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By L. W. Casteel, E. A. Jones

MINING the lead deposits of Southeast east Missouri has reached a high stage of technical development dictated by the scattered occurrences of low-grade ore through favorable horizons in the Bonne Terre formation. The rock-breaking, handling, and related practices described here have evolved as the best way of mining these particular deposits. These methods are applied in the production of about 19,000 tons of lead ore per operating day from four mines in Southeast Missouri. Development drilling Drifts 10 ft wide and either 8 or 9 ft high are driven in this district on contract. Miners are guaranteed standard wages plus a bonus on the footage advanced, if earned. Labor, fuse, caps, wire, and dynamite used are charged against the contract. Normally the cycle of operations in drifting is performed by a two-man crew, a motor operator and a shovel operator who first load out the rock broken by the preceding shift. The drift crew then sets up two vertical column and mounts the drills. Cleveland HC-10's are used which have a steel lug integral with the cylinder for connection with the air feed. All drilling in drifts is wet. Air pressure is 85 to 100 lb at the face. From 28 to 32 holes are drilled per swing in a pyramid cut. Cut holes

Jan 1, 1947

By Allan D. Taylor

INTRODUCTION From the designer's view, the installation starts with the first definition of the orebody, and progresses through a long and complex development. The design is affected not only by the characteristics of the ore, but by all of the personalities and events of the project during its development. The following discussion attempts to touch on the most important aspects which define the context in which the designer must work in apply the do's and don'ts. That context is the basis of the viewpoint. WHAT CAN GO WRONG The Project Is Going Over Budget This is a common and serious concern to the plant designer. The Project Falls Behind Schedule Another common and disturbing condition with which the plant designer must cope. Some Equipment Fails to Perform This can be due to either faulty equipment or operating deficiencies. It can be the result of a wide variety of causes, but the designer will be an interested party in the search for the cause and the cure. The Plant Isn't Flexible Enough Sometimes a plant will handle some or even most of the ore satisfactorily but is unable to treat another type properly. This can be a significant problem. An example might be a case where low capacity of a cyclone feed pump makes it impossible to accompany an increase in grinding mill throughput with a corresponding increase in dilution water. This could lead to an increase in cyclone feed density, and a loss in product grade or a limit on the plant capacity. Spillage And Cleanup Are Excessive This is one of the most common and annoying defects in metallurgical plants, and one for which the designer can rarely delegate blame. Maintenance Is Excessive Another common complaint in new plants, and also one for which the dedesigner must accept most of the responsibility.

Jan 1, 1982

By L. H. E. Weyher

As a result of past developments, mainly at universities, the coal industry has had access for a decade or more to a number of computer programs for coal mine planning. Using some of these programs Bethlehem Steel's Research Department in 1969 launched jointly with Bethlehem Mines Corporation an extensive research and development program aimed at: (1) testing the capabilities of these programs through trial applications as the need and opportunity existed, (2) defining what additional capabilities were required to make mine planning computer systems fully useful in the hands of Bethlehem's mine-planning engineers in the field, and (3) developing and implementing in the field the mine-planning systems agreed on. This program is now nearing completion, and several of Bethlehem's operations routinely use the planning tools that were developed. The progress of this research program is discussed in terms of our initial trial applications of computer methods to mine planning and the incorporation of several innovative features into our new set of computer programs, in particular, the use of time sharing, data base management systems, and general-purpose simulation languages.

