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By F. W. Wood

The use of consumable.-electrode arc melting as a production technology is growing. One advantageous feature of this process is that it avoids ingot contamination by soluble crucible materials by employing a chilled metal crucible. Because the thermal balance under these conditions is rather delicate and does not necessarily provide a favorable environment for solidification, catastrophic imbalances can occur. The effectiveness and mechanistic roles of various factors are mostly unknown, and more intelligent insight regarding the distribution of temperature and heat is needed. Experience has provided several pertinent observations, some of which are quite superficial. The most meaningful data have resulted from studies of molten pool shapes and sizes and from measurements of heat flow through crucible walls. Overall experience, intuitively interpreted and supplemented, is sufficient nevertheless as a basis for a boundary-value treatment of the problem. A mathematical analysis based on a separation of variables, using conventional differential equation methods, provides a useful solution. For a cylindrical ingot, the temperature varies as a Bessel function of an argument proportional to the radius and as an exponential function of longitudinal position. Trial calculations using the problem solution seem to verify the general correctness of the result as compared with experience. The role and nature of solution parameters are also clarified, though not entirely resolved. It is revealed that the barrier to heat flow at the ingot-crucible surface has a prominent influence. Utility of the model embodied in the problem solution is readily demonstrated by considering a variety of contemporary questions about arc melting, and it is hoped that utility can be enhanced by improvement of the model.

Jan 1, 1968

By K. A. Gschneidner, O. D. McMasters

DgIel-ential thermal, nretallographic, and X-ray paramzetric methods were used to establish the Yb-Pb phase dingram. The terminal solid solubilities in the system are less than 0.2 at. pct. Lead additions lower the 792°C transformation tewzperature of pure ytterbiun~ at 787°C by means of an inverted peritectic veaction. Ytterbium additions raise the 327oC melting point of lead to 329°C by means of a perilectic reaction. Three intermetallic compounds Yb2Pb, YbPb, and YbPb, melt congruerttly at 1246", 1116o, and 740°C. respectively. YbsPb3 forms by a peritectic reacliorz at 1250°C. YbzPb crystallizes in the PbCh (C23) type structure and the orthorhombic latliceo constants are a, = 7.478. bo = 5.225, aud C0 = 9.549A. YbsPbs crystallizes in the hfnsSi3 (D8a) type structure. The hexa~nal lattice constants for this phase are a, = 9.325 and co = 6.92d. YbPbl crystallizes in the cubic AuCU3 (Ll2) type structure with a: = 4.8628 + 0.0008A. YbPb is diwrorphic with the structure change occurring al 507°C upon healing. The crystal structures of the two forttzs were not determined. Eulectic reactions occur at 5.1 at. pct Pb and 769oC, 41.5 at. pct Pb and 1086oC, and G8.0 at. pct Ph and 717°C: RELIABLE information concerning the alloying behavior of most of the rare-earth metals is scarce. A systematic study of the rare earth-lead alloy systems now in progress is an effort to supply such information. Determination of the phase diagram of the Yb-Pb alloys is the first step of this study. Variations in the valence of normally divalent ytterbium may be studied by comparing the characteristics of the Yb-Pb alloys to those of the trivalent rare earth-lead and of the divalent alkaline-earth-lead systems. Of particular interest are the melting temperatures of the intermetal-lic compounds since these are known to be high relative to the melting points of the constituent metals. Crys-tallographic and magnetic susceptibility data for the rare earth-lead alloys are to be included in the comparative study. Results from this and subsequent investigations should provide a better understanding of alloy formation. EXPERIMENTAL PROCEDURE Materials. The major impurities in the ytterbium and lead used in this investigation are listed in Table I. The lead was obtained from Cominco Products, Inc., and was specified to be 99.99 pct pure. The ytterbium was prepared in this laboratory by the lanthanum reduction of the oxide followed by a distillation of the ytterbium. Alloy Preparation. The alloys were prepared by

Jan 1, 1968

By T. N. Rushton

Rate minima are encountered in the reduction of magnetite with hydrogen. In a certain temperature zone, the reaction rate decreases with rise in temperature. This is inexplicable by classical kinetic theories; neither is a transition in reduction mechanism suitable for interpreting the observed behavior, This anomaly can be fully explained by hypothesizing two species of chemisorbed hydrogen with different adsorption coefficients and activation energies for adsorption. Competition between two energetic states of adsorption occurs with temperature rise, with the low energy state predominating below the anomalous temperature zone and the high energy state above it. The presence of two possible adsorption sites appears to be characteristic for oxidic adsorbents.

