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By H. T. Kang

Various geological anomalies are encountered in underground longwall mines, and they cause stability problems. In this study, a number of detailed two-dimensional finite-element models were made, consisting of mine floor, roof, coal seam, shield structure, gob, etc. to analyze the influence of geological anomalies on longwall shields. Two different categories of anomalies were simulated. The first ones are shear zone and sandstone channels, with variable sizes and locations in the roof. The second category is fault or fracture plane, with variable friction factors, locations, and orientation of the fracture plane. The results of the analyses are' integrated with an artificial intelligence system for developing a forecasting guideline for prevention of underground hazards due to the existence of geological anomalies.

Jan 1, 1996

By Charles Camsell

Few persons ever stop to consider how vital an influence minerals, and especially metals, have had upon human history, how they have affected the every-day life of the individual or how at different periods they have altered the course of nations and determined their progress. Students and writers of history have dealt very fully with political history and have given us a great deal of detail about the careers and policies of kings, parliaments and nations, but frequently have not touched the economic causes that have been the real forces influencing the development and carrying out of these policies. So far as minerals are concerned there is no single work from which one can get a concise and consecutive account of the growth in the use of minerals, nor of the diverse ways in which the. geographical distribution, the .search for, the development and the use of mineral resources have affected human progress from the beginning of man's history. The reason for this is quite plain, and when one takes a little time to think of it he begins to appreciate the magnitude of the job and he will realize that the story of minerals and mineral resources touches a tremendous range of human activity, not only of mining .and metallurgy, but the whole field of agricultural and industrial growth, of exploration and colonization, transportation and commerce, monetary system, commercial policy, in short, almost every phase of economic life.

Jan 1, 1926

By Kamil Nuzha, Jianchao Li, Bashar S. Qubain

"The Philadelphia Water Department is rehabilitating Belmont Raw Water Basin. As part of this work, a 500-ft long, temporary cofferdam was designed to retain 35 ft of combined water and soil at the western half during the reconstruction of the eastern half. A cofferdam that comprises two integral rows of sheet piles was selected to take advantage of the soil’s weight between the sheet piles for increased stability. To fine tune the design, a geotechnical investigation was carried out to verify the subsurface conditions and, in particular, the top of rock variations along the centerline of the cofferdam. A detailed finite element analysis was performed based on the subsurface findings and incorporating the construction sequence to evaluate the behavior of the cofferdam at the following stages: installation of tie rods to connect to the two rows of sheet piles; partial excavation and installation of tiebacks; complete excavation of the east basin, and demolition of the cofferdam. Inclinometers and survey markers were installed every 100 ft along the cofferdam and were monitored throughout construction. The deformation measurements were in good agreement with the finite element results.INTRODUCTIONThe Philadelphia Water Department (PWD) Belmont Raw Water Basin is located at the intersection of City Line and Belmont Avenues in Philadelphia, PA. The facility actually contains two raw water basins, east and west, separated by an earthen dividing dike. Water leakage at the bottom of the basins and through the dividing dike together with increasing demand for a larger storage capacity dictated the replacement of the wide earthen dike with new narrower concrete structure. The temporary cofferdam was designed for a two-year period to facilitate excavation support, water cutoff, removal of the existing earthen dike and replacing it with a new concrete dike. During this construction sequence, the water level in the west basin had to be maintained at or near its full capacity.Various excavation support systems were considered for this project prior to the selection of a double wall sheet pile cofferdam. Fig. 1 shows a plan view of the cofferdam and the new dividing dike. A typical cross section of the two structures is shown in Fig. 2. Double row sheet pile walls are commonly used as both temporary and permanent retaining systems in open water applications such as construction works, quaywalls, breakwaters and revetments for storing industrial waste as indicated by Ohori, et al. (1984), Ohori et al. (1988), and Khan, et al. (2001). There are many advantages to double row sheet pile systems as recognized by Ohori, et al. (1984; 1988): (1) It can be installed and removed in the presence of water easily and quickly; (2) it provides stability with small width to height ratio, utilizing the existing soils between the installed sheet pile rows; and (3) it serves well as a means for water cutoff. These advantages meet the specific project requirements."

