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By M. W. Hayward

THE object of this paper is to record and tabulate the data and field observations obtained by the writers and their associates during 10 years of intensive study of lead-zinc deposits in the Cretaceous limestone areas in Northern Mexico, particularly in mines owned by the Cia. Minera de Peñoles, S. A. At the El Paso meeting of the Institute in October, 1930, J. G. Barry made the suggestion that a committee be appointed to correlate the ideas and theories which have been put forth by the numerous engineers and geologists who, during recent years, have made a study of the ore deposits in the area under consideration. The first step in a work of this nature would be to record all of the observed facts, and these facts would have to be accepted by those who attempted to formulate a theory of ore deposition. It is with this idea in mind that the writers have described as accurately as possible the actual, observed facts pertaining to the occurrence of the lead-zinc ores in dolomites or dolomitic horizons. By most writers the term "dolomite," is loosely used to designate magnesium-bearing limestones, regardless of the percentage of MgO present. Since no, true dolomites exist in the areas to be described, we shall also loosely use the terms dolomite or dolomitic limestone to designate those beds having a magnesia content of 5 per cent MgO or more. For a number of years the writers have been impressed with the fact that in areas where dolomite beds occur a large percentage of the lead ore is found in these beds, in spite of the fact that such beds may be overlain or underlain by pure limestone, which one would assume to be just as favorable for replacement as the dolomite, if not more 'so on account of its being more soluble in acid solutions than the dolomite. It is true that in some limestone areas, such as the Erupcion-Ahumada districts, Chihuahua, and Providencia, Zacatecas, where no dolomite beds have been found, large tonnages of lead ores have been mined. We venture to predict, however, that had there been dolomitic beds in these areas, the

Jan 1, 1931

By Richard F. Miller, W. E. Milligan

Work was undertaken two years ago at the Hammond Laboratory for the purpose of determining the magnitude of the elastic range in single crystals of pure metals by means of creep tests, the assumption being made that if a true elastic range exists, the elastic limit represents the maximum stress for no creep. A sensitive extensometer was constructed, and creep tests were made on zinc single crystals at a variety of loads and temperatures1. It was soon discovered that there is no measurable elastic limit in ductile zinc single crystals at, or above, room temperature. The inference that pure metallic single crystals may not possess a definite elastic range was not justified, however, since zinc had been tested in creep only above its recrystallization temperature, and several investigator2,3,4 had already shown that above the recrystallization temperature polycrystalline metals will flow under very small stresses, while below that temperature stresses of a much larger magnitude are required. For that reason, it was decided to extend the study of the elastic limit to other metals having a higher recrystallization temperature than zinc. Aluminum and silver were selected, because of the ease of obtaining pure materials and of preparing large single crystals, and because the crystallo-graphic glide system of these metals is well known. Owing to the limited time available, the elastic range was investigated by slow tensile tests rather than by creep tests. Production of Specimens A luminum Recrystallized single crystals were prepared from 99.95 per cent aluminum supplied by the Aluminum Company of America. The ingots were melted in an Acheson graphite crucible in a gas furnace, and cast

Jan 1, 1937

By C. R. Fast, George C. Howard

Laboratory and field testing of various squeeze cementing techniques and materials revealed that many improvements could be made in squeeze cementing operations. The use of a slow-pumping squeeze cementing procedure permitted the control of the quantity of cement displaced into a formation and aided in obtaining a high final squeeze pressure. Field testing indicated the desirability of obtaining high final squeeze pressures, the need for improved formation breakdown fluids, and the necessity of controlling the pressure differential during testing after a squeeze job. INTRODUCTION During the past few years, squeeze cementing operations have been investigated, both from the theoretical as well as the practical point of view, in an effort to arrive at some solution to the many and varied problems that arise with this type of operation. A review of well files indicated that in many instances, wells were being squeeze cemented four and five times before a satisfactory pressure buildup was obtained. There seemed to be considerable variation in opinion as to the proper method of squeeze cementing, as well as disagreement as to the proper breakdown agent, the quantity of cement that should be used, type retainer and length of WOC* time that was necessary. Consequently, it was deemed advisable to approach this problem theoretically, field testing each idea developed in hopes of eventually arriving at a squeeze cementing procedure that would give reasonable assurance of a successful job after one squeeze cementing operation. This investigation was. therefore, divided into two broad headings: (1) Preliminary studies, which include both theoretical and laboratory studies, and (2) Field investigations to determine the proper squeeze cementing methods. PRELIMINARY STUDIES Overburden Pressure Studies Squeeze cementing problems are so intimately related to the earth's overburden pressure that solutions to them are very difficult, if not impossible, without an understanding of the nature and magnitude of the overburden pressures encountered at the depths of producing wells. It was thus felt that the first approach to research on squeeze cementing should be made through a study of these pressures. Since there has been rather loose usage of a number of the terms related to overburden preasure by different writers, the terms to be subsequently used are defined here. Theoretical overburden pressure is the calculated pressure at any given depth exerted by the theoretical weight of overlying formations as calculated from the average rock density. Fluid displacement pressure is that pressure at which fluid can be injected into a formation after it has been broken down. It may be more or less than the theoretical overburden pressure. Formation breakdown pressure is that pressure at which a formation parts or breaks and is usually thought of as fluid displacement pressure plus rock strength. Breakdown agent is that fluid with which the formation is fractured. The first step in the study of the earth's overburden pressures involved a review of pertinent technical literature. The general opinion expressed was that the overburden pressure gradient of the earth's formations is roughly 1.0 psi per foot of depth, and that application of sufficient pressure to stratified formations. will cause them to part at or parallel to the bedding planes. The second step in the study of overburden pressures involved a study of available well data in an effort to obtain some definite information as to the actual values experienced in the field for the above mentioned terms. Data from 115 cement squeeze jobs in the Gulf Coast area and 46 cement squeeze jobs and acid jobs in the West Texas-New Mexico area were closely analyzed. The analysis of these data showed that the average formation breakdown