Jan 1, 1968

By William K. Burriss

Computer technology was applied to solve three problems in the selling of certain industrial minerals to the glass and foundry industries. The computer solutions provide for better service to customers and have helped increase sales. II. Summary Electronic data processing techniques were applied: 1. To automatically and continuously "trace" rail car shipments of bentonite. 2. To aid our sales people in recommending to glass plant purchasing agents which of several possible feldspathic materials is the best value at any of about 100 glass plants and to give guidance on the amount of value difference. 3. To help in locating plant sites for three blending or pre-mixing stations to serve the foundry industry at minimum cost and with maximum tonnage and maximum profitability.

Jan 1, 1968

By R. P. Fischer

The Colorado Plateau region has been the principal domestic source of uranium, vanadium, and radium. The value of these commodities produced from the region through 1964 slightly exceeds $2 billion. Most of the deposits occur in streamlaid lenses of sandstone in the Chinle and Morrison Formations. The ore minerals below the zone of oxidation are low-valent oxides and silicates of uranium and vanadium; all of these, except the quite stable vanadium silicates, oxidize readily to a variety of high-valent uranium and vanadium minerals. The ore minerals partly replace fossil wood but mainly impregnate sandstone, typically forming tabular ore bodies that are nearly concordant to the bedding of the host rock. The deposits range in size from those containing only a few tons of ore to those containing more than 1 million tons. Stratigraphic, lithologic, and sedimentary structural factors obviously influenced the localization of these deposits, but igneous activity, hydrothermal mineralization, and tectonic structures show no similarly consistent influence on localization. The deposits are epigenetic, but the source of the ore metals, the nature of the ore-bearing solutions, and the time of ore emplacement are uncertain. A few uranium deposits in the region are dominantly discordant to bedding and occur in collapsed breccia pipes or along linear fractures. Their origins are also uncertain.

Jan 1, 1968

By Oliver C. Fursman

The Bureau of Mines undertook this investigation in order to determine the feasibility of producing commercially acceptable alumina and iron by application of the Pedersen process to high-silica, high-titania, ferruginous bauxites of the Pacific Northwest. Calcium aluminate slags were produced by smelting bauxite with coke and lime in an electric-arc furnace. Over 90 percent of the total alumina can be extracted by sodium carbonate solution from slags of properly controlled ternary-phase composition (CaO-Al203-SiO2) that are cooled slowly enough to permit adequate crystallization of the 2CaO-SiO2 and the calcium aluminate compounds. Most of the iron charged was recovered in the regulus; the slag contained about 2 percent iron (as iron oxide), regardless of smelting time.

Jan 1, 1968

By David J. Kusler

This study is an appraisal of the feasibility of recovery and the possible chemical and physical uses of the limestone from the Greenbrier Formation in western West Virginia. Data on minability, occurrence, quality, and markets were obtained from published and unpublished sources and by a limited mail survey combined with personal contacts. The estimated costs of recovery by deep mining techniques are considerably higher than competitive surface and shallow subsurface operations. Compositional in formation available for this study was limited but indicated the suitability of the limestone for most physical uses and some chemical process uses in appraisal of the uses and demand reveals that immediate markets may be difficult to establish, but for some uses long-term prospects may be encouraging, especially if the quality of limestone would be suitable for lime manufacture or use as metallurgical fluxstone.

Jan 1, 1968

By H. C. Rolseth

The first step in the quarrying of granite, following removal of any overburden material, involves the freeing of large blocks from the formation. For many years the use of explosives was the accepted method of obtaining these blocks. Even today there are operations where this is considered to be the most economical method even though it does result in a high percentage of damaged stone. In more recent times the preferred procedure at most quarries has been to produce a continuous vertical cut or slot completely around the block to be separated. Originally, this was done by drilling a series of closely spaced holes around the block and breaking the web between the holes with a chisel-like tool known as a broaching bar. The machine used in this mechanical method of producing the relief slot is known as the channel bar. The modern day approach to the production of continuous channels was introduced to the industry around 1955 by the Linde Division of Union Carbide Corporation. The method employs a small rocket - jet burner producing a high temperature, high velocity exhaust flame which when directed against the granite causes it to disintegrate. This method, which has come to be known as "Jet Channeling", is now used by practically every major granite producer in the United States and Canada.

Jan 1, 1968

By Israel Liebman

The Bureau of Mines conducted an investigation to determine those factors that are significant in affecting the velocity of flames propagating along the boundary separating gaseous fuel and air. In addition the aerodynamic motion of the gases in the vicinity of such interfacial flames was delineated. Parameters in the study included flammable zone thickness, flammable zone concentration of gradient, fuel type, and position of the flame relative to various environmental surfaces. Of all these factors, the flammable zone thickness and burning velocity of the stoichiometric mixture were found to have the most significant effect on the flame speed. Notion of the gases in the vicinity of the interfacial flames was examined by particle track and interferometric techniques. The relative velocity of the interfacial flame with respect to the unburned gas on the central streamline was found to equal the burning velocity of a stoichiometric homogeneous fuel-air mixture. In addition, it was observed that the composition of the lean fuel-air mixture at the boundary of the combustion zone appears to be less than that defined as the fuel's lower flammable limit.