Jan 1, 1977

By A. J. Williams

THE province of Saskatchewan, situated in the center of the Great Plains region of Canada, has, like most prairie areas, an essentially agricultural economy. Most of its population of about 860,000 is located in the southern half of the province in the farming and ranching areas. To the north of the prairie is a broad forested belt supporting a considerable timbering industry, and the northern one third of the province is glaciated pre-Cambrian rock formation. This latter area is, relatively barren of vegetation, but the presence within it of a considerable variety of radioactive, noble and base metals, and industrial minerals has been shown by prospecting in recent years.1 Glacial Geology The Keewatin ice sheet, considered to have accumulated in the country to the west of Hudson Bay in Pleistocene time, covered at its maximum advancement almost all of Saskatchewan and extended south of the international boundary. Only in the Cypress Hills in the southwest and around Wood Mountain in the south central portion of the province did the preglacial formations escape the action for this glacial period. The bedrock of the plains and forest areas therefore is overlain by moraines and modified glacial drift, which vary in thickness from a few feet to 400 or 500 ft.2 Glacial action in the pre-Cambrian area of the province was largely erosional, most of the more recent formations and some of the pre-Cambrian rock being transported out of the area to the south and west. It has been estimated that about 13 pct of this area is composed of lakes and rivers not too adaptable to rail or water transportation, so that until the use of aviation for exploration purposes became general; development of the area was slow. To the south, the heavy. mantle of glacial drift has to some extent deterred the discovery of industrial minerals in the bedrock underlying the forest and prairie regions.3 At the same time, this drift contains numerous deposits of those most elementary and necessary industrial minerals, sand and gravel. Sedimentary Basin The major feature of the sedimentary deposits underlying the plains regions is the basinal structure known as the Moose Jaw syncline, which runs from the southeast corner of the province in a northwesterly direction. To the west. of this syncline the formations curve upward, then have been faulted and further upthrust to appear at the surface in the foothills of-the Rockies in Alberta; to the east and north they curve upward into Manitoba and northern Saskatchewan, but the surface contacts are covered mostly with glacial drift.2,3 The axis of the syncline dips to thee southeast, so that there is also an upward trend of the formations along the axis to the northwest. In illustration of the regional structure underlying the province, the pre-Cambrian basement has been logged in drillholes at the following depths in several locations: Ogema (south central), 9390 ft; Gronlid (northeast), 2599 ft; Vera (northwest), 4422 ft; Big River (north northwest), 2348 ft. Fig. 1 indicates the general surface geology of the province, ignoring such glacial overburden as may overlie many of the bedrock formations. Also indicated is the approximate location of the axis of the Moose Jaw syncline.4 Industrial Minerals Clays: The province is fortunate in possessing a widespread distribution of clays of ceramic value, ranging from those used for heavy structural products to the high grade pottery and china clays. Shales suitable for brick and tile production are found in the Upper Cretaceous and Tertiary formations across the south of the province where the glacial drift is thin or nonexistent. Many deposits of glacial lake clays suitable for such wares are found scattered over the rest of the province south of the pre-Cambrian area. The Whitemud formation of the Upper Cretaceous is a narrow sedimentary, band of secondary clays found intermittently, at points, across the, south of the province where glacial action did not disturb or remove them.8 In the southwest corner of the province, around Eastend in the Frenchman River valley, the refractory clays of this formation are contaminated somewhat with iron compounds or other alteration products of basaltic rocks. This eliminates the use of those clays in true whitewares, as they fire to creamy buff shades at the lower temperatures and to a blue-specked grey at cone 8 to 12, (2280°F to. 2390°F), the range commonly used in firing whiteware. However, for use in the production of colored artware, caneware, stoneware or crockery, and sewerpipe, this type of clay makes an excellent body that requires little or no addition of flint, feldspar, or other fluxing materials such as are required in the higher class of ware.9 It is not a grade of clay that can be shipped great distances to the manufacturing centers, but a market for considerable tonnages has developed at nearby Medicine Hat, where cheap natural gas is available for the firing of the ware. Farther east in the south central portion of the province, the clays of the Whitemud formation are generally more refractory and white burning. The formation is divided into three zones, consisting of white clays, brown shale, and white sandy clays.

Jan 1, 1952

By Yu A. Chernegov

Building up the USSR's economic strength was the result of all the achievements and successes of our economy. The Soviet Union was the first to begin planned guidance of the economy. The mining industry of the USSR, which holds the first place in the world output of mining production, has always been considered as the main raw materials basis of the country's economy. High and stable development rates are a feature of planned economic management, based on the social ownership of the means of production. During the past ten years from 1965 to 1875 the national income used for consumption and accumulation increased practically by 1.9 times. There has been no inflation, no unemployment in the Soviet Union for about forty years already. High and stable growth rates of the production of mining industries and that of the branches, which are their direct consumers are characterized by the data in table I. The achievements and successes of the economy's development are to a great extent determined by the three planning components, which are as follows:

Jan 1, 1977

By C. K. Leith

THE outstanding fact of the mineral world today, at home and abroad, is the surplus of current production, and particularly of capacity for production, over current requirements. This is not by Any means a new condition, but never before has it loomed up in such' menacing form. - Those of us who have devoted most of our professional efforts to the discovery and development of 'new mineral supplies now suddenly find ourselves with the job apparently accomplished, waiting for some one else to find an outlet for excess mineral production before we can further. The management of the industry is in much the same boat. The psjrcho16gy of the industry has been so grooved in the direction of acquisition of, minerals that at the present moment the mineral industry confronts the new problem of surplus in more or less of a daze.

Jan 1, 1931

By Zay Jeffries

From the title of this chapter the reader could expect an attempt to out- line the anticipated shape of things to come, mineralwise. We have no crystal ball and if we possessed one we could claim no expertness in its use. In the first place no one can tell the future status of man. No one has any way of knowing to what extent peace will prevail, nor to what extent changes may occur in national sovereignties or forms of government or in international relationships. So future man is an uncertainty. Nor can we predict new developments that may result in significant changes in man's status or in the mineral industry or both. If, for example, this chapter had been written in the middle 1930's, nearly everything that has happened since in the fields of atomic energy and space technology would have been missed. Yet what vast changes these I have made in the status of man! Also the changes in the mineral industry have been important. A writer would have been bold indeed had he prophesied that uranium would play such an important role. But we need not confine our foggy vision to these fields. The steep rise in the use of aluminum, titanium, and germanium reflects the unpredictable in what may be thought of as the more normal pursuits. This should not discourage one from using the past and currently observable trends as bases for limited predictions. To do this, however, it is desirable to make certain assumptions about man's status without pretense that these assumptions have a high probability of fulfillment: 1. Only minor changes will occur in the geographical boundaries of the nations of the world. 2. World War III will not take place in the near future. 3. As a consequence of (2), man will not destroy himself by wanton use of atomic weapons. 4. Disarmament will take place, if at all, gradually rather than all at one time. Under the above assumptions the world will enjoy a period of relative peace even though the status may be one of an armed truce. The assump-