Jan 1, 2016

By Justin Simmons, Michael Arnold, Bob Faulhaber

"In order to remodel an existing beach resort on the Gulf of Mexico, an existing three story structure, founded on stepped tapered piles, was to be replaced by a ten-story building with service rooms on a daylight basement level, conference rooms on the next levels and up-scale hotel rooms on the upper levels. The new building was founded on augered-cast-in-place (ACIP) piles. The pile caps and the basement required excavations between nine and fifteen feet (three to five meters) below ground surface.BAUER Foundations Corp. (BFC) successfully used Cutter Soil Mixing (CSM) to install the support of excavation walls. This technique allowed for the adjustment of the wall alignment during execution in order to avoid existing and new piles and other underground obstructions. Nearly 1600 – 16-inch (400 mm diameter) ACIP piles were installed to an average depth of 71.5 feet (22m) below ground surface (BGS) by BFC to support the new hotel structure. Initial grout overages in piles were excessively high and ground stability issues were encountered in some pile locations. By identifying specific areas of concern BFC was able to modify the approach to ACIP installation, effectively mitigating the ongoing risks and successfully completed the project.PROJECTMarriott Hotels began the $300 million renovation and upgrade of their Marco Island Marriott Beach Club Hotel in Marco Island, FL to JW Marriott status in May 2015. The renovation included the demolition of a portion of their existing hotel tower, and the construction of a new 10-story hotel tower consisting of 94 new guest rooms and a 10,000 SF (900 m2) ballroom, among other amenities. As is typical with hotel construction, time was of the essence. The schedule was the driving factor of this project as the owner had already booked events in their new ballroom starting in January of 2017.BFC provided the client with a deep foundation package that included the installation of 1562 Augered Cast-In-Place (ACIP) piles supporting the new tower, and the design and construction of approximately 36,500 SF (3,400 m2) of soil-mixed retaining wall for support of excavation (SoE)."

Jan 1, 2017

By Carlandrea Albonico, Salvatore Miranda

After a brief introduction of the whole Project, the paper describes two special geotechnical engineering solutions provided within the scope of the Galataport Project, in Istanbul, Turkey. The first refers to the new quay of Salıpazarı, which is a combination of retaining structure and ground improvement, formed by a combiwall, a reinforced concrete diaphragm wall and a soil improvement by deep soil mixing (Turbojet). The second, refers to the soil improvement works executed underneath three existing buildings. Single-fluid jet grouting columns had the scope of improving the mechanical properties of the bearing soil and reducing the associated risk of liquefaction. A set of underpinning micropiles was installed in order to allow the excavation of a partial basement inside two of these three buildings. All activities were conducted from inside the existing buildings, with reduced headroom. The paper highlights the importance of employing cutting-edge technologies within the foundation engineering field and state-of-the-art electronic control devices, in parallel with the essential human expertise, in order to obtain the desired results in this high-profile Project.

Nov 1, 2022

By A K. B Chigwada

Mining organisations grapple with the same problems year after year, wasting incredible amounts of time and money. According to estimates from the International Labour Organization (ILO), over one million work-related deaths occur annually, and hundreds of millions of workers suffer from workplace accidents and occupational exposure to hazardous substances worldwide. Many accident reports cite human failure as a primary cause (Busse and Johnson, 1998). The workers at the Bhopal chemical plant pumped methyl isocyanate into a leaking tank (Morehouse and Subramaniam, 1986). On 3 December 1984, more than 40 tons of methyl isocyanate gas leaked from a pesticide plant in Bhopal, India, immediately killing at least 3800 people and causing significant morbidity and premature death for many thousands more. The company involved in what became the worst industrial accident in history immediately tried to dissociate itself from legal responsibility (Broughton, 2005). Australia is not spared from safety problems either (Lucas, 2022). The ILO Convention 176 (1995) as a response provides that national law should inter alia provide for the supervision of safety and health in mines; the inspection of mines by designated inspectors of the competent authority; the procedures for reporting and investigating of fatal and serious accidents; the compilation and publication of statistics on accidents, occupational diseases and dangerous occurrences; the competent authority to suspend or restrict mining activities on safety and health grounds until conditions giving rise to the suspension are addressed; and worker consultation on matters related to safety and health in mines. This has assisted in getting enough data to define the magnitude of the problem to the mining sector.

