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By M. C. Udy, C. H. Lorig

THROUGH the years much interest has been centered in attempting to develop a direct method of iron-ore reduction, to replace or supplement the present indirect blast-furnace process. It would not be difficult to produce a list of more than 500 patents dealing with the direct production of iron and steel, but the few of this type of process that have proved successful do not produce in competition with the blast furnace; they produce special products. A survey of the literature reveals that the equilibrium conditions for the reduction reactions (iron oxides with carbon monoxide and with hydrogen) have been fairly well established but that data on the rate of reaction are discordant, although the general effects of the variables are known. This dissertation deals with the rate of reduction of a magnetite concentrate with hydrogen. The following variables have been studied: bed depth, gas velocity, particle size and temperature. The behavior of a single particle was also studied. LITERATURE Two general factors should he considered in a study of reduction of iron oxide: (1) equilibrium relations, and (2) rate of reaction. The first factor, equilibrium, has received the attention of many investigators and the equilibria Fe3O4-FeO-H2-H2O, Fe304-FeO-CO-CO2, FeO-Fe-H2-H2O, FeO-Fe-CO-CO2 are fairly well established. Of the second factor, the rate of reaction, much less is known. Data are comparatively scarce and there is very little concordance. The discordance probably results from the large number of variables influencing the reactions. However, the general effect of the variables is known. Among these variables are temperature, gas velocity, particle size, porosity, gas composition (distance from equilibrium), presence of impurities, greater or less prevalence of side reactions, and even design of the apparatus itself. Wetherill and Furnas1 published an excellent paper in 1934. They point out that any one or more of five processes (the chemical reaction, diffusion of the reactant through the gas film, diffusion of the reactant through the solid phase, diffusion of the reaction product through the solid phase, or diffusion of the reaction product through the gas film) may be the slow process, and thus the rate-controlling process. It is regretted that the work of these authors was limited to experiments at one temperature, and that the range of gas compositions was limited. Langmuir2 has shown that heterogeneous reactions take place at phase boundaries.

Jan 1, 1942

By J. Parke Channing

These days of great industrial and social problems in America produce many suggested solutions and great changes. The practical engineer and employer of labor views these problems differently from the labor leader or the social reformer, but as never before he is sincerely interested in solving them in a way that will be just to all. The inevitable tendency of the day is toward "industrial betterment," " safety," '(industrial education," " efficiency," and the many other things which have become so familiar to progressive employers. There is no longer any question that these things are worth while from both the human and economic standpoints. They "pay" in dollars and cents. The very center of final success in improving conditions and increasing the efficiency of workingmen must be the spirit of fairness and a knowledge on the part of the employer of how to deal sympathetically and intelligently with his employees. Every progressive employer knows how greatly he desires foremen, superintendents, managers and others who possess these qualities. On the other hand, we are all familiar with serious mistakes made by young graduates of engineering schools who have had no opportunity to develop these qualities, and who have no real appreciation of the worth of the workers. Indeed, one wonders whether much ill-feeling, labor difficulties, and many strikes could not be avoided if such men had the right attitude. Is there any way of remedying this condition? If this particular difficulty can be solved, if these young engineers, many of whom are our coming leaders of industry, can be given the right perspective and the right understanding of these other problems in addition to fair, sympathetic methods of handling men, many of our other problems will be solved—not at once, but gradually and permanently, as these men make good and become influential in paths of industrial righteousness and industrial peace. Many progressive employers of to-day have enlarged their own perspective and realize the great importance of enlarging the perspective of those who shall follow them. How can it be done? For seven years a movement has been making