Jan 1, 1964

Jan 1, 1908

By V. A. Phillips, M. Safdar Ali

The tensile properties of Cu-0.20 pct Al, Cu-0.45 pct Mg, Cu-0.27 pct Cr, and Cu-0.22 pct Be solid-solution alloys were studied at -196°, 18°, 2509 and 500°C on wires internally oxidized at 900°and 1000°C. Internal oxidation produced marked increases in yield strength relative to pure copper, particularly at low temperature. The yield strength decreased with increase in temperature to a much greater extent than predicted by current theories of dispersion hardening. The strengthening effect of internal oxidation persisted throughout the entire stress-strain curve, but since a marked loss of ductility occurred at all test temperatures, only modest increases in tensile strength were realized. INTERNAL oxidation involves the preferential oxidation of a baser solute in a relatively noble solvent by diffusion of oxygen into the solid. Since the process is diffusion controlled, it is expedient to carry it out at a high temperature often approaching the melting point. The amount of solute is limited and the oxidation conditions adjusted so that oxygen diffuses inwards to meet the solute causing reaction to progress inwards and form subscale instead of only sur face scale. The reaction can be made to occur throughout the thickness of thin material producing a fine dispersion of oxide inside the metal. C. S. Smith1"3 appears to have been the first to recognize the true nature of the process of internal oxidation. Although extensive kinetic and metal-lographic studies followed by Rhines and coworkers,4-5 Chaston7 andMeijering and Druyvesteyn8 working independently were the first to report hardening effects due to internal oxidation. These results prompted detailed studies of the effects of internal oxidation on the hardness, tensile, creep, and fatigue properties of a number of alloys by G. C. Smith and coworkers9-12 in England, on hardness by Gottardi13 in Italy, and on hardness and tensile properties by wood14 in the U.S.A. Publications dealing with other aspects of internal oxidation will not be reviewed here. Internal oxidation of solutes having a high affinity for oxygen provides a means of obtaining very fine dispersions stable in a suitable atmosphere at temperatures well above those at which most age harden ing precipitates coalesce. The process therefore offers a method of producing thin sheet and wire of possibly outstanding creep resistance. The size limitation might be overcome by internally oxidizing porous powder compacts made from alloy powder before final sintering. PREPARATION OF ALLOYS The alloy ingots, which were approximately 5 1/2 in. long by 1 in. diam, were made up in a high-frequency furnace, using as raw materials OFHC copper, 99.99 + pct Al, high-purity magnesium, and master alloys of Cu-4.19 pct Be and Cu-10 pct Cr. The alloys containing aluminum and magnesium were melted ii closed high-purity graphite crucibles and solidified in the crucible which was lowered partly Out of the coil to give a hot-top effect. The alloys containing beryllium and chromium were made by melting in vacuo in alumina-lined sillimanite crucibles. The magnesium, chromium, and beryllium

Jan 1, 1960

By Richard H. Jahns

GRANITIC pegmatite deposits are the chief source of commercial feldspar, sheet mica, beryllium, tantalum-columbium, and lithium minerals, and certain types of kaolin. They also have yielded significant quantities of cassiterite, gems, scrap mica, molybdenite, tungsten minerals, uranium-thorium and rare-earth minerals, and zircon, either directly or as the sources of placer deposits. The output from pegmatite mines in the United States is small as compared to other mineral products in terms of bulk or value, and much of it comprises minor metals and nonmetals. Nevertheless, pegmatite minerals play a vital part in domestic industrial economy, particularly in the ceramic and electrical industries. Numerous special purpose uses also are important, even though they require small quantities of raw materials. Never was United States dependence upon pegmatite mining more clearly emphasized than during World War 11, when greatly expanded demands and uncertainties of foreign sources of supply caused much concern. Such commodities as beryl, tantalite, and sheet muscovite remained high on the critical list for months at a time, and for some minerals there was a real struggle to achieve and maintain a favorable ratio of supply to demand. Satisfactory stock piles of certain sizes and qualities of sheet mica, for example, were not built up until late in 1944, when wartime requirements already had begun to level off or even to decrease. Production of all the strategic pegmatite minerals from domestic deposits during World War I1 constituted only 10 pct or less of the total domestic consumption of these minerals, but the importance of this contribution should not be minimized. Domestic production often represented the difference between increase and further reduction of existing stocks of commodities already in seriously short supply, and in the early stages of the war it was the only assured source if imports were cut off. During the recent war period, the U. S. Geological Survey carried on a program of pegmatite studies in the New England and Southeastern States, in the Black Hills area of South Dakota, in the Rocky Mountain region of Wyoming, Colorado, and New Mexico, and in various parts of Washington, Idaho, Utah, Nevada, Arizona, and California as shown in Fig. 1. Several papers and reports already have appeared as an outgrowth of this work,'-= and others are in preparation. This paper outlines some results of data obtained by the writer during the period 1942 to 1946, when he was engaged in studies of pegmatites in the Southeastern, Southwestern, and Rocky Mountain States. Beryllium Minerals Beryl is the present commercial source of beryllium metal and beryllium compounds, which are used in ceramics, in the preparation of X-ray tubes and fluorescent lamps and screens, in special processes of paint and textile manufacture, and in the optical systems of some electrical instruments. The metal also is used in nuclear physics, chiefly as a source of neutrons. Beryllium is alloyed with aluminum for certain light-metal uses and is a constituent of some nickel and iron alloys. Currently the chief demand, however, is for copper-base alloys, which are exceptionally resistant to fatigue and wear, are responsive to hardening treatments after