Jan 1, 1950

By C. P. Fiske

The pottery of the New Jersey Zinc Co. (of Pa.) is equipped to make three classes of refractories; namely, spelter vessels, spelter condensers, and high-grade fire-brick. The most important of these are the spelter vessels, on account of the extreme severity of the service which they must perform, necessitating great care in the selection of materials and in the whole process of manufacture. Next to the spelter vessels in importance come the condensers, as large numbers are used in the manufacture of spelter, and improvements in quality result in material decreases in working cost. While the fire-brick which form the laboratory, or high-temperature portion of the spelter furnaces, are placed at the foot of the list, they are nevertheless of much importance, since high quality will decrease the frequency of the always expensive shutdowns for repairs. To promote simplicity, the manufacture of these three products will be described separately in this paper, except in so far as materials and the crushing and handling system common to all are conccrned. Materials Bond Clay.—The bond clay used entirely at the Palmerton pottery is a St. Louis clay furnished by the Grand View Fire Clay Co. It is stored in a system of covered bins, and no attempt is made to weather it in the accepted sense of the term " weathering." Some years ago our clay was weathered before pugging, but we did not find the benefit sufficient to offset the additional handling and the loss of clay incurred. Furthermore, we believe that the rotting of the pugged mix (described later) accomplishes the same results to better advantage. That there is some action taking place in the clay while stored in the covered bins, however, is evidenced by an increase in volume which at times has caused damage to the retaining walls of the bins. We have at present a stock of bond clay weathering in the open, and when this is put into service an opportunity will be afforded for making comparisons with the clay as usually handled.

Jan 1, 1918

By A. Bauer, P. Calder, N. H. Carr, G. R. Harris

Since both rotary and jet piercing drills are used by the Iron Ore Co. at Smallwood, it is often desirable in planning to know in which regions of the orebody or new orebodies a particular drill will be the most economic. This makes it necessary to establish a correlation between drillability and pierceability and some physical rock properties. For rotary drills a good correlation was found with penetration rate and grinding factor index. The jet piercers were found to have a reciprocal relationship in the sense that the best rotary ground was the worst jet ground and vice versa. It is also indicated how an economic comparison could be made using these penetration rate versus grinding factor index curves, the hole size distribution curves for single pass and chambered holes and the mine distribution curve for grinding factor index. A discussion is presented on the fuel oxygen ratios to be used in jet piercing and on the site gas sampling and analysis which has been used to set up the drills. The fuel has been cut back so that stoichio-metric conditions exist, carbon monoxide is drastically reduced and pop-up or exploding holes eliminated. No decrease in penetration rate has been observed contrary to the published results of previous workers. The blasting procedure and results at Smallwood are discussed and the operation of Iron Ore Co.'s slurry pump-mix truck is also described briefly. Smallwood mine is part of the Iron Ore Co.'s Carol Lake operation and is situated in Labrador, 240 miles north of Sept-Iles, Quebec. Last year 15 million tons of crude ore were crushed to yield 6.3 million tons of concentrate and pellets. This year the figures will be 17 million tons of crude and 7% million tons of concentrate and pellets which is the full plant capacity. Carol Lake ores consist primarily of specularite and magnetite mixed with quartz. For convenience the ore has been split-into the following classifications depending on the percentage of magnetics in the sample, shown in brackets: specularite (0 to 10%), specularite-magnetite (10 to 20%), magnetite- specularite (20 to 30%), magnetite (>30%). The order of classification also represents the order of increasing grinding difficulty - the specularite generally being the easiest and the magnetite the hardest. The orebody also contains a small percentage of waste materials consisting of limonite carbonate, quartz carbonate and quartz magnetite. The first two materials are among the softest in the mine, generally softer than the specularite, and the quartz magnetite is amongst the hardest. The bulk of the material in the mine is of the specularite-magnetite and magnetite-specularite classifications. As a result of test drilling at Smallwood in 1960 with rotary, jet and percussion drills, the Iron Ore Co. purchased four JPM-4 jet piercers for the bulk of production drilling and set up an oxygen plant to supply 20 tons of oxygen per day. This oxygen is sufficient for two machines operating full time and one part time. In addition, there are two 50-R, one 60-R and one 40-R machines in use. The benches are 45 ft high and 50 ft holes are generally drilled. JET DRILLING At the onset of jet drilling in the late fall of 1962, two major problems were encountered: 1) freezing due to winter operations; experience and the use of heat at more places, such as the rotary head, has eliminated this,'" and 2) exploding or "popping" drilled holes; this happened frequently (several holes "popping" each day) and was the cause of two lost time accidents. In one instance a hole was being measured with a tape which fell down the hole causing it to "pop." Safety glasses though pulverized saved the wearer's eyesight. Various methods were then employed to detonate the holes before measuring or loading (dropping lighted rags of fusees down, or sparking across a spark gap). These methods were time consuming and far from completely successful. Consideration was given to the fuel oxygen ratio on the machines and what this would produce in the way of product gases. A fuel oxygen weight ratio of 0.35 which was quite oxygen negative was being used. Theoretically appreciable carbon monoxide would be produced at this fuel oxygen ratio. On the close down procedure of the jet which calls for low oxygen after flame out, oxygen would be left in the hole along with this carbon monoxide. This is an explosive mixture. The fuel oxygen ratio was cut back to stoichiometric

