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By V. A. Zanadvoroff

The mine and concentrator of the Howe Sound Co., Chelan Division, are at Holden, in a remote section of the Cascade Mountains of northwestern Washington. Holden is at an elevation of 3200 ft., in the narrow valley of Railroad Creek. This creek drains into Lake Chelan, at a point some 40 miles up the lake from the town of Chelan. The concentrator treats 2000 to 2500 tons of low-grade copper-gold-zinc ore per day. Concentration is achieved by the differential flotation process, with recovery of 94 per cent copper and 82 per cent gold in the copper concentrate, followed by the recovery of 65 to 70 per cent zinc in the zinc flotation circuit. The final flotation tailing is deslimed, and coarse . sands, representing 60 to 70 percent of the total, are cyanided. The tonnage of tailing material amounts to 1900 to 2370 tons per day. General Considerations The property is within the Chelan National Forest. Railroad Creek is a fishing stream, being stocked regularly with trout from State hatcheries. Consequently, in planning a milling operation, the Howe Sound Co. was obliged to avoid any pollution of the stream by tailing material, and also destruction of valuable stands of timber. Moreover, the selected tailing- disposal sites should not mar the natural beauty of the valley. In addition to these requirements, the problem of tailing disposal at Holden was complicated by topography and climatic conditions. The valley is long and narrow, averaging 1200 to 1500 ft. in width. Its walls are flaring at a steep angle. There are no extensive flat areas suitable for deposition of tailing. All valleys tributary to Railroad Creek, also the well-marked paths of snowslides, must be avoided. Finally, the direction of prevailing winds and possible dust hazard arising therefrom dictated the necessity of selecting the tailing-disposal sites downstream from the mill building and two campsites. Heavy snowfall during the winter months of November to March, inclusive, impedes building of the retaining dike, making it necessary to prepare the needed storage space during the summer months. It is inadvisable, also, to do any dike building during the freezing weather, because the dike becomes unstable with the spring thaws, producing inevitable "sloughing" of the built-up borders. Tailing-disposal Sues The existing tailing-disposal areas are near the south wall of the valley. They were developed, and put to use in the following sequence: No. I. Area.—Covers approximately 10 acres. Built up to the height of 60 ft. and abandoned. Total length of dike border is 1900 feet.

Jan 1, 1947

By E. F. Raffo

THE design of the Chuquicamata concentrator offered an unusual combination of problems, all of which had, in one way or another, a definite effect upon the final arrangement of all the equipment and necessary facilities. First of all, a remotely located project of this magnitude required careful selection of equipment with an adequate supply of replacement parts and in some cases necessitated stand-by spare equipment ready for immediate use. Fortunately, in the course of determining the proper flowsheet, in itself a prime factor in the concentrator design, it was possible to conduct numerous grinding and flotation tests at the Anaconda and Andes concentrators. As a result of these tests made under actual operating conditions, most of the major equipment best suited for treating the Chuquicamata ore efficiently was decided upon while preliminary design layouts were still being made. The design has been based primarily on the treatment of sulphide ore crushed to about 3/4 or 1 in. However, until the new sulphide crushing plant is completed it will be necessary to handle ore crushed to 3/8 in. in the existing oxide crushing plants and to some extent a mixed ore which has had its oxide copper content removed by leaching. This mixed ore, known as leached residue, will contain a certain amount of sulphuric acid from the leaching process which necessarily requires special protective measures. Several factors influenced the final location of the Concentrator. The only established fact known during preliminary design layout was the elevation of the dumping floor over the fine ore bin. This was predetermined by the desired level railroad grade across part of the existing tailing and leached residue dumps from the oxide plant to the bin. Next it was necessary that a site be chosen that would not require an excessively long haul from either the present oxide plant or the mine and in addition provide a fairly constant natural ground slope sufficiently wide to accommodate the length of the ultimate concentrator. The site as finally chosen to meet the foregoing restrictions provided a natural ground slope of 6 to 7 pct. This was excellent, especially in a region subject to earthquakes, as it assured that foundations of heavy equipment and footings for building and crane columns would rest on cut or undisturbed ground. However, this shallow slope, although having some definite advantages in the overall consideration of plant layout, resulted in the need for extensive studies in the general arrangement of equipment. Wasteful and excessive vertical drops had to be eliminated in the

Jan 1, 1952

The object of crushing and grinding for leaching is obviously to permit contact of the solvent and mineral and subsequent removal of pregnant solution in a reasonable time. Heap leaching is the leaching of ores that have been mined and transported to prepared, relatively impervious pads for leaching by sprinkling or ponding, and percolation of the lixiviate through the ore. Dump leaching is the leaching of dumps or low-grade ore or overburden without the use of prepared pads under them. Run-of-mine material, e. g., low -grade ore from open pit stripping operations, may be leached without crushing, and a fairly high recovery made by heap leaching. An alternate method for better grade gold/silver ores is to crush to 9 to 13 mm (318 to112 in. ) size for pad heap leaching, as used by Smoky Valley Mining Company at Round Mountain, Nevada, on gold ore, and to 38 rnrn (1 -1 12 in.), which will be done by Candelaria Partners, at Candelaria, Nevada, on silver ore. Heap leaching of copper probably began at Rio Tinto, Spain, about the year 1752. This was done by the leaching of weathering piles of ore in the open air followed by iron cementation of the liquor that drained off the heaps. Its application to the low -grade southwestern United States copper ores was overlooked for many years, and low- grade ores from Sacramento Hill at Bisbee, Arizona, were the first to be heap leached in 1923. Site preparation used a half century ago is the same today. "The need for some form of waterproofing of the pad was evident. Before leaching ore was piled, the site was cleared of cactus and brush. After clearing a gentle sloping area, it was then covered with a blanket of rolled and tamped clay or slime tailing. When heaps are built, a layer of coarse fragments may be put down first to assist drainage. A second method of leaching without grinding, usually for higher grade ores, is by vat or tank leaching of material crushed to 9 to 13 mm (318 to 112 in.) size. Such a plant is considerably more expensive than a heap leaching installation but much less costly than grinding for agitation leaching, and a recovery higher than that obtained by heap leaching is to be expected. Vat leaching has been widely used by the copper industry on higher grade copper ores but has been used in only a few small operations on that size gold or silver ores. However, such a plant should be considered for a modest tonnage of a few million tons, 3 to 7 g per mt (0.10 to 0.20 oz per st), of Carlin-type leachable ores crushed to 9 mm (318 in.).