Apr 16, 2024

By Yassine Lahmadi, Edoardo Trivellato, Christian Chereau, Bénédicte Robert

Within the framework of the adaptation of the South-East European Technicentre (Technicentre Sud-Est Européen TSEE), SNCF Voyageurs appointed Pini with the project management mission (MOE) for the design and construction monitoring of a road tunnel. This investment has a dual function: during the site transformation phase, it facilitates the work logistics (and shorten traffic flows); and in the operating phase, it is intended to ease all movements on the site over the long term. This is a limited-length gallery (50 meters) to be performed in conventional excavation below Poniatowski Avenue (Paris 12e). The excavation, crossing the entire width of the boulevard, constitutes a major challenge, given the very low coverage (less than 5.5 m), and the surrounding main infrastructures. The same project mis- sion includes the design of the tunnel accesses, via reinforced-concrete frame structures. The targeted design questions several aspects of its execution framework, and particularly, continuous operation must be guaranteed to the neighboring networks during the works. The installation of an umbrella- pipe all along the excavation profile, the progression in divided sub-sections, and the implementation of a complex monitoring system are hence key elements for limiting and controlling any deformation. An exhaustive 3D finite element modelling was performed, taking into account the detailed phasing of construction (pre-support, excavation in divided section, preliminary support and definitive lining), to dimen- sion the structures, and, overall, to analyze the impacts on the neighboring structures and facilities. During the execution phase (planned for mid-2024), monitoring activities with back-analyses as close as possible to the works are planned.

Jun 23, 2024

By Thomas D. Humbert, Christopher J. Ramsey

Construction of a new underground parking structure in State College, Pennsylvania, is situated on a site constrained by limited ROW and required excavations ranging in depth from 25 ft to 40 ft. Additional complications included busy surface streets, an active intersection, and numerous underground utilities that could not be disrupted by construction activities. To combat these challenges, an innovative approach for earth retention was designed that combined multiple types of retention systems. The overall system included alternating sections of soil nail walls and a hybrid system of soldier pile walls (consisting of micropiles) that were partially restrained by a soil nail wall in the lower portions of the excavation. Further, due to the limited space within the property limits that inhibited the length of the permanent nails, the wall design team collaborated with the project designers to develop a solution such that the completed wall became an integral part of the final design/construction of the underground parking structure. INTRODUCTION HERE at State College is a mixed-use, high-rise building in State College, Pennsylvania. The 12-strory building has up to 3 levels of below-grade parking, with the above-grade levels consisting of residential and commercial/retail space. The existing property was a parking lot bound by the streets Calder Way to the north, Garner Street to the east, East Beaver Avenue to the south, and Heister Street to the west. The overall property sloped approximately 20 ft in elevation from southeast to northwest. Excavation for the below-grade levels extended 21 ft to 36 ft (6.4 m to 11 m) below street level. During design-development phases of the project, it became evident that due to subsurface conditions and right-of- way limitations, conventional construction techniques would not be feasible. The full perimeter of the excavation would require earth retention including the weak shale bedrock along the bottom of the excavation. The project developer (CA Ventures) and general contractor (Brinkmann) coordinated with the specialty contractor and wall design engineer to find a solution. At this time, Coastal Drilling East (specialty contractor) and Wood Environment & Infrastructure Solutions (wall design engineer) became involved. The project developer and general contractor were aware they needed an earth retention system, but given the many variables the project faced, a single, straightforward solution would not work in this application.

Jan 1, 2019

By Amalia Giannakou

When designing structures in seismically active areas, foundations of critical structures are typically located away from known faults. Indeed many seismic codes prohibit construction in the immediate vicinity of seismically active faults establishing minimum setbacks from the faults. However, for long structures such as bridges, tunnels and pipelines, a fault maybe unavoidable, and fault rupture risk impossible to preclude. This paper presents a case study of a bridge foundation design that incorporates the consequences of fault deformations passing through the foundation. A series of site surveys were conducted to characterize the fault environment, and fault displacement hazard analyses were conducted to develop design displacement demands. Subsequently, numerical analyses were performed to evaluate the fault rupture-induced demands on a pier foundation in terms of displacements and rotations. Initially, analyses were performed that model the free field fault rupture propagation to the ground surface of the fault to ensure that the basic site characteristics are captured. Subsequently, the foundation elements were introduced in the model and the fault rupture is simulated again. The interaction and influence of the foundation on the fault rupture propagation is calculated, and the consequent demands and distortions of the foundation block provide a basis for structural engineers to design the bridge.