Jan 1, 1967

By T. E. Schmieman, J. E. Miller, M. L. Rizzone

Both centrifugal and reciprocating-type pumps have been widely used in the transport of slurries. Although with some limitations, centrifugal pumps may be used, especially for short-haul systems, however, for the long pipelines the reciprocating pumps are better suited. A state-of-the-art review is presented in which a discussion of applications is made and some of the problems associated with meeting the proper design conditions for satisfactory service are discussed. Several developments underway give considerable promise of better pumps in the future, although the current level of development provides for an economical means to move slurries. The movement of liquids in pipelines necessarily occasions the use of pumps. The petroleum industry is familiar with the transport of solids through mud pumps and cementing and fracturing pumps where the movement of slurries is an everyday matter. In the drilling of an oil well, the circulating fluid utilized to remove drill cuttings is called drilling mud. This substance is usually a fairly sophisticated material designed to develop certain characteristics desirable in the drilling process. The cuttings are suspended in a moving column of this fluid and brought to the surface. The separation of the cuttings from the drilling fluids is accomplished by the use of shaker screens and settling pits; however, it is impractical to remove the cuttings completely and as a result they are pumped through the mud pumps back into the circulating stream. Over the years, mud pumps have been improved so that rather long life can be obtained from liquid end parts subject to the attritional effects of the abrasive-laden fluid. It is from this background that reciprocating-type slurry pumps have been developed. Centrifugal Pumps Centrifugal pumps have also been used to transport solids, where low heads are required, typically up to 200 ft or so, and for short hauls. The centrifugal pump is a hydrokinetic device wherein the increase in velocity of a fluid stream is converted to head, and to achieve high heads a large change in velocity is necessary. Abrasive laden fluids cause wear on impellers and casings as a result of erosion by the fluid and the suspended particles. Centrifugal pumps, therefore, can only be used where the internal velocity of flow is rela- tively low. The advantage of centrifugal pumps is their high capacity at relatively low capital cost and usually relatively small space requirement. One of the disadvantages of the centrifugal pump when used in slurry pipelining can be seen in its typical pressure-volume performance relationship, which tends to work against the application (see Fig. I). If an increase in pressure (head) is occasioned by flow restrictions in the pipeline, say by the dropping out of solids, a desirable characteristic of a slurry pump would be that it develop increased pressure to overcome the restriction. The centrifugal pump provides the increased pressure only at the expense of considerably reduced volume which then results in a lower flow velocity. With the reduced flow rate, adequate velocity to hold the material in suspension and keep it flowing in the line might not be achieved. If centrifugal pumps are considerd for the movement of solids in a long line, a series of pumps must be staged in order to provide the necessary motivating force. A large number of pumps in the line would be required, since each of the pumps could provide only a small pressure increment. An equal number of standby pumps

