new feature of this diagram is the eutec-toidal decomposition, below about 970°F, of the s phase into two stable body-centered-cubic solid solutions, one rich in iron and the other rich in chromium. An observation of Heger5 that the amount of s phase has increased and the amount of chromium-rich body-centered-cubic phase decreased in the interval 5000 to 32,600 hr at 900°F, even though the alloy increased in hardness, casts some doubt on this diagram. If precipitation hardening causes the embrittlement, the precipitate probably is always coherent with the matrix, since no evidence of overaging has been reported. It cannot be stated positively, however, that Fisher's body-centered-cubic constituent is the embrittling phase. According to Preston's data,6 such a chromium-rich phase should have a parameter less than about 0.5 pct larger than that of the iron-rich matrix lattice. Moreover, the constitutional relationships whereby Fisher's constituent forms, and whether it is stable, metastable, or a transition phase, are not yet completely clear. The recent studies of Wright4 and of Lommel,7 as well as the earlier studies of Becket8 and of Hochmann,9 have shown that 885°F hardening occurs in relatively pure Fe-Cr alloys. No evidence of its occurrence or absence in chromium itself has been reported. The rate of hardening in high purity alloys seems appreciably slower than that in alloys containing larger amounts of impurities (chiefly carbon and nitrogen). This may be due merely to the absence of hardening and straining effects from precipitated carbides and/or nitrides. These observations on high purity alloys make it seem unlikely that 885 °F hardening is caused by a constituent containing other than iron and chromium atoms, e.g., carbides and/or nitrides. Wright,4 Lommel,7 and Lena and Hawkes10 emonstrated the accelerating effects of a finely dispersed precipitate of (probably) chromium nitride on the hardening reaction. This appears to be evidence that lattice straining increases the rate of nucleation of the hardening constituent. Some new observations on 885°F hardening are reported here. They show an effect of preheat treatment that should contribute to a better understanding of the 885°F hardening phenomenon. They also clarify a discrepancy which exists in the literature. Some investigators have reported most rapid hardening at 885", whereas others have reported it at 930°F. The present work also shows that 885°F hardening does not occur in electrolytic chromium, and that any long range ordering type of reaction affecting any sizeable part of the volume is unlikely. Materials Studied Table I shows the currlposition of the alloys used in this investigation. In these alloys carbon and nitrogen are present in roughly similar amounts. Presumably both elements precipitate, as carbides and/or nitrides, during the heat treatments given.

Jan 1, 1958

By R. M. Hudson

The removal of nitrogen from a nitrogenized low-carbon sheet steel that contained 0.011 wt pct N was determined during heat treatment in Hz-N, mixtures. TIze process followed a first-order rate law; that is, plots of the logarithm of nitrogen content in steel were linear with the time of treatment at a given temperature. The rate of removal increased with an increase in temperature from 900" to 1300°F. By 1400°F the rate in dry hydrogen had decreased to a value intermediate between the rates at 1200" and at 1300°F; in wet (2.47 vol pct water vapor) hydrogen the rate at 1400°F was less than the rate at 1300°F and nearly the same as the rate at 1200OF. The rate at a given temperature increased as the 3/2 power of hydrogen concentration in the atmosphere. While wet atmosplzeres were generally more effective than the corresponding dry atmosplzeres, the effect of water vapor was much less pronounced than the influence of hydrogen content. NITROGEN is the principal agent in the strain aging of ferrite, the effect of carbon being secondary.' To eliminate the return of the yield point after straining and aging, it is claimed2 that the amount of nitrogen in solution in steel must be reduced to 0.0002 wt pct. Strong nitride-forming elements (titanium, vanadium, zirconium, and aluminum) can act to eliminate strain aging by combining with nitrogen. It is extremely difficult to decrease the nitrogen content in commercial steels to the low level required by conventional coil annealing because of the poor contact between the strip surface and the reactive atmosphere. However, a variety of gas-metal reactions can be effected by use of the open-coil annealing method,3 in which the metal surface is fully exposed to the atmosphere. With this possibility in mind, the Applied Research Laboratory has studied the influence of time, temperature, and atmosphere composition on the removal of nitrogen from low-carbon sheet steel. MATERIALS AND EXPERIMENTAL WORK Samples from a commercial nitrogenized low-carbon steel (0.010 in. thick) in the cold-reduced condition were used. The chemical composition of this steel is given in Table I. The gas mixtures used are listed in Table 11. The moisture content in the "wet" annealing atmospheres was controlled at a +70°F dew point (2.47 vol pct water vapor) by passing the gas mixture through a glass tube packed with a solid mixture of 10 pct anhydrous oxalic acid and 90 pct oxalic acid dihydrate held at 127°F; this technique has been described previously.4 For "dry" atmospheres, the gas mixtures were passed through a cold trap immersed in liquid nitrogen. A hinged-top Hevi-Duty electric furnace was used with a Vycor-glass furnace tube. When the furnace was at the desired temperature, the gas mixture was passed through the furnace at a flow rate between 1.1 and 1.2 cfh; coupons (size 3 by 3/4 in.) of the steel were pulled into the center of the Vycor-glass