Jan 1, 1952

By R. M. Hardgrove

Pulverized coal was first used for firing cement kilns about 45 years ago, with such success that it has continued in general use. Based on cost, pulverized coal is usually the most economical fuel. In some localities natural gas or oil is cheaper, but 85.5 per cent of all cement kilns at present are fired with pulverized coal. The pulverized-coal flame is well suited to kiln conditions. Its soft, luminous nature gives it a high radiating property and the length of the flame can be readily varied to suit conditions in a kiln of any length. Ash and slag cause most of the dificulties incident to the burning of coal. In a. cement kiln, however, the ash, being similar in composition to the raw mix and being deposited uniformly in the mix and clinker, occasions no difficulty as long as it remains constant in quality and quantity. Until 6 years ago almost all cement kilns using pulverized coal employed the bin system. The coal was dried and pulverizeti in a separate plant and delivered into a bin at the kiln. Thus the bin system requires driers, storage-type pulverizers, conveying systems, individual kiln bins, pulverized-coal feeders and primary air fans. The direct-fired system requires only a pulverizer and a blower. Fig. I shows typical plants. The first installations of direct-fired pulverizers were of the impact type but fineness of pulverization was both inadequate and variable. About 1927 a few direct-fired installations employing tube-type pulverizers were made, which were much more satisfactory. As more efficient pulverizers were developed from 1934 on, equipment for direct firing was installed at a large number of plants, until now 196 of about 900 kilns in use in the United States are direct-fired. Most of these replaced antiquated bin systems. Process of Burning Cement Clinkers The process of burning cement clinkers is fundamentally one of heat transfer. In boilers and other heat-exchange apparatus the area of the surface receiving heat from the gases is the best unit for comparing output, This seems to be equally true for kilns. The inside kiln surface is the heat-receiving surface and its area is used as the unit of kiln size in the following comparisons. Heat input is based on British thermal units in the fuel. E. G. Bailey,' in his work on boiler-furnace heat absorption, has used the unit "B.t.u. available." This is the practical calorific power of the fuel, plus the heat in the air used for combustion. In other words, it is the heat available for useful work in the furnace or kiln. The unit of kiln output is barrels per hour. The composition of the raw mix, the percentage of water in the slurry of wet plants and hardness of burning all affect the output. These conditions, however, are hard to evaluate and probably have less effect on the output than irregularities of raw feed and clinker discharge and inexpert control of combustion. Wet vs. Dry Plants The study presented here covers 88 plantsl of which 41 are wet and 47 dry. Of

Jan 1, 1942

By R. M. Hardgrove

Pulverized coal was first used for firing cement kilns about 45 years ago, with such success that it has continued in general use. Based on cost, pulverized coal is usually the most economical fuel. In some localities natural gas or oil is cheaper, but 85.5 per cent of all cement kilns at present are fired with pulverized coal. The pulverized-coal flame is well suited to kiln conditions. Its soft, luminous nature gives it a high radiating property and the length of the flame can be readily varied to suit conditions in a kiln of any length. Ash and slag cause most of the dificulties incident to the burning of coal. In a. cement kiln, however, the ash, being similar in composition to the raw mix and being deposited uniformly in the mix and clinker, occasions no difficulty as long as it remains constant in quality and quantity. Until 6 years ago almost all cement kilns using pulverized coal employed the bin system. The coal was dried and pulverizeti in a separate plant and delivered into a bin at the kiln. Thus the bin system requires driers, storage-type pulverizers, conveying systems, individual kiln bins, pulverized-coal feeders and primary air fans. The direct-fired system requires only a pulverizer and a blower. Fig. I shows typical plants. The first installations of direct-fired pulverizers were of the impact type but fineness of pulverization was both inadequate and variable. About 1927 a few direct-fired installations employing tube-type pulverizers were made, which were much more satisfactory. As more efficient pulverizers were developed from 1934 on, equipment for direct firing was installed at a large number of plants, until now 196 of about 900 kilns in use in the United States are direct-fired. Most of these replaced antiquated bin systems. Process of Burning Cement Clinkers The process of burning cement clinkers is fundamentally one of heat transfer. In boilers and other heat-exchange apparatus the area of the surface receiving heat from the gases is the best unit for comparing output, This seems to be equally true for kilns. The inside kiln surface is the heat-receiving surface and its area is used as the unit of kiln size in the following comparisons. Heat input is based on British thermal units in the fuel. E. G. Bailey,' in his work on boiler-furnace heat absorption, has used the unit "B.t.u. available." This is the practical calorific power of the fuel, plus the heat in the air used for combustion. In other words, it is the heat available for useful work in the furnace or kiln. The unit of kiln output is barrels per hour. The composition of the raw mix, the percentage of water in the slurry of wet plants and hardness of burning all affect the output. These conditions, however, are hard to evaluate and probably have less effect on the output than irregularities of raw feed and clinker discharge and inexpert control of combustion. Wet vs. Dry Plants The study presented here covers 88 plantsl of which 41 are wet and 47 dry. Of