Jan 1, 1971

Discussion of the paper of L. C. MORGANROTH, presented at the Pittsburgh meeting, October, 1914, and printed in Bulletin No. 93, September, 1914, pp. 2345 to 2352. D. T. DAY, Washington, D. C.-I would like to hear some further detail as to the California deposits. L. C. MORGANROTH, Pittsburgh, Pa.-We have examined the California deposits at various times; I have been over practically all of them myself. These deposits are all of the massive variety. While it is possible that it could be mined and used for metallurgical purposes, it is not feasible because it costs too much. At the present time magnesite which is mined in California is used in the making of plaster, or by the paper trade. Careful figures show that if the California magnesite could be delivered to Atlantic seaports in the crude state at not over $4 a gross ton, and assuming that it would give the same results as the Austro-Hungarian magnesite, it would be cheaper to use the latter. It is also more difficult to dead-burn the massive magnesite, for while it starts to give up its gas readily, the difficulty consists in driving off the last few per cent., and unless this is driven off the magnesite will absorb C02 from the air, so that in a few months it may have 10 or 12 per cent. DAVID T. DAY.-How is the Austro-Hungarian supply at the present time ?

Jan 4, 1915

By C. E. Nelson

The purpose of this discussion is to outline briefly the practices commonly followed in this country for the melting and refining of magnesium and its alloys. The processes used for the various forms of primary magnesium, as far as there are differences in the physical shape or behavior, will be discussed. The refining of general fine scrap or secondary magnesium was presented in an earlier paper.1 Inasmuch as the use of fluxes is an essential part of all the melting and refining processes, the principal aim of this paper will be to deal with these in sufficient detail to point out their unique characteristics, in order to make their use more effective. Types oF Melting Practice All melting and refining processes for magnesium and its alloys require the use of fluxes. These fluxes have a magnesium chloride base and other halide salts or oxides are added to give a density or behavior exactly suited to the particular melting practice. The successful handling of magnesium depends upon the proper use of the correct fluxes. There are four general methods of melting, summarized in the following paragraphs and treated in more detail in the section on Melting and Refining. Open-pot Method The open-pot method makes use of No. 230 flux.2 The flux provides protection during melting and a molten pool of flux into which the solid magnesium melts. It is stirred through the molten metal bath and agglomerates oxide or similar foreign bodies; then on quiet standing separates away, leaving the refined metal ball floating in an encircling layer of molten flux. It forms only a thin fluid film over the surface of the molten metal, which may be ' parted for hand-ladling processes and tends to cover the metal again after the ladle is removed. A very light dusting of the pot surface with fresh flux immediately after the ladle is removed is usually desirable. The open-pot method is used generally in the following processes: (I) alloying and secondary smelting in the production of ingot, (2) in sand foundries for premelting and to a smaller extent for the production of small castings requiring hand ladling, (3) in permanent-mold founding for premelting and also direct ladling to castings, (4) for continuous methods of preparing metal in the production of billets or ingots from which wrought products are fabricated, (5) in general scrap recovery. Crucible Process The crucible process makes use of No. 310 flux, which has the property of being thinly fluid at the start, to provide protection and refining qualities, and then drying out or thickening after a time, leaving a protecting crust on the pot surface until the time of casting. At that time it can be readily skimmed off or held back, thus allowing the contents of the crucible to be poured out directly into castings without fear of flux contamination. This flux is not

Jan 1, 1944

By F. Julius Fohs

Centrally located with relation to the largest iron- and steel-producing districts of the United States, the fluorspar-deposits of Kentucky possess increasing interest and importance. As typical of the numerous fluorspar-mines of Kentucky and Illinois, I have selected for description the Memphis, because it and others of its immediate group exhibit the conditions characteristic of all. I. The Memphis MiNe. This mine lies 5 miles NW. of Marion, in Crittenden county, Kentucky, a station on the Chicago and Nashville division of .the Illinois Central R. R. For the first mile and a half out of Marion we see only Birdsville or Middle Chester sandstones of Mississippian age. Then we cross a fault of about 850 ft. displacement, and the Ste. Genevieve oolite sets in. Beyond the fault, oolite is the predominant rock, except that the hills to the north have a capping of Cypress or lowest Chester sandstone, 80 ft. below which is an outcrop of from 6 to 10 ft. of Ste. Genevieve (Rosiclare) sandstone. Occasional sink-holes are noticed, and as the mines are approached evidence of faulting is again seen. A line of .crude head-frames and open-cut dumps, extending for more than a quarter of a mile, marks the Klondike vein. The open-cuts are from 15 to 20 ft. deep, and in most of them, from the surface down, was found the reddish gravel which is really fluorspar—some of it white or purple and crystal-clear (if the red clay is washed off), and some carrying iron and silica, and stained by waters from the decaying limestone walls. In one of these cuts, at a depth of 20 ft., white and purplish honey-combed fluorspar was found, in which the larger cavities are due to the leaching of limestone and calcite, and the minute ones to the leaching of zinc-hlende.