Jan 1, 1964

By R. E. Hathaway

INTRODUCTION For a number of reasons, the mineral processing industry has been slow to adopt significant automation of its processes. Most ore grinding operations can be operated manually so the pressure for automation to run the process has not been there. Furthermore, many plants had proven over years of operation that manual operation would produce a profit, so why automate? Until recently, the instrumentation necessary for automation of the grinding process was not available. All this has now changed, however. Increasing costs for labor, fuel, power, grinding media, reagants, and capital equipment have not been matched by the market price of the finished product. This cost-price squeeze has made it mandatory to reduce operating costs and improve the efficiency of the process to remain profitable. A number of other factors have added to the direct operating cost to make the problem even worse. These include environmental pressures to conserve natural resources and reduce smelter stack emissions; increased competition--especially from developing countries, varying economic conditions, stockpiling, governmental controls, and to top it all off, lower grade ore bodies. Although many of these other influences are good overall, they take their toll in cost per ton of delivered product. Fortunately, many operators are finding the solution to the cost-price squeeze in instrumentation and process control. Automated processes yield tighter spec. products, require less operating labor, produce more product from a given plant, and reduce unit cost by increasing process efficiency. The plant manager has a "handle" on the plant through process control so that he can change operating modes as economics dictate by changing the set point of some process controllers. He can even respond to economic conditions by switching control strategies from one that maximizes production to one that maximizes recovery, or minimizes unit cost, etc. This has all been made possible by the advent of on-line analytical instruments and practical process control computers. On-stream particle size (1), x-ray, and silica analyzers are now available and in use in many plants. Digital computer hardware and software has become practical so operators can use it without trying to become computer experts. This chapter describes the approach toward design and implementation of automatic grinding circuit control that has proven to be the most cost effective, based upon results from a number of

Jan 1, 1982

By F. F. Aplan, D. W. Fuerstenau

This chapter presents modern concepts of the flotation of nonmetallic minerals. In particular, it is concerned with such minerals as metal oxides, silicates, sulfates, carbonates, and halides. It is not the purpose to duplicate the two excellent, recent treatises by Gaudin l and by Sutherland and ark,^ but rather to expand their correlations of data, particularly in view of recent, ex- citing new experiments which are shedding new light on the principles of non- metallic flotation. Outstanding success has been achieved over the past 50 years in separating one sulfide from another or from the gangue constituents using a minimal amount of reagents. In contrast to this, selective flotation in nonmetallic systems is often difficult in that one class of compounds alone, the carboxylic acids, may float nearly the entire array of nonmetallic minerals under the appropriate conditions. Moreover, while lime, cyanide, sodium sulfide, and copper sulfate constitute the principal modifiers used to obtain selectivity among the various sulfides, the nonmetallic mineral flotation engineer is con- fronted with a vast array of modifying reagents. In sulfide and native-metal flotation, a strong chemical adsorptive bond is generally formed between the mineral and sulfhydral collector. In fact, re- cent radio-tracer studies show that below monolayer coverage as much as 98% of added mercaptan is adsorbed on the surface of gold.? Contrasted to this, Bloecher's data indicate that for the quartz-amine system only about 60% of the collector is adsorbed.4 This greater residual concentration in the solution results from weaker forces of adsorption in the quartz-amine system. In the flotation of nonmetallic oxide minerals, collector adsorption results from rather weak physical forces, primarily electrostatic attraction and van der Waals attraction between hydrocarbon chains. In the flotation of salt-type minerals, carboxylic acids are adsorbed both by physical and chemical forces. It is a study of the effect of the electrical forces superimposed on the chemical adsorptive forces that contributes most toward understanding nonmetallic mineral flotation. The need for quantification of general rules for the flotation of nonmetallic minerals is so great that Taggart 5 with unmasked sarcasm suggested that after trying anionic and cationic collectors:

Jan 1, 1962

By M. H. Pilkuhn, H. Rupprecht

p layers on n-type substrates of GaAs were prepared by difhsion of zinc into these substrates. Experimental details about the diffusion technique will be presented. It will be shown that inhomogeneity in the substrate doping level and crystal shucture defects cause nonplanarity in the junction plane. These nonplanarities give rise to high threshold current densities. From incremental sheet-conductivity measurements the zinc profile is derived. Data about surface concentration and gradient of the zinc concentration at the junction are presented. Finally, some results of laser diodes, which were made of wafers with extremely planar diffusion fronts, are discussed. ThE investigations reported here are part of a program concerned with the materials aspect in the fabrication of GaAs laser diodes. This includes studies of the influence of crystal defects introduced both during the growth of the crystal and as a consequence of subsequent diffusion. Compared with the progress made in the investigation of structure defects, for instance by X-ray microscopy in materials like silicon, no similar results are known so far for the case of GaAs. The further progress in laser diodes will depend very much upon our knowledge of these structure defects and subsequently upon our ability to avoid them. Laser diodes of GaAs had been made mostly by diffusing an acceptor impurity, normally zinc, into an n-type substrate. This procedure was found more convenient than the inverse one for various technical reasons. We will follow this line and restrict ourselves to zinc diffusion only in this paper. DIFFUSION TECHNIQUES AND EXPERIMENTAL DETAIL In order to set a refgrence for our experiments, we used a standard procedure for the diffusion runs. The diffusions were carried out in a sealed quartz tube for 2-1/2 hr at 850°C. One milligram zinc arsenide (ZnAsz) per cu cm of the tube volume served as zinc source. Under these conditions the junction depth was between 25 and 30 p. It is assumed, according to the investigations of the zinc arsenide system by V. Lyons and V. ilvestri,' that ZnAs2 dissociates completely at 850°C into ZnsAsz and Asg. Since there is a condensed phase of ZnsAs2 in the tube at 850°C, the partial pressure of zinc is controlled by the pressure of the arsenic formed by the dissociation of ZnAs2. Due to the fact that the zinc partial pressure resulting from the dissociation of ZnsAsz is only a weak function of the partial pressure of arsenic, the amount of the initial ZnAs2 is not very critical. Experimentally, we found that the junction depth, as well as the surface concentration, was practically the same, if the ingots of ZnAs2 varied between 0.2 and 5.0 mg per cu cm. The wafers were oriented with the main faces in (100). Surface damage due to cutting and lapping was removed by a chemical-etch treatment in a rotating beaker (etch solution: HzSOr, H202, and HzO in a ratio 3:l:l). The GaAs substrate material was n type and doped with tellurium, selenium, silicon, or germanium. It was grown by means of horizontal or Czochralski techniques. After the diffusion process, junction depth and planarity were checked either by grooving with a