Jan 1, 1981

By James J. Wise

INTRODUCTION One basic design feature utilized in all caving and sublevel stoping techniques is the drawpoint. These draw- points may be located on sublevels when using sublevel caving methods, or may be located at the floor pillar when using block caving, sublevel stoping, or vertical crater retreat methods. How the drawpoint is designed and developed, how the ore is withdrawn from it, and how the ore is hauled to the shaft or portal encompasses the loading and hauling function. Historically, predominate loading and hauling equipment for caving and sublevel stoping has been scraper slushes, air powered overshot loaders, and rail mounted train haulage. All of this equipment has two common constraints. 1. The equipment locked into specific work sites and is not easily shifted to another work site. This constraint can often lead to low utilization and low productivity of the equipment. 2. The equipment is designed to work in the horizontal plane, which requires that the various horizontally-oriented working levels be connected by vertical raises. Vertical development by means of raises is not only increasingly expensive, but also is not well adapted to movement of large equipment into the s topes. In the last 20 years, two revolutionary labor saving concepts have become common in caving and sublevel stoping. 1. Long-hole drilling, which has mechanized the development of the drawpoint extraction structures as well as the actual stoping and undercutting. 2. Vertical access by means of trackless ramps between levels, and the consequent use of rubber-tired vehicles not only for loading and hauling ore, but also for the rapid movement of men, material, and equipment into the stopes. The introduction of trackless mining systems for loading and hauling has not been easy. Mine planners have had to re-orient their thinking to the larger operating space required by trackless equipment. Larger access drifts have necessitated reconsideration of mine layouts to insure proper ground support. Spiral ramp developments were often laid out on slopes steeper than the equipment could negotiate economically. Mine operators had to accept the added responsibility of roadway maintenance, water removal, increased ventilation, and more technical mechanical maintenance. As the mine operators enthusiastically embraced the superior productivity of trackless mining systems, they some- times disregarded opportunities to combine the older types of equipment with trackless vehicles to maximize productivity at lowest cost. In order to gain a proper perspective on this problem, it is necessary to review the various techniques of loading and hauling and to become more aware of the advantages or disadvantages that each system or combination contributes. LOADING Loading consists of two functions, (1) primary loading from a drawpoint and (2) secondary loading into long- haul system, a truck, train, or possibly a belt conveyor. Mine planners have four basic loading systems available to fit various operating conditions. These are, (1) gravity, (2) scrapers, (3) rail-mounted loaders, and (4) trackless loaders. Each system can produce optimum results under specific conditions. Gravity Loading Gravity loading is probably the oldest system in general use today.

Jan 1, 1981

By C. M. Shigley

The record of the largest magnesium plant in the country utilizing sea water as a primary raw material stands as another victory in the struggle for large-scale production of pure chemical elements from the oceans. Bromine was the first element to be economically and commercially recovered when, in 1933, a six million pound per year unit was built on the Atlantic Coast near Wilmington, North Carolina, by the Ethyl-Dow Chemical Co.' The bromine was reacted with ethylene to produce ethylene dibromide, a necessary associate of tetraethyl lead in ethyl antiknock fluid. Within eight years that plant was doubled and redoubled, and another large unit was put into operation at Freeport, Texas, taking bromine from the Gulf of Mexico. In 1940, in fortunate anticipation of the impending demand for magnesium and the limitations of the production from natural brines, the Dow Chemical Co. turned again to the sea, and designed and erected a plant at Freeport to produce 18,000,000 lb. of magnesium per year from sea water.2 In March 1941, two months after the new plant had been put into successful operation, construction of an 18,000,000-lb. Government-financed addition was started. Late in 1941, as a part of the $400,000,000 defense program intended to produce 600,000,000 to 700,000,000 lb. of magnesium per year, Dow was asked to build and operate for the Government a 72,000- ooo-lb. plant near its original plant at Freeport. Within a few days after the Japanese made their attack at Pearl Harbor, preparation of a site was started at Velasco, Texas, for the construction of the Texas plant of the Dow Magnesium Corporation—the largest known magnesium plant utilizing sea water as its raw matcrial. Less than six months after the first piling was driven, urgently needed magnesium was in steady production. Five months later, the plant had exceeded its rated capacity. It remained above rated production until the general magnesium curtailment was applied to Government-owned plants in September 1944. Credit for the construction and operation record of the Dow magnesium plant must be divided among the efforts of a very determined group of men, an extremely favorable location, and a simple process. It is with the two latter aspects of the plant that this article will deal. The site for the new enterprise was chosen near Velasco, Texas, on property bordering the Brazos River at a point approximately 6 miles inland from the original magnesium plant and 7 miles inland from the Freeport Harbor on the Gulf of Mexico. This location was far enough away from the operating units to reduce both interference from construction and the vulnerability of closely bunched manufacturing operations to the then feared air attack. Yet the distance inland was not too great for the economical construction of a barge canal from the harbor to serve both the transportation of raw

Jan 1, 1949

By R. D. Rubright, Owen J. Hart

In the Bingham district over a span of more than 90 years, 43,947,104 tons of "non-porphyry" copper, lead, zinc, gold, and silver ore have been mined from a folded and faulted alternating series of Pennsylvanian and Permian limestones and sandstones and from some Tertiary intrusives. This ore came from six major mine areas located east, south, and west of the Bingham stock, site of Kennecott's porphyry copper deposit. The sediments were affected by varying degrees and types of metamorphism within 2000 feet or more of the Bingham stock. The intrusives consisting of the mineralized Bingham and the unmineralized Last Chance stocks and numerous dikes and sills of granite and monzonite were intruded into the asymmetrical northwest-trending and plunging Bingham syncline. Extrusives, although present, contain no ore. The bulk of the non-porphyry ore in the district was found above the Midas thrust. The primary ores are found in three major types of deposits: concordant bedding fissures, crosscutting fissures, and replacement deposits. These deposits consist of both copper and lead-zinc ore bodies that contain various amounts of gold and silver. These are in places roughly zoned both laterally and vertically and have been mined for up to 10,000 feet outward from the center of the Bingham stock and up to 5000 feet vertically below the surface. Secondary ore was of minor importance and was found in and under the oxidized zone at shallow depths. Genetically the Bingham stock, the ores, and related phenomena have had a common source.