Jan 1, 1915

By Chester T. Sims

RECENTLY, a new type of superalloy material called TD Nickel* has been marketed.' It is a sim- ple, two-phased alloy, consisting of thoria particles dispersed in nickel of rather high purity (Ni-2 pct Thoz). Its mechanical properties appear relatively superior to previous experimental material attempting to use the oxide nonmetallic dispersion concept (except SAP), and superior to conventional nickel-base alloys at high homologous temperatures. This is derived from an interesting method of creating the dispersion, arising during chemical processing of the nickel and thorium salts in solution while reducing the nickel to metal. An evaluation of the thoria phase was conducted at this laboratory. Material and Procedure. TD Nickel was made available, consisting of several inches of 0.470-in. rod, extruded at a ratio of 64: 1, straightened, and centerless ground. Property determinations on this rod by the supplier at 1800°F showed an ultimate tensile strength of 11,400 psi, yield strength of 9600 psi, and 6 pct elongation. Specimens were removed from the rod for as-extruded metallography, and two 1/2-in. lengths supported on high-purity Al2O9 bricks were placed in a laboratory muffle furnace for exposure at 2000° F. The furnace door was left cracked to allow a slight amount of circulation. One specimen was removed at 200 hr for examination; the other was left for 2000 hr. Metallography. The micro structures obtained for the three conditions of exposure are shown in Fig. 1. Elongation of the grain structure in the extrusion direction is readily evident. The grains appear to be up to 0.001 in. (0.003 cm) long, with a length/width ratio of about 10: 1. Allowing for modest local in-homogeneities in structure, no significant change in thoria particle size or nickel alloy grain size occurred during the 2000°F exposure. However, etching depth varies slightly from one specimen to another, changing the number of particles visible. The thoria dispersion appears to be in the order of 0.01 (min) to 0.5 (max) p diam. The minimum diameter is difficult to estimate at X10,000, and may be less. Interparticle spacing appears to be about 0.1 p. Etching effects can be seen, depending upon grain orientation. A cubic etch-pit pattern appears in certain grains, apparently when etching is started by an anodic particle of thoria, Fig. l(c). The cubic pattern appears related to crystallographic orientation, and is prominent when the [ l00 ] direction is perpendicular to the plane of polish. The grains which present a ridged appearance in the photograph appear to be oriented with the [110} direction perpendicular to the plane of polish. Analysis. The thoria particle size was measured by a line intercept method perpendicular to the extrusion direction. Only particle sizes measuring 0.001 in. at X10,000 or larger could be extimated. Within limits of experimental error, particle size distribution appears to be unaffected by exposure, Fig. 2. To check structural stability further, a grain-growth evaluation was made. The number of grain-boundary intersections was counted at X500 on each of several traces normal to the extrusion direction for each condition. It can be seen from Table I that grain diameter appears unchanged by the 2000°F exposure. The slightly finer grain diameter after 200 hr may be attributed to variations in grain size from area to area in the original extrusion. From the present rather limited study of Ni-2 Th on, it appears that: 1) for time-temperature exposure up to 2000 hr at 2000°F (Larsen-Miller parameter = 57, homologous temperature = 0.8) thoria particles of the size studied are highly thermally stable; they do not significantly react, agglomerate, or diffuse; and