Jan 1, 1964

By R. H. Jacoby, V. J. Berry

Future depletion performance and ultimate oil recovery from reservoirs producing under volumetric control are often predicted with the aid of a material balance equation. When the reservoir fluid is very volatile, however, certain assumptions implicit in the use of the conventional methods are no longer valid. This is became laboratory differential vaporization test procedures do not adequately represent the reservoir depletion process and the performance of surface separation facilities. In such cases recovery of stock tank oil per unit of pressure decline can be predicted only from a detailed knowledge of the separator conditions and the over-all composition of the fluid entering the wellbore at each stage of depletion. Surface recovery is not simply related to the total quantity of liquid flowing into the well under reservoir conditions. In order to improve predictions for reservoirs which produce volatile oils, a step wise method of calculation has been developed. This method uses relative permeability data and multicomponent flash calculations to predict oil and gas production as a function of reservoir pressure. Calculations are presented for a reservoir containing a volatile crude oil, and predicted tank oil recovery by primary depletion is more than twice that predicted by conventional methods which are known to be adequate for ordinary black crude oils. Calculated maximum produced gas-oil ratio is less than one-fourth of the conventional prediction. Wellstream compositions have also been used to determine variation in stock tank oil composition and liquid content of the separator gas. This information is of particular importance for crude stabilization calculations and for design of gasoline plant facilities to recover LPG and natural gasoline. INTRODUCTION The estimation of oil reserves and the prediction of future recovery performance of petroleum reservoirs is a frequent task of the petroleum engineer. If the reservoir produces under volumetric control, performance calculations for primary depletion are made by combining oil and gas material balances with the gas-oil flow characteristics of the reservoir rock. For black oil reservoirs, the Schilthuis1 type material balance is commonly employed. For gas or gas-condensate reservoirs, where only one phase is flowing under bottom-hole conditions, a more simplified material balance is used. In the period in which these material balance methods were conceived and put into practice, it was common to classify reservoirs according to the type of fluid produced as (1) black oil reservoirs, or (2) gas or gas-condensate reservoirs. Recently, however, deeper drilling and more extensive studies of reservoir fluid properties have led to the recognition of reservoir fluids with phase characteristics between those of ordinary black oils, and gases or gas-condensate fluids. These intermediate fluids contain relatively large amounts of the hydrocarbons ethane through decane and are found in deep, high temperature (250°F) reservoirs. Such fluids are often referred to as high shrinkage crudes or "volatile oils." They are usually characterized by tank oil gravities above 45° API. high solution gas/oil ratios,

Jan 1, 1958

By L. A. Rapport, J. R. McCord, W. P. Drews, K. H. Coats

Water movement about an oil or gas reservoir can be predicted provided an aquifer influence function is known. This function is generally determined from an electric analyzer study or by fitting an idealized mathematical model to field data. A prohlem arises in determining that influence function which best reproduces field data and satisfies certain smoothness requirements, without making any idealizations concerning aquifer geometry and heterogeneity. This study shows the problem to be solvable through the linear programming technique and presents applications to one oil reservoir and two gas storage reservoirs. In addition, a theorem is stated and proven which confirms influence junction smoothness requirements heretofore accepted on physical intuition and establishes additiotzal smoothness constraints formerly not recognized. INTRODUCTION The pressure decline accompanying production results in water encroachment into oil and gas reservoirs situated adjacent to aquifers. The importance of this water movement derives from the significant dependence of production rate upon reservoir pressure and of pressure, in turn, upon water encroachment. Pressure and rate of water movement are uniquely related through an "influence" function which may be in the form of reservoir pressure response to a unit water encroachment rate or of water movement caused by a unit reservoir pressure drop. This influence function reflects the heterogeneity and geometry of the aquifer and is therefore particular to each reservoir. If the influence function is known, then reservoir pressure may be predicted from a production rate schedule, or vice-versa, with the aid of the material balance equation which relates water influx to reservoir production and pressure. The problem of determining this influence function for a given reservoir has been approached in three different ways. Van Everdingen and Hurst calculated and tabulated certain influence functions pertinent to idealized mathematical models which satisfy simplifying assumptions such as aquifer homogeneity and elementary reservoir-aquifer geometries.' Other studies developed additional tables for a variety of elementary reservoir-aquifer geometrical con- figurations and demonstrated their validity and utility.:' Hicks, et al. described the use of an electrical network to determine an influence function giving "best" match of field history and allowing prediction of future performance.' Finally, Hutchinson and Sikora5 and Katz, Tek and Jones attempted to develop a calculation method for deriving the influence function directly from field data with no idealizing assumptions concerning aquifer geometry and homogeneity. They encountered difficulties with inaccuracies in field data and with satisfaction of well-known smoothness requirements of the influence function. This study is concerned with the determination of influence functions from field data and, more specifically, treats the following problem: given field pressure-production data of arbitrary accuracy, how does one determine the influence function which, subject to satisfaction of known smoothness requirements, gives best agreement with field history? A rigorous solution to this problem is ohtained through linear programming as described below. Example applications to one oil and two gas storage reservoirs are presented. In addition, a theorem is proved which confirms influence function smoothness requirements heretofore accepted on physical intuition and establishes additional smoothness requirements formerly not recognized.