Jan 1, 1968

By V. L. Minear

This paper presents some of the problems encountered and solved by the construction industry during recent years while pressure grouting the foundation rock of dams. Pressure grouting has become "Standard Operational Procedure" and consequently many hundreds of thousands of bags of cement have been used for that purpose. There is nothing weird, mystical, or even particularly difficult about the basic idea. Holes are drilled in the rock and grout is pumped into them. This procedure is used to shut off the flow of water under the dam and to reduce the uplift on the dam. Like most other engineering and construction problems, the fundamental principle is simplicity itself, but some of the "minor details" are rather complex. When faced with the problem of actually forcing the grout into the rock, or keeping it there once it has been injected, an engineer frequently has need for all of the ingenuity and initiative that he has at his disposal. It is proposed to discuss these minor details at length, even at the risk of boring the reader. The difference between success and failure in a grouting program can well hinge upon some such detail that may not be fully understood. Pressure grouting is a method used to make good foundations from bad ones by plugging actual or potential passages within the rock through which water might escape and thereby diminish or even destroy the usefulness of the dam. In some special cases, pressure grouting has been used for the purpose of consolidating broken rock to increase its bearing power. Lacking this useful method, many of the dams constructed during recent years could not have been built. Most of the really excellent dam sites in this country have been utilized long ago. Consequently it becomes necessary to find methods of utilizing the less desirable sites. Pressure grouting plays a vital role in the methods developed. Engineers have learned the hard way, that the term "solid rock" is a misnomer. Solid rock does not exist to any considerable extent in nature. Practically all rock contains imperfections such as shrinkage cracks, bedding planes, joints, solution channels, folds, shear zones, crush zones, and the like. All these imperfections are weaknesses through which ground water is likely to flow. The function of rock grouting is to rectify these imperfections and make the rock as nearly "solid" as practicable. The location, direction, depth and number of grout holes to be drilled are important. Clearly, a hole must pierce fractures in order to serve a useful purpose, for grout cannot be forced into the rock itself. Were it possible to determine the pattern and extent of the cracks within the rock, it might be feasible to drill two or three strategically placed holes so as to make practicable the grouting of the whole integrated network of cracks from them. Such is not the case. While a study of the geology, surface indications, and drill cores is helpful in gaining an idea of subsurface conditions, in the final analysis, the seams must be located by trial and error methods. There can be no doubt that the closer the

Jan 1, 1949

By George A. Morrison

THE Columbia Chemical Division of the Pittsburgh Plate Glass Co. is at Barberton, Ohio, 35 miles south of Cleveland. For many years large tonnages of limestone have been brought to the Barberton plant from distant points. The stone is here burnt in vertical kilns, the resultant product then hydrated and the hydrated lime used in chemical processing. To eliminate the expense of these shipments, the company decided to investigate a limestone bed known to exist on company property at Barberton, where the stone is used. The bed lay at a depth of more than 2000 ft. and was known locally as the "Deep Lime." Chemical analyses of sludge from churn-drill holes made some years ago proved that the limestone was of sufficient purity to warrant diamond-drill exploration. Four diamond-drill holes were put down at well-spaced intervals, to represent fairly an area of four miles by one mile. Cores logged as to chemical and physical conditions were found to compare closely, and to corroborate the earlier evidence that the limestone was of superior quality for chemical use. A plant of 300 tons per hour was subsequently decided upon. SITE The yard at the chemical plant was already so congested that location of the projected mine within its area could not be considered. Eventually a site was selected 2 miles northwest of the plant, near the main line of the Erie Railroad. Here 412 acres were owned outright by the company and stone rights were obtained on 250 additional acres. This location required a transportation line of nearly 2 miles (8800 ft.), crossing two major highways, and to avoid interruption of deliveries to the plant, overpasses were planned. GEOLOGY The limestone in the immediate vicinity lies about 2200 ft. below the surface. Geologists* identify this stone as Delaware of Devonian age. It is overlain by 18 ft. of unconsolidated (sand and gravel), 100 ft. of water-bearing sandstone, and finally 2080 ft. of shale into which sandstone in thin layers is interbedded. The contact of shale and limestone is abrupt, flat-lying and very pronounced. Berea sandstone, often found at 520 ft., is absent, but Euclid sandstone was encountered, together with a seepage of oil and a small amount of methane gas. The limestone bed itself is 345 ft. thick, and overlies 200 ft. of gypsum. The lower part becomes dolomitic as it approaches the gypsum. A detailed study of the drill cores indicates that the upper 50 ft, are highest in lime and reasonably low in silica. The physical make-up shows several separating cherty layers. These occur at definite horizons and cause distinct partings, which become horizontal planes of