Jan 1, 1910

By Oliver C. Ralston

This paper reports the results of the use of salt in some research work carried on during the past 3 years at the Salt Lake City Station of the Bureau of Mines, which is quartered in the University of Utah, whose Metallurgical Research Department cooperates with the Bureau. Only the work involving the use of salt is described. The authors wish equal credit given to J. F. Cullen, C. L. Larson, C. Y. Pfoutz, C. E. Sims, H. C. Neeld, R. W. Johnson, F. G. Moses, N. C. Christensen, and G. H. Wigton, who have all in some way contributed toward the success of this work, while connected with the station in one way or another. Lead Metallurgy Popularly Supposed to be Without Problems In lead metallurgy it is difficult at first to find metallurgical problems, as the prevailing conception has been that lead is so easily concentrated in its various ores and so easily reduced to its metallic form that the only progress possible is that involved in cheapening methods of mining and of reduction. Most of the problems usually considered are of minor nature and do not involve radical metallurgical changes. During the three years of work of the Salt Lake Station, the following classification of problems in the metallurgy of lead has been made: Oxidized Ores. 1. Ores containing only lead. 2. Ores containing lead and silver or gold. 3. Ores containing lead and zinc, with or without silver. Sulphide Ores. 1. Ores of pyrite carrying some lead. 2. Ores of complex zinc-lead-iron sulphides. 3. Complex sulphides containing precious metals.

Jan 1, 1918

By G. H. Clevenger

(Continuing the discussion of the paper of James Johnston, presented at the New York meeting, February, 1914, and printed in Bulletin No. 85, January, 1914, pp. 107 to 133.) This paper cannot fail of being of great interest and value to all who are interested in the cyanide process, on account of the important developments which it records. Mr. Johnston is to be commended for the large amount of detail which he gives, and the company and its management for permitting the publication of data of this character, which while of great value to others could well be considered private property. It might be discussed from a number of standpoints: First, as an example of recent practice in mill and cyanide plant construction; second, the mill practice; third, the cyanide practice; and fourth, the new features in cyanide treatment involved. Perhaps a more vivid way of expressing it would be : First, the equipment or tools with which the various operations are carried on, are they the best and most efficient which could have been selected for their respective uses; and, second, is the best use in every case made of these tools? It may be well inquired is the highest possible recovery of silver made at the lowest cost per ounce recovered? For after all, the making of the greatest ultimate profit is inseparably associated with successful metallurgical practice; there must therefore be at all times a careful balance maintained between recovery and cost of obtaining it. I wish to call attention in a very general way to the equipment used and to an anticipation of questions which are bound to arise in this connection. However, the. bulk of my discussion will be confined to the presentation of certain additional data, together with a more or less general discussion showing the line of development which leads up to the present practice and .the applicability of certain features of it to similar problems elsewhere. There are a number of vital points of broad general interest involved in Nipissing low-grade practice upon which metallurgists will by no means be agreed to which I wish to call particular attention in the hope that it will lead to the presentation of data y others of practice in other districts which will' assist in reconciling this divergence of opinion.

Jan 7, 1914

By J. W. Pamplin

SOME 40 miles east of Tampa is the center of the Florida pebble phosphate deposits. These are of Pliocene age and consist of several members of the Bone Valley formation.1 Physically the phosphate-bearing formation, locally called the "matrix," varies in thickness from nothing to about 25 ft., usually averages 10 ft., and consists mainly of clay, quartz and phosphate pebble, the latter particles varying in size from colloidal to one inch diameter. The pebbles range in color from dark gray, through white, to cream, and in hardness from that which must be broken with a hammer to that which can be scratched with the fingernail. They assay from 66 to 80 per cent bone phosphate of lime (called "B.P.L." in the trade) or tricalcium phosphate (Ca3P20s) and are secondary apatites. They form from 15 to 50 per cent by weight of the matrix, Over the matrix lies a varying thickness (5 to 40 ft.) of overburden composed of quartz and clay. Briefly, mining consists of two operations2 in open pits about 200 ft. wide by ½ mile or more in length. In the first step overburden is removed by large electric draglines at the rate of about 700 cu. yd. per hour. This is followed closely by hydraulic mining of the matrix at the rate of about 300 cu. yd. per hour. This matrix yardage is moved from an improvised sump in the floor of the pit to an ore-dressing plant, some-times a mile distant, by one, two or three "pit-cars" (pumping units) working on a 12-in. pipe line called the "rock line" to distinguish it from the high-pressure water line feeding the hydraulic giants, which is known as the "hydraulic line." This 700 yd. of overburden and 300 yd. of matrix-1000 yd. in all-amounts to about 1500 tons of material moved each hour. The over-burden is dumped into the mined-out pit alongside the pit being mined. The matrix moves to the ore-dressing plant at the rate of about 7 ½ long tons in 4000 gal. of water per minute-a ratio of approximately one to two by weight, or one to six by volume. This constitutes the "mill heads," but in the pebble district it is called the "matrix."

