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By A. B. Kinzel, Thomas R. Cunningham

Silicon, unfortunately, is not in the same category as some other metals with respect to the absolute value of the highest purity material prepared. Tucker, in England, and Becket, in this country have developed procedures for the purification of silicon, and Becket's process has made industrially available silicon of a purity of 99.8 per cent or better. However, even the term "silicon metal" may be a paradox to some people, although not more so than the term "amorphous" as applied to silicon. These terms come from commerce, and "metal" is used to distinguish industrially high-purity silicon from ferrosilicon, silicon-aluminum, and other high-silicon alloys. Alloys of iron and silicon with 95 per cent Si or less are known as ferrosilicon, with a designation of silicon content where necessary, arid the term "silicon metal" is invariably applied to the grades containing 96 per cent Si and higher. The Becket method of purification was referred to in a monograph on the Alloys of Iron and Silicon, and the Tucker procedure was described in some detail in that publication.' In order to get silicon of still higher purity, a sample, prepared by the Becket method, analyzing 99.84 per cent Si, 0.020 Fe, 0.016 Al, 0.005 Ca, 0.025 C, 0.033 per cent 02, 0.006 H2, 0.006 N2, and 0.001 per cent Mn, was crushed to pass a 100-mesh sieve and further purified by a modification of Tucker's procedure. This modification differs from Tucker's method in that after treatment the 100-mesh alloy was centrifuged to remove the last traces of acid. Our directly determined analysis of this purified sample shows: Si, 99.952 per cent; Fe, 0.009; Al, 0.012; Ca, 0.003; C, 0.006; or 99.982 per cent. Silicon by difference equals 99.97 per cent. The variation between silicon by difference and silicon as directly determined is important. Although Tucker mentions the amount of insoluble matter in commercial silicon both before and after his treatment, he does not mention the existence of carbon in the alloy; nevertheless, he reports silicon by difference. Any final figure as to purity obviously results from agreement between direct determination and

Jan 1, 1940

By George F. Comstock

It has been reported recently1 that the hardenability and toughness of forging steels may be improved appreciably by the use of complex deoxidizers containing titanium, aluminum, and vanadium. In the light of these results, an investigation of similar deoxidizers containing various hardening and grain-refining elements was proposed. These deoxidizers included three manganese-silicon-aluminum-titanium al- loys with and without boron and calcium, three titanium-aluminum ferroalloys with vanadium, molybdenum and zirconium, respectively, an aluminum-zirconium ferroalloy, and plain ferroboron. Their approximate compositions are given in Table I, and the results obtained so far in the investigation of their effects on steel are presented in the later parts of this paper. Method of Using Deoxidizers The deoxidizers listed in Table I were used in three series of 0.40 per cent carbon steels, which were melted in a small basic-lined induction furnace and cast in the form of I7-lb. ingots about 2.75 in. square. The basic charge for each heat was 10 lb. Armco iron and 6 lb. of clean low-carbon sheet-steel scrap. When melted, this charge was deoxidized with 15 grams of ferrosilicon, then about 500 grams of pig iron was added to give the desired carbon content. After the pig iron was dissolved, nickel shot and high-carbon ferrochromium were added if required, and additions of 80 per cent high-carbon ferromanganese and 50 per cent ferrosilicon were made to provide the proper amounts of those elements. Aluminum was added to every heat 2 min. after the silicon, for grain-size control and preliminary deoxidation. One minute later the special deoxidizer was added to the clean bare surface of the molten steel, and 2 min. afterward the steel was poured into the ingot mold, using a hot-top and pipe-preventing compound after pouring to decrease the depth of the shrinkage cavity. The special deoxidizers were used mostly in the form of about ½ to¾-in. lumps,

Jan 1, 1942

By George F. Comstock

IT has been reported recently1 that the hardenability and toughness of forging steels may be improved appreciably by the use of complex deoxidizers containing titanium, aluminum, and vanadium. In the light of these results, an investigation of similar deoxidizers containing various hardening and grain-refining elements was proposed. These deoxidizers included three manganese-silicon-aluminum-titanium al- [ ] loys with and without boron and calcium, three titanium-aluminum ferroalloys with vanadium, molybdenum and zirconium, respectively, an aluminum-zirconium ferro-alloy, and plain ferroboron. Their approximate compositions are given in Table I, and the results obtained so far in the investigation of their effects on steel are presented in the later parts of this paper. METHOD OF USING DEOXIDIZERS The deoxidizers listed in Table I were used in three series of 0.40 per cent carbon steels, which were melted in a small basic-lined induction furnace and cast in the form of I7-lb. ingots about 2.75 in. square. The basic charge for each heat was 10 lb. Armco iron and 6 lb. of clean low-carbon sheet-steel scrap. When melted, this charge was deoxidized with 15 grams of ferrosilicon, then about 500 grams of pig iron was added to give the desired carbon content. After the pig iron was dissolved, nickel [ ] shot and high-carbon ferrochromium were added if required, and additions of 80 per cent high-carbon ferromanganese and 50 per cent ferrosilicon were made to provide the proper amounts of those elements. Aluminum was added to every heat 2 min. after the silicon, for grain-size control and preliminary deoxidation. One minute later the special deoxidizer was added to the clean bare surface of the molten steel, and 2 min. afterward the steel was poured into the ingot mold, using a hot-top and pipe-preventing compound after pouring to decrease the depth of the shrinkage cavity. The special deoxidizers were used mostly in the form of about ½ to ¾ -in. lumps,