By Hugo Meggitt, Damian R. Siebert, Wystan Carswell

Excavation-induced ground movements are a critical component in the design and construction of deep excavations in urban settings due to the potential adverse effects on adjacent structures and infrastructure. Ground movements are influenced by soil stratigraphy, soil properties, adjacent structures, and construction means and methods. The use of empirical relationships, computer models, and reliance on experience with similar excavations in similar soil conditions often provides a basis for predicting excavation-induced ground movements. In this paper, data from 21 deep excavations approximately 20 ft to 75 ft deep supported by concrete diaphragm “slurry” walls in the Greater Boston area are compared to published literature, considering how different foundation systems (e.g. shallow foundations, caissons, and piles) of abutting structures have been affected by adjacent excavations. The influence of construction method (conventional vs. top-down) on adjacent foundation movements indicate that top-down construction typically results in smaller foundation movements. INTRODUCTION Estimation of ground movements due to excavation is a challenging endeavor, even with complex three- dimensional finite element modeling and high-order constitutive models that are increasingly available in modern engineering practice. Aside from the expense of the soil exploration and testing used to inform these higher-order models, the challenges of modeling past stress history, adjacent structures, and the groundwater conditions during excavation require not only large investments of time during design but also validation from past experience (to avoid a “garbage in, garbage out” paradigm). While site conditions such as soil stratigraphy, soil properties, groundwater conditions, and as-built conditions of adjacent structures can be obtained, measured, and estimated, the effects that means and methods of construction have on ground movements are difficult to quantify. During early phase design, assessments of predicted ground movement are unable to account for all aspects of project construction, nor is it cost-efficient to fully design an excavation while project parameters such as site size and excavation depth are under consideration by the design team. While construction is in progress, benchmarking support of excavation performance and associated ground movements in the context of successfully completed projects allows for a more nuanced view of system performance and provides the opportunity for more informed decision-making (if required) as construction proceeds. For these reasons, the use of empirical relationships and the collection of historical support of excavation performance holds high value for the practicing geotechnical engineer at all phases of the project.

Jan 1, 2019

By Tony Suckling

The commercially available finite element program Plaxis has a key benefit over other finite element analysis programs in that it has a relatively simple user interface to input and output data. This benefit though may also be it?s weakness in that anyone, regardless of their grounding in geotechnical engineering, may use the program and produce results for design. It is essential, as for all engineering design, that the models are checked by competent engineers. This paper describes the key recurring problems found by the authors when checking Plaxis models, such as the generation of the initial in-situ ground stresses and the modelling of groundwater. Interestingly, the authors have not encountered similar problems when checking finite element models produced using other programs and conclude that this may be due to the higher calibre of modeller needed to use these other programs. The geotechnical industry is in a situation at the moment where senior managers who may not have been trained in finite element modelling are relying on less experienced staff who have had some training in modelling, either at university or post graduation. The quality of this training is variable and all organisations running easy to use programs need to be aware of the potential risks and dangers. Management procedures and engineering checks that are essential to validate the results of these models are described, assuming that those in charge are not experienced modellers themselves. The model checking process by competent persons is absolutely essential and it is hoped that this paper will help those organisations that do not have such procedures as part of their own internal Quality Assurance or design validation system. The procedures described are valid for all finite element programs.

Jan 1, 2010

By K. Bowes, M. D. Maley, R. J. Ring

The Honeymoon Uranium Project is an acid In-Situ Recovery (ISR) mine in South Australia. It was previously operated for approximately 18 months before being placed on care and maintenance in 2014, it was then acquired by Boss Resources in 2015. Boss has been performing a number of studies to plan for reopening of the mine, including a successful field leach trial (FLT) in 2017. The current configuration for uranium precipitation at Honeymoon is a batch process. Whilst this achieves effective uranium recovery, the precipitates produced are often very fine, with poor settling and solid/liquid separation characteristics. Continuous precipitation, involving recycling of solids, has reportedly been successfully utilised in other operations to increase the particle size and density of the product, leading to solids that can be more readily dewatered, dried and drummed, with less fines and dust generation. However, no operational data are available from such operations.