Jan 1, 1968

By P. M. Johnson

A design for a laser-powered optical interferometer, using a specimen whose thermal expansion is to be measured as part of the optical system, was conceived and applied in a prototype dilatometer. The object of thin work was the development of an absolute dilatometer capable of use at elevated temperature, particularly above 1,000° C. The prototype has been operated at temperatures exceeding 1,510° C. Results obtained with this device agree within 2.5 percent with the published data for the coefficient of expansion of columbium.

Jan 1, 1968

Ammonium nitrate-fuel oil (ANFO) explosives are unstable in hot, reactive sulphide-rich ground at Mount Isa. Under certain conditions associated with background heat, moisture, and chemical impurities from natural oxidation, ANFO composites in contact with hot ground disproportionate and the ammonium nitrate can undergo rapid exothermic reactions with sulphide.Reactions can occur in confined charges from prolonged contact with reactive sulphides, or by contamination with sulphide in loading. Partial interaction can result in misfires or premature detonation. Spilt, scattered and unpropagated explosive will undergo further reaction in sulphide-rich environments. ANFO-sulphide interaction is invariably exothermic and causes an irreversible chemical transformation of the ore.The heat generated during reaction may be dissipated, heating the environment, or rapidly accumulated to yield hot spots or areas in excess of 400°C. These can result in forced ignition of bulk sulphide and sustained combustion.Thermal analysis was used to define the critical conditions for ANFO-sulphide interaction and sulphide combustion.The occurrence of incandescent ore is attributed to the thermal interaction between exothermic hydrolysis oxidation, ANFO-sulphide, and combustion processes.Chemical agents and control methods have been developed to prevent ANFO-induced oxidation and combustion.

Jan 1, 1968

By Elbridge W. Gresseth

Rock deformational structures in a deep mine were analyzed by petrofabric techniques to learn (1) the relative magnitude and direction of the principal stresses involved in tectonic deformations prior to mining, (2) the preferred orientation of rock planar discontinuities which define rock anistropy prior to mining, and (3) the relationship of mining-induced rock failure to inherent rock stresses and inherent rock anisotropy. Rock fabric elements used for petrofabric analysis consisted of bedding planes, faults, joints, fractures, foliation, sericite plane (001), quartz axis [0001], quartz deformation lamellae, and microfractures. Structures and structural symmetries from different areas within the mine and from different scales of observation were compared to learn the nature of rock anisotropy and the orientation of the principal stresses defined by rock deformations. Analysis of such fabric as regional and macroscopic faults, b-c joints, quartz [0001], sericite (001), and microfractures, indicate that during the epochs of tectonic deformation, the maximum and minimum principal stresses were horizontally oriented and acted along northwest and northeast axes, respectively. This condition of regional stress appears to have continued during folding and the associated period of faulting. The most recent tectonic deformation represents a rotation of the minimum principal stresses into a vertical position, as shown by the development of a tensile joint system, quartz deformation lamellae, and microfractures. Good interscale correlation and statistical homogeneity of tectonic fabric indicate a stress field homogeneity in this area during tectonic deformation. Rock physical anisotropy is genetically associated with tectonic fabric and consists of preferentially oriented planar discontinuities intersecting along a nearly vertical axis. The mining-induced deformations were correlated with the inherent rock anisotropy which either directly controls or greatly affects their development. This phase of rock deformation shows a greater degree of stress field heterogeneity than was the case with tectonic deformations This is explained as a result of nonconfinement afforded by underground openings and the increase in ground stresses due to mining activity"

Jan 1, 1968

A process was developed to produce electrolytic manganese dioxide, suitable for use in high quality dry cells, from Risdon anode mud. ImpurItIes present In the anode mud were removed prior to the electrolysis which was performed from a manganese sulphate bath using the following conditions.Temp. 95°CH2S04 50-55 g/l.Mn2+ 55-60 g/l.Anode c.d. 10·0 A/sq. ft.Operation under these conditions yielded current efficiency and power consumption figures of 95 per cent and 0·8 kWh/lb respectively. The product conformed to battery manufacturers' specifications as regards physical and chemical properties and performed satisfactorily in a battery testing programme.