Jan 1, 1942

By George F. Comstock

It has been reported recently1 that the hardenability and toughness of forging steels may be improved appreciably by the use of complex deoxidizers containing titanium, aluminum, and vanadium. In the light of these results, an investigation of similar deoxidizers containing various hardening and grain-refining elements was proposed. These deoxidizers included three manganese-silicon-aluminum-titanium al- loys with and without boron and calcium, three titanium-aluminum ferroalloys with vanadium, molybdenum and zirconium, respectively, an aluminum-zirconium ferroalloy, and plain ferroboron. Their approximate compositions are given in Table I, and the results obtained so far in the investigation of their effects on steel are presented in the later parts of this paper. Method of Using Deoxidizers The deoxidizers listed in Table I were used in three series of 0.40 per cent carbon steels, which were melted in a small basic-lined induction furnace and cast in the form of I7-lb. ingots about 2.75 in. square. The basic charge for each heat was 10 lb. Armco iron and 6 lb. of clean low-carbon sheet-steel scrap. When melted, this charge was deoxidized with 15 grams of ferrosilicon, then about 500 grams of pig iron was added to give the desired carbon content. After the pig iron was dissolved, nickel shot and high-carbon ferrochromium were added if required, and additions of 80 per cent high-carbon ferromanganese and 50 per cent ferrosilicon were made to provide the proper amounts of those elements. Aluminum was added to every heat 2 min. after the silicon, for grain-size control and preliminary deoxidation. One minute later the special deoxidizer was added to the clean bare surface of the molten steel, and 2 min. afterward the steel was poured into the ingot mold, using a hot-top and pipe-preventing compound after pouring to decrease the depth of the shrinkage cavity. The special deoxidizers were used mostly in the form of about ½ to¾-in. lumps,

Jan 1, 1942

By D. MacGREGOR, VERA TUREK

The Badgeley Island quartzite deposir in Georgian Bay is worked by lndusmin Limired and was developed in 1969 to produce a high-qualiry silica for use in rhe ferrosilicon and glass industries. The quartzire is part of the Precambrian Bar River Formarion, and is a generally whire, fine-grained rock containing rhin sericire seams. Primary sedimenrary features wirhin the deposit are bedding and ripple marks. Amphibolite and diabase dykes cur the quarr zire body.

Jan 1, 1984

By Clyde E. Eilliams

In recent ye.ars much intere,t has been centered on the possibility of pro­ducing alumina from clq, a.nd proposed methods tor the recove:r,v of alumina are appearing constantly in parent lit,erature, As a good· grade of clay contains from 30 t<> 40 per cent of al"WDina, the prospect of tecovering it is alluring, al though obviously ditfieul t. A patent typical of m projected thermal processes is that 0£ Paul Migu.et, (U, S, Patent No, l,376,563) entitled nprocess for the preparation of pure alkaline alu:ninates.'' Re proposes to prepare alkaline a.luminate by fusing clay, lime, and acrap iron with a reducing aget in the electric furnAce, thereby reducing the silica a.r.d formin1s calcium alumina.te and ferrostlicon, The calcium aluminate, being lighter, would. float on top substantially free from foreign oxides, It could. then be tapped ott, cooledf ana later crushed and leached with aodium carbonate solution to torm, by double decomposition, sodium aluminate, and calcium carbonte. The fonMr is soluble and yields readily aluminum hydroxicie. 'l'he ferrosilicon wo'Uld be r,covered as such and sold at a profit.