Jan 1, 1965

By T. D. Tiemann

The caustic extraction of silica from Wisconsin and Minnesota taconite was investigated by bomb digestion over the temperature range from 312 to 40S°F at caustic concentrations from 25 to 500 gpl. Residual concentrates containing as much as 65 pct iron were obtained. The high rate of silica extraction is related to a microcrystalline variety of quartz, since it is shown that the rate of extraction of silica from quartz is directly proportional to its surface area. Increasing dependence on foreign ore reserves makes the need for developing the technology necessary for treatment of our low grade ores even greater than it was at the time of World War 11, when much research was conducted on the extraction of alumina from clays. Representative of these were the studies carried on at the University of Illinois.' More recently, the U. S. Bureau of Mines investigated the production of alumina from anorthosite, and currently the aluminum industry is showing renewed research interest in this field. The studies reported here are part of a continuing research program based on the above concepts and aimed at the eventual development of processes for the treatment of low grade ores, particularly those of iron. The fact that large reserves 3 of low grade nonmagnetic taconite are contained in the iron formation of the Wisconsin Gogebic range have made this ore an important and attractive target for investigation. The idea of removing silica by caustic extraction is not new.495 The digestion in caustic solution of ground flint, diatomite, and other forms of chalcedonic silica is the basis for the production of soluble sodium silicates by the wet-process. Upgrading bauxites by the caustic extraction of silica has been investigated6 and is the subject of a German patent.7 Although mention is made by Roe' of the caustic extraction of silica from low grade Michigan and Wisconsin iron ores, and he lists a number of patents and references on the subject, recent work in the field does not appear to be extensive. As far as the author knows, there has been no work in this field on these particular ores. It is hoped that this paper will stimulate further investigation which will eventually lead to an econclmic means of processing these large low grade reserbes. TACONITES The taconites investigated in this study were from Minnesota and Wisconsin. That from Minnesota, a semi-taconite, Nas obtained from the Oliver Iron Mining Division, U. S. Steel Corporation, and represents a sample of an oxidized iron formation from their King Mine on the Mesabi range. The Wisconsin taconite came originally from the trench sampling of the U. S. Bureau of Mines, and represents a composite of the Norrie, Pabst, Yale, Plymouth, and Pence members of the Gogebic iron formation. Assays on these samples are given in Table I. A typical calcu1atr:d average analysis of the Wisconsin taconite is given in Table 11. Chemically, the Minnesota semi-taconite sample contains about 39 pct iron and 39 pct silica, while the Wisconsin taconite contains 30 pct iron and 53 pct silica, both on the dry basis.

Jan 1, 1962

By J. B. Conway

RECENT studies of first-stage creep data have led to a special least-squares procedure for use in calculating the Andrade creep-equation constants. This procedure is easy to apply, uses only experimental data, and yields results which do not vary with the individual making the analysis. Taking logarithms of the Andrade equation I = lo(1 +ßl1/3)ekt leads to In l = In lo + In(1 + ßl1/3) + kt A residual can then be defined as the difference between the logarithm of an experimental length value and the logarithm of a calculated length value. Following the usual least-squares approach differentiation with respect to 10 and k of the expression for the sum of the squares of the residuals leads to two equations which cannot be solved directly for the three constants involved. However, values of ß can be assumed and corresponding values of lo and k can then be calculated. Then the sum of the squares of the residuals can be calculated. For a certain value of ß this sum will exhibit a minimum value to identify the least-squares values for ß, lo, and k. An illustration of the application of the above least-squares approach is obtained by employing the creep data for lead originally presented by Andrade' in the development of the one-third creep law. A plot of the sum of the squares of the residuals as a function of ß is shown in Fig. 1 along with the corresponding lo and k values. The minimum is seen to occur at ß = 0.0143 from which lo = 39.149 and k = 7.27 x 10-5. Based on these results the Andrade equation for these lead data is 1 = 39.149(1 + 0.0143 t1/3)e7.27 x 10-5t compared to the equation I = 39.13(1 + 0.01457/l/3)e6.95 X 10-5t developed by Andrade (calculation procedure not given but was probably a graphical solution). Calculating length values using the above equations and comparing with the experimental length values, residuals corresponding to the difference between experimental and calculated length values can be obtained. The sum of the squares of the residuals can then be calculated. For the case of the least-squares approach a value for this sum was found to be 2.37 x 10-3 compared to a value of 3.47 x 10" for the equation originally proposed by Andrade. In other words, while the constants proposed by Andrade provide an excellent fit for the lead data, a still better representation is afforded by applying the least-squares approach discussed above. A similar result was obtained for the lead data at 162oc.l The least-squares approach led to 1 = 9.866(1 + 0.0497 t1/3)el.011 x 10-2t compared to the equation I = 9.94(1 + 0.0433 l1/3)e1.06 X 10-2t given by Andrade. In this case, too, the sum of the squares of the residuals is slightly smaller for the equation based on the least-squares approach. It should be pointed out that a double trial and er-

Jan 1, 1965

By A. W. Schlechten, W. J. Kroll

As this paper is written, the only method for the commercial production of lithium metal is by the fusion electrolysis of LiCl-KCl mixtures, as first proposed by Guntz.2 The details of the industrial process have not been made public but Osborg8 stated that an efficiency of more than go pct is obtained with a lithium metal recovery above 95 pct and that the metal is 99.5 pct pure. Pletenev9 gave a power consumption of 66 kw-hr per kilogram of lithium metal produced with a salt consumption of 9 kg of LiCl and 0.4 kg of KCI. Pletenev's figures indicate a somewhat lower recovery than that given by Osborg. In a recent report on German lithium plants, Motock7 gives figures that are also less favorable than those reported by Osborg. At the German plants the lithium recovery in electrolysis was only 83.4 pct, with a power consumption of too kw-hr per kilogram of lithium. The metal averaged only 97 pct pure, with sodium and potassium as the chief impurities. The presence of SO2, SO3, Si02, Ba, Ca, and appreciable amounts of Na and Fe2O3 were especially disturbing in the electrolysis, and it was necessary to run the cell for some time to eliminate most of these impurities and condition the bath. It may be noted here that most of these impurities do not interfere with a thermal reduction process. These facts show that the present method of producing lithium is fairly efficient and would suggest that other methods could not compete. However, fusion electrolysis has certain drawbacks, such as the necessity of supplying costly, low-voltage direct current and of collecting and processing the anodic chlorine if it is not to be wasted. An even greater disadvantage is that lithium chloride must be used for an electrolyte. It is one of the most expensive salts of lithium, since it cannot be produced in anhydrous form by precipitation from aqueous solution, as is done with LiF or Li2CO3. The reduction of lithium by a vacuum process similar to the ferrosilicon method for the production of magnesium would have certain advantages. Small units, such as Pidgeon retorts, would give flexibility of production to meet demand, and a small plant would require moderate capital outlay. There is a possibility of using idle Government-owned magnesium plants for such purposes. The raw materials needed for vacuum thermal reduction would not have to be extremely pure, especially with respect to the iron and calcium content. This paper describes a series of experiments to determine the effectiveness of various agents for the reduction of lithium compounds. The investigation is part of a program of vacuum metallurgy con-