Jan 1, 2020

JOHN H. NELSON, Worcester, Mass.-At our plant we have done considerable work on notch-bar testing and are farther at sea now than when we started. So far, we have been unable to get the notch-bar test to be consistent with any other known test. Lately, I have been investi-gating the effect of the position of the notch-bar specimen in a, bar. To do this I took a 3, ½ in. square bar and quartered it, then heat treated the four quarters. Each of these pieces was again quartered and a specimen machined and notched. "In this way we would have notch-bar tests from the exterior to the interior of the bar. These were made of such lengths that it was possible to make four impact tests on each speci-men. Extreme care was taken in marking the position of these test speci-mens in the original bar. The notches were then cut with relation to position of the specimen in the original bar. The second notch was cut 90° from the first, and so on around the specimen. In this way, we have found that, with a 3 ½ in. bar of 0.4 or 0.5. per cent. carbon steel when properly heat treated, we could get impact values ranging from 15 to 100 ft.-lb. Just why this is the case we are unable to state; but it does appear to be a fact that along the outside of the original bar the notch-bar test seems to be low and increases toward the center, but it is not always consistent. For instance, we may have, on a single specimen; one notch-bar test giving us 15 ft.-lb. and another 100 ft.-lb. We have not found such inconsistencies in alloy steels. Alloy steel is consistently good or consistently bad. If it. is good, you cannot readily destroy the impact value, no matter what you do; if it is bad-that is, if it is a poor notch-bar steel-and you have sufficient latitude in your draw, you may correct it. In other words, if the hardness you are working to will allow you to draw to about 1050° F.(561° C.) or over and then quench this steel from the draw heat, you. can raise the im-pact value of the steel from about 4 or 10 ft.-lb. up to-40-or 50 ft.-lb: Just what occurs I do not know. There is evidently a critical-point in steels that have poor impact value, in the neighborhood of 1000 F. to 1050° F. (536° to 561° C.).

Jan 12, 1919

By John Chipman, Eric R. Jette, O. B. Ellis

IN the study of the chemical reactions occurring in the open-hearth furnace, it is frequently assumed that a condition of equilibrium between slag and metal is attained. In order to test this assumption it is necessary to have dependable operating data as well as an exact knowledge of the equilibrium state. Considerable progress has already been made in the study of slag-metal equilibria, notably in the earlier work of Herty1 and of Oberhoffer and Schenck2 and in the more recent researches of Krings and Schackmann3 and of Koerber and Oelsen.4 None of these investigators, however, have employed basic slags comparable to those encountered in basic open-hearth practice, so that up to the present time our only information regarding the equilibria of these slags is based upon observations drawn from steelmaking practice in which there is little assurance that actual equilibrium was attained. The original plan of this investigation was to secure simultaneous slag and metal samples at intervals during the making of an open-hearth heat, recording the heat history in detail and obtaining complete analyses of slag and metal, then to bring these slag samples into equilibrium with liquid iron in the laboratory induction furnace and thus to determine directly whether or not the observed relationships in the open hearth represent conditions approaching equilibrium. This plan was only partly successful. While slags were obtained from the open hearth under satisfactorily recorded conditions and these were remelted in the laboratory under equilibrium conditions, changes in slag composition, which accompanied the remelting operation, were so great that the final slag from the induction furnace bore little resemblance to its open-hearth parent and the direct comparison was therefore abandoned. The results, however, lie within a range of slag composition that is of interest in the making of low-carbon steel. As far as we are aware, they represent the first published laboratory study of equilibria involving slags that contain all the constituents of basic open-hearth slag. EXPERIMENTAL HEATS The first set of measurements on slagmetal equilibrium was made in the Research Laboratories of the American Rolling Mill Co. at Middletown, Ohio. This will be known as series A. The second set was made in the Metallurgical Research Laboratories at Massachusetts Institute of Technology, and will be referred to as series B. Series A.-The induction furnace used has been described.5 Approximately I kg. of a special ingot iron containing less than