Jan 1, 1938

By J. W. Pamplin

SOME 40 miles east of Tampa is the center of the Florida pebble phosphate deposits. These are of Pliocene age and consist of several members of the Bone Valley formation.' Physically the phosphate-bearing formation, locally called the “matrix," varies in thickness from nothing to about 25 ft., usually averages 10 ft., and consists mainly of clay, quartz and phosphate pebble, the latter particles varying in size from colloidal to one inch diameter. The pebbles range in color from dark gray, through white, to cream, and in hardness from that which must be broken with a hammer to that which can be scratched with the fingernail. They assay from 66 to 80 per cent bone phosphate of lime (called "B.P.L." in the trade) or tricalcium phosphate (Ca3P2O8) and are secondary apatites. They form from 15 to 50 per cent by weight of the matrix. Over the matrix lies a varying thickness (5 to 40 ft.) of overburden composed of quartz and clay. Briefly, mining consists of two operations2 in open pits about 200 ft. wide by ½ mile or more in length. In the first step overburden is removed by large electric draglines at the rate of about 700 cu. yd. per hour. This is followed closely by hydraulic mining of the matrix at the rate of about 300 cu. yd. per hour. This matrix yardage is moved from an improvised sump in the floor of the pit to an ore-dressing plant, some- times a mile distant, by one, two or three "pit-cars" (pumping units) working on a 12-in. pipe line called the "rock line" to distinguish it from the high-pressure water line feeding the hydraulic giants, which is known as the “hydraulic line." This 700 yd. of overburden and 300 yd. of matrix-1000 yd. in all- amounts to about 1500 tons of material moved each hour. The over- burden is dumped into the mined-out pit alongside the pit being mined. The matrix moves to the ore-dressing plant at the rate of about 7 ½ long tons in 4000 gal. of water per minute-a ratio of approximately one to two by weight, or one to six by volume. This constitutes the "mill heads," but in the pebble district it is called the "matrix."

Jan 1, 1938

By E. P. Shoub, J. P. Riott, R. C. Buehl

Pilot-plant tests have demonstrated that it is possible to produce low-sulphur sponge iron (0.03 to 0.0; per cent sulphur) as a continuous process in an internally fired rotary kiln from iron ore or mill scale; a solid carbonaceous reducing agent; and dolomite to control the sulphur content. The proportion of dolomite employed is small, so that it does not add materially to the cost of the sponge iron. The entire operation is carried out at temperatures well below the melting point of iron, so that the product is discharged in granular form. Compared with other methods for the production of sponge iron, the rotary-kiln method has the advantage of simplicity and low cost of equipment and, in addition, requires little labor for the operation of the process. The pilot-plant equipment used for this work was sufficiently large to demonstrate that the production of low-sulphur sponge iron in rotary kilns is feasible and that the costs are not excessive for applications in which sponge iron has distinct advantages over competing materials. This report constitutes a part of a program by the Bureau of Mines under a special Congressional appropriation for studying gaseous and solid fuel reduction of iron ores. Numerous articles on various phases of these investigations have appeared in Bureau of Mines publications or technical journals. Other articles are being prepared and will be published in the near future. The present program, which is under the supervision of Dr. R. S. Dean, Assistant Director of the Bureau of Mines, was initiated in 1942. However, a considerable portion of the work was a continuation of previous research performed by the Bureau. Previous investigators1-4 utilizing the rotary kiln for the production of sponge iron did not develop a suitable method for controlling the sulphur content. A review of the literature shows that the sulphur content in the product usually exceeded 0.1 per cent unless reducing agents with very low sulphur contents were employed. This high sulphur value made the product generally undesirable for use as melting stock in electric or open-hearth furnaces. The production of sponge iron in an internally fired rotary kiln has been described in detail in Bureau of Mines Bullelin 2702; consequently, this article will be confined mostly to new features of the process—that is, means for controlling the sulphur content of the sponge iron. Suitable raw materials include iron ores or mill scale; coal or coke for reducing them, and sized dolomite ( — poi-100-mesh) as the sulphur-controlling agent. A mixture of the raw materials in granular form is fed into the elevated end of the kiln, which is fired axially from the lower or discharge end. In the reducing zone, which is approximately one third the length of the kiln measured from the dis-

