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By H. L. Lovell, L. H. E. Weyher

Cyclones have been used successfully in the mineral industries to solve solid-liquid as well as solid-solid separation problems in the processing of fine particles. Substantial information is available about the operation of cyclones as thickeners, classifiers, and concentrators using a dense medium. However, very little is known about the operation of the cyclone as a fine coal concentrator not using dense medium. This application of the cyclone, namely to wash fine coal in water, requires that classification phenomena be minimized in order to arrive at an effective separation of the high density ash and sulfur-bearing mineral particles from the low density coal particles over a wide particle size range. The authors have investigated the role of feed pressure, orifice diameters, and vortex-finder length in the cyclone washing of fine coal (--1/4 in.) in water. The results of this investigation show that cyclone washing of fine coal in water is an effective unit operation particularly capable of reducing the inorganic pyritic sulfur content. The combination of hydrocyclones with complimentary equipment such as Sieve bends, shaking tables, and flotation units appears to be especially promising and may ultimately yield fine coal processing systems that could approximate the high recovery efficiencies of today's coarse coal cleaning circuits. In the future, fine coal beneficiation can be expected to receive even greater research emphasis as a result of increasing sulfur restrictions on all major coal markets. In a previous paper, work, conducted at the Pennsylvania State University, on the hydrocyclone washing of fine coal was discussed.' The initial evaluation based on that wo-rk demonstrated the feasibility of hydrocyclones as fine-coal cleaning devices, and in that previous paper selected test data were presented that showed in principle how product yield and assay respond to variations of the major cyclone operating variables. The present paper reports in greater detail on the findings and presents a comprehensive evaluation of the data as follows: (1) Hydrocyclone throughput rates were related to feed pressure and other variables by regression equations. These equations are compared with other capacity-vs.-pressure drop expressions taken from the literature on classification cyclones. (2) The flow ratio was found to be the most important variable for the separation of the solids. Control of this ratio through various cyclone operating parameters is discussed. (3) The data on the product yield as well as the ash and sulfur assays from the tests were evaluated by means of correlation and multiple regression analyses. Because size-classification phenomena cannot be suppressed completely in hydrocyclone washers, product yield and assay data are regressed against cyclone operating variables separately for different size classes. These equations then reveal how the interactions of the cyclone operating variables vary in terms of the separation for different size classes. (4) Density partitions from additional tests were analyzed by supplementing product-size analyses with sink-float analyses of the separated product size classes. The evaluation of these data show how classification phenomena affect separation by density. The results demonstrate in particular the feasibility of the hydrocyclone washer for removing pyritic sulfur from fine coal. In addition to these specific findings, the investigation points up the value, in general, of using hydrocyclone washers in combination with unit operations such as screening, table concentration, and flotation. In order to make optimum use of the hydrocyclone washers and work out the most effective combination of unit operations, it is important to have careful flowsheet analyses corresponding to the given feed and product requirements. Analyses of this kind are now possible by means of computer simulation of flowsheets and other operation research tools. INTRODUCTION Before proceeding with the detailed treatment and evaluation of our results, it will be useful to review the fundamental aspects of cyclone separators and also restate the experimental procedures and data handling employed in these studies. Review of Cyclone Fundamentals: AS shown in Fig. 1, the basic components of cyclones commonly used

Jan 1, 1970

By Y. L. Su, R. Stefanko, Y. J. Wang

This chapter describes a new approach to the solution of stress distribution around underground openings utilizing the finite element method and employing stochastically simulated rock properties. It is well-known from extensive laboratory tests that the properties of rocks, e.g., Young's modulus and Poisson's ratio, are not single-valued but form some distribution. If the scatter of test data is attributed to the variability of the rock itself rather than due to an inadequacy in test procedure, then stress solutions have to consider these variations. Utilizing this basic philosophy, the present study was initiated. A long circular opening subjected to plane strain in a hydrostatic stress field was chosen as a specific example to illustrate this approach. The technique adopted in solving stress distributions was based on the finite element method. This method is essentially a generalization of standard structural analysis procedures in which the continuum is idealized as an assemblage of "elements," interconnected at a finite number of nodal points. It is capable therefore of handling different material properties for individual elements in the model, if desired. In this study, each individual element was assumed to be isotropic, homogeneous, and elastic. However, values for Young's modulus and Poisson's ratio were randomly varied from element to element according to an assumed frequency distribution.