Jan 1, 1942

By Walter Rose

Theoretical expressions are presented to describe wetting and non-wetting phase relative premeability relations. These expressions have then been compared with existing published data, the conformance noted being sufficiently good to satisfy the requirements of some engineering use. As a consequence, it may be supposed that relative permeability characteristics of porous media now can be inferred from basic core analysis data, in a manner more convenient (although less direct) than presently available methods of experimental evaluation. INTRODUCTION This paper presents a new approach to the problem of relative permeability evaluation. A classification of published discussions of relative permeability concepts which have appeared in the petroleum literature will show that previously emphasis has been placed on methods of experimental measurement, on the interpretation of the data so obtained with respect to the variable properties of the system, and on theoretical and practical considerations which relate relative permeability to gross fluid behavior in petroleum reservoirs. Essentially, no detailed examination has appeared which treats the fundamental factors controlling the quantitative features of the relative permeability relation*, although cer- tain references can be Cited where a qualitative awareness of their existence and nature is indicated. This condition is explainable in terms of the recognized complexity of the problem, and in order to provide some basis for theoretical development, the general emphasis has been placed in the past on experimental procedures of evaluation, the validity of which, in principle, could be confirmed by the analysis of well and reservoir performance. However, because of the experimental difficulties which have been encountered (notably, difficulties due to the so-called "end effects"), and because of the general unreliability of field performance tests required to study the applicability of the data, relative permeability phenomena continue to be incompletely understood and described.? In this paper is examined the possibility of predicting relative permeabilities entirely from fundamental considerations. In addition, attention is called to certain important factors, previously unemphasized in the published literature, which now can serve as a basis for the eventual experimental confirmation of this and similar theoretical approaches, as well as the experimental solution of the problem in general. Therefore, the analysis presented herein has the dual purpose both of orienting future experimental activity and also of providing an immediate solution for the relative permeability porblem, sufficiently adequate for some engineering use. It will be seen that the conclusions reached are supported by theoretical and intuitive considerations, and they are not contradicted insofar as gross features are concerned by existing concepts and interpretations of published experimental data, except as specifically noted. Darcy's law, expressed simply as: k dp q = k/u dp/dx .......(1) where q is linear rate of flow (assumed horizontal), k is the † The poor comparison usually obtained between laboratory and field gas-oil ratios (c.f.. Fig. 4 of paper by L. E. Elkins) is illustrative of conditions which dimcourage unqualified acceptance of the results of previous studies except as presently useful approximations. In this connection, Evinger and Muskat have discussed in detail the discrepancy observed between field well productivity values and values obtained from the analysis of laboratory flow data.

Jan 1, 1949

By Walter Rose

Theoretical expressions are presented to describe wetting and non-wetting phase relative premeability relations. These expressions have then been compared with existing published data, the conformance noted being sufficiently good to satisfy the requirements of some engineering use. As a consequence, it may be supposed that relative permeability characteristics of porous media now can be inferred from basic core analysis data, in a manner more convenient (although less direct) than presently available methods of experimental evaluation. INTRODUCTION This paper presents a new approach to the problem of relative permeability evaluation. A classification of published discussions of relative permeability concepts which have appeared in the petroleum literature will show that previously emphasis has been placed on methods of experimental measurement, on the interpretation of the data so obtained with respect to the variable properties of the system, and on theoretical and practical considerations which relate relative permeability to gross fluid behavior in petroleum reservoirs. Essentially, no detailed examination has appeared which treats the fundamental factors controlling the quantitative features of the relative permeability relation*, although cer- tain references can be Cited where a qualitative awareness of their existence and nature is indicated. This condition is explainable in terms of the recognized complexity of the problem, and in order to provide some basis for theoretical development, the general emphasis has been placed in the past on experimental procedures of evaluation, the validity of which, in principle, could be confirmed by the analysis of well and reservoir performance. However, because of the experimental difficulties which have been encountered (notably, difficulties due to the so-called "end effects"), and because of the general unreliability of field performance tests required to study the applicability of the data, relative permeability phenomena continue to be incompletely understood and described.? In this paper is examined the possibility of predicting relative permeabilities entirely from fundamental considerations. In addition, attention is called to certain important factors, previously unemphasized in the published literature, which now can serve as a basis for the eventual experimental confirmation of this and similar theoretical approaches, as well as the experimental solution of the problem in general. Therefore, the analysis presented herein has the dual purpose both of orienting future experimental activity and also of providing an immediate solution for the relative permeability porblem, sufficiently adequate for some engineering use. It will be seen that the conclusions reached are supported by theoretical and intuitive considerations, and they are not contradicted insofar as gross features are concerned by existing concepts and interpretations of published experimental data, except as specifically noted. Darcy's law, expressed simply as: k dp q = k/u dp/dx .......(1) where q is linear rate of flow (assumed horizontal), k is the † The poor comparison usually obtained between laboratory and field gas-oil ratios (c.f.. Fig. 4 of paper by L. E. Elkins) is illustrative of conditions which dimcourage unqualified acceptance of the results of previous studies except as presently useful approximations. In this connection, Evinger and Muskat have discussed in detail the discrepancy observed between field well productivity values and values obtained from the analysis of laboratory flow data.