Jan 1, 1943

By D. W. Frommer, M. M. Fine

Mineral dressing research showed that iron concentrates of commercial quality could be produced from the Pea Ridge deposit near Sullivan, Mo. Magnetic separation and flotation, on a laboratory scale, yielded concentrates ranging from 60.0 to 71.4 pet Fe at recoveries of 89.9 to 97.6 pct. Early in 1957 St. Joseph Lead Co. announced discovery of three new centers of iron ore deposition in east central Missouri.' The discovery resulted from exploratory drilling in the vicinity of a magnetic anomaly or high. A deep hole, drilled into the Pre-Cambrian porphyry to determine the cause of anomaly, penetrated a magnetite-rich deposit.' The magnetic surveys that revealed the anomalies were begun by the Missouri Geological Survey in 1929 and were continued into the 1930's.3 At that time an area in Crawford County known as the Bourbon magnetic high was located. A second anomaly, similar in size and intensity, was discovered about six miles to the northeast in Franklin County in the vicinity of Sullivan. This area was not studied in detail until the early 1940's. To determine the cause of the anomalies, the USBM drilled four holes at the Bourbon site in 1943-1944.4 The most productive hole penetrated four mineralized zones having a total thickness of 127.5 ft. These zones contained magnetite in rhyo-lite porphyry at depths between 1600 and 2000 ft. Additional iron ore below 2000 ft was considered a possibility at the time. Some years later, the USGS, Missouri Geological Survey, St. Joseph Lead Co., and others cooperated in sponsoring an aeromagnetic survey of the Bourbon-Sullivan area which resulted in discovery of a third high, about eight miles distant at Pea Ridge. This deposit, with an estimated reserve of 50 to 100 million tons of iron ore, is considered the main find, although other orebodies in the same general area are of definite interest.' When this discovery was announced, St. Joseph Lead also revealed plans to exploit the deposit jointly with Bethlehem Steel Co. A new corporation, Meramec Mining Co., was established, and 1962 was set as the target date for completing physical plant.2 Annual production goals of 2 million tons of beneficiated and pelletized iron ore were proposed. Preparation of the site for shaft sinking was begun in June 1957. Orebody and Character of Samples: Drilling to date has established the Pea Ridge orebody as a crescent-shaped pipe about 300 ft wide. Some drillholes were bottomed at 2800 ft in very good iron ore.6 he orebody is predominantly magnetite, although hematite and a mixture of hematite and magnetite occur in the upper areas and peripheral walls. Drillhole cores representing ore from different areas and depths of mineralization were grouped into composites for testing. These composites consisted of: 1) medium grade mixed hematite and magnetite, 2) high grade mixed hematite and magnetite, and 3) high grade magnetite. The medium grade ore came from three holes with depths of i350 to 1900 ft. The high grade mixed hematite and magnetite cores came from the 1790 to 2812-ft interval of one hole. Partial chemical analyses of the three samples, given in Table 1, reveal that all are excessively high in phosphorus and sulfur, and sample 1 is

Jan 1, 1960

LIBERIAN ore has been called the richest iron ore mined in the world, and thus far, the output from the Liberian Mining Co.'s Bomi Hills mine has lived up to its reputation. Iron content has been variously given as 68.47 pct to 68.825 pct. A recent United Nations survey gave it first place, surplanting the previously top-rated Swedish product. The first shipment of Liberian ore to the United States reached Baltimore in June, 1952 and went into blast furnaces at Republic Steel's Cleveland plant, where excellent results were reported. The physical make-up of the ore was hard, dense lumps, free of fines and with ideal size distribution. The Bomi hills mines were scheduled to be in full operation by the end of 1952. At the close of 1951, 200,000 tons of ore had been delivered to Baltimore. Liberian Mining Co. states that production is about 90,000 tons of ore per month at present. Between 1200 and 1500 men are employed at the mine site, with about 25 pct of them Americans. The Bomi Hill project was financed with the aid of the Export Import bank, which loaned Liberia Mining part of the sum needed to initiate and put the development into production. No definite expansion plans are in the making but extensive diamond drilling is being pursued. Original estimates of annual production for Bomi Hills ran in the neighborhood of 1.5 million tons, but the figure is no longer applicable. Liberia's potential as an iron producing country has been known for a long time, but the physical obstacles in the way of large scale production were such as to prohibit even contemplation of the project. Until recent years, the only route from the mine site to Monrovia was a foot trail. Once to the coast, over swamps and unbridged rivers, the ore was still useless because of the lack of loading facilities. Transportation Solved One problem was solved with the completion of the artificial harbor at Monrovia. Harbor construction was well under way when the mine project began in 1948. The island location of Monrovia also made the building of a bridge across the St. Paul River necessary. The 980 ft reinforced concrete structure, accommodating railroad and vehicular traffic, was opened in 1949. Meanwhile, preliminary work on railroad construction started. Grading was completed quickly. In April, 1951, the first train made the trip from Monrovia to the Bomi Hills. About half of the cost of the entire project went into railroad construction. More than 2200 men, often forced to resort to primitive methods, were engaged in clearing a path through the heavy forests between the mine and port. Swamps were drained and filled, and bridges, including the William V. S. Tubman, named for the Liberian President, were constructed. At the port, a Robbins Conveyor Belt Co., orehandling plant was installed. Ships can be loaded from the stockpile at the rate of 3000 tons per hr and vessels need spend only one day in port. Liberian Mining is operating under an 80 year lease, giving the company exclusive mining rights to all minerals, except gold, platinum, and diamonds, within a 40 mile radius of Bomi Hills. The contract provides a fixed royalty to the Liberian Government of five cents per ton of ore extracted, and a premium -based on the New York market price for Bessemer-grade pig iron. The entire project started because an American,