Jan 1, 1947

By R. A. L. Black, J. E. Jennings

The problems of slope stability in open cast mines are examined. A criterion, the instantaneous stripping ratio, is suggested for use in the design of pit slopes and as an index of control at all stages of the exploitation of the orebody. This criterion may also be related to safety and to the maximizing of profits. Two approaches to safe design of slopes, one from the point of view of soil mechanics and the other from the point of view of rock mechanics, are described and critically compared. The effect on slope stability of the regional tectonic stress field is discussed. Explanation is given of the application of the Terzaghi effective stress concept to problems in both soil and rock environments, including possible effects when borehole deformation techniques are used to measure stresses in rock in situ. A company embarking on open cast mining is faced with two basic questions: 1) will the venture be profitable and 2) can it be carried out with safety? The two questions are obviously interrelated because both depend upon the slope angles adopted for the pit. The cost of open cast mining depends largely upon the stripping ratio, defined as the volume of overburden that must be removed to the volume of ore recovered. The steeper the slope angles, the more favorable the stripping ratio, but the stability of the slopes, and therefore the safety of men and materials in the pit, require that the angles be made relatively flat. Consequently, the design depends upon a compromise: the slopes must be steep enough to result in economical mining and flat enough to ensure safety. Today there is a world trend towards deeper mining by open cast methods. This is mainly due to the higher cost of underground mining and the lower cost of open excavation resulting from the introduction of large modern earth and rock-moving machinery. Deeper open cast mining has led to a very great increase in the volumes of wasted overburden, and much thought is being given to the considerable economic benefits which would result if pit slopes could be made steeper by even one or two degrees. The result has been an increasing interest in research into slope stability problems in the expectation that the application of scientific principles will provide solutions leading both to economies and to more predictable operation of the mines. In at least four places, the U.S., Australia, Western Germany and Southern Africa, comprehensive investigations are at present in progress, and it is the object of this paper to review some of the more important aspects of these programs. RELATION BETWEEN ECONOMY OF OPERATION AND SLOPE ANGLES The main object of any industrial enterprise in a free economy is to make a profit. In mining, where profits must be made from a wasting capital asset, a further definition of the profit motive is imposed, namely that the economic aim should be to maximize the total possible profit. But since profits deferred for a number of years are not as valuable as profits that are immediately available, it is usual to discount deferred profits at some rate of interest which reflects their current or present value in the hands of the investor. Thus, in mining the logical aim can be defined more closely still: to maximize the present value of the total future profits. In commercial terms the present value represents the market value of the operation as a going concern. Many factors enter into the forecast of current and future profits. They include the volume of production, the price of the salable product and the cost of production. Current profits can be estimated with reasonable accuracy by the operating engineers; but it is the task of economists and management to assess future trends in the mineral markets and in the economy as a whole, and together with the engineers, they can then estimate the future cost and profitability of the mining operations. In open cast mining, the rate of ore production once decided on remains a virtually constant factor unless a major change in the capital structure of the mine is made. But one factor over which the operator has a considerable measure of control is the ratio of the volume of ore mined to the volume of waste over-

Jan 1, 1963

By Elton A. Youngberg

J. H. HEARDING, Jr.*—Extremely hard ferruginous chert (taconite) was encountered in driving a drift at the Fraser underground mine near Chisholm, Minn., on the Mesabi Iron Range. In order to get better results in drilling in this ground, it was decided to try tungsten carbide bits. In the beginning, 1½ in. tungsten carbide bits and 1 1/8 in. round-lugged alloy steel drill rods with "jack-stud" inserts were used. Considerable difficulty was encountered because the jack-stud became loose in the drill rods. Because there was not enough alloy steel drill rod on hand, we began to insert jack-studs in the ordinary high carbon drill rods and found, to our surprise, that there was less trouble with jack-studs working loose in these rods than there had been with the alloy steel rods. As a result, use of the alloy steel rods has been discontinued entirely. Under the heading "Drilling Procedures" the statement is made that all holes are started with detachable bits or conventional steel to prevent undue strain on the tungsten carbide bit inserts when collaring a hole on uneven ground. This practice was followed in our work originally for the same reason. It was soon found, however, that the holes could be started with the tungsten carbide without injuring the inserts if the drill operator was careful and did not give the drill too much air until the bit had a chance to seat itself in the rock. J. C. FRANZ*—In a discussion of other technical papers with reference to percussion drills and the use of carbide tungsten bits, it was my impression that the authors reported one of the first difficulties experienced with the use of standard, conventional percussion drills, was insert bit failures due to crushing of the bit inserts when the bits became dull. During the past few years, some of the rock drill manufacturers, I am told, have adopted an air drill for use with the carbide bits that have a lighter blow and faster rotation than the regular machine. This machine has been tested and the carbide bit failures have been considerably reduced. L. W. DUPUY†—The difficulties Mr. Youngberg mentions that were had with rod and coupling breakage call to mind similar troubles experienced at the Picacho mine in California near Yuma.6 The commercial couplings then available were found to be tempered almost to brittleness. Rod breakage was usually in the threads near the end of the rod. The highly-tempered couplings would break as soon as the rod broke. The solution was to thoroughly anneal the couplings and to put in only a very mild temper. Subsequently the alloy used in making the couplings was changed from the original by the manufacturer, but still only a very mild temper was used. The result was that the softer coupling would give but would not snap and release its hold on the broken rod thread. Fishing jobs were reduced to the few where the rods broke at the rod end of the thread. Thread breakage on the rods was further reduced by thorough annealing prior to tempering. The data Mr. Youngberg presents regarding the use of carbide inserts on long blasthole drilling is most interesting and it would appear that the use in this manner of percussion drills and carbide bits will have many applications. W. M. WOODWARD*—How many feet of hole, on the average, do you get from a tungsten carbide bit, and is there much variation from this average? E. A. YOUNGBERG (author's reply) —In recent months the 2 in. tungsten carbide bit footages in long hole drilling hake varied from 115 .to 140 ft monthly. The footages obtained from individual bits vary from several feet to over 300 ft, however the life of a majority of the bits will be within 25 ft of the average.

