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By E. W. Steele

In the copper-casting department of a modern electrolytic copper refinery there are two kinds of casting furnaces: the anode, for casting crude copper into anodes for electrolysis; the refined-copper, for casting the cathodes resulting from electrolysis into market shapes, such as ingots, wire bars, and cakes. Both furnaces are reverberatories of practically the same general design and are operated intermittently, putting through a charge normally in 24 hr. The treatment of the copper in the two furnaces is similar, in that oxidation followed by skimming and reduction (poling) is carried on in both; but in the refined-copper furnace, the work must be done with greater care and it is of extreme importance that not the slightest trace of impurity be introduced into the copper. The furnaces usually hold from 150 to 300 tons of molten copper, which constitutes the daily charge. Except in the case of furnaces in the Lake district, where the concentrates from native-copper ores are charged through the roof, the furnaces are charged through the side doors by charging machines similar to those used in open-hearth steel practice. In 1916, at the Perth Amboy plant, of the American Smelting & Refining Co., located at Maurer, N. J., a study was made of the possibility of firing the copper refinery furnaces with pulverized coal instead of by hand. The proposed method possessed obvious advantages over hand firing and coal was a much cheaper fuel than oil at that time. However, there were several objections to its use, the principal ones being the possibility of increasing the sulfur content of the refined copper and the additional slag that might be produced from the ash. The increase of the sulfur content of the refined copper was the more serious, as more than 0.002 per cent. sulfur is objectionable. Any increase of the slag would be expensive as the copper in this slag would have to pass again through the entire smelting and refining process. It was thought that certain modifications in operations and furnace conditions, which will be described later, would overcome these objections SO the proposition was discussed with a manufacturer of coal-pulverizing equipment. He was uncertain concerning the use of pulverized coal

Jan 1, 1925

By A. N. Khayyat, R. G. Temple, R. Skelton

The fluid energy mill has been in use since the 1930's when an early patent was granted to N.H. Andrews in the USA. The microniser design has been basically unaltered since that date and current designs such as the Airfilco "Micronizer" have been progressively developed from results based on wide experience. The authors have been engaged in a research programme to establish optimum design and operational parameters for the Micronizer so as to provide a more quantitative basis for scale-up prediction of results. An introductory section will first trace the development of fluid energy milling including reference to other designs which have developed alongside the micronizer (especially the “Jet-o-miser"). With regard to design features the number of fluid injection nozzles and their size was investigated to establish the optimum range. Injection angle and, the consequent diameter of the internal "tangential circle" was carefully studied to determine the effect of this parameter on product size. The research was carried out using fine limestone as the test material with air as the grinding medium. Feed size fractions of 0-120µm, 0-250µm, 0-500µm, and 300-600µm were milled and product size analyses were carried out using the Coulter Counter technique.

Jan 1, 1980

By ElRoy Nelson

WATER provides to many mineral industries functions similar to those performed by money in the economic system. Water is a medium of exchange. It is also required in chemical reaction for cooling, for transfer of minerals, and for cleaning. To a great extent, water is also a raw material in almost every industrial operation; it becomes a component of the finished product. In the Rocky Mountain region, water is treated with a great deal of respect. There has not been enough of it when needed. Long ago storage facilities were planned and devised to assure a supply during periods of shortages. This comes from the history of the region in irrigation and mineral processing. Within this region the shovel was always the most lethal weapon used in settling disputes over the use or misuse of water.