Aug 1, 1922

By T. R. Curr, W. A. Gericke, J. Basson

South Africa is a leading player in the international ferro alloys industry. Historical factors that have contributed to this dominant position include an abundance of natural resources and relatively low cost electricity. A number of relatively recent developments are potentially threatening this position. These include new legislation affecting the mining and minerals industry, a shortage of some types of suitable reductants, depletion of surplus electricity generation capacity with resultant threat of real escalation of electricity prices and pressure resulting from the recent strengthening of the South African Rand. The industry is addressing these challenges in a number of ways to ensure long-term viability. Some of these measures include investments in more efficient technologies that have economy of scale benefits and are less dependent on expensive reductants and electricity. Local macro-economic impacts include new legislation regarding ownership of enter-prises, mineral rights and royalties on mineral sales, development plans for port and rail infrastructure, as well as initiatives to expand electricity generation and coke production capacity. The fundamentals for being a successful ferro alloy producer are still largely in place for South African producers. Therefore the South African ferro alloy industry will remain competitive and is well placed for continued growth in line with the international growth in ferro alloy demand. The industry should emerge leaner, more efficient and ready to respond to any future demands of the industry. This paper will cover the present status of the industry, the factors that are impacting thereon and a view on its future outlook.

Jan 1, 2007

In dense medium processes for the beneficiation of minerals the consumption of medium (generally ferrosilicon) represents a major component of the operating cost. This provides a strong incentive for improvements in heavy medium recovery circuit design and operation. A major thrust in heavy medium plant design over the past decade has therefore been towards circuits which reduce medium losses. In this paper recent trends in plant design are examined in relation to the factors infl uencing circuit performance and medium losses. Operational details &apos; which have a significant effect on losses are discussed and illustrated by means of plant and pilot plant test data, with particular emphasis on the performance of wet drum magnetic separators. While the emphasis is on reducing the consumption of the high-cost ferrosilicon medium used in minerals beneficiation, most of the principles described in this paper are equally relevant to the design and operation of magnetite recovery circuits for coal preparation plants.

Jan 1, 1987

By Z. D. Hora

Traditionally, industrial minerals in British Columbia comprise about 10 per cent of the combined value of mineral, coal, petroleum and natural gas production. Over the years a wide variety of industrial minerals have been produced in British Columbia, often with a different level of marketing success. For some products such as building stone, common brick or expanded shale, once strong demand gradually disappeared; for others such as asbestos and barite, new discoveries or new industrial activities created demand and new markets. For yet other minerals such as fluorite, talc and perlite, wider use has been prevented by the small size, poor quality or remote locations of the deposits. Bentonite (1926 to 1944-as a by-product from coal mines) Building stone (intermittently since the mid-1800s) Chromite (1918 and 1929) Over the past years, the list of industrial minerals produced has been expanded to include several new commodities: glassgrade silica sand, magnesite, pumice and silica for ferrosilicon and silicon carbide manufacture.

Jan 1, 1984

By E. G. De Coriolis

The development of huge production facilities and of new or improved processes for manufacturing magnesium from its raw sources has been an outstanding achievement of this war. Furthermore, at least one new method has reached a stage of pilot production that offers promise. Its potentialities seem to indicate that a reduction in cost and simplification or elimination of problems incident to the use of at least one of the present processes are quite within the realm of possibility. Although magnesium of very high purity (99.9 per cent and higher) is obtained, and the rate of recovery reasonable (60 to 70 per cent). the ferrosilicon reduction process is open to a serious objection, which at the time its use was proposed was thought to be sufficient to raise some doubts as to its success, at least on a high production basis. The temperature range at which the reaction is carried out—namely, 2100" to 2150°F.—is very close to the failure temperature of the material of which the retort is made. It is so close that for a time it was assumed it might make commercial use of the process an impossibility. However, at the time under discussion, the demand for magnesium was so great that it was felt by those who had to go ahead and produce this essential metal that the emergency warranted their taking a chance on this process. Subsequent developments have fully justified the soundness of their decision. Fortunately for the war effort, when the plants were put into operation it was discovered that although the retorts did collapse in rather short periods of time, as predicted, they could be blown back into operable shape by application of high-pressure air. This practical method of operation so relieved the situation that the problem disappeared. Nevertheless, if the process had not been successful, or the production of magnesium by the electrolytic process had not been able to keep pace with demands, our war program would have been seriously impaired. Fireless Cooker&apos;&apos; Process For this reason a program was set up and assigned for the development of a new method that had been suggested to the War Production Board in 1941. It is believed justifiable in terming the method "new" for several reasons: (I) while utilizing the same (ferrosilicon) process as the Pidgeon, hence involving similar reactions, the type of retort or furnace is essentially different, (2) the method of operation, reaction temperatures, etc., differ materially, and, most important of all, (3) the problems to be overcome in making the process successful were not and could not have been anticipated by anything previously known about the Pidgcon process. As will be shown later, the briquetting process, the condenser, the furnace lining