Jan 1, 1941

The decrepitation technique is a rapid means of measuring abundances, temperatures and to some extent the fluid compositions, of fluid inclusions in transparent and opaque minerals. The method has been used to investigate the hydrothermal fluid systems associated with gold mineralisation in the Tennant Creek, Pine Creek and Halls Creek Goldfields. At the Enterprise Mine, Pine Creek, several different stages of quartz veining are distinguished and within these, gradational changes in fluid temperatures and compositions help to define the centre and nature of the thermal system responsible for the mineralisation. In the surrounding Pine Creek region and at Tennant Creek and Halls Creek, the results were applied on a regional scale to characterize outcrops and aid in the discrimination between potentially mineral- ized and barren outcrops. The decrepitation method involves the heating of a small (lgm) sample of crushed and sized grains up to as high as 800 degrees celsius. During the heating the fluid inclu- sions within the grains develop sufficient internal pressure to physically burst, the temperature of such bursting being dependent on the type of fluid and the prevailing tem- perature at the time the inclusion was originally trapped. The resulting tabulation of the number of inclusion bursts per 10 degree temperature interval is plotted as a histogram of decrepitations versus tempera- ture and called a decrepigram. The decrepi- grams frequently show several distinct peaks at different temperatures which are caused by different populations of inclusions in the sample. The areas of the peaks indicate the abundances of inclusions in each population while the shape and mean temperature of the peak provides a guide to the type of fluids involved. Of particular importance in this study is the presence of decrepitation peaks at fairly low temperatures (around 2000 C. These are characteristic of C02 rich fluids which build up internal pressure very quickly when heated. The Enterprise Gold Mine at Pine Creek comprises a number of overlapping quartz vein systems hosted by Burrell Creek Formation sediments. The geology of this mine has been described at this conference by Dann and Delaney, who have defined several distinct stages of quartz veining based on structural, mineralogical and physical features of the veins. For this decrepitation study, 19 quartz samples from the mine and environs, including some from each stage of veining were collected. These results suggest that there are 4 major vein types, within 3 of which additional small variations can be discerned which are due to gradational changes in the temperatures and fluid compositions in the mine area.

Jan 1, 1984

By Edwin M. Chance

During the last decade many conditions have been encountered that have materially increased the cost of the production of coal. As in most cases it has not been practicable to increase the selling price of such coal sufficiently to insure the necessary margin of profit, the mine management has been forced to avail itself of what might be termed unusual means that costs might be held at as low a figure as possible. The so-called efficiency engineer has been called upon, costly power plants have been built and machinery has been installed to replace manual labor wherever possible. Another aid used recently to secure economies through the more intelligent production of coal, is the chemist. As the coal industry, barring the production of byproduct coke, does not at once give evidence of its need of the services of the chemist, the writer will endeavor to point out a few of the services that this branch of the staff has been able to render. The preparation of coal in the past has been carried on entirely upon an empirical basis, that is, the criterion adopted has been an ocular inspection. Unfortunately, the appearance of a coal and especially of an anthracite, has but little relation to its fuel value, and as long as coal is purchased for the heat that can be obtained from it by its combustion, the quantity of such heat that is purchased must be one of the principal desiderata in selecting or preparing a coal. Were coals purchased for use as bric-a-brac or for exhibition in museums it might be both wise and just to purchase them upon their appearance. After 4 or 5 years of investigation the fact has been established that coals of very inferior appearance, and I now have special reference to anthracite, might and often did possess heating and burning properties superior to those possessed by bright coals which in the past had commanded considerable and uniform premiums in the market. This being the case the question arose as to whether the trade could be convinced of this fact. While at first some difficulty was experienced in establishing the quality of such dull coals, still it was found that the real obstacle to the sale of these materials in the past had been the fact that the coal producers' own sales departments felt convinced of the inferiority of this type of fuel and when complaints were registered they were given ready credence. Upon convincing the sales department of the quality of this type of fuel, but