Jan 10, 1954

By Thomas M. Drown

THE method usually employed in accurate determinations of sulhur in pig-iron and steel is to treat a weighed sample of borings in a flask with muriatic acid, and to pass the gaseous products through an alkaline solution of lead or silver, which precipitates all the sulphur of the sulphuretted hydrogen in the form of sulphide of lead or silver. The sulphide thus formed is subsequently oxidized by aqua regia, bromine, or other oxidizing agent, and the sulphuric acid formed precipitated in the usual way by chloride of barium. I have substituted for the alkaline metallic solution, a solution of permanganate of potash in the strength of one gramme of permanganate to 200 cubic centimetres of water, and find that it gives results quite as accurate as those obtained by using an ammoniacal solution of silver. By the employment of the permanganate it will be readily seen that there is considerable saving of time and work. In order to test the accuracy of the method, six samples of pig-iron borings were weighed out (about six grammes each) and treated identically

Jan 1, 1874

By Thomas M. Brown

The method usually employed in accurate determinations of sulphur in pig-iron and steel is to treat a weighed sample of borings in a flask with muriatic acid, and to pass the gaseous products through an alkaline solution of lead or silver, which precipitates all the solphur of the sulphuretted hydrogen in the form of sulphide of lead or silver. The sulphide thus formed is subsequently oxidized by aqua regia, bromine, or other oxidizing agent, and the sulphuric acid formed precipitated in the usual way by chloride of barium. I have substituted for the alkaline metallic solution, a solution of permanganate of potash in the strength of one gramme of permanganate to 200 cubic centimetres of water, and find that it gives results quite as accurate as those obtained by using an ammoniacal solution of silver. By the employment of the permanganate it will be readily seen that there is considerable saving of time and work. In order to test the accuracy of the method, six samples of pig-iron borings were weighed out (about six grammes each) and treated identically

By J. H. Nead

Discussion of the paper of J. H. NEAD, presented at the New York meeting, February, 1916, and printed in Bulletin No. 108, December, 1915, pp. 2341 to 2357. E. D. CAMPBELL, Ann Arbor, Mich.-Any one at all familar with research work can at once see that Mr. Nead has condensed into his tables and curves the results of a carefully planned set of experiments which must have involved a great amount of work on his part. He deserves much credit for the way in which he has carried out these experiments, for it is to the results of such systematic experimentation that we must look for further knowledge of the underlying causes which determine the physical properties of steel. It will probably be many years before we have sufficient knowledge of all the factors of the problem of the constitution of steel, but every set of carefully carried out experiments such as Mr. Nead has made adds something to our knowledge and brings us a little nearer to the final solution of the problem.

Jan 5, 1916

By Eckley B. Coxe

(WITH FIGURES ON PLATES II, III, AND IV.) I DESIRE to call the attention of the Institute to two deep vertical shafts, which are now being sunk in Schuylkill County, Pennsyl¬vania, about 1 1/2 miles north of Pottsville. These shafts are of interest to the mining engineer, not only on account of the novelty of the method of sinking adopted, which promises to produce a revolution in that branch of mining engineering, but also as examples of the manner in which such work should be undertaken. GEOLOGICAL SKETCH OF THE TERRITORY TO BE WORKED BY THE SHAFTS AND REASON FOR SINKING THEM. The Mammoth or E Vein of the anthracite coal-measures in that part of the Schuylkill region near and north of the town of Pottsville lies at a great depth below the surface, and has, in consequence, never been worked in that locality.

Jan 1, 1873

By D. L. Harris, A. M. Gaudin

THE following results, presented here in condensed form,1 were obtained in a preliminary study of the adsorption of n-hexane thiol, hexyl mercaptan, on sphalerite, zincite, willemite, and quartz, from aqueous solution and from a gas. Interest in this subject was aroused by a Belgian report2 of effective use of hexyl mercaptan for flotation collection of oxidized zinc minerals. The relatively low boiling point, 149°C, of the mercaptan3 suggested the desirability of extending the usual measurements of partition of collector between aqueous solution and gas and between gas and mineral. It is believed that this paper presents the first measurements of this type on a flotation system. Attempts were made to carry out the measurements at equilibrium, but as the work progressed it became increasingly doubtful that this desirable condition had been achieved. To control composition and extent of the gas phase, the apparatus was a wholly-enclosed thermally-controlled glass system. Because of these constraints and the desirability of dealing with pure minerals, a scale of operations was chosen in which a few grams of deslimed mineral were used in each test. It was also necessary to choose a particularly sensitive method for mercaptan analysis, and in fact a method that would permit the experimenters to follow the approach to equilibrium. For these reasons mercaptan marked by radiosulphur 35 was used. An analysis was made for the radiosulphur by a modification of the method of Gaudin and Carr.4