Jan 1, 1949

By E. G. De Coriolis

THE development of huge production facilities and of new or improved processes for manufacturing magnesium from its raw sources has been an outstanding achievement of this war. Furthermore, at least one new method has reached a stage of pilot production that offers promise. Its potentialities seem to indicate that a reduction in cost and simplification or elimination of problems incident to the use of at least one of the present processes are quite within the realm of possibility. Although magnesium of very high purity (99.9 per cent and higher) is obtained, and the rate of recovery reasonable (60 to 70 per cent), the ferrosilicon reduction process is open to a serious objection, which at the time its use was proposed was thought to be sufficient to raise some doubts as to its success, at least on a high production basis. The temperature range at which the reaction is carried out-namely, 2100° to 2150°F.-is very close to the failure temperature of the material of which the retort is made. It is so close that for a time it was assumed it might make commercial use of the process an impossibility. However, at the time under discussion, the demand for magnesium was so great that it was felt by those who had to go ahead and produce this essential metal that the emergency warranted their taking a chance on this process. Subsequent developments have fully justified the soundness of their decision. Fortunately for the war effort, when the plants were put into operation it was discovered that although the retorts did collapse in rather short periods of time, as predicted, they could be blown back into operable shape by application of high-pressure air. This practical method of operation so relieved the situation that the problem disappeared. Nevertheless, if the process had not been successful, or the production of magnesium by the electrolytic process had not been able to keep pace with demands, our war program would have been seriously impaired. "FIRELESS COOKER" PROCESS For this reason a program was set up and assigned for the development of a new method that had been suggested to the War Production Board in 1941. It is believed justifiable in terming the method "new" for several reasons: (1) while utilizing the same (ferrosilicon) process as the Pidgeon, hence involving similar reactions, the type of retort or furnace is essentially different, (2) the method of operation, reaction temperatures, etc., differ materially, and, most important of all, (3) the problems to be overcome in making the process successful were not and could not have been anticipated by anything previously known about the Pidgeon process. As will be shown later, the briquetting process, the condenser, the furnace lining

Jan 1, 1945

By Keith L. Harris

The U.S. economy continued to grow moderately in the third quarter, but at a slightly higher rate than in the previous quarter. According to the Department of Commerce&apos;s preliminary estimate, real gross national product (GNP) grew at a seasonally adjusted annual rate of 3.3% during the third quarter of 1985, compared with a revised 1.9% for the second quarter and 1.6% for the third quarter of 1984 (table 1). Civilian unemployment dropped from the constant 7.3% rate between February and July to 7.0% in August and 7.1% in September. Employment on nonagricultural payrolls continued to increase (table 2), resulting in a continued rise in personal income, which in turn supported growing consumer purchases. Although purchases of services continued to provide the underlying foundation for the economic growth, the manufacturing sector received additional stimulus from significant increases in consumer purchases of durable goods, particularly automobiles. The increased demand for durable goods resulted in significantly higher industrial production for August and September, compared with levels attained previously this year (table 3). Capacity utilization increased to 80.5% in August but returned to 80.2% in September, matching the 1985 low previously reached in July (table 4). The real net export deficit grew only $0.2 billion in the third quarter; at $34.0 billion, however, it continued to exert a negative influence on the economy. On September 22, in an effort to reduce the deficit and make U.S. goods more competitive on world markets, the U.S. Government agreed to cooperate with the Governments of France, the Federal Republic of Germany, Japan, and the United Kingdom in attempting to lower the-value of the dollar in relation to other world currencies. Low inventories, rising factory orders and construction spending, the possibility of a lower U.S. dollar, and aggressive automobile production plans announced by domestic producers for the fourth quarter indicate the potential for an increase in manufacturing activity in the United States.