Jan 1, 1949

By John T. Norton, Matthew J. Donachie

Residual lattice strai?zs were produced in 2024 aluminum and ingot iron by uniaxial tensile deformation. These strains were rneasured on the original surface and ulith depth below the surface. The strains conformed approximately to those from a macroscopic stress distribution but they were not truly macroscopic in nature. The exact mechanism which apparently causes the coherently difi9,acting region of each grain to behave as if macroscopically stressed was not determined. MACROSCOPIC stresses in metals produce strains in the lattice which result in X-ray line broadening and line displacements. The latter effect can be utilized in a technique for determining stresses in metals as first shown by Lester and born.' Subsequent advances in technique have enabled the X-ray method of stress measurement to be satisfactorily applied to many problems involving residual stresses of a macroscopic nature, such as those due to welding, grinding, shot-peening, and so forth. In the case of stresses such as those described above, the correlation of X-ray- and mechanically determined data has been generally good. However, plastically extended polycrystalline metals have sometimes been reported2 to show line displacements upon release of the applied tensile load, yet the nature or origin of the residual lattice strains, rls, producing these displacements has never been clear. As will be pointed out, this lack of clarity regarding the macroscopic or microscopic nature and origin of these stresses casts doubt on the validity of results achieved by the commonly accepted techniques of X-ray stress measurement. This anomalous behavior requires clarification to remove the doubts concerning X-ray stress measurement. The present paper is the result of an investigation of the interesting behavior of such plastically extended polycrystalline metal bodies. The studies were originated to carry out the following tasks: 1) Observe whether a residual lattice strain is produced as a result of plastic extension and show whether any residual lattice strains produced can be related to the usual concept of a macrostress. 2) Examine the origin of any residual lattice strains observed. 3) Consider the implications or consequences of the existence of such residual lattice strains on the problem of X-ray stress measurement. THEORY 1) Lattice Strains. The theoretical developments necessary for the treatment of lattice strains and their relation to stresses follow from the classical theory of elasticity and have been adequately covered by arrett. For an isotropic solid under homogeneous deformation, it can be shown that, for uniaxial stresses where Dl is the macrostress acting in the longitudinal direction; E$L is the lattice strain in the plane defined by the surface normal and the longitudinal direction at an angle, , from the surface normal; ET is the similar strain in the transverse plane; E is Young's modulus; and v is Poisson's ratio. Eq. [2] is independent of angle + and Eq. [I] is a linear function of sin2, see Fig. 1, and can be solved analytically for DL if E and u are known and EL is measured. Thus, a uniaxial macrostress will be indicated by a linear E,L vs sinZ plot and a

Jan 1, 1962

By R. F. Hehemann, Darrell W. Smith

The kinetics of alloying- in W-5 rot pct Re powder compacts were investigated at temperature about the upper limit for the formation of the x phase, such that a single intermediate phase was involved in the process. The rates and directions of motion of the a-o and o-b interface were assessed as functions of tinze at the sintering teri7peraticve by quantitative izetallog-ralhic techtziques. The iiotion 01 these interjuces could be specified approxitnate1.y by u Parabolic )-ate law and deviations from this ,rate law were attribuled to a complex interaction between surface dif'fusion and volume diffusion during the initial stages of sintering. WHEN binary or more complex alloys are produced by sintering compacted blends of elemental powders, a complication is encountered which does not arise in the sintering of pure metals. In addition to concern for grain size and densification, the rate of inter diffusion of the component elements must be considered. The general problem of alloying during sintering has been treated by numerous investigators.'-7 These investigations have been concerned only with systems that form continuous series of solid solutions and a concentric-sphere diffusion model4 provides a useful description of homogenization in these stems.' Some controversy remains, however, over the contribution of surface and grain boundary diffusion to the homogenization process. Heckel% ePorts that homogenization can be described by volume diffusion at all temperatures, whereas other invetiators'' recognize the importance of surface and grain boundary diffusion, particularly at lower temperatures. Analysis of the homogenization process in partially miscible systems is complicated by the motion of the interfaces separating the individual phases. A simple analytical solution does not exist for such finite systems with spherical symmetry. It was the purpose of this work to examine the kinetics of the formation and dissolution of an intermediate phase in a binary system through an assessment of the motion of the interfaces separating this phase from the terminal solid solutions. PROCEDURE The W-Re system is an example of a partially miscible binary system and was selected for study because of its current importance in refractory-metal technology. The equilibrium phase diagram, Fig. 1, shows that the o phase will be formed by interdiffu-sion between tungsten and rhenium. At temperatures between approximately 2125" and 282O°C, the o phase will appear as the only intermediate phase in the diffusion system. In this work, a mixture of elemental powders containing 5 pct Re was employed. In such a mixture, the rhenium particles will be distributed randomly in a tungsten matrix. During sintering, a o-phase layer will form at the W-Re interface. The development and subsequent disappearance of the o phase are controlled by the relative rates and directions of motion of the 0-0 and a-p interfaces. The motion of these interfaces can be inferred from quantitative metallographic measurements of the average radii of the o shells surrounding rhenium particles. Elemental tungsten and rhenium powders of commercial purity were employed in these investigations. The rhenium powder was spheroidized from +200 mesh agglomerates by plasma-arc spraying and was then classified to yield a powder composed of essentially