Jan 1, 1963

By J. H. Swisher

In measuvements of the solubility of nitrogen in fer-rilic Fe-P alloys, tile nitrogen solubility is found to be Less in pIrospliorus-bearing alloys than in pure iron. The reduction in solubility is about 20 pct in a 1.0 wt pct P alloy at 1300°C and about 30 pct in a 0.23 wt pct P alloy at 440°C. Diffusion coefficient measurements at 1150 and 585°C show that phosphorus also decreases the nitrogen diffusivity in iron. In previous work on the Fe-P-N system, phosphorus was found to reduce the nitrogen solubility in liquid iron slightly.&apos; Indirect evidence for similar behavior in a Fe at low temperature was obtained by Dickenscheid and Brauner.&apos; These authors found that phosphorus reduces the height of the internal-friction peak due to dissolved nitrogen. The results of Dickenscheid and Brauner were confirmed by J. C. Swartz of this Laboratory in a single internal-friction experiment using the same specimen stock as in the solubility measurements described below. In the present investigation, the solubility of nitrogen in a fer rite-stabilized Fe-1.0 wt pct P alloy was measured in the temperature range from 800" to 1300°C. Additional experiments were performed in the temperature range from 440° to 585°C, using an Fe-0.23 wt pct P alloy and NH3-H2 gas mixtures. EXPERIMENTAL The experiments were performed in a vertical tube furnace wound with platinum wire. For experimental temperatures of 800°C and above, a mixture of 5 pct Hz in N2 was used as the reacting gas. The gas mixture was prepurified from oxygen by passage over platinized asbestos at 450°C, and subsequently over anhydrone to remove water. Flow rates of the gases were measured with capillary flow meters. The temperature was measured before and after each experiment with a Pt/Pt-10 pct Rh thermocouple. The specimens used for the high-temperature solubility measurements were in the form of rectangular plates, 0.534 by 1.6 by 3.8 cm. The specimens were cleaned in trichloroethylene and annealed for 2 hr in hydrogen at the beginning of each experiment. In measuring the nitrogen solubility, the specimens were held in the reacting gas until equilibrated, then cooled in a water-cooled copper block at the bottom of the furnace. The time needed for equilibration at 1150°C was determined by measuring the average nitrogen content of the 1.0 pct P alloy as a function of reaction time. As will be described, the nitrogen diffusivity in the alloy at 1150°C is only slightly less than its calculated diffusivity in pure iron. At temperatures other than 1150°C, the reaction time used in measuring the nitrogen solubility was about twice the calculated equilibration time for pure iron at the same temperature. With a few exceptions, the procedure for the low-temperature solubility measurements was the same as that described above. The compositions of the NH3-H2 gas mixtures were determined by collecting gas samples from the gas train and analyzing them for NH3 by titration with HC1. The specimen thicknesses were less than those used for the high-temperature experiments, eg., 0.124 and 0.051 cm for measurements at 585° and 440°C, respectively. Nitrogen concentrations were obtained by chemical analysis, using the Kjeldahl method. The Fe-P alloys were made by adding ferrophos-phorus to electrolytic Plastiron (Type 104 A). Commercial ferrophosphorus, containing 3 pct Mn and 0.35 pct Si as the major impurities, was first purified by melting under an FeO slag. In a separate heat, the electrolytic iron was melted and vacuum-carbon-deoxidized prior to making the ferrophosphorus addition. The principal impurities and their concentrations in weight percent in the 1.0 pct P alloy are as follows: Mn, 0.01; Si, <0.01; C, 0.01; 0, 0.003; and N, 0.0012. The impurity levels in the 0.23 pct P alloy are con-

Jan 1, 1968

By A. H. Tousley

The cement industry is on the horns of an economic dilemma. Within the last ten years, its over- capacity in the United States has varied from 139- 127% of demand (Fig. 1). The most direct effect of this is seen in cement prices, which reached a peak in 1960, retreated steadily through 1966 and only recently climbed back to the 1960 level again. With prices in a slump and production costs estimated to be up almost 30%, there has been a steady drain on cement profits. Since 1960, labor costs have increased 86% while fuel costs have risen 18%. Meanwhile, customer service costs have also soared owing to the competition for cement customers and the wider variety of available cement products. This search for sales advantage has in turn led to a higher Blaine number, which means more grinding and hence bigger mills, more power, and, once again, higher costs. New plants as well as expansions and revisions to existing plants are also costing more owing to higher

Jan 1, 1971

Jan 5, 1953

By W. G. Whildin

This paper will be confined to a discussion of the methods in use in the property of the Lehigh Coal and Navigation Co. in the Panther Creek valley.

Jan 1, 1915

To Install Waste Heat Boiler at White Pine White Pine Copper Co.&apos;s smelter 18 miles southwest of Ontonagon, Mich., will have a six story high boiler utilizing what otherwise would be waste heat from a copper reverberatory furnace. Designed and under construction by the Babcock & Wilcox Co., the boiler will supply steam to a turbo-generator furnishing power for the projected development. The boiler will be in line with and following the reverberatory furnace. Using waste heat from the furnace in place of fuel for steam generation, about 50 pct of heat in the fuel originally supplied to the furnace will be recovered by the waste heat boiler. Exploration conducted over the past 15 years at White Pine, wholly owned subsidiary of Copper Range Co., has disclosed reserves of 309 million tons averaging 21.3 lb of copper per ton. Ore mineral is chiefly chalcocite (Cu2s).