Jan 1, 1952

By J. A. Snyder, W. L. Finlay

G. Edmunds—Solid solubility is considered to be of either the interstitial or the substitutional type. Is it possible, in a binary alloy as the simplest case, that some of the solute atoms are present in the normal lattice sites (substitutionally or filling lattice vacancies) while simultaneously others are in interstitial positionss One might even ask whether a distribution of the two types may be the normal situation. H. M. Meyer—Metastable states of interstitial atoms occupying vacant lattice sites possibly occur as well as of substitutional atoms squeezed in between regular matrix positions. However (as we know since Hume-Rothery), the solute atoms choose between the two kinds of solutions; consequently, every solute will be unequivocally either substitutional or interstitial in the equilibrium state of the solid solution. M. Balicki—In view of the fact that the authors apparently correlate the analysis of the alloys at the ingot stage with the properties exhibited at the testing stage, I would like to ask whether this is a fully justifiable procedure. In other words, how good are their determinations of solute concentration for correlating them with the mechanical properties. The answer to this question may explain some of the divergencies. Assuming good enough homogenization of the samples and exact determination of mechanical properties the position of the plotted experimental points will depend solely upon the accuracy of composition determination. If this is not accurate, say due to loss or pickup of elements during processing from the ingot to the testing stage, or due to a systematic error in the method employed for obtaining solute concentration data, the points will deviate from their true position and may align themselves along a different curve than the one expected. H. V. Kinsey—We have been studying the creep-rupture properties of titanium-base alloys at 1000°F. In the course of this work, anomalies in behavior of the alloys that would suggest that the material under test was becoming stronger as the test progressed have been observed. If this was so, the most likely explanation that we could think of was that the test bars were absorbing oxygen and nitrogen from the air during the test and were thereby becoming strengthened. In an attempt to determine the strengthening effect of absorbed oxygen and nitrogen the following experiment was conducted. A length of cold-rolled titanium was supplied by the E. I. du Pont Co. Two test bars, having a 1/4 in. diam gauge length, were prepared from this material. One bar was tested in the as-received condition. The second bar was heated in air at 1550°F for 100 hr and subsequently air cooled prior to testing. A testing temperature of 1000°F was employed. The results of these tests are tabulated in table 11. In the author's opinion, is it reasonable to assume that the bar that was exposed to air at 1550°F for 100 hr was stronger because it absorbed oxygen and nitrogen from the air during this heat treatment? W. L. Finlay (authors' reply)—Direct experimental evidence for or against Mr. Edmunds' interesting suggestion will probably never be available. It seems possible, however, that mixed interstitial-substitutional solid solution might well occur with interstitial elements. The less likely possibility of interstitial solution of a normally substitutional element like copper in aluminum was recently discussed at length by the

Jan 1, 1951

By R. G. Jones, W. L. Kinney, R. E. Schilson, R. S. Wilson, G. A. Clark, H. Suralo

This paper describes the field opeturluns at the Fry in situ combustion project in Crawford County, 111. Field operations may be divided into three phases—-preliminary engineering studies of 1960 and 1961, ignition, and, finally, operation of the test. The Fry combustion project was a pilot test of cocur-rent in situ combustion on a 3.3-acre inverted five-spot. In the summer of 1960, air injection tests were conducted using old wells in the area and a new air injection well drilled especially for the test. In the summer of 1961, four new oil wells were drilled on a 3.3-acre pattern for the pilot test. All old wells in the near vicinity of the pilot test were abandoned to preclude any possibility of gas escaping to adjacent formations. A compressor plant was also installed at the test site in 1961. Air injection tests and other engineering studies were made. At the conclusion of these tests, ignition was accomplished with a 40 kw electrical igniter. Operation of the Fry combustion test was little different from the usual oilfield operation with the exception of the high rate of air injection. No difficulty was found with the openhole completion. There were no unusual corrosion or emulsion problems until bottom-hole temperatures exceeded 150F. Four cores were drilled into the burned-out portion of the reservoir with no mechanical difficulties. INTRODUCTION A cocurrent or conventional in situ combustion test was conducted on the Fry unit of the Marathon Oil Co., in Crawford County, Ill. Besides testing combustion in the Fry type of reservoir, the test was intended to evaluate various operating procedures. This paper presents a discussion of the Fry combustion test field operations. The geology of the reservoir and the test performance are discussed in other papers.'.' HISTORY OF THE FRY UNIT The Fry unit consists of 11 leases totaling 337 acres in an area in which oil was originally discovered in 1906. Production from this reservoir, as from all Robinson sand reservoirs in the area, was very high during the first few years. As the dissolved-gas energy was dissipated, early attempts to retard the decline consisted of vacuum, air, and gas repressuring, and recently, most of the area has been subjected to water flooding. Following early air repressuring, the Fry waterflood unit was formed and water flooding initiated in July, 1952. In the area in which the Fry combustion test was conducted, a peripheral water flood of a 160-acre area was developed as shown in Fig. 1. Between 1956 and 1960, it became apparent that the water flood was unsuccessfd. In looking for a suitable site for an in situ combustion test, the Marathon Oil Co. selected the Fry unit as possessing those features most desirable for such a research project. Field operations associated with the Fry combustion test began in the spring of 1960.

Jan 1, 1966

By George A. Morrison

The Columbia Chemical Division of the Pittsburgh Plate Glass Co. is at Bar-berton, Ohio, 35 miles south of Cleveland. For many years large tonnages of limestone have been brought to the Barberton plant from distant points. The stone is here burnt in vertical kilns, the resultant product then hydrated and the hydrated lime used in chemical processing. To eliminate the expense of these shipments, the company decided to investigate a limestone bed known to exist on company property at Barberton, where the stone is used. The bed lay at a depth of more than 2000 ft. and was known locally as the "Deep Lime." Chemical analyses of sludge from churn-drill holes made some years ago proved that the limestone was of sufficient purity to warrant diamond-drill exploration. Four diamond-drill holes were put down at well-spaced intervals, to represent fairly an area of four miles by one mile. Cores logged as to chemical and physical conditions were found to compare closely, and to corroborate the earlier evidence that the limestone was of superior quality for chemical use. A plant of 300 tons per hour was subsequently decided upon. SITe The yard at the chemical plant was already so congested that location of the projected mine within its area could not be considered. Eventually a site was selected 2 miles northwest of the plant, near the main line of the Erie Railroad. Here 412 acres were owned outright by the company and stone rights were obtained on 2 50 additional acres. This location required a transportation line of nearly 2 miles (8800 ft.), crossing two major highways, and to avoid interruption of deliveries to the plant, overpasses were planned. Geology The limestone in the immediate vicinity lies about 2200 ft. below the surface. Geologists* identify this stone as Delaware of Devonian age. It is overlain by 18 ft. of unconsolidated (sand and gravel), 100 ft. of water-bearing sandstone, and finally 2080 ft. of shale into which sandstone in thin layers is interbedded. The contact of shale and limestone is abrupt, flat-lying and very pronounced. Berea sandstone, often found at 520 ft., is absent, but Euclid sandstone was encountered, together with a seepage of oil and a small amount of methane gas. The limestone bed itself is 345 ft. thick, and overlies 200 ft. of gypsum. The lower part becomes dolomitic as it approaches the gypsum. A detailed study of the drill cores indicates that the upper 50 ft. are highest in lime and reasonably low in silica. The physical make-up shows several separating cherty layers. These occur at definite horizons and cause distinct partings, which become horizontal planes of