Jan 1, 1967

By H. L. Gilbert, H. A. Johansen, R. G. Nelson

High purity electrolytic chromium plate has been hydrogen-reduced and arc-melted under inert atmosphere to give sound ingots. These ingots may be hot forged to break the as-cast structure and then worked at 500°C to finished form. An intermediate and final high temperature anneal gives best ductility and grain refinement. HE increasing interest in refractory metals for I use in high temperature gas turbines, jets, and rockets has led to great efforts in exploiting the fifth and sixth groups of transition elements. Much of the interest has centered upon production of metals that can be worked and fabricated by normal means to produce various engine parts or components having the high temperature characteristics of oxidation resistance and high creep strength required for such uses. If these pure elements do not exhibit all of the desired characteristics, it may be possible to obtain a high purity alloy that will. Since, in all cases, development of these transition elements has depended to a large extent upon removal of oxygen and nitrogen as a means for producing ductile metal, the hypothesis has been accepted that oxygen is the normal embrittling material in a high grade electrolytic chromium metal. Various methods have been employed in an effort to remove this oxygen by direct or indirect attack.' Many workers have endeavored to produce pure chromium through reduction of the oxide by carbon or active metals, while others have recommended fusion electrolysis of chromium salts or reduction of these salts by active metals, such as sodium or calcium. Hydrogen reduction of the oxide or chloride and thermal dissociation of the iodide have been reported to give high purity metal. Experimental Work The U. S. Bureau of Mines, Northwest Electro-development Laboratory, has systematically re-examined the more promising methods and developed two which produce metal having ductility at temperatures lower than heretofore described. It has been found' that oxide-free chromium chlorides in a NaCl-KCl carrier salt may be mag- nesium-reduced and the byproduct salts distilled off in vacuo to give a high purity chromium sponge. Fusion analysis conducted under the supervision of W. W. Horton of Knolls Atomic Power Laboratory showed the oxygen and nitrogen both to be below 10 parts per million on a selected sample. A small amount of carbon is carried over in the final metal from the chlorination and reduction steps which are carried out in graphite crucibles. This trace of carbon is not detrimental to hot ductility. A more practical method for producing ductile metal is through hydrogen reduction of high purity electrolytic chromium. Normal electrolytic chromium will, if "developed" for a few minutes at 1100°C in high vacuum, be found by the method of Adcock:; to contain about 1 pct chromium sesquioxide (Cr2O3). This small amount of oxygen may be effectively reduced by hydrogen.2, 4 The method employed was to crush electrolytic chromium plate in a gyratory crusher to pass 60-mesh; finer crushing appears to offer no advantage. A nitric acid leach removed the iron picked up during crushing. The leached powder was rinsed until neutral with distilled water and vacuum-dried.

Jan 1, 1954

By Paul J. Bennett, James E. Castle

The kyanite minerals, including kyanite, silimanite, and andalusite, are anhydrous aluminum silicates with the formula Al2O3SiO2. lumortierite and topaz are also included in this group because they are closely allied in composition and thermal behavior. However, leither are mined commercially today. They ire typical metamorphic minerals which are found in metamorphic rocks on every continent. Kyanite minerals are prized chiefly for their refractoriness and are important components in a broad range of acid refractory products, especially in mortars and castables. World production of kyanite minerals is currently about 250,000 tpy and has been increasing at the rate of 3 to 8% a year for many {ears (Anon, 1972). While kyanite minerals lave widespread occurrence, the consumption of kyanite minerals is concentrated in the relatively few highly industrialized areas where refractories are manufactured, and which in turn are typically close to the major iron and steel producing regions of the world. Thus northern Europe, England, the United States, and Japan are the principal consumers of refractories and kyanite minerals. Of these countries only the U.S. is a significant producer. The largest use for domestic kyanite, both raw and calcined, is in the manufacture of refractory mortars, cements, castables, and plastic ramming mixes. In these applications kyanite constitutes from 10 to 40% of the mixture, the balance being refractory clays and coarser grog materials. A certain proportion of raw kyanite is used to offset the shrinking of the clay binder, whereas the calcined kyanite is used in the coarser sizes for body. Certain high grade refractory shapes and kiln furniture are composed chiefly of graded sizes of calcined kyanite bonded with a little ball clay. In most applications, however, kyanite is used only to fortify the mix or as a minor ingredient. Some manufacturers of mullite brick use domestic calcined kyanite for the fine-grained portion of the brick, but seldom in quantities exceeding 10% by weight. Kyanite is used by ceramic manufacturers of wall tile and sanitary ware to offset shrinkage and cracking after firing. Indian kyanite has traditionally been used to make the coarse grog sizes needed for the manufacture of mullite brick, and for the grog portions of mortar, cement, and castable mixes. It has been largely replaced, however, by synthetic mullite, high fired flint, and diaspore clay or calcined bauxite for other applications. Indian kyanite is available in lump as well as in granules and concentrates, as are sillimanite materials from India and South Africa. Andalusite is available as 8 mesh granules and as fines with chemical analyses not unlike those of domestic kyanites. From time to time and from place to place minor amounts of other aluminum silicate minerals such as dumortier- ite, topaz, and pyrophyllite have been made available at various prices and specifications, but have not been significant factors in the refractory industry. A mixture of kyanite and sillimanite of relatively fine grain-size and of low iron content was at one time offered to the molding sand industry by the Du Pont Co. as a byproduct from their deposits of heavy