Jan 1, 1917

By O. B. Ellis, Eric R. Jette, John Chipman

In the study of the chemical reactions orcurring in the open-hearth furnace, it is frequently assumed that a condition of equilibrium between slag and metal is attained. In order to test this assumption it is necessary to have dependable operating data as well as an exact knowledge of the equilibrium state. Considerable progress has already been made in the study of slag-metal equilibria, notably in the earlier work of Hertyl and of Oberhoffer and Schenck2 and in the more recent researches of Krings and Schack-mann3 and of Koerber and Oelsen.4 None of these investigators, however, have employed basic slags comparable to those encountered in basic open-hearth practice, so that up to the present time our only information regarding the equilibria of these slags is based upon observations drawn from steelmaking practice in which there is little assurance that actual equilibrium was attained. The original plan of this investigation was to secure simultaneous slag and metal samples at intervals during the making of an open-hearth heat, recording the heat history in detail and obtaining complete allalyses of slag and metal, then to bring these slag samples into equilibrium with liquid iron in the laboratory induction furnace and thus to determine directly whether or not the observed relationships in the open hearth represent conditions approaching equilibrium. This plan was only partly successful. While slags were obtained from the open hearth under satisfactorily recorded conditions and these were re-melted in the laboratory under equilibrium conditions, changes in slag composition, which accompanied the remelting operation, were so great that the final slag from the induction furnace bore little resemblance to its open-hearth parent and the direct comparison was therefore abnndoned. The results, however, lie within a range of slag composition that is of interest in the making of low-carbon steel. As far as we are aware, they represent the first published laboratory study of equilibria involving slags that contain all the con stituents of basic open-hearth slag. Experimental Heats The first set of measurements on slag-metal equilibrium was made in the Research Laboratories of the American Rolling Mill Co, at Middletown, Ohio. This will be known as series A. The second set was made in the Metallurgical Rescarch Laboratories at Massachusetts Institute of Techology, and will be referred to as series B. Series A.—The induction furnace used has been described. Approximately I kg. of a special ingot iron containing less than

Jan 1, 1941

By John Chipman, Eric R. Jette, O. B. Ellis

In the study of the chemical reactions orcurring in the open-hearth furnace, it is frequently assumed that a condition of equilibrium between slag and metal is attained. In order to test this assumption it is necessary to have dependable operating data as well as an exact knowledge of the equilibrium state. Considerable progress has already been made in the study of slag-metal equilibria, notably in the earlier work of Hertyl and of Oberhoffer and Schenck2 and in the more recent researches of Krings and Schack-mann3 and of Koerber and Oelsen.4 None of these investigators, however, have employed basic slags comparable to those encountered in basic open-hearth practice, so that up to the present time our only information regarding the equilibria of these slags is based upon observations drawn from steelmaking practice in which there is little assurance that actual equilibrium was attained. The original plan of this investigation was to secure simultaneous slag and metal samples at intervals during the making of an open-hearth heat, recording the heat history in detail and obtaining complete allalyses of slag and metal, then to bring these slag samples into equilibrium with liquid iron in the laboratory induction furnace and thus to determine directly whether or not the observed relationships in the open hearth represent conditions approaching equilibrium. This plan was only partly successful. While slags were obtained from the open hearth under satisfactorily recorded conditions and these were re-melted in the laboratory under equilibrium conditions, changes in slag composition, which accompanied the remelting operation, were so great that the final slag from the induction furnace bore little resemblance to its open-hearth parent and the direct comparison was therefore abnndoned. The results, however, lie within a range of slag composition that is of interest in the making of low-carbon steel. As far as we are aware, they represent the first published laboratory study of equilibria involving slags that contain all the con stituents of basic open-hearth slag. Experimental Heats The first set of measurements on slag-metal equilibrium was made in the Research Laboratories of the American Rolling Mill Co, at Middletown, Ohio. This will be known as series A. The second set was made in the Metallurgical Rescarch Laboratories at Massachusetts Institute of Techology, and will be referred to as series B. Series A.—The induction furnace used has been described. Approximately I kg. of a special ingot iron containing less than