Jan 1, 1948

By R. C. Buehl, J. P. Riott, E. P. Shoub

Pilot-plant tests have demonstrated that it is possible to produce low-sulphur sponge iron (0.03 to 0.0; per cent sulphur) as a continuous process in an internally fired rotary kiln from iron ore or mill scale; a solid carbonaceous reducing agent; and dolomite to control the sulphur content. The proportion of dolomite employed is small, so that it does not add materially to the cost of the sponge iron. The entire operation is carried out at temperatures well below the melting point of iron, so that the product is discharged in granular form. Compared with other methods for the production of sponge iron, the rotary-kiln method has the advantage of simplicity and low cost of equipment and, in addition, requires little labor for the operation of the process. The pilot-plant equipment used for this work was sufficiently large to demonstrate that the production of low-sulphur sponge iron in rotary kilns is feasible and that the costs are not excessive for applications in which sponge iron has distinct advantages over competing materials. This report constitutes a part of a program by the Bureau of Mines under a special Congressional appropriation for studying gaseous and solid fuel reduction of iron ores. Numerous articles on various phases of these investigations have appeared in Bureau of Mines publications or technical journals. Other articles are being prepared and will be published in the near future. The present program, which is under the supervision of Dr. R. S. Dean, Assistant Director of the Bureau of Mines, was initiated in 1942. However, a considerable portion of the work was a continuation of previous research performed by the Bureau. Previous investigators1-4 utilizing the rotary kiln for the production of sponge iron did not develop a suitable method for controlling the sulphur content. A review of the literature shows that the sulphur content in the product usually exceeded 0.1 per cent unless reducing agents with very low sulphur contents were employed. This high sulphur value made the product generally undesirable for use as melting stock in electric or open-hearth furnaces. The production of sponge iron in an internally fired rotary kiln has been described in detail in Bureau of Mines Bullelin 2702; consequently, this article will be confined mostly to new features of the process—that is, means for controlling the sulphur content of the sponge iron. Suitable raw materials include iron ores or mill scale; coal or coke for reducing them, and sized dolomite ( — poi-100-mesh) as the sulphur-controlling agent. A mixture of the raw materials in granular form is fed into the elevated end of the kiln, which is fired axially from the lower or discharge end. In the reducing zone, which is approximately one third the length of the kiln measured from the dis-

Jan 1, 1948

Jan 1, 1901

By E. A. Holbrook

RESEARCH, primarily, is finding out the truth. Research applied to engineering opens the door to new principles and processes, the application of. which benefits mankind in a material way. The engineer believes that investigation instituted with the primary view of making the results directly applicable to the industries is the highest type of research. Coal is essentially the basis of modern industrial civilization; therefore, any, considerable research pertaining to coal must link itself to the industry by, practical application of the results of the research. In other words, all investigational work connected in any way with coal leads to conclusions that permit a better understanding of the origin, nature of occurrence, composition, better and safer mining, more careful preparation, or greater efficiency in utilization of coal. Modern engineering research has been fostered essentially by universities and in the laboratories of institutions of learning. Coal problems that lend themselves to solution in the laboratories have been first attacked and are perhaps the farthest toward solution. For example, a great amount of research work has been carried out with the various phases of chemistry connected with coal. On the other hand, the equally important problems connected with methods of mining have received but little attention, primarily because their solution involves the continued use of a great and expensive laboratory, which is none other than the mine itself. As many of the problems already solved have had chemistry as their background, so many of the problems unsolved have physics as their background; there are also unsolved problems that deal in- coal economics. Even psychology must be called upon in future coal-mining research as a basis for solving those great problems that deal with human relationships. In general, considerable advance has been made in coal research dealing with chemistry, not so much progress has been made with problems having physics and engineering as a background, while there is a tremendous range of untouched problems that deal essentially with business and psychology.

Jan 9, 1919

By Clarence E. Sims

DURING the past several years the steel casting industry has made studies of heavy castings in which the test bar has been taken from heavy sections rather than from attached or separately cast coupons. It has been noted that the ductility properties of these heavy sections are often lower than those normally expected. Such lowered ductility is usually accompanied by a spotty test bar fracture and the ductility values often can be greatly improved if a low-temperature aging treatment is given to the casting. A loss of ductility of this type is considered "abnormal," since it is not accompanied by an increase of tensile strength or hardness, and "temporary" when the ductility can be restored by aging. The cure of such an abnormal condition represents a real improvement in the quality of the steel. Some hundreds of previous investigations, largely qualitative in nature, have established beyond reasonable doubt that hydrogen is normally present in newly manufactured steel and that this gas, in small amounts, can cause a temporary abnormal loss of ductility. The commonly observed association of high gas content and low ductility has given strong evidence for the presumption that hydrogen, possibly assisted by other gases, is the primary cause of the low ductility observed. Accordingly, the Steel Founders' Society of America has, since Nov. 1, 1944, sponsored investigations at Battelle Memorial Institute whose primary objective is to obtain quantitative information on the relation of the amount of hydrogen and nitrogen in steel, together with associated methods of steelmaking and treatment, to low-ductility effects and porosity.