Jan 9, 1954

By M. A. Torcaso, P. Raimondi

To study mass transport in systems simulating oil recovery processes, different porous media were saturated with a mobile (carrier phase) and a stationary phase. Slugs of carrier phase containing a small amount of solute were displaced with pure carrier phase. By analogy to the chromato-graphic processes, the velocity of the solute can be predicted from a knowledge of the partition coefficient and the saturation provided that equilibrium between the two phases exists. Equilibrium was found to exist for different porous media, solutes and rates. The conditions were varied over the range normally encountered in the laboratory and in the field. The longitudinal dispersion of a solute undergoing interphase mass transfer was also investigated. INTRODUCTION The production of hydrocarbons by gas cycling, enriched gas drive and C02 or alcohol displacement involves, among other factors, relative motion between two phases and compounds, hereafter called solute, which are soluble in both phases. The solute is carried forward by the faster flowing phase at a lower velocity than the average velocity of that phase. Retardation of the solute is caused by chromatographic absorption and desorption in the slower flowing phase and by the degree of departure from equilibrium. At equilibrium the concentration of solute in the two phases can be related by the equation* CSw = K Cso ,............(1) where C, and C are the concentration of solute in the aqueous and oleic phases respectively and K is the equilibrium ratio, or partition coefficient. Displacement theories must contain an explicit assumption with regard to equilibrium, i.e., whether the compositions can be related by Eq. 1. The existance of equilibrium depends, in general, on the relative velocity between the phases. Unfortunately, other factors such as gravity segregation and viscous fingering, also depend on velocity. For this reason, whenever effects of rate on displacement were observed,2-4 it was practically impossible to discern what caused them — lack of equilibrium or the factors mentioned above. Equilibrium between phases has been the subject of extensive studies in fields such as extraction or chroma to graphy. It has received only small attention in flow through the type of porous media encountered in oil production.5 For this reason a method was developed which makes it possible to study the movement of a solute as it is affected by rate, type of porous media, partition coefficient and carrier phase, but in the absence of segregation or fingering. The information obtained enables one to determine when the assumption of equilibrium can be made. Briefly, the method consists of (1) saturating the core with a mobile and an immobile phase, (2) injecting a slug made up of the same fluid as the mobile phase and a small concentration of mutually soluble solute, (3) measuring the lag and the peak height of the slug at arrival and (4) correlating these variables with fluid properties such as partition coefficient and mixing constants of the medium. PROPOSED MECHANISM The principles of chromatography are combined with the equation of longitudinal mixing to predict the velocity of a solute slug compared to the bulk velocity and the peak height of a slug.6-9 The equation so obtained is valid under equilibrium conditions only. Therefore, a comparison between experimental and predicted results will give a measure of departure from equilibrium. This work was done with either the oleic or the aqueous phase being immobile. For simplicity, the following development is based on the case where the oleic phase is immobile. However, the treatment is the same in either case.