Jan 5, 1953

By Paul Billingsley

THE term Boulder batholith was first applied in 1897 by W. H. Weed&apos;2 to the extensive mass of granite in western Montana within whose borders occur the ore, deposits of Butte. In a general, way this was known to extend from Helena on the north to the Highland Mountains near Butte on the south, and to be relatively narrow in its east-west diameter. Its intrusive relations to the surrounding sedimentary , rocks, and its probable Tertiary age, were described by Weed, but in many ways his statements, based upon incomplete data, have required revision. Most notable of the errors of this description of the batholith were the failure,3 since corrected, to recognize the intrusive contact of the granite with the capping of andesite, and the complete absence of any reference to the many extensions of the granite beyond the somewhat narrow limits of its largest exposure.

Jan 1, 1915

By Francis T. Freeland

The deeper workings of the Leadville mines show refractory ores, consisting principally of sulphides of iron, lead, and zinc, carrying silver, in place of the easily reduced carbonate ores lying nearer the surface. The largest and most extensively developed deposit is that of South Iron Hill.* It lies on the north side of California Gulch,

Jan 1, 1886

Jan 3, 1953

By T. E. Kihlgren

SYSTEMATIC data are presented on the relation of composition of nickel silvers to color, tarnish resistance, hardness and liquidus temperatures, for alloys containing up to 30 per cent nickel and 50 per cent zinc, further modified at certain nickel and zinc contents by 0 to 8 per cent of tin and 0 to 10 per cent of lead. Attention has also been directed, using a still more limited range of alloys, toward a study of tensile properties and such casting properties and characteristics as fluidity, shrinkage and pressure tightness. In some of these, rather broad ranges of composition are dealt with; in others, it has been expedient to focus attention on the Federal Specification 20 per cent nickel silver casting alloy, WWP-541. INTRODUCTION The demand for an alloy essentially white in color, which could be cast and worked by simple methods and which possessed strength and corrosion-resisting properties superior to the usual brasses, led to the discovery and early use of cupronickel alloys containing zinc, and some-times tin, lead and other metals. This type of alloy was generally known as German silver until the war, when the term "Nickel Silver" became generally accepted. The element principally responsible for the white color of the alloy and for its strength and corrosion resistance is nickel, which may constitute from 8 to 30 per cent of the alloy. The functions of the other elements will be described later. The manifold uses of nickel silver are largely due to its color, corrosion resistance, ease of casting, fabrication, joining and rather moderate cost. In many instances the alloy is finished by grinding and polishing while in others it may be finished with a silver or nickel plus chromium plate. Electroplates

Jan 1, 1935

By Stanley Lefond

Industrial Minerals, often called the Cinderella Minerals or the Building Blocks of industry continued their growth patterns through 1973, although profits were slightly lower due to the cost-price squeeze. Most of the individual reports which follow indicate growth rates of 3-15%. Surprisingly such commodities as sulfur held firm in spite of the over supply in the Canadian gas fields; cement was in short supply while the asbestos industry reported a worldwide shortage of group 4 and 5 fibers. Talc and perlite production set new records. In synopsis, 1973 was a productive year for industrial minerals. However 1974 onward appears to be one of contradiction. The unsettled conditions of world economics, the energy shortage, compounded by the Arabs oil embargo have created great problems for all industries. The high energy consuming segments of the Industrial Minerals field will be under intense pressures. On the other hand limestone, lime and perhaps trona, nahcolite might be consumed in ever increasing tonnages in SO2 removal systems connected with smelters and coal-fired power stations. The effects of the proposed changes in the staking, claiming and exploitation of federal lands by the BLM may also have serious repercussions not only to the industrial minerals field but to the entire mining industry. 1974-1975 will certainly be ear-marked as a year of frustrations and difficult decisions.