Jan 1, 1946

By M. T. Simnad, C. E. Birchenall, M. H. Davis

The transport mechanisms previously proposed in wustite and hematite have been confirmed by movement of inert markers during the growth of these phases. By similar measurements the mechanism for magnetite has been determined. The rates of growth of multilayer scales on iron, magnetite and hematite on wustite, and hematite on magnetite have been measured. All rates are found to be diffusion controlled under the conditions of the experiments. MANY studies have been made of the rate of oxidation of iron in both the low temperature, film-forming region and the high temperature scaling range. The interpretation of the results has been greatly complicated by the formation of multi-layered scales containing the various phases of iron oxides. In most cases no attempt has been made to determine the composition of the scale and its dependence on time of oxidation in a quantitative manner. However, several recent studies'" have taken this variable into account. It is generally agreed that the growth of thick scales on iron follows a parabolic rate law for the increase of total thickness. In the thin film region agreement has been claimed with parabolic equations of various forms and with logarithmic equations. The discussion here will be concerned only with the formation of scales of considerable thickness, greater than several microns, although some of the conclusions may be applicable to thin films. A brief survey will be given of the solid phases of the iron-oxygen system, the stability of wiistite in bulk and in thin films, the relative densities of iron in the metal and oxides, and the kinetics of forma- tion of oxide scales on iron. New experimental results will be introduced at several points during the discussion, and an attempt will be made to formulate a mechanistic picture consistent with these observations. The experimental techniques are described in an appendix. Iron-Oxygen System Fig. la shows the iron-oxygen phase diagram. Wüstite ("FeO"): The lowest of the oxides has a NaCl type cubic lattice formed by close-packing of the relatively large oxide ions with the smaller iron ions arranged in the interstices. The ionic radius for 0' is about 1.3 A, while Fe++ has a radius of about 0.8A and Fe"' about 0.7A. Its range of existence on the phase diagram is very wide for an ionic material of this type and does not seem to include the stoi-chiometric composition FeO. These deviations appear to be well established as vacancies on iron lattice sites by the comparison of lattice parameters and densities for a series of compositions by Jette and Foote.4 The limits of the field are disputed, but the work which seems most reliable" indicates vacancies in from 5 pct to more than 12 pct of the iron sites. In order for the crystal to be electrically neutral, there must be electron holes which correspond to the formation of trivalent iron ions equal to twice the number of vacancies. Magnetite ("Fe³O4"): Considerable disagreement also exists in the literature about the stable range of the Fe³O4 field. Some diagrams show the Fe³O4 composition to be lower in oxygen than the formula indicates, but Schenck6 gives a diagram from the

Jan 1, 1952

By Norman Weiss, H. W. Kaanta

CUSTOM ores reach across the New Mexican mesa to American Smelting & Refining Co.'s new lead-zinc mill at Deming. The influx of ores justified increasing mill capacity from 12,000 tons per month to 20,000 tons per month with the installation of a second milling section. Deming mill has met a complex material handling problem with the successful instrumentation of modern machinery and knowledge. A tight, compact plant does a big job with the aid of the latest ore moving equipment. Location and Layout The mill is located three miles northwest of Deming in the tumbleweed covered valley of the Mimbres River, 30 miles north of the Mexican border. Deming has a population of 4000 and is about halfway between Lordsburg and Las Cruces and 54 miles southeast of Silver City. The AT&SF and the SP railroads and U.S. Highways 70, 80, and 260, cut across the mesa to the town. Asarco mill station is east of the AT&SF single track, and north of Deming. The nearly level terrain is covered with fine sand supporting only yucca and tumbleweed. Compacted gravel at depth affords excellent foundation bearing. The climate is semi-arid, but the district is underlain by water-bearing strata. Tailing disposal space is plentiful. The Deming site appeared favorable because of easy rail and highway access, central location in a mining district, excellent climate, plentiful water supply, space for all present and future requirements, and proximity to a town. The milling plant is a 250-ft square. The rail spur forms the west side; sampling plant, fine-ore conveyor and bins are on the east; track hopper, primary conveyor, and crushing plant lie on the south; and the mill building completes the north side of the square. Construction The mill site was chosen and the land purchased in 1,946 and 1947. Design began in 1948, and Stearns-Roger Mfg. Co. of Denver started construction in June 1949 completing work in April 1950. Construction is steel and concrete throughout, with main concrete floors supported on cellular steel beams. The building is covered by galvanized corrugated iron, attached to the frame by welded Nelson studs, and made dust tight at the joints with roofing paper and asphalt sealing compound. Crushing and Sampling Custom ores, delivered to the mill by railroad cars or trucks, are weighed on arrival. A Robbins car shaker dumps the ore into a 100-ton capacity steel hopper. Adjacent is a 40-ton truck hopper. Three 36-in. Pioneer apron feeders supply ore from the receiving hoppers to a 36-in. conveyor which runs to the crushing plant. A tramp-iron detector protects the primary crusher except when handling magnetite containing ores. A 2 ½ -in. spaced grizzly precedes the primary Traylor 24x36 in. jaw crusher set at 4 in. A Symons 4-ft cone crusher in closed circuit with 48x78 in. Robbins Gyrex screen completes crushing to 5/8 in. The discharges of both crushers drop upon a common conveyor, which, after gaining sufficient elevation, transfers ore to a return conveyor. This return conveyor passes under a suspended magnet and over a magnetic head pulley to the Gyrex screen. Screen undersize is conveyed by a 20-in. belt to the sampling plant. Crushing rate varies from 60 to 90 tons per hour. Ores containing magnetite and pyrrhotite nullify the magnetic detector and overload the magnets