Jan 1, 1985

By F. L. Toy, C. E. Sims

PNEUMATIC processes for converting molten pig iron to steel were the major producers of steel during the latter half of the 19th Century and until shortly after the turn of the century, when these processes began losing ground to their rival—the basic open hearth process. The first pneumatic process for converting molten pig iron to steel was introduced almost simultaneously by Sir Henry Bessemer in England and by William Kelley in the United States during the decade 1850-1860, but it was Bessemer who pushed it to a successful commercial operation. The process itself is so basically simple that it has not lent itself to many extensive or revolutionary improvements since its inception. During the first 30 yr, numerous&apos; designs of vessel and many modifications of practice were tried before the industry standardized on something resembling current practice. The evolution in construction has resulted in proportions and arrangements based more on mechanical expedience than on metallurgical requirements. Many of the early converters were stationary and had to be tapped similarly to the cupola or open hearth furnace. Such types were used for many years in Sweden and Germany, but the rotating or tilting types were favored in England and the United States. There was evident trouble with bottom tuyeres, becAuse about half of the early designs were constructed for side blowing with tuyeres submerged below the metal-bath surface. Even portable tuyeres, introduced from above, were tried. The principal advance, which made bottom blowing practical, was the invention, in 1863, by Henry Bessemer, and subsequent improvement by A. L. Holley, of a detachable bottom so that the tuyere section could be renewed. In the meantime, it was the demonstration, by Robert Mushet, of the value of manganese in overcoming hot-shortness in converter steel, that made the process metallurgically feasible. At first, only the acid practice was used, and Swedish pig iron, because of its low sulphur and phosphorus, was in great demand. The development of a suitable basic lining, by Sidney G. Thomas and Percy G. Gilchrist in 1876-1879, made the process applicable to the high-phosphorus ores of Europe. From the beginning of the use of the Thomas-Gilchrist process, trouble was experienced in obtaining sufficiently high temperatures in the blown metal, particularly in small heats. It is necessary, of course, to have the low-carbon blown metal at a considerably higher temperature for handling from vessel to ladle to molds than is needed for the molten pig iron. All of the increase in temperature in a pneumatic process must be obtained from the heat of combustion of the elements contained in the pig iron plus that from silicon when ferrosilicon is added. In bottom blowing practice, carbon is almost completely burned, but inasmuch as it cannot be oxidized to a higher state of oxidation than to CO when in contact with liquid iron, only a minor portion of the heat-producing capacity is utilized. Under such conditions, it is not considered to be an efficient source of heat. In the acid practice, therefore, silicon and manganese are the large heat producers, are quickly oxidized, and are efficient fuels. Too much manganese, however, thins the slag greatly and tends to promote excessive slopping or throwing of slag and metal from the converter during the blow. Most operators, therefore, like to keep the manganese content of the iron below 0.60 pct, and thus the main source of heat is the silicon, which must be at least 1 pct and sometimes 2 to 3 pct for small blows such as for castings. Ferrosilicon is sometimes added during the blow to obtain an adequate temperature level. In the basic (Thomas) practice, even more heat is required, because cold lime is added to flux the phosphorus after it is oxidized, and the basic slag must be maintained at a proper temperature. Silicon

Jan 1, 1951

By R. H. Frazier, C. H. Lorig, F. W. Boulger

THERE are both advantages and disadvantages in using semikilled steels in place of killed steels. One advantage of semikilled steels is they provide a higher ingot-to-product yield. This is especially important to shipbuilders in the time of national emergency. By using semikilled steel for hull plates, a greater number of ships can be built from the same ingot tonnage. Consequently, if semikilled steel plates are adequate for the service, the advantage of the higher product yield is of considerable importance. The performance of hull plates is closely associated with the ductile-to-brittle transition temperature, and this, in turn, is strongly dependent on the composition of the steel. A low transition temperature is desirable because it indicates that the steel is less likely to fail at low ambient temperatures. Killed steels are known to have lower transition temperatures than semikilled steels. It is believed that the better qualities of killed steels in this respect are due mainly to the low oxygen contents of the steel. The principal deoxidizers, aluminum, silicon, and manganese, lower the oxygen content. Fundamental studies1-0 have shown that the oxygen content remaining after the addition of one of these three elements is influenced by the residual amounts of the other two present. In the current study, therefore, various amounts of silicon and aluminum were added to steels containing different manganese contents for the purpose of studying the influence of silicon and aluminum on the notched-bar properties of hot-rolled steels. Eleven types of steels were studied. The temperature at which the plates were finish-rolled was care- fully controlled at 1850°F. All plates were rolled to ¾-in. thickness, and tested in the as-rolled condition. The total number of steels prepared in the laboratory for this study was 95. The charge consisting of ingot iron and ferrosilicon equivalent to 0.10 pct Si was melted in a 200-lb induction furnace under an atmosphere of argon to insure low, uniform nitrogen contents. After the charge was melted and the desired temperature was obtained, the melt was partly deoxidized with either silicomanganese or aluminum. Aluminum was used for this purpose in only those steels with very low silicon contents, where the finished steel was to contain some aluminum. This initial deoxidizing addition was made to obtain consistent recoveries of subsequent additions of ferro-manganese, ferrosilicon, and aluminum. Carbon, in the form of graphite, was added, either just prior to tap or to the final aluminum addition. The entire heat of 200 lb was poured directly into a 6x6-in. big-end-up mold. The ingots of semikilled steel were capped with a steel plate. The killed steels, on the other hand, were poured with a hot-top containing 14 pct of the total volume of the ingot. The ingots were processed by heating to 2250°F, followed by forging to slabs 1¾ in. thick and 6 in. wide. After reheating to 2250°F, the slabs were rolled to 0.9-in. gage, using reductions of approximately 1/6 in. per pass. The 0.9-in. thick plates were immediately recharged in a furnace held at 1850°F. After 30 min in the furnace at 1850°F, the plates were rolled to ¾ in. in one pass. Following the final pass, the plates were stacked on edge on a brick floor, with a brick separating one from another, where they were allowed to cool in air. Drillings for chemical analysis were taken from the plates at locations corresponding to the top and bottom of each ingot. Carbon, manganese, silicon, phosphorus, sulfur, and nitrogen contents of each sample were determined. The analysis of each steel was carefully controlled so that the contents of