Jan 1, 1966

By E. H. Rose

THE present symposium on flotation machines provides a unique opportunity for group reappraisal of standard or habitual viewpoints. A symposium is by definition a trading post for observations that might prove complementary when put together, thus leading to useful thoughts that might not have been evident from the original observations individually. The present paper, pertaining to power consumption in flotation, is deliberately an experiment of that kind. Data were solicited from the operating superintendents of several of the major flotation plants on this continent. The information received, covering a total of 14 separate operations in seven plants, has been collated in terms of power intensity; that is, the total power input per cubic foot of cell volume. This departs somewhat from the conventional expression of power per ton of ore treated, though the latter figure is also given for the plants concerned. Because of wartime restrictions, particularly in Canada, identifying names of plants and machines are withheld. Not as a firm conclusion, but as a tender for symposium discussion, the following points are made: I. That flotation is a power operation in much the same sense as ball milling. 2. That contact time is the complement of power intensity and may be decreased as the latter is increased. 3. That a decrease in flotation power per ton of ore can result from an increase in power intensity. ANALOGY WITH GRINDING In grinding, it has become axiomatic that the more the power put into a given operation, the greater the work performance. The analogous view is now proposed that the effectiveness of any flotation operation will be related to the mechanical energy usefully applied to that operation. Under this view, each increment of properly directed input energy should give either an increase in unit tonnage or an improvement in the metallurgical separation (concentrate grade or tailing grade), until either the theoretical limit imposed by mineral constitution or surface condition is reached, or until further increments of power become uneconomic under the law of diminishing returns. Thus, as in grinding, there are two forms of output that greater power input or improved utilization of power can produce. As for the law of diminishing returns, lower unit cost of power through improved generating efficiency in the past decade has pushed the limit back. Over and above this, however, there is strong indication in the operationg data herein presented that higher power intensity results in an actual economy of over-all power consumption. Like crushing and grinding, flotation accomplishes a rupture of the forces of molecular attraction, by taking particles from the common environment and placing them in the two separate environments of

Jan 1, 1944

By J. L. Huitt, B. B. McGlothlin

The introduction of new fracture propping agents that are brittle but much stronger than sand created the problem of what loading strength is required for a propping agent to be effective in a given formation. It is shown that the load at which the propping agent crushes should exceed the load at which total embedment in the fracture faces is possible. Simple laboratory tests to determine loading strength of the propping agent and embedment in the fracture faces, and use of these data in selecting a propping agent for a given formation, are discussed. INTRODUCTION One of the most important factors in the design of hydraulic fracturing treatments is the selection of a propping agent that can effectively provide the fracture flow capacity needed for stimulation of a well. Sand, once generally accepted as being synonymous with propping agent in hydraulic fracturing, is now recognized as having limited effectiveness in many formations because of its low resistance to crushing. Sand particles are brittle and have relatively low strength. Because of this property, sand particles are crushed in rocks that offer high resistance to the penetration of fracture faces by the proppant particles when the fracture attempts to close under the action of the overburden load. For rocks that offer a high resistance to penetration, deform able particles are more effective propping agents than sand. However, for this same type of rock, a propping agent that does not deform, yet does not crush, is often more effective. Thus, a rigid propping agent with sufficient strength to prevent crushing is desirable. A method for determining the strength required for a rigid propping agent to function effectively in given formations is discussed. BEHAVIOR OF RIGID PROPPANTS AND FRACTURE FACES RELATED STUDIES An early qualitative description of the reaction of propping sand in fractures was given by Hassebroek et al.' In discussing fracturing in deep wells, the authors mentioned that even though propping sand entered the fractures, a high flow capacity did not result due to crushing or embedding of the propping sand. Dehlinger et al.2 in discussing the reaction of propping sand surmised that, because of the hardness of sand particles, deformation occurred in the fracture faces contacting the propping sand. In later studies,3,4 methods of determining the embedment of propping sand in fracture faces of soft rock and the critical load at which propping sand is crushed by the fracture faces in hard rock were discussed. In working with de-formable proppants, Kern et al. considered proppant particles to be deformed into cylindrical disks by action of the overburden and then pressed slightly into the fracture faces by further action of the overburden. Rixie et al.'0 reported on embedment pressure and presented a method of selecting a propping agent for use in given formations. The propping agents included sand, walnut shells and aluminum pellets. All these studies have contributed materially to a better understanding of propping agent behavior; however, the strength of brittle proppants (sand, glass and ceramics) required to result in embedment rather than crushing has not been discussed. This topic will be covered in the ensuing discussion. PROPPANT PARTICLE CRUSHING—-EMBEDMENT For this discussion, a rigid propping agent is considered to be one that is brittle and fails under tensile stress when loaded to a critical value. In an earlier study4 it was shown that the Hertzian4 loading theory could be applied to a spherical brittle propping agent if the propping agent and fracture faces behaved elastically. At the failure of the proppant, the ratio of the load to the square of the diameter of the particle should be constant for a given material combination, or: Lc/dp2=C ............(1) A partial derivation of this equation from proppant and formation properties is included in the Appendix. Should a rigid particle not be crushed as a load is applied, it embeds in the fracture faces. A study3 of particle embedment in fracture surfaces has been published. The embedment can be described by an equation based on Meyer's metal penetration hardness relationships: d1/dp=B 1/2[L/dp2]m/2..........(2) In Eq. 2, B and m are constants that are characteristic of the rock; the significance of the other terms is shown in Fig. 1. A STANDARD DEFINITION FOR PROPPANT LOADING STRENGTH Eq. 1 is useful in appraising propping agent strength," but it is strictly applicable only when the area of contact between a particle and a fracture face (or loading plate)