Jan 1, 1950

By Paul M. Tyler

Higher freight rates and better methods of beneficiation now may make it more economical to open inferior deposits closer to a glass factory than to work higher-grade deposits farther away. Nature of impurities and special treatments as well as common practice of sulphuric acid leaching are described. HISTORICAL concepts of the economics of the glass-sand industry are changing rapidly. The greatly expanded demand for glass containers combined with higher freight rates on raw materials and manufactured products have induced a migration of glass factories toward densely populated centers and the creation of new standards of place value for substandard sand deposits. This migration has been facilitated by the construction of pipelines to bring cheaper natural gas and liquid fuel to large cities and may be further speeded by the adoption of modern mineral dressing methods to permit economical utilization of local raw materials. Our national resources of naturally high-grade silica sand are abundant, but most of the best deposits are situated so far from large centers of population that it now costs $3.00 to $5.00 a ton to carry the sand from the mine to the optimum site for a factory making beverage bottles, scientific and electrical glassware, and miscellaneous blown and pressed ware for local markets. It follows that on the basis of freight savings alone it may be economical to use material from inferior deposits closer to the factory even though the f.O.b. cost of mining and treatment may be much higher than at a higher grade deposit farther away. Particle-size distribution is a feature of glass-sand specifications. As long as glassmakers insisted upon having their sand principally coarser than 100-mesh, any material was automatically excluded from consideration that could not be purified without fine grinding or other drastic treatment which greatly reduces the size of the quartz grains. However, re- cent large-scale tests in Norway' showed that finely-crushed quartz used in a soda-lime-silica glass batch caused it to melt and become refined appreciably faster than when ordinary coarse (Belgian) sand was employed. Dust losses were negligible. Since the pre-war cost of sand was only 3 pct of the manufacturing cost of the glass, it was deemed economical to pay twice as much for crushed quartz because of the saving in wear and tear on the furnace walls. In the author's unverified opinion, sand ranging in size between 150 and 400-mesh would probably be superior to that in the more usual range of 20 to 100-mesh. Former objections to fine sand (other than dust) were doubtless fostered by the natural concentration of impurities in the finer sizes. Ordinarily the most objectionable, as well as the commonest, impurity from the standpoint of the manufacturer of any but the cheaper qualities of colored glass is iron. No natural sands are really pure silica. Even water-clear quartz crystals are likely to contain impurities in the form of solid solution as well as inclusions which cannot be eliminated except by chemical treatment that will break down the silica lattice. Pure white pegmatite quartz will usually analyze 0.01 pct or more of iron oxide, and ordinary vein quartz and the quartz grains in most

Jan 1, 1951

The papers discussed in the following pages were presented during two sessions of the Geophysics Education Committee of the Mineral Industry Education Division on Feb. 17 and 18, 1941. At the first meeting, to consider the "Influence of Geophysics upon Geology Curricula," this Committee was joined by the Geophysics and Mining Geology Committees of the A.I.M.E., the Society of Economic Geologists, representatives of the American Geophysical Union, and delegates from the Committees on College Curricula and on Applications of Geology of the American Association of Petroleum Geologists. Quentin D. Singewald and Sherwin F. Kelly presided. At the ensuing session, especially emphasizing the integration of geology, physics and chemistry for the solution of earth problems, the joint participants with the Geophysics Education Committee were the Geophysics Committee, and representatives of the American Geophysical Union and of the Committee on College Curricula of the American Association of Petroleum Geologists. Richard M. Field and W. R. Chedsey presided. In the following summary of the discussion at the two meetings, written discussion submitted subsequently is not differentiated from that offered orally at the session. A provisional report of the Geophysics Education Committee was presented at the second session, and some of the following discussion refers to it. This report has not been printed (it is anticipated that a more comprehensive, final one will be rendered at the 1942 annual meeting). A few mimeographed copies of this provisional report were made. Dr. W. P. Haynes presented some notes prepared by Dr. F. H. Lahee, Chairman of the American Association of Petroleum Geologists' Committee on College Curricula. This Com- mittee's inquiries reveal the general opinion that a four-year academic preparation is inadequate, five or six being advisable. The fundamentals, mathematics, physics, chemistry, and English composition, should be stressed in the first three years, with specialization in the last two or three years. Some companies provide an apprenticeship period, and themselves give additional training. During academic years more attention needs to be given to engineering training, to field mapping, and in geology to stratigraphy and sedimentation. The amount of mere memory work should be cut, and men trained to observe and reason. Dr. Lahee emphasized the need of more adequate preparation in English composition, because of the inability of many graduates to compose acceptable reports. Sherwin F. Kelly pointed out that much time in university training, which ought to be devoted to technical subjects, was taken .up with English courses. He emphasized that it is the part of the universities to demand of the high schools that the students they send to the university be properly trained to speak and write English. Prof. W. T. Thom protested against the crowding of high-school material into already overcrowded college curricula. C. E. Dobbin, chairman of the Committee on Applications of Geology of the American Association of Petroleum Geologists, described briefly the work of his committee in publicizing geology, and said that it found a widespread popular interest in the subject but a lack of appreciation of its importance. He recommended that attempts to coordinate the works of geologists and geophysicists be expanded somewhat toward the further developing and encouraging of a "species of geopolitician" capable of assisting the progress of geology and geophysics by more vigorous advertising of