Jan 1, 1957

By E. C. Tveter, L. A. Roe

The authors present a general outline of the theory and development of heavy-liquid application to mineral processing. Patent literature and processes are reviewed with special emphasis on liquid recovery systems which have been employed or proposed. Advantages and disadvantages of the process are discussed together with the recent developments which have revived interest in this old concentration method. The most important single factor in this resurgence of interest is concluded to be the narrowing gulf between chemical engineering and mineral dressing which has opened the field for new concepts of mineral plant design. A partial summary of patents on heavy liquid separations is included. In spite of the fact that heavy-liquid separation with organic liquids has been used in the laboratory for over 50 years, this process has never graduated to large scale commercial use for any extended period. However, a variation of this process, the sink-float or heavy-media separation process has found wide acceptance and is used to separate minerals from diamonds to gravel. Materials used to increase the specific gravity of the pulps used as heavy media include sand, clay, barite, magnetite, galena, hematite, atomized lead and ferrosilicon. Because of the greater ease of recovery, the magnetic materials, magnetite and ferrosilicon, are the preferred media today. In the U. S. alone, heavy-media iron ore plants with a capacity of over 10 million tons of concentrate per year are in existence. Heavy-media separation involving use of solid, inorganic particles suspended in water rapidly found a wide range of commercial use with the introduction of magnetic media. The minerals engineer is experienced in working with suspensions and quickly learned to develop and control such media at a cost compatible to the type of separation desired. The natural superiority of a heavy liquid with uniform chemical and physical properties has never been questioned since its first use in laboratory mineral separatory procedures. It offers the only method for gravity separation of fine particles of relatively close specific gravity. The most important early attempt to make heavy liquid separations commercial were made by the DuPont Co. which began experimental work on Virginia limonite in 1904. The appended "Partial Summary of Patents" compiled by W.L. O&apos;Connell of The Dow Chemical Co. demonstrates the quantity and sequence of this work. Both inorganic and organic parting liquids were investigated and numerous patents were issued on the use and recovery of these liquids. The work culminated in the heavy liquid plant of the Weston Coal Co. at Shenandoah, Pa. Chemical engineering design of this plant was the responsibility of Francis I. and Hubert I. DuPont. Heavy-liquid separation of coal almost achieved commercial status at this plant which actually processed over 20,000 tons of coal. The liquids used were tetrabromethane, pentachloroethane and trichlo-roethylene, with liquid losses ranging from 8.9 to 12.4 oz per ton of cleaned coal. The reasons for failure of this plant are not clear but probably involved toxicity problems as well as other problems in chemical engineering. Excellent economics were reported. A more recent pilot plant was built in 1954-55 by Norris Goodwin for the Inerto Co. to treat hectorite clay. This plant employed carbon tetrachloride in jigs with liquid recovery by evaporation. Although good separation was achieved, incomplete removal of the CCl, from the clay prevented commercial operation. The only present operations known to the authors employing heavy liquids for gravity separations are limited to the use of calcium chloride in certain coal washers and bromochloromethane in a small batch operation (one ton solids per day) for the separation of beryllium metal particles from slag materials. This is not strictly a minerals beneficiation problem but it has demonstrated the feasibility of such separations. PROBLEMS Critics of early attempts to commercialize heavy-liquid separation of minerals summarize the draw-

Jan 1, 1963

By John Convey

"IRON ORE was first smelted in Canada about the year 1736 at Les Forges, Quebec -a most appropriate name for such a historic locale. During these early years of the 18th, 19th, and first quarter of this century, about six million tons of ore were mined and employed in the manufacture of items ranging all the way from kettles, stoves, and cannon for the early settlers to weapons of war for the allied armies of World War I.But this symposium on iron ore is not concerned with this early period. Instead, it is concerned with the iron ore industry of today -an industry which will soon be-come one of the two most valuable mineral industries in Canada.The subject in its broad geographic and economic aspects will be introduced by Mr. Buck; Dr. Harrison will describe the geology and origin of the principal iron ore deposits; Dr. Downes will go into beneficiation as it applies to iron ores; and Mr. Gertsman will discuss primary processing. The symposium will not deal with the steel end of the industry, because that phase itself could well form the subject of a symposium."