Jan 1, 1968

ABSTRACTOperations Research and associated techniques have wide application in the Mining Industry and have been used in Mount Isa since 1961.Typical of the projects undertaken by the OperatIons Research staff are1. the development of a complex computer programme for use in economic evaluation of mineral deposits,2. development of a production scheduling and control system for a complex mining operation,3. SImulatIon of a metallurgical plant operation to test the adequacy of design specifications and4. analysis of vehicular accident data to valuate alternative courses of insurance action.

Jan 1, 1968

By Gerald Blackmore

This paper discusses the present state and future trends within the coal industry, and then goes into the reasoning behind these planned trends. Such factors as marketing, costs, new mining techniques and machinery, and manpower and human resources are considered. Finally, the author refers to the effect that these trends will have on the coal industry of Cape Breton.

Jan 1, 1968

Further evidence is presented as to the widespread occurrence of Thiobacillus ferrooxidans in nature in association with sulphide minerals. Leaching rates are discussed in terms of the effect of environmental parameters, particularly Eh and pH, on the bacterial process.The methods used to investigate leaching phenomena are described and the advantages and limitations of each method are discussed. A theoretical treatment of the bacterial leaching process is given which indicates that the optimum conditions arrived at by traditional methods are compatible with those deduced from consideration of the mathematics of continuous culture and thermodynamics

Jan 1, 1968

A description is given of the construction and operation of an automatic version of the coarse batch particle sizer which requires a minimum of operator supervision and which is capable of processing a sample every 4 min.

Jan 1, 1968

The occurrence of molybdenite in a small shaft in the western margin of the Wuuluman Granite in central western New South Wales is noted. Full petrographic and mineragraphic descriptions are given of a mineralized contact zone between the granite and a basic hornfels.Mineralogical data .indicate a similarity between this mineral occurrence and other occurrences in larger mines remote from the granite.

Jan 1, 1968

By E. N. Harshman

Uranium mining and milling are rather new industries in Wyoming and South Dakota, but, in the past 15 years, ore valued at more than $400,000,000 has been mined and milled in the region. The major uranium deposits are in structural and/ or erosional basins or on the flanks of uplifts. The principal host rocks are medium- to coarse-grained sandstones that were deposited in continental or brackish-water environments and were derived in large part from the granitic cores of the uplifts and the sedimentary rocks that flank the cores. The ages of the host rocks range from Cretaceous to Miocene, but more than 95 per cent of the known reserves in the region are in rocks of early Eocene age. The bulk of the ore in the region is unoxidized and lies below the water table; some oxidized ore has been mined in the Powder River Basin and Black Hills districts. The unoxidized ore comprises pyrite, uraninite and/ or coffinite, marcasite, hematite, jordisite(?), and selenium. Minerals in the oxidized ore include hydrous uranium carbonates, phosphates, and sulfates and hydrous uranium and/ or vanadium silicates. The deposits are in the form of ore rolls that contain from a few hundred to a few hundred thousand tons of ore, ranging in grade from 0.1 per cent to 1.0 per cent U3O8. The rolls are at the margins of large tabular bodies of sandstone that has been altered by the orebearing solutions. The deposits are believed to have resulted from the interaction of an alkaline; oxidizing, ore-bearing ground water and a reducing environment. Exploration guides include the spatial relations of ore to altered sandstone, favorable lithology in the host rock, the content of certain elements and/ or compounds in ground water, and the relation of deposits to major paleodrainages.

Jan 1, 1968

By E. A. Mihok

A pilot plant for treating mine drainage by neutralization with limestone was designed, fabricated, and operated by the Bureau of Mines. The process consists of (1) producing a very fine (minus 400-mesh) limestone slurry, (2) mixing the slurry with the mine water, (3) aerating the resulting mixture to remove carbon dioxide and precipitate iron, and (4) separating the solids from the liquid by sedimentation. A mine discharge of pH 2.8, containing 1,700 ppm total acidity, 36 ppm ferrous iron, and 360 ppm total iron, was treated at rates from 300 to 400 gpm. The treated water ultimately reached a pH of 7.4 and contained no detectable iron. The resulting sludge compacted to approximately one-third the volume of sludge from mine water neutralized with lime. The advantages of the limestone process, compared with the conventional lime process are as follows: Widespread distribution and lower cost of run-of-mine, indigenous limestone; simplicity of plant design; reduced hazards and plant operating and maintenance costs accruing from the use of a less reactive chemical agent; higher solids concentration of the precipitated sludge; and no deleterious effect caused by accidental overtreatment. While total process costs could not be determined, it is conservatively estimated that the cost of treating mine water by the limestone process is one-third to one-half the cost of the lime process, depending on the characteristics of the water to be treated and the availability and quality of limestone used.

Jan 1, 1968