Jan 1, 1967

By S. Fugleberg

As a result of research work done during the planning of the Kokkola zinc plant it was found that a very efficient cementation of impurities from the suspension obtained after leaching copper and cadmium cakes was achieved by adding zinc dust to the batch without filtration after the leaching. All elements nobler than cadmium are precipitated with the exception of lead, which must be removed in a separate step. Using pure zinc dust, free from noble metals, the cadmium sponge produced will only contain elements that can be re- moved from cadmium by meltrefining. The process is thus : 1. Leaching and purification 2. Removal of lead (with BaCO3) 3. Precipitation of cadmium sponge with pure zinc dust 4. Meltrefining of briquetted sponge with NaOH for removal of Zn (and others) The paper deals with the removal of the most critical elements, i.e. Co, Ni, As, Sb, Cu, Pb, T1 in the liquid phase and Zn and T1 in the melt. A survey is also given of the behaviour of most of the other elements normally found in Cd raw material, such as Ge, Te, Se, Sn, In, Ga. It is shown that in most cases the benefit of an electrolysis in Cd production is very limited. In Kokkola 99.998% Cd is achieved by this method, but in favourable cases it may be possible to come quite close to five nines.

Jan 1, 1973

By D. K. Crampton

THE object of this work was to obtain and correlate information on effect of internal stress in variously drawn tubes on several properties. Also, a simple approximate method of comparing types of stress distribution in such variously drawn tubes was sought. There is also included some work on comparison of single and polycrystalline materials and effect of different types of operation and preferred orientation. PREPARATION OF MATERIAL A series of tubes was drawn to study the effect of the type and degree of final reduction on various physical properties and the approximate distribution of stress intensity across the tube wall. The material used all came from a single heat of 70-30 brass melted in a regular production Ajax-Wyatt induction furnace. The analysis of the metal as cast was: copper, 70.36 per cent; lead, 0.04; iron, 0.02; zinc, balance. The material was cast in "shells" with 4 in. outside diameter and 3/4 in. wall thickness. It was drawn part way down according to the usual standard mill schedule and then by suitable individual schedules to finish by a variety of types and degrees of drawing to the same final cases in every instance; namely, 0.750 in. outside diameter by 0.080 in. wall thickness. The exact final draws, together with the percentage area reductions, diameter reductions and gage reductions are given in Table 1.

Jan 1, 1932

By Auguste J. Rossi

As is well known, practically all the phosphorus of the ironores smelted in the blast-furnace passes into the pig-metal, increasing its fluidity, but diminishing its strength to such an extent that, if phosphorus exceeds a certain amount, the metal is only fit for fine castings, not required to resist strains, and it cannot be used for the ordinary purposes of good foundry-iron. No phosphorus being eliminated in the acid Bessemer process, the quantity admissible in pig-metal destined for that process must be very small, and hence the ores smelted must be strictly Bessemer ores, of which, in many districts, the supply is taxed to the utmost. On the other hand, very highly phosphoric pig, a metal of little or no value by itself, when refined by the Thomas-Gilchrist process in the basic converter, furnishes an excellent steel; but such pig-iron must be made from ores particularly high in phosphorus; and these ores are not everywhere abundant, and are much sought after for this special purpose. But there are many iron-ores containing a moderate, though still important, amount of phosphorus, which yield a pig-metal