Jan 1, 1946

The papers discussed in the following pages were presented during two sessions of the Geophysics Education Committee of the Mineral Industry Education Division on Feb. 17 and 18, 1941. At the first meeting, to consider the "Influence of Geophysics upon Geology Curricula," this Committee was joined by the Geophysics and Mining Geology Committees of the A.I.M.E., the Society of Economic Geologists, representatives of the American Geophysical Union, and delegates from the Committees on College Curricula and on Applications of Geology of the American Association of Petroleum Geologists. Quentin D. Singewald and Sherwin F. Kelly presided. At the ensuing session, especially emphasizing the integration of geology, physics and chemistry for the solution of earth problems, the joint participants with the Geophysics Education Committee were the Geophysics Committee, and representatives of the American Geophysical Union and of the Committee on College Curricula of the American Association of Petroleum Geologists. Richard M. Field and W. R. Chedsey presided. In the following summary of the discussion at the two meetings, written discussion submitted subsequently is not differentiated from that offered orally at the session. A provisional report of the Geophysics Education Committee was presented at the second session, and some of the following discussion refers to it. This report has not been printed (it is anticipated that a more comprehensive, final one will be rendered at the 1942 annual meeting), but a few mimeographed copies of this provisional report are at the A.I.M.E. headquarters and will be mailed on request. . Dr. W. P. HAYNES presented some notes prepared by Dr. F. H. LAHEE, Chairman of the American Association of Petroleum Geologists' Committee on College Curricula. This Committee's inquiries reveal the general opinion that a four-year academic preparation is inadequate, five or six being advisable. The fundamentals, mathematics, physics, chemistry, and English composition, should be stressed in the first three years, with specialization in the last two or three years. Some companies provide an apprenticeship period, and themselves give additional training.. During academic years more attention needs to be given to engineering training, to field mapping, and in geology to stratigraphy and sedimentation. The amount of mere memory work should be cut, and men trained to observe and reason. Dr. Lahee emphasized the need of more adequate preparation in English composition, because of the inability of many graduates to compose acceptable reports. SHERWIN F. KELLY pointed out that much time in university training, which ought to be devoted to technical subjects, was taken up with English courses. He emphasized that it is the part of the universities to demand of the high schools that the students they send to the university be properly trained to speak and write English. Prof. W. T. THOM protested against the crowding of high-school material into already overcrowded college curricula. C. E. DOBBIN, chairman of the Committee on Applications of Geology of the American Association of Petroleum Geologists, described briefly the work of his committee in publicizing geology, and said that it found a widespread popular interest in the subject but a lack of appreciation of its importance. He recommended that attempts to coordinate the works of geologists and geophysicists be expanded somewhat, toward the further developing and encouraging of a "species of geopolitician" capable of assisting the progress of geology and geophysics by more vigorous advertising of

Jan 1, 1941

The papers discussed in the following pages were presented during two sessions of the Geophysics Education Committee of the Mineral Industry Education Division on Feb. 17 and 18, 1941. At the first meeting, to consider the "Influence of Geophysics upon Geology Curricula," this Committee was joined by the Geophysics and Mining Geology Committees of the A.I.M.E., the Society of Economic Geologists, representatives of the American Geophysical Union, and delegates from the Committees on College Curricula and on Applications of Geology of the American Association of Petroleum Geologists. Quentin D. Singewald and Sherwin F. Kelly presided. At the ensuing session, especially emphasizing the integration of geology, physics and chemistry for the solution of earth problems, the joint participants with the Geophysics Education Committee were the Geophysics Committee, and representatives of the American Geophysical Union and of the Committee on College Curricula of the American Association of Petroleum Geologists. Richard M. Field and W. R. Chedsey presided. In the following summary of the discussion at the two meetings, written discussion submitted subsequently is not differentiated from that offered orally at the session. A provisional report of the Geophysics Education Committee was presented at the second session, and some of the following discussion refers to it. This report has not been printed (it is anticipated that a more comprehensive, final one will be rendered at the 1942 annual meeting). A few mimeographed copies of this provisional report were made. Dr. W. P. Haynes presented some notes prepared by Dr. F. H. Lahee, Chairman of the American Association of Petroleum Geologists' Committee on College Curricula. This Com- mittee's inquiries reveal the general opinion that a four-year academic preparation is inadequate, five or six being advisable. The fundamentals, mathematics, physics, chemistry, and English composition, should be stressed in the first three years, with specialization in the last two or three years. Some companies provide an apprenticeship period, and themselves give additional training. During academic years more attention needs to be given to engineering training, to field mapping, and in geology to stratigraphy and sedimentation. The amount of mere memory work should be cut, and men trained to observe and reason. Dr. Lahee emphasized the need of more adequate preparation in English composition, because of the inability of many graduates to compose acceptable reports. Sherwin F. Kelly pointed out that much time in university training, which ought to be devoted to technical subjects, was taken .up with English courses. He emphasized that it is the part of the universities to demand of the high schools that the students they send to the university be properly trained to speak and write English. Prof. W. T. Thom protested against the crowding of high-school material into already overcrowded college curricula. C. E. Dobbin, chairman of the Committee on Applications of Geology of the American Association of Petroleum Geologists, described briefly the work of his committee in publicizing geology, and said that it found a widespread popular interest in the subject but a lack of appreciation of its importance. He recommended that attempts to coordinate the works of geologists and geophysicists be expanded somewhat toward the further developing and encouraging of a "species of geopolitician" capable of assisting the progress of geology and geophysics by more vigorous advertising of