Jan 1, 1941

By B. M. Larsen, W. E. Shenk

This paper describes a method of reversal control of the open-hearth furnace that obtains in practice those effects considered below as essential to a completely automatic control, without appreciable interference with the natural rise and fall in temperature of the regenerative portions of the furnace system. Growing out of some studies of radiation pyrometry in open-hearth regenerators, it was developed during 1934-1938, and has been successfully applied to a number of commercial furnaces. The goal of open-hearth furnace operation is the highest rate of production of steel of proper quality consistent with good refractory life and fuel economy. This requires rapid heat transfer from furnace to charge, which in turn is dependent upon heating the furnace refractories to the highest safe operating temperature. The greater the heat input to the melting chamber, the sooner this limiting temperature will be reached, so that control methods in general that are designed to protect against overheating of refractories should help to maintain maximum fuel input and production rate. For the typical open-hearth system, with fixed regenerator capacity and with rate of fuel input usually restricted in its range of variation, our basic assumption is the idea that the only other important variable —that is, the time interval between successive reversals—should also be held constant or within a small range. The present reversal control was designed therefore so that, under normal operating conditions, no arbitrary limitation is imposed other than to keep the reversal interval within the optimum time range. However, since a near approach to completely automatic operation involves protection of refractories through the balancing of furnace end temperatures as well as emergency protection against temperature peaks above some upper limit, it was also felt essential to employ, as an integral part of the control unit, a temperature-measuring instrument to register the true temperature of the refractory surfaces at some critical region in the hot ends of the regenerative zones. As the basic elements of the control, we thus have one "maximum" and one lLminimum" time relay and a potentiometer recorder-controller, combined with switches and relays to operate as follows: I. Reversal normally occurs within an optimum range limited by the maximum and minimum settings to about 4 to 6 min. variation, but the actual interval usually is less variable and closer to the minimum setting. 2. The margin between minimum and maximum time is utilized, together with a "floating temperature limit" in the potenti-ometric control instrument, to correct any tendency toward temperature unbalance between ends of the furnace. 3. A second "maximum temperature

Jan 1, 1945

By Max Y. Seaton

THE scope of this paper will be limited to finished materials that contain a large preponderance (around 80 per cent or more) of magnesium oxide. The large and commercially important production of refractory dolomite and modified dolomites is not discussed here, and the production of magnesium basic carbonate for use as a heat insulator is barely mentioned. The discussion is confined mainly to magnesias produced in comparatively great quantity by direct processing of naturally occurring raw materials and hence excludes secondary or highly purified products such as pharmaceutical products or U.S.P. light and heavy calcined magnesias of commerce. NOMENCLATURE The nomenclature of the magnesia products that will be discussed is somewhat confusing, in that it is customary in the trade to designate as "calcined magnesite" the materials that result from the calcining of magnesite to temperatures that remove the contained carbon dioxide. The finished product, therefore, is not magnesite at all but simply a more or less pure magnesium oxide or magnesia. Furthermore, partly for statistical and partly for commercial reasons, it has been customary, during recent years, to classify as "calcined magnesite" products that result from the heat-treatment of magnesium hydroxide precipitated from magnesium-containing brines; products that, obviously, have no relationship whatever to magnesite. In the listing of magnesia-containing materials, tonnages of which are regularly reported by the Bureau of Mines, reports ordinarily are made under two headings: "caustic calcined" magnesite, in which all of the varieties of products treated at relatively low temperatures are lumped; and "dead-burned" magnesite, in which are included both high-purity and low-purity, and particularly both high-iron and low-iron, materials that have been so heat-treated that the magnesium oxide occurs predominantly as crystalline periclase-materials used almost entirely for refractory purposes. In 1940 the apparent domestic consumption of "caustic calcined" magnesite was approximately 17,000 tons, about 95 per cent of which was produced in this country. The apparent consumption of "dead-burned" magnesite was approximately 172,000 tons, some 82 per cent of which was domestically produced. In both total quantity and percentage of material produced within the United States, these figures are record highs for many years past. UTILIZATION As indicated by these figures, the major tonnage outlet for magnesia is the refractories industry, in which magnesia is employed principally in three ways: (I) as dead-burned grain magnesite for the construction and maintenance of the hearths or bottoms of basic open-hearth furnaces; (2) in the form of refractory magnesite bricks and shapes; and (3) as a chemical

Jan 1, 1942