Jan 1, 1897

Edwin A. SpeRry, Denver, Colo. (communication to the Secretary*) :—Since writing my former paper on this subject I have had several discussions concerning some of the statements contained therein, with men who have had a large experience with the old form of buddle, both in this country and in Cornwall. The present paper gives a brief statement of some of the points debated, together with the arguments and proofs in their substantiation. The first point is the question of the capacity. In my origi-

Jan 1, 1904

By Thos Gibson

THE object of taxation is the raising of a revenue. Unless a tax accomplishes this, it is a failure. The right to take for public purposes a part of the moneys obtained from the carrying on of private enterprises is an attribute possessed only by a lawful government, and may indeed he called the supreme attribute of government. In free, democratic communities this power must of necessity rest upon the consent of the governed. Power implies obligation, hence it is obviously the duty of a government, in framing a system of taxation, to provide one which, while effective in producing a revenue, is also just and impartial. It will be conceded that mines and mining property ought to bear a fair share of the public expenditure. The question is, upon what basis taxation should proceed. Two separate taxing principles are usually contended for: Taxation should be proportionate to the benefits received by the person or property taxed; taxation should be based on ability to pay. A third is sometimes added, taxation should have reference to the extent and value of the natural resources enjoyed. As applied to mining taxation, it is pointed out by those who support the first mentioned basis that, mines being usually situated in rocky and hence sparsely peopled regions, mining companies are frequently obliged to construct roads, railways, telegraph and telephone lines, schools, water and sewerage systems, and many other amenities and conveniences of civilization, the cost of which in regions better suited for agriculture and consequently more thickly populated, has either been defrayed locally, or can be spread over a sufficiently large taxable group of people to materially lighten the financial burden on the mine. The mining com¬pany, it is argued, having made these outlays, should receive credit for, them and be relieved of taxation to a corresponding extent. There may be some force in this contention, but the situation is capable of relief without attempting to place taxation upon so unworkable a basis as the value of benefits received. Who is to be the judge of these benefits, and how are they to be valued? The very existence of a mining company and its ability to carry on business in peace and security, depend on the prevalence of law and order, which is a result of good government. The state provides protection against violence, and courts of law for

Jan 4, 1919

By B. M. Larsen, T. E. Brower

For some years we have been carrying on a rather comprehensive investigation of the occurrence of oxygen in liquid open-hearth steel. This investigation was interrupted by the war emergency and is therefore incomplete, with many questions still answered only partially, if at all; yet it seemed worth while to present a report of progress on this difficult field of research, if for no other reason than to promote discussion and further investigation of this important problem. The significance of such studies depends in large measure upon the accuracy of measurements of oxygen content in liquid steel while it is still in the furnace or as it flows into the ladle, or thence into the mold and there is, as we shall show, good reason for believing that the main source of uncertainty is in the sampling, not in the analytical method as such. The difficulty arises from the fact that any method of sampling is of itself apt to alter the amount of oxygen in solution in the liquid steel, because this oxygen is in a readily reactive condition. On the one hand, being usually present at a concentration appreciably in excess of that corresponding to equilibrium with the carbon then present, it may decrease rapidly in percentage by reaction with carbon and evolution of CO, especially if the liquid metal is in any way shaken or brought in contact with a cooler solid surface. On the other hand, it may increase rapidly by ab- sorption of oxygen from a slag, a furnace atmosphere, or from air. These circumstances, which are inherent in the problem, as well as our conclusion that, despite the considerable amount of careful work already done, there is still no method of sampling liquid steel acceptable as an unquestioned standard, ed us to undertake systematic comparisons of oxygen content of large numbers of samples taken: (I) by a single method at different positions and levels in the bath; (2) at the same place by different sampling methods; and (3) from bath, tapping stream and pouring stream. The different sampling methods yield somewhat different values and there is as yet no way to tell with certainty which is the most accurate. But the general reproducibility and consistency of the results give us some confidence in certain inferences we draw from them: namely, that the "spoon" method of sampling, properly carried out, gives somewhat more consistent results than the "bomb" method, as it has usually been practiced; that, in the bomb method, an aluminum cap is preferable to a steel cap; that the oxygen content of liquid steel in a finished heat is substantially the same all over the bath at the same level, and tends to decrease at lower levels further from the slag interface; also that it tends to decrease, and to decrease erratically, from furnace bath to tapping stream entering the ladle. Accordingly it seemed desirable to report these observations in detail as a first step, so that the reader may judge their significance as a contribution towards solution of the main problem, which is to find a means of pre-2