Jan 2, 1974

By R. A. Swalin, A. H. Geisler

THIS study represents an investigation of the effect of annealing temperature on the texture of drawn molybdenum, iron, and an iron alloy containing 14 pct Al. The effect of temperature on annealing textures has not been widely investigated in the past. One of the obstacles in making such a study using usual X-ray diffraction techniques results from the

Jan 1, 1957

By Ernest Kirkendall

THE amount of research done in the last few years on the subject of diffusion in solid metals is significant of the importance of this problem. To review the literature dealing with diffusion is unnecessary here. Desch1 in 1912 reviewed the work that had been done on diffusion in solids and gave a bibliography of the literature published before that time. Mehl&apos;s paper in 1936 2 is an excellent review of diffusion in metals and contains a large bibliography. Of importance also for its review and bibliography is an article by A. I. Krynitsky.3 While considerable material has appeared in the literature on diffusion in brass, the amount of information is not great compared to that pertain-ing to some of the other alloys. Most of the information published is of a qualitative nature; that which is quantitative varies considerably. Thus the quantitative determination of the rates of diffusion of copper and zinc in alpha brass by a new method appeared worth while. In the present investigation the rate of diffusion of zinc in approxi-mately the same composition alpha brass has been determined at three temperatures.

Jan 1, 1938

By Thomas P. Oxford, Leslie G. Bromwell

The waste clay slurry produced during beneficiation of Florida phosphate ore presents a major environmental problem. The large volume of waste requires impoundment in above-ground disposal areas surrounded by earthen dams. As the result of a comprehensive research effort, three approaches to improving clay dewatering involving admixing of sand tailings have been developed. These provide satisfactory performance and appear to be compatible with the technological and economic constraints of the industry. Means of determining waste clay characteristics and analyzing mining waste disposal situations by computer simulation have been devised in support of the planning and field testing effort. Detailed examples demonstrating the applicability of the computer programs are presented.

Jan 1, 1980

By S. LeFevre

THE solution of the housing and sanitation problem in mining communities, keeping in view both economic and humanitarian aspects, demands the best thought of the management of such enterprises. Upon the solution depend the health and comfort of the employee and his family, and as a consequence his contentment and efficiency. The following description covers briefly the methods installed for Witherbee, Sherman & Co. The operation of the system has been for about two years under the direct supervision of T. A. Hammond, Land Agent, and I am indebted to him for a compilation of the results.

Jan 2, 1915

By Wolfgang Pietsch

Direct Reduced Iron is a product obtained during solid state reduction of iron oxides into metallic iron. General chemical and physical characteristics of all direct reduced iron materials result in a noticeable reoxidation tendency and a relatively low ignition temperature. As most of the chemical reactions are exothermic, normally heating occurs and if water is present hydrogen evolves. Dry direct reduced iron deactivates quickly in air but is still reactive if it comes into contact with moisture. Because of these characteristics, special requirements are necessary for safe storage, shipment, and handling. In an effort to improve this situation passivation techniques were and still are being developed. The paper discusses the properties of direct reduced iron, presents past experience with storage, shipment, and handling of MIDREX® Iron, a direct reduced iron material produced in the MIDREX® Direct Reduction Process, and evaluates benefits derived from different passivation techniques.

Jan 1, 1978

By H. Souder

The object of this paper is to bring to the notice of engineers a safety detonating fuse by the use of which misfires in blasting may be eliminated and safety in blasting operations promoted.

Jan 1, 1915

By A. Haas, L. Bubenicek

The Lorraine deposit of minette iron ore has been mined for more than a century. During this time, the economic conditions have changed frequently, and especially during the past decade. Thus, it has become economically prudent to proceed to new iron ore reserves with consideration of many and varied parameters. In the past, only traditional mining parameters were considered. Today, the quantity of information that must be taken into account is of such magnitude that the only practical means of data processing is by use of a digital computer and a mathematical model. One such model, based on geostatistics, was developed by G. Matheron. Much of the required input information, such as the petrology of ores, has been generated through IRSID investigations. This paper deals with several aspects of data processing in mining including information recording, reserves calculation, and stages of shrinking data in the calculation of mining iron beds, variograms, kriging, and tonnages.

Jan 1, 1969