Jan 1, 1946

By Paul M. Tyler

Higher freight rates and better methods of beneficiation now may make it more economical to open inferior deposits closer to a glass factory than to work higher-grade deposits farther away. Nature of impurities and special treatments as well as common practice of sulphuric acid leaching are described. HISTORICAL concepts of the economics of the glass-sand industry are changing rapidly. The greatly expanded demand for glass containers combined with higher freight rates on raw materials and manufactured products have induced a migration of glass factories toward densely populated centers and the creation of new standards of place value for substandard sand deposits. This migration has been facilitated by the construction of pipelines to bring cheaper natural gas and liquid fuel to large cities and may be further speeded by the adoption of modern mineral dressing methods to permit economical utilization of local raw materials. Our national resources of naturally high-grade silica sand are abundant, but most of the best deposits are situated so far from large centers of population that it now costs $3.00 to $5.00 a ton to carry the sand from the mine to the optimum site for a factory making beverage bottles, scientific and electrical glassware, and miscellaneous blown and pressed ware for local markets. It follows that on the basis of freight savings alone it may be economical to use material from inferior deposits closer to the factory even though the f.O.b. cost of mining and treatment may be much higher than at a higher grade deposit farther away. Particle-size distribution is a feature of glass-sand specifications. As long as glassmakers insisted upon having their sand principally coarser than 100-mesh, any material was automatically excluded from consideration that could not be purified without fine grinding or other drastic treatment which greatly reduces the size of the quartz grains. However, re- cent large-scale tests in Norway' showed that finely-crushed quartz used in a soda-lime-silica glass batch caused it to melt and become refined appreciably faster than when ordinary coarse (Belgian) sand was employed. Dust losses were negligible. Since the pre-war cost of sand was only 3 pct of the manufacturing cost of the glass, it was deemed economical to pay twice as much for crushed quartz because of the saving in wear and tear on the furnace walls. In the author's unverified opinion, sand ranging in size between 150 and 400-mesh would probably be superior to that in the more usual range of 20 to 100-mesh. Former objections to fine sand (other than dust) were doubtless fostered by the natural concentration of impurities in the finer sizes. Ordinarily the most objectionable, as well as the commonest, impurity from the standpoint of the manufacturer of any but the cheaper qualities of colored glass is iron. No natural sands are really pure silica. Even water-clear quartz crystals are likely to contain impurities in the form of solid solution as well as inclusions which cannot be eliminated except by chemical treatment that will break down the silica lattice. Pure white pegmatite quartz will usually analyze 0.01 pct or more of iron oxide, and ordinary vein quartz and the quartz grains in most

Jan 1, 1951

By C.F. Pascoe, H.J. Roast

The object of this investigation was to compare the arsenical antimony-lead alloy with some of the regular bearing-metal alloys. With this end in view, the following tests were made: 1. Chemical analyses to show the composition. 2. Thermal analyses. 3. Macroscopic examination of fractures. 4.Microscopic examination. 5. Tensile tests. 6. Crushing tests. 7. Scleroscope tests.' 8. Brinell tests, at temperatures from 80' to 400' F. Tests 3 to 8 were conducted on both sand-cast and chill-cast specimens. For the purposes of this paper the alloys have been numbered from 1 to 6; their composition is as follows: Lead. ' Antimony, Tin, CoppeR ARSEnic, NumBeR PeR CENT. PER CENT. PeR Cent. PeR CeNt. PeR Cent. 1 82.64 12.95 4.40 0.01 none 2 27.54 9.04 59.87 2.65 none I 3 none- 0.13 ------------1.47 4 82.95 16.85 none 0.20 none 5 83.78 15.35 none 0.05 0.82 6 0.15 7.87 . 84.13 7.85 none The analysis, in the case of the antimony, was made by solution in sul-furic acid and titrated with permanganate. For tin, the ferric-chloride method was used; for copper, the alkaline separations, and the thio-cyanate methods; for arsenic, volatilization of arsenic and titration with iodine. The lead, with the exception of alloy 6, was taken by difference. With the exception of No. 5, the alloys were taken as received from the manufacturer. About 40 lb, were melted in a graphite crucible and recast into small ingots to insure uniformity of composition; samples

Jan 1, 1923

By C. F. Pascoe, H. J. Roast

The object of this investigation was to compare the arsenical antimony-lead alloy with some of the regular bearing-metal alloys. With this end in view, the following tests were made: 1. Chemical analyses to show the composition. 2. Thermal analyses. 3. Macroscopic examination of fractures. 4.Microscopic examination. 5. Tensile tests. 6. Crushing tests. 7. Scleroscope tests.' 8. Brinell tests, at temperatures from 80' to 400' F. Tests 3 to 8 were conducted on both sand-cast and chill-cast specimens. For the purposes of this paper the alloys have been numbered from 1 to 6; their composition is as follows: Lead. ' Antimony, Tin, CoppeR ARSEnic, NumBeR PeR CENT. PER CENT. PeR Cent. PeR CeNt. PeR Cent. 1 82.64 12.95 4.40 0.01 none 2 27.54 9.04 59.87 2.65 none I 3 none- 0.13 ------------1.47 4 82.95 16.85 none 0.20 none 5 83.78 15.35 none 0.05 0.82 6 0.15 7.87 . 84.13 7.85 none The analysis, in the case of the antimony, was made by solution in sul-furic acid and titrated with permanganate. For tin, the ferric-chloride method was used; for copper, the alkaline separations, and the thio-cyanate methods; for arsenic, volatilization of arsenic and titration with iodine. The lead, with the exception of alloy 6, was taken by difference. With the exception of No. 5, the alloys were taken as received from the manufacturer. About 40 lb, were melted in a graphite crucible and recast into small ingots to insure uniformity of composition; samples

Jan 1, 1923