Jan 1, 1955

1. Domestic Production and Use: In 1979, 12 companies operated 32 primary aluminum reduction plants, with 3 firms accounting for 64% of production. Washington, Oregon and Montana accounted for 32% of the total production; Gulf Coast States 20%; other Northern States 32%; and other Southern States 16%. Based on published producer prices output of primary metal in 1979 was valued at over $6 billion. Aluminum consumption by 25,000 firms was centered in the East Central United States. Of aluminum consuming industries in 1979, building accounted for about 24%; packaging 23%; transportation 22%; electrical 11%; consumer durables 8%; and other uses, 12%.

Jan 1, 1980

The value of domestic raw nonfuel mineral output in 1985 was estimated at $23.7 billion, 2% above the 1984 value of $23.1 billion. This crude mineral output was the basis for approximately $244 billion worth of processed materials of mineral origin. [ ] A U.S. company permanently closed its alumina plant in St. Croix, U.S. Virgin Islands, reducing domestic alumina capacity by 10%. Another U.S. company sold its 26% interest in an alumina plant in Jamaica to its two U.S. partners. On completion of the purchase agreement, the two remaining partners promptly closed the plant for an indefinite period, citing a world oversupply of alumina and unacceptably low prices.

Jan 1, 1986

By J. Chipman, N. J. Grant, J. H. Walsh, T. B. King

WITH the development of adequate sampling and analysis techniques, much information has been obtained concerning the behavior of hydrogen in the steel bath during the course of steelmak-ing operations. From studies of this type it has become clear that the slag has an important role to play in determining the hydrogen content found in commercial products. A knowledge of the behavior of hydrogen in slags is necessary to round out our knowledge of hydrogen in steelmaking practice; with this information we are better able to assess practical methods of control. In this paper a method developed for analyzing slags for hydrogen content, studies of the solubility of hydrogen in synthetic slags, and studies of the variation of hydrogen content in slag and steel in industrial heats will be described. Previous Work—While very little has been done in the past to determine the hydrogen content of metallurgical slags, measurements have been made on such slag-like materials as geologic magmas and glasses. Goranson as made extensive studies of the solubility of water in natural and synthetic granites. Many workers have investigated the solubility of gases in synthetic and commercial glasses, but the recent work of Russell" is the most extensive. Russell found that the solubility of water in glass was proportional to the square root of the water vapor pressure in water vapor-oxygen mixtures. It was found that the solubility could either increase or decrease with temperature depending on the glass composition. Wentrup, Fucke, and Rief,&apos; and Piper, Hagedorn, and Backes&apos; have extracted hydrogen by holding a slag at 1300" and 800°C respectively in vacuum. Wentrup et al. reported hydrogen and water vapor as evolved together while Piper et al. passed the evolved gases from the hot extraction treatment over hot ferromanganese to reduce the evolved water vapor to hydrogen and, therefore, reported the analyses in terms of total dissolved hydrogen. Yavoiskii has reported hydrogen and nitrogen analyses on steelmaking slags. Dobrokhotov, Povol-skii, and Khan have studied the hydrogen content of basic open hearth steel under slags of varying viscosity. These authors reported that the hydrogen content of the steel bath increased as the fluidity of the slag was increased by the addition of bauxite. They recommended that a viscous slag be used and the steel tapped without deoxidation in the furnace to ensure a low final hydrogen content. Analysis of Slags for Hydrogen Development of Apparatus—The vacuum fusion analysis equipment described by Shields, Chipman, and Grant" was modified for the analysis of slags." This method depends upon the reduction of water in the slag to hydrogen, which is readily determined by the method used for hydrogen in steel. Preliminary experiments were made with a eu-tectic ferrosilicon melt as the reducing agent. Other experiments included the use of graphite and molybdenum crucibles. The ferrosilicon alloy bath was found to produce a thick coating on the furnace tube which could adsorb hydrogen. Graphite produced CO by the reduction of FeO, MnO, and SiO2 in such quantities that analysis for hydrogen was virtually impossible. Molybdenum, while giving a low blank value, could reduce the slag sufficiently to produce a volatile oxide which again was found to adsorb hydrogen. The arrangement finally adopted is shown in Fig. 1. The molybdenum sheet served as the induction-heated susceptor, and was separated from the escaping gases by alumina guide tubes. An outer jacket of alumina protected the quartz furnace tube, and alumina and quartz stools completed the assembly. The falling sample is shown wrapped in aluminum foil, 0.002 in. thickness, which acted as the reducing agent&apos; This foil was careful&apos;~ washed in acetone and an d and then dried in hot air before wrapping the weighed slag sample for charging into the apparatus. Investigation of the hydrogen content of the aluminum foil itself showed that a small quantity of hydrogen was released in vacuum, but had no relation to the weight of the aluminum charged. This quantity of hydrogen was