Jan 1, 1952

By C. M. Shigley

Tan record of the largest magnesium plant in the country utilizing sea water as a primary raw material stands as another victory in the struggle for large-scale production of pure chemical elements from the oceans. Bromine was the first element to be economically and commercially recovered when, in 1933, a six million pound per year unit was built on the Atlantic Coast near Wilmington, North Carolina, by the Ethyl-Dow Chemical Co.1 The bromine was reacted with ethylene to produce ethylene dibromide, a necessary associate of tetraethyl lead in ethyl antiknock fluid. Within eight years that plant was doubled and redoubled, and another large unit was put into operation at Freeport, Texas, taking bromine from the Gulf of Mexico. In 1940, in fortunate anticipation of the impending demand for magnesium and the limitations of the production from natural brines, the Dow Chemical Co. turned again to the sea, and designed and erected a plant at Freeport to produce 18,000,000 lb. of magnesium per year from sea water.2 In March 1941, two months after the new plant had been put into successful operation, construction of an 18,000,000-lb. Government-financed addition was started. Late in 1941, as a part of the $400,000,000 defense program intended to produce 600,000,000 t0 700,000,000 lb. of magnesium per year, Dow was asked to build and operate for the Government a 72,000000-lb. plant near its original plant at Freeport. Within a few days after the Japanese made their attack at Pearl Harbor, preparation of a site was started at Velasco, Texas, for the construction of the Texas plant of the Dow Magnesium Corporation-the largest known magnesium plant utilizing sea water as its raw material. Less than six months after the first piling was driven, urgently needed magnesium was in steady production. Five months later, the plant had exceeded its rated capacity. It remained above rated production until the general magnesium curtailment was applied to Government-owned plants in September 1944. Credit for the construction and operation record of the Dow magnesium plant must be divided among the efforts of a very determined group of men, an extremely favorable location, and a simple process. It is with the two latter aspects of the plant that this article will deal. The site for the new enterprise was chosen near Velasco, Texas, on property bordering the Brazos River at a point approximately 6 miles inland from the original magnesium plant and y miles inland from the Freeport Harbor on the Gulf of Mexico. This location was far enough away from the operating units to reduce both interference from construction and the vulnerability of closely bunched manufacturing operations to the then feared air attack. Yet the distance inland was not too great for the economical construction of a barge canal from the harbor to serve both the transportation of raw

Jan 1, 1945

By K. P. Gupta

The Cb-rich boundary of the (Cb,Al) a phase field at 1250OC is near 41 pct Al. The Al atoms tend to occupy the C. N. 12 sites in this structure. A homologous (Ta,Al)a phase was identified. No a phase was found in the Mo-Al system at 1200°C. The first binary o-phase with a non-transition element as a major component was found1,2 in the Cb-Al system. The composition of this phase was reported2 as approximately 34 at. pct Al, based on X-ray diffraction patterns taken of alloys in the as-cast condition. Further study of the composition of this o-phase, therefore, appeared desirable. Since Si was previously found3,4 to occupy preferentially the lowest C.N. sites (I and IV) in the a phase, and preliminary resultsa indicated that Al may show similar ordering, one of the aims of the present work was to obtain more complete information on ordering in (Cb, Al) o. Among the binary systems of Al with Ti-, V-, and Cr-group elements, the Ti-Al, Zr-Al, V-Al, and Cr-Al systems are known to comprise no o-phase. In the present work a Ta-Al and a Mo-Al alloy were studied in an effort to find additional o phases with Al as a major component. EXPERIMENTAL PROCEDURES AND RESULTS An alloy with the intended composition of Ta + 40 at. pct Al was prepared by arc melting in He atmosphere. In both the as-cast condition and after annealing for 10 days at 1250°C and quenching in cold water this alloy consisted of two phases, as seen in the X-ray pattern and the microstructure. One of these phases was identified as the o-phase; the observed and calculated d-spacings are shown in Table I. The lattice parameters of this o-phase are a = 9.972 A, c = 5.214 A and c/a =0.5228, as determined from a Debye-Scherrer pattern using Fe K a radiation. The d-spacings for the unknown second phase are given in Table 11. The alloy contained approximately 25 pct of the unknown phase after annealing, as estimated on the basis of microscopic examination. A Mo-Al alloy was prepared by arc melting, with an intended Al-content of 35 at. pct. The alloy button was annealed for 7 days at 1200°C and water quenched. The X-ray pattern of the alloy in both the as-cast and the annealed state showed the reflections of Mo3Al (Cr30 type structure) and an unknown phase different from a. Six Cb-Al alloys were prepared in the composition range 30 to 50 pct Al. All alloys were arc melted in He atmosphere. After annealing for three days at 1175oC in evacuated silica capsules and quenching in water, the alloys with 30 to 40 pct Al contained three phases, namely the o-phase, Cb3Al (Cr3O-type structure) and an unknown phase. The alloys with more than 40 pct Al contained two phases, namely, what appeared metallographically, the o-phase and the same unknown phase. In the alloys containing less that 38 pct Al, the unknown phase was not present after annealing for 4 days at 1250°c,