Jan 1, 1945

By H. M. Crankshaw

THE early methods of mining anthracite in the steep pitching Mammoth bed consisted in driving breasts up the pitch from the gangways and airways driven in the bed along the strike (Plate 2, Fig. 1). Breasts are simply rooms driven up the pitch the full thickness of the bed (Plate 2, Fig. 2), having a width of from 18 to 30 ft., and a manway or traveling way on one or both sides. (For detail of breast method see Whildin, Trans., vol. 50, p. 704). Many difficulties were encountered, and the maintenance cost of the timbered gangways was so great as to be practically prohibitive. To reduce this .expense, the gangways were driven in the thin Skidmore bed underlying the Mammoth, and the coal mined through rock holes. (Plate 2, Fig. 2;-A.) It was found that after the breasts were driven up 80 to 100 ft., the coal almost invariably rushed or "ran away," making good ventilation almost impossible and the extraction of coal from the upper portion of the lift very difficult. The economic length of a lift is from 200 to 250 ft., and the percentage of extraction by the old method above mentioned was often under 50 per cent., while the coal recovered was so badly broken up as to reduce materially the percentage of large sizes.

Jan 7, 1916

By R. T. Hukki

THE accepted basis of comparisons between mills of different diameter is the percentage critical speed. If n = actual mill speed, rpm, nc = calculated critical speed, rpm, np = calculated percentage critical speed, and D == inside diameter of the mill in feet, then n, In the following analysis capacity, T, is expressed in short tons per hour, tph, and power consumption, P, in kilowatts, kw. Accordingly power consumption per unit of capacity, P will be expressed in kilowatt hours per short ton, or kw-hr per ton. In all equations D refers to the inside diameter of the mill in feet and v to the peripheral speed of the mill in feet per minute inside the liners. ' Comparison between separate mills must be based on equivalent grinding conditions, i.e., same feed, same size distribution of feed, same size distribution of product, and same percentage of solids. In addition, comparisons between separate rod mills must be based on the same rods, same type of liners, and same percentage rod load. Comparisons between separate ball mills presuppose the same balls, similar liners, and same relative ball load. The practical np-range through which the equations apply varies, being narrower for fine grinding in ball mills and wider for coarse crushing in rod mills. The Relationship between Capacity and Speed It is the general belief that the capacity, T, of a tumbling mill is directly proportional to the speed of the mill, other things remaining constant.' Mathematically this is represented by the equation T - c¹ n tph [4] where c, is a factor related with the grinding characteristics of the ore, method of reduction, and the units chosen. It is proposed here that the general equation relating mill capacity and speed should be of the form T = c¹ nm tph [5] In other words, the capacity should be proportional to the mill speed raised to power m, the numerical value of the exponent being 1 5 m 5 1.5, depending on the circumstances. Eq. 5 can also be written in the following forms: T = c, (np)m tph, and [6] T=Ca vm tph, [71 where v = peripheral speed of the mill in feet per minute. If the observed capacity of a mill at speed n¹ is = T¹ tph, the capacity T² of the same mill at speed n² should be T² = T¹ (n²/n¹)tph [8] The Relationship between Power Consumption, Mill Diameter, and Speed The only well known theoretical deduction relating power consumption, P, and mill diameter appears to be the formula of duPont introduced by Gow, Guggenheim, Campbell, and Coghill.' According to duPont, the power required to operate a mill is a function of the mass of the balls, of the lever arm of the ball mass, and of the speed of the mill. The ball mass per unit of mill length is proportional to the square of the diameter, the lever arm is directly proportional to the diameter, and the critical mill speed or any percentage thereof is inversely proportional to the square root of the mill diameter. Following this reasoning, the original duPont formula is of the form P = c4D² c D • c6D-0.5 = c7D2.5 [9] If the mill speed in the above equation is expressed in terms of Eq. 3, the duPont formula may be written as follows: P=f1(D2) f2(D) f³(—np) or [10] vD P = c np D2.5 kw [11] Eq. 11 may also be derived from the mechanical principle of force, which is equal to mass x acceleration. Power necessary to operate a mill may be considered to be an homogeneous linear function of the force developed. Ball or rod mass per unit of mill length is a function of D2. The acceleration factor of the ball or rod mass is a function of the peripheral speed of the mill. Thus P = f4(F) = /x(D2) f5(v) Indicating that v = nDn, and n = c9 np /vD, the above equation becomes P = f2 (D2) -fa (D ca np/vD