Jan 1, 1975

By R. C. Buehl, M. B. Royer

A three ton per day blast furnace using blast temperatures up to 2200°F was operated to recover manganese from open-hearth slag and manganiferous iron ore. The spiegel product containing 12 to 24 pct Mn was blown in a basic converter to high manganese oxide slag as described in the paper which follows this one. HE steel industry, which uses over 900,000 short tons of contained manganese yearly, depends on the maintenance of supplies of manganese from foreign sources such as India, Gold Coast, and Union of South Africa. Domestic ores furnish less than 10 pct of the yearly requirements of metallurgical ores and, unfortunately, the United States has no large, or even moderate, grade deposits that could supply a major portion of the requirements for many years. It may be necessary to obtain manganese from low grade materials, even though the cost is appreciably higher than when imported ores are used. An American Iron and Steel Institute questionnaire prepared in 1949 revealed the startling fact that open-hearth slags contained about as much manganese as is imported annually. The quantity of slag produced each year by integrated steel plants (not including cold-melt shops) and the manganese contained in the slag follows: Flush slag, 4,500,000 net tons a year containing 408,000 net tons Mn; tap slag, 7,230,000 net tons a year containing 364,000 net tons Mn; for a total of 772,000 net tons Mn. Some of this slag is returned to blast furnaces but about 75 pct would be available for the recovery of manganese. In several decades, when many of the present sources of high manganese ores have been depleted, open-hearth slag and manganiferous iron ore may become the major source of the manganese required for steel production. In 1948, manganese-ore imports from the U.S.S.R. were 427,000 net tons or 34 pct of the foreign ore. Imports from this source were only 81,000 tons in 1949. It became evident that adequate stockpiles of manganese could not be accumulated for many years. The Bureau of Mines initiated an extensive research program on methods for increasing domestic production of manganese and entered into a cooperative agreement with the American Iron and Steel Institute for recovering manganese from open-hearth slags whereby the Institute provided additional research funds and trained operating personnel. Description of Process and Equipment Numerous pyrometallurgical and hydrometallur-gical processes and combinations of the two can be applied to the recovery of manganese from open-hearth slag and manganiferous iron ore. The process being developed at the Pittsburgh Station of the Bureau of Mines consists of: 1—Reduction of open-hearth slag in a blast furnace to recover the iron and manganese as spiegel-eisen with 12 to 24 pct Mn. 2—Selective oxidation of the manganese from the blast-furnace metal in a basic-lined converter to produce a high manganese slag with up to 60 pct Mn content, which is a synthetic ore for the production of ferromanganese. This process has the advantage over other processes in that the equipment which would be used, such as blast furnaces and converters, has been highly

Jan 1, 1953

By Walter B. Lenhart

Introduction and Importance of the Industry Sand, as described in this chapter, is a crude product used for ballast on railroads and highways, and as the fine aggregate in concrete, mortar, plaster and in asphalt paving materials. The sand used in glass, as a molding sand, and as a source of silica is described in Chapter 43. Sand and gravel together constitute the mineral raw materials of largest volume produced from the earth. In 1958, as reported by the U.S. Bureau of Mines,21 680,080,000 tons of sand and gravel (including industrial sand) were produced in the United States. The nearest competitor was crushed rock of which 532,818,000 tons were produced. Coal, both bituminous and anthracite accounted for only 431,616,689 tons in the same year. In dollar value, sand and gravel were exceeded only by cement, crushed rock and fuels. Hence it is a major unit of the mineral-producing industry. As an example, one plant in California operates around the clock at an average rate of 1,500 tons per hour, and at peak intervals has shipped over 4,000 tons per hour, all by trucks. Nevertheless, it is controlled by one man through a panel of push buttons that control the crushing, screening, washing, grading, stock piling, and reclaiming of the products. Because sand and gravel are low-valued commodities, but are used in every construction undertaking in every city, village, farm, dam and highway, they are produced in almost every county in the United States and southern Canada, by thousands of individual operators, very few of whom operate in more than one community. Many operations, particularly those established to supply the needs of major dams that are under construction, or of major segments of new highways, are temporary in nature, and the equipment installed is more or less portable. Because of the bulky nature of sand and gravel, there is very little interstate movement, and almost no exports or imports, except a little movement back and forth across the border of the United States and Canada. First, the material needs definition. Definitions Sand and gravel have been defined as continuously graded unconsolidated materials that appear in the earth's surface as a result of the natural disintegration of rocks. Both normally appear together, but in a wide variety of sizes, types and range of size classification. The American Society for Testing Materials has tentatively revised its definition of "sand" as: granular material passing the 3/8-in. sieve and almost entirely passing the No. 4 (4760-micron) sieve and predominantly retained on the No. 200 (74-micron) sieve, and resulting from natural disintegration and abrasion of rock or processing of completely friable sandstone (ASTM Designation C 58-55T). The Society's tentative revision of its definition of "gravel" is: granular material predominantly retained on the No. 4 (4760-micron) sieve and resulting from natural disintegration and abrasion of rock or processing of weakly bound conglomerate (ASTM 125-55T). Sand and gravel deposits contain materials from the finest silt to the largest boulders. Chemical definition of the two materials is nearly impossible. Sand and gravel always are

Jan 1, 1960