Jan 1, 1947

By J. B. Wagstaff, R. A. Buchanan, J. F. Elliott

High speed photography through blast-furnace tuyeres showed coke particles moving rapidly. Model studies showed a raceway was formed and gave quantitative results which were correlated with actual blast furnaces. Another study showed the similarity between hanging and the flooding of a packed column. This was explored by models. THE combustion zone before the tuyere in an iron blast furnace is a vital region because here are generated: 1—most of the gases on which the furnace depends to carry out its basic operation of reducing iron ore to the metallic state, and 2—the major fraction of the heat required in the nearby regions of the furnace for the various reduction reactions, the fusion of the slag, and the melting of the iron. Since the greater part of the coke is consumed in this region, the descent of the burden must be greatly affected by the characteristics of the tuyere zone. This region then would seem to be a profitable field for study. Fortunately, a view into this important zone is available to the operator through the tuyere peep sight. Here he sees relatively dark pieces of coke "dancing" in the blast. What he sees is of considerable help in interpreting the behavior of the furnace at a given time but the very rapidly moving particles and the intense radiation obscures what is happening very deep in the zone. This investigation was initiated in the hope that a better understanding of the combustion region could be obtained by using a high speed camera with a maximum speed of 3000 frames per sec. It seemed the best practical method of "slowing down" this characteristically violent action within the highly luminous field. Model studies and tuyere probing also have been used to aid in explaining the observed phenomena. Above the combustion zone, but below the fusion zone, there is probably a region in which the coke is comparatively stationary. Here are zones in which the gases must flow up through the granular bed counter to descending liquid slag and metal. There is no easy way to observe this zone in a blast furnace, but model studies have been of some help in explaining the nature of the zone and the laws governing the flow of the fluids involved. The whole problem is difficult and involved and any approach to a complete solution may require long investigation. This preliminary report has been written, therefore, because it is believed that appreciable progress has already been made that would be of interest to others. Tuyere Studies, Chemistry and Kinetics It is well known from the early work of Kinney and coworkers1,2 that combustion of carbon before the tuyeres appears to occur in two zones: Zone A: C + O, = CO2; AH77°F. = — 14,108 Btu per lb of carbon [I] Zone B: CO2 + C = 2CO; H77°F = + 6,183 Btu per lb of carbon [2] Zone A (Fig. 1) is close to the tip of the tuyere and zone B is somewhat farther back; there being a transition region in which both reactions occur. It is interesting to estimate the rate at which coke is burned before a tuyere with a wind rate of 90,000 cfm in a modern furnace having 18 tuyeres. Approximately 0.55 lb of carbon is consumed by eq 1 per tuyere per sec. A like amount disappears by eq 2 for a total consumption of 1.11 Ib per sec per tuyere. Assuming the coke is 85 pct C and has a bulk density of 30 lb per cu ft, this figure can be converted to a total of 1.30 lb of coke with a bulk volume of 0.043 cu ft disappearing per sec per tuyere. At the temperatures prevailing in the combustion zone (according to Kozlovich,³ he maximum is about 3400°F), the rate at which carbon is con-

Jan 1, 1953

By James P. Dr. Kimball

SULPHUR is always present in mineral coal of every variety. In the oxidized state it may exist as sulphuric acid in combination with a base. In the unoxidized state it exists in combination with iron as bisulphide of iron. It is also supposed by some chemists to exist in unknown combinations with the organic elements of the coal. This supposition requires the demonstration as a fact that certain coals yield more sulphur than what may exist in a free state, or what belongs to recognized combinations, not only with the accompanying iron but with other inorganic bases abundantly occurring in coals, but which unfortunately are very rarely estimated. This practically as well as theoretically important question it is at present impossible to decide, simply for want of available thorough ultimate coal analyses including the ash. Such analyses, at the best imperfect, are laborious and intricate, and therefore seldom made, the much simpler proximate analyses, so-called, being resorted to by most chemists for technical purposes, and commonly substituted for more scientific work even in the laboratories of government surveys. And it is unfortunate enough that few ultimate analyses are extended to the composition of the ash, much less to its relation to the original constitution of the coal. Sulphur chiefly occurs in most coals in the form of yellow pyrites (pyrite) and white pyrites (marcasite), both minerals, characterized by differences in crystalline form and in physical properties as well as in color, but having the same chemical composition (FeS2). No coal is entirely free from one or both of these dimorphous forms of bisulphide of iron. It may be disseminated through the mass so as to be invisible, in plates or scales between the laminæ of the coal, or in conspicuous segregations or nodules, sometimes of considerable dimensions. Coals greatly differ as to the proportion of sulphur which they contain. They also differ as to the relative proportion in which its several forms of combination occur. Such qualitative and quantitative disparities are scarcely, if at all, more marked in separate coal seams of a uniform type than in different parts of one and the same coal seam, whether it be considered locally as constituted of several

Jan 1, 1880