Jan 1, 1955

By J. K. Edgar

For a number of years the production and use of super-purity aluminum (better than 99.99 pct) has been steadily increasing. High-grade lots of. such aluminum show certain outstanding characteristics not found in lower grades containing principally silicon, iron and copper as impurities. One such characteristic is the so-called "self annealing," that is, the re-crystallization of the heavily cold worked metal at room temperature.' Interest therefore is aroused as to the effects of the impurities. It is well known that the amounts of silicon and copper which occur in aluminum of better than 99.95 pct are completely soluble, at least at elevated temperatures (above 200°C). Iron, on the other hand, is known to be fairly insoluble in solid aluminum. Thus, a knowledge of the limits of this solubility would he of considerable use in studying the characteristics of the high purity metal. All investigators have agreed that iron has very low solubility in solid aluminum. Rosenhain, Archbutt and Hanson2 reported traces of an aluminum-iron phase in the "purest samples of aluminum obtainable." Gwyer and Phillips3 reported that an iron constituent was visible under the microscope in metal containing ".0088 per cent iron." Roth4 found that in the solid state the solubility of iron in high purity aluminum was 0.01, 0.01, 0.017 and 0.022 pct at 225, 320, 500 and 600°C respectively. Dix5 working with alloys containing less than 0.03 pct impurities, concluded from microscopic and chemical analyses of eutectic areas that the eutectic composition was close to 1.7 pct iron. Dix placed the eutectic temperature at 65s°C. Archer and Fink,6 using high purity aluminum-iron alloys, found that the hypoeutectic liquidus intersects the eutec-tic horizontal at 1.7 pct. This is in fair agreement with the investigation of the aluminum-iron system by Gwyer and Phillips who placed the eutectic at 1.89 pct iron with a freezing point of 653'C. Preparation and Chemical Analysis oP Alloys Electrolytically refined aluminum (99.991 pct aluminum) and a high purity alumi-num-iron alloy (11.45 Pet iron) were used in the preparation of the alloys for this investigation. To aid in controlling the iron content of the experimental alloys, an alloy of lower iron content was prepared first from these materials. The high purity aluminum was melted and heated to about 700°C in a plumbago crucible coated with alundum cement and the aluminum-iron alloy was then added. The alloy was thoroughly stirred, fluxed and skimmed and then chill-cast into notch bars. The aIlalyses of the three materials are given in Table I. The alloys for the determination of the solid solubility of iron in aluminum were prepared by melting 600 g total of the aluminum plus the required quantity of the aluminum-iron alloy (No. 92531). These

Jan 1, 1949