Jan 1, 1962

By Patricia J. Rand, Kailish Narayan

Atlantic Richfield Co. began operating a commercial uranium solution mining project in April 1975, in Live Oak County, Tex., 10 miles southwest of the town of George West. The operation is designed to produce 250,00 lb of U308 per year and is jointly owned by Atlantic Richfield Co., Dalco, and U.S. Steel. The proprietary process employed in this operation consists of injecting an alkaline leaching solution into the ore-bearing formation through a pattern of injection wells. The uranium-bearing solution is then removed through producing wells using submersible pumps in central production wells. The produced solution is pumped through a pipeline to the plant area where the uranium is extracted. The barren solution is refurbished and returned to the pattern area for reinjection. The injection field and plant site are located in the drainage of Spring Creek, a small intermittent stream tributary to the Nueces River. Land use in the area is primarily agricultural cattle ranching and farming---but several producing gas fields are present in the areas as well. A nine month enviromental baseline study was conducted on the property beginning in Feb. 1975. Plants and animals of the Clay West area were identified and representative terrestrial and aquatic communities were analyzed. Physical and chemical parameters of the soils were described and analyzed. The surface and underground waters were analyzed chemically; radionuclides, heavy metals, nutrients, and pesticide concentrations were measured in the creek sediments; bacteriological measurements were made in creek water and sediments; radionuclide and chemical levels in plants and animals, both terrestial and aquatic, were measured. These studies, though not required by existing, state or federal laws, were considered necessary to assess the existing conditions before operations began on site. The in-place leaching technique for uranium mining eliminates the enviromental disturbances associated with open pit or underground mining. No grinding and crushing of ore is needed, nor are large tonnages of waste tailings produced. Surface subsidence is not expected since less than 5 lb of uranium is present per ton of rock and even complete removal of such small amounts should not cause subsidence. Solution mining has fewer environmental problems than conventional mining. Members of the Texas Water Quality Board recognized the differences which exist and have recently formulated new environmental control procedures which apply specifically to solution mining. Some of the solution mining activities which are of particular concern are discussed in the following pages. Process Description The produced uranium-bearing solution is pumped through a pipeline from the pattern area to the plant area. The first pattern area consists of a nest of 125 fluid injection, production, and monitor wells [(Fig. 1)]. Injection wells have 4-in. casings and are spaced 50 ft apart on a square grid. Production wells have a 6-in. casing and are located in the center of each square. A block flow sheet of the plant is given in [Fig. 2]. The produced solution goes through parallel trains, each consisting of a carbon column and an ion exchange column in series. The carbon column removes any sand present in the produced solution and the ion exchange column extracts the uranium. The depleted solution is treated with chemicals and returned to the field for reinjection. The uranium retained in the ion exchange column is removed periodically with a sodium chloride solution. Uranium-bearing solution from the ion exchange column is passed through a charcoal column for removal of impurities and then to a precipitation tank where the uranium is precipitated as yellowcake slurry. The yellowcake slurry is clarified, filtered and dried to produce a granular yellowcake product. Environmental Considerations Sources of waste solutions to storage reservoirs, the backwash reservoir and atmospheric discharges are shown in the block flow sheet [(Fig. 2)]. These waste solutions pose a relatively small problem and are adequately controlled by conventional means. There is one area, however,

Jan 1, 1978

By W. Rostoker, H. Nichols

It has been demonstrated in previous work1'2 that wetting of aluminum alloys by liquid mercury can cause fracture to occur with substantial suppression of prior plastic flow. This has been interpreted as the action of a critical liquid species in reducing the cohesive strength of a stressed solid at sites of potential crack nucleation. In this way the critical transverse stress for fracture nucleation is reached at much lower stresses than is normally the case. The stresses for both fracture nucleation and fracture propagation are depressed by the same mechanism. In so doing the plastic-energy component of fracture energy is reduced to a level which is of the same order of magnitude as the surface, interfacial, or cleavage energy. Recent work2 has illustrated the influence of dispersed precipitates, cold work, and combinations of these on brittle fracture associated with plastic strains of the microyield order of magnitude. This has been rationalized in terms of the contribution of internal microstress fields to the stress magnifications at points of obstruction of active slip bands in a stressed metal. The presently reported studies on an Al-4-1/2 pct Mg alloy amplify this subject by introducing thermal-mechanical conditions which can produce strain aging. As amply demonstrated by Phillips, Swain, and borall, the tensile behavior of aluminum alloys containing magnesium reveals a yield-point elongation and successive discontinuous elongations over the whole plastic-strain range. This gives a stepped or serrated character to the stress-strain diagram. The yield-point elongation is not temperature-dependent. On the other hand, the discontinuous extensions in the plastic-strain range are gradually suppressed by lower temperatures of testing. At -78"C, only the yield-point elongation persists. The yield-point elongation itself can be suppressed by rapid quenching to room temperature from an annealing temperature of 500°C. The argument presented by Phillips et 1. and Cottre114 is that the yield-point elongation derives from surmounting at a critical stress the restraint to slip by grain boundaries which have been reinforced by appreciable magnesium-atom segregation. The serrated character of the plastic-strain range is the result of rapid strain aging during the test. This is made possible by the inevitable proximity of magnesium atoms to any dislocation line. In the Al-4-1/2 pct Mg alloy there is one magnesium atom for every twenty-two aluminum atoms and, with a coordination number of 12, a magnesium atom is on the average only about two atomic distances from any given lattice site. Rapid strain aging is therefore a reasonable expectation. A study of mercury embrittlement of the Al-4-1/2 pct Mg alloy (commercial designation 5083) provides an opportunity to relate the interplay of grain size, grain boundary restraint to slip and strain aging in the brittle-fracture process. One lot of commercial sheet material of 0.125-in. thickness was used for all of the tests. The specimen shape and test procedures used were the same as those described in a previous publication.2 A range of grain sizes between 0.0057 and 0.0125 mm was produced by various combinations of plastic prestrain and annealing. The coarsest grain was somewhat elongated in shape. In this case the measurement was taken in the direction transverse to the axis of tension as more meaningful to a brittle-fracture process. In the annealed condition, specimens wetted with mercury failed with zero permanent elongation at stresses slightly below the normal yield point, i.e., stresses at 0.05 to 0.2 pct strain. Since this occurs before yield-point elongation can begin, fracture derives from slip contained within individual grains and restrained from propagating across grain boundaries. No significant difference in wetted fracture stress was observed between specimens which had been water-quenched or furnace-cooled from the annealing temperatures. This signifies that the degree of magnesium segregation at grain boundaries

Jan 1, 1964

By AIME AIME

COMPLETION of the Rainbow Bridge across the Niagara River and Gorge this fall marks a new page of achievement in the annals of bridge- building. Symbolic of the amity between two great nations, the new bridge provides an additional gateway across the most peaceful border in the world. Ground was broken for the project May 16. 1940, at a site close to that formally occupied by the Falls View Bridge which was destroyed by a record ice jam in 1938. At this point, about 2000 ft. deep and 1000 ft. downstream from the American Falls, the gorge is about 200 ft. deep and 1000 ft. wide. The great steel arch of the bridge has a span of 950 ft. and rises from its supporting abutments on the American and Canadian sides of the river to the level of the top of the gorge. This is said to be the longest hingeless arch in the world.

Jan 1, 1941