Jan 1, 1957

By R. H. Frazier, J. M. Hodge, F. W. Boulger

This paper reports the results of studies of the impact properties of quenched and tempered alloy-steel plates as a function of sulfur content. It was found that the impact energy levels decreased continuously as the sulfur content increased and that there was a straight-line relationship between impact energy and sulfur content when plotted on logarithmic coordinates. Cross rolling raised the level of these Lines for transverse tests and lowered the level for logitudinal tests proportionately to the amount of cross rolling. ALTHOUGH it has been generally recognized that, for applications in which notch toughness is critical, the sulfur content of the steels used should be held to a low value, quantitative information on the effect of sulfur on notch toughness has not been available. For such applications, it is a common practice to specify minimum impact values, and in order that these may be met consistently it is important that the steel producer know quantitatively the effect of sulfur on notch toughness so that realistic sulfur content limits can be applied to the steels they produce. In many instances, particularly in flat-rolled products, impact properties are specified in the direction transverse to the principal rolling direction, so that the factors affecting the anisotropy or directionality of impact properties are also of concern to the steel producer. For some applications, furthermore, it is a common practice to increase the sulfur content of steels in order to improve their machinability, and, in such instances, the effect of this practice on notch toughness may often be of concern. This paper reports on an investigation, carried out at Battelle Memorial Institute, designed to furnish this quantitative information on the effect of sulfur on notch toughness and also to furnish further information on the factors affecting the anisotropy of impact properties in wrought heat-treated alloy steels. MATERIALS AND EXPERIMENTAL PROCEDURE The experimental steels were of intended base analysis: 0.30 pct C, 0.80 pct Mn, 0.25 pct Si, 2.5 pct Ni, 0.80 pct Cr, and 0.45 pct Mo. Steels were made with sulfur contents varying from 0.005 to 0.179 pct. The steels were prepared from 600-lb induction-furnace melts. Steels containing 0.020 pct or more sulfur (at meltdown) were melted from a charge of ingot iron (except for one heat): lower-sulfur steels were made from electrolytic iron. The charge consisted of ingot or electrolytic iron, ferrosilicon to give 0.10 pct Si, and ferromanganese to give 0.05 pct Mn. At meltdown, electrolytic nickel, ferromolybdenum, iron phosphide, and pyrite were added followed in sequence by ferrochromium, sili-comanganese, ferrosilicon, and ferromanganese. The slag was then removed and graphite added to give the desired carbon content. Bath temperature was adjusted to 2850°F and, when no other additions were to follow, 2 lb per ton of aluminum was added, immediately before tapping. Compositions of the experimental steels appear in Table I. Analyses are from single determinations, except sulfur which was analyzed in duplicate. A test sample (3 in. in diam by 6 in. long) and a 575-1b ingot were poured from each heat. The test sample was poured in a sand mold; the cooling rates of the test sample and the large ingot were approximately the same. Chemical analysis chips and metal lographic specimens were taken from the test samples. The ingot was 8 in. sq at the base and 9 in. sq at the top. A 5 X 5 X 6-in. sand mold hot top was completely filled in teeming the ingot. After solidification, the mold was stripped from the ingot which cooled to room temperature. Ingots were reheated to 2250"F and rolled to 1.9-in. slabs on a commercial mill. The slabs were box-cooled to room temperature. Sections of the 1.9-in. slabs were heated to 2250°F and rolled on a Battelle laboratory mill according to one of three schedules: 1) rolled straightaway to 0.5-in. plate; 2) rolled straightaway to 1.3-in. thickness, then cross rolled to 0.5-in. plate (29 pct cross rolling); or 3) cross rolled from 1.9-in. to 0.5-in.-thick plate (46 pct cross rolling). The 0.5-in.-straight- or cross-rolled plates were normalized at 1700°F for 1 hr and then water quenched from 1600°F. Plates were then tempered 2 hr at 1240°, 1170°, 1080°, or 860°F to obtain Rockwell C hardness of 25, 30, 35, and 40, respectively. Tempering was followed by quenching to room temperature to avoid temper embrittlement. Slack-quenched plates were isothermally transformed for 26 min at 800°F, quenched, and tempered 2 hr at 1170°F. Pearlitic microstructures were obtained by holding 168 hr at 1200° F, followed by quenching. Charpy V-notch specimens were taken both transverse and longitudinal to the main rolling direction, notched perpendicular to the plate surface, and tested. Slabs and plates which were to be homogenized

Jan 1, 1960