Jan 1, 1970

By M. Murakami, Y. Murakami, O. Kawano

The formation and growth of Guinier-Preston zones in Al-Zn alloys containing 4.4, 6.8, 9.7, and 12.4 at. pct zn have been studied by the X-ray small-angle scattering method. Particular attention was paid to the effects of small amounts of third elements silver, silicon, and magnesium on the formation and growth of G.P. zones. It was noticed that an appreciable number of G.P. zones were formed during the course of rapid cooling and that the size, volume fraction, and number of these G.P. zones were influenced by the existence of the third elements. During subsequent aging it was also found that the addition of both silver and silicon lowered the temperature for the growth of G.P. zones, whereas the addition of magnesium raised it. These results were explained in terms of the mutual interactions among zinc atoms, vacancies, and the third elements. A number of studies on the formation and growth of Guinier-Preston zones in Al-Zn alloys have been reported.1-4 Panseri and Federighii have found that the initial stages of zone growth take place at temperatures as low as around -100°C. For investigation of the mechanism of the initial stages of zone growth, growth studies must be carried out at low temperatures. In order to investigate the possibility of the formation of G.P. zones by the nucleation mechanism or the spinodal decomposition during quenching which was reported by Rundman and Hilliard,5 the examination of the as-quenched structure must be performed. In this paper the investigation of the early stages of the formation and growth were determined by means of the X-ray small-angle scattering method. With this technique, change of X-ray scattering intensities was measured while quenched specimens were heated slowly from liquid-nitrogen temperature to room temperature. At as-quenched state and after heated to room temperature, investigation of zone size, volume fraction, and zone number per unit volume was carried out. Measurements on these specimens yielded information on the early stages of zone formation and growth. Measurements were made also on specimens quenched to and aged at room temperature. From these measurements the previously reported model6 for the later stages of growth is confirmed; namely, the larger zones grow at the expense of smaller ones. Three elements, silver, silicon, and magnesium, were chosen as the third elements for the following reasons: Silver. In the binary A1-Ag alloy the spherical disordered 77' zones were observed immediately after quenching.7 Therefore, in the Al-Zn-Ag alloys, it is suggested that silver atoms might induce cluster formation during quenching. Also, since the migration energy of the zinc atoms was found to be raised by the addition of silver atoms,' silver atoms may have a great effect of the zinc diffusion, especially during low-temperature agings. Silicon. The effects of the addition of silicon atoms were found to be marked, especially at low-tempera-ture aging. In the binary Zn-Si system, no mutual solid solubilities between silicon and zinc9 and no in-termetallic compounds10 are reported to exist. Shashkov and Buynov11 investigated the behavior of silicon atoms in Al-Zn alloys and showed that silicon was not in the G.P. zones. The interaction between silicon atoms and vacancies is strong enough to increase the quenched-in vacancy concentration.* Magnesium. Magnesium atoms are reported to trap quenched-in vacancies and after much longer aging times these trapped vacancies will become free and act as diffusion carriers.13 Therefore at intermediate aging times, the diffusion of zinc atoms in Al-Zn-Mg alloys will be slower than in the binary Al-Zn alloys, whereas at longer times zinc diffusion will become faster. EXPERIMENTAL PROCEDURE The alloys used in this investigation had compositions of 4.4, 6.8, 9.7, and 12.4 at. pct Zn with or without 0.1 and 0.5 at. pct Ag, Si, or Mg. The alloys were prepared from high-purity aluminum, zinc, silver, silicon, and magnesium, with each metal having a purity better than 99.99 pct. The analyzed composition of the specimens is given in Table I. The measurements of the X-ray small-angle scattering were carried out with foils of 0.20 mm thick. The change of the scattering intensity was always measured at the fixed scattering angle of 20 = 2/3 deg. This angle exists nearly on the position of the intensity maximum. The value of the interparticle interference function14 which has large effect in this range of angles may not change abruptly in the case of the spherical shape of small zones. Therefore, from the above considerations, it is concluded that an increase of the intensity measured at this constant angle corresponds to an increase of the average radius and volume fraction of G.P. zones. The specimens were homogenized at 500°, 450°, and 300°C for 1 hr in an air furnace. For the study of the formation and growth at low temperatures, the foil

Jan 1, 1970

By A. Tonejc, A. Bonefacic

As can be seen from the phase diagram A1-W1 the equilibrium solubility of tungsten in aluminum is practically nil at room temperature. By quenching from the liquid state (50,000°C per sec), Varic, Burov, and Kolesnicenko2 obtained A1-W solid solutions up to 0.15 at. pct W. The quenched alloys were in the form of foils, 0.2 to 0.3 mm thick. Considering the results of Duwez and Willens,3 it is obvious that this thickness, which makes impossible a sufficiently rapid quenching, was the main reason for the relatively low content of tungsten dissolved in aluminum found by varic.2 he present note shows that the metastable solubility of tungsten in aluminum can be appreciably extended in aluminum-rich A1-W alloys. The quenching technique and the procedure employed for the preparation of the alloys have been described previously.475 The resulting quenched flakes varied in thickness from 1 to 20 µm from experiment to experiment. However, the measurements of the lattice parameters were carried out only with flakes thinner than 5 µm. The areas of quenched flakes were between 0.1 and 15 mm2. The quenched flakes were placed into a 0.3-mm glass capillary tube which was then mounted in a 114.6-mm-diam Debye-Scherrer camera. Straumanis asymmetric film position and nickel-filtered CuKa radiation were used. The lattice spacings were computed taking X(CuKa1) = 1.54050A for resolved and ?(CuKa) = 1.54178A for unresolved doublets. All specimens were rotated at room temperature, 26o +2°C. The lattice parameters were estimated from extrapolation against the Nelson-Riley function. It was estimated that the error in the lattice parameter of the measurements on a single film lies within +0.0004A for lower and about +0.001A for higher concentrations of tungsten. The lattice parameters of the metastable solid solutions A1-W are plotted vs the concentration of tungsten in Fig. 1 together with the parameters measured by previous investigators.' Each point of the present measurements represents a determination of the lattice spacing on different quenched flakes, for a given concentration of tungsten. With experimental accuracy, the lattice parameters of the metastable solid solutions fall on the straight line passing through the already known data.' As estimated from the uncertainties in the lattice spacings of the solid solutions, the alloys were homogeneous within 0.1 at. pct W. The solubility of tungsten in aluminum-rich A1-W solid solutions obtained by a very rapid quenching technique is increased to about 0.95 at. pct W. This value is 6 times greater than the amount known up to now. -he lattice parameters of the resultant aluminum solid solutions with higher concentrations of tungsten than 0.95 at. pct W did not remain constant AUGER electron spectroscopy has been used to clarify the role of impurities in the embrittlement of AISI 3340 steel. Analysis of fracture surfaces has shown that the embrittled condition is correlated with appreciable antimony segregation at grain boundaries. The low temperature (400" to 600°C) temper embrittlement of low alloy steels containing various combinations of Cr , Ni , Sb , Mn , P , Sn , and As has been examined extensively for many years. General reviews of the area have been made by McMahon1 in 1968, LOW' in 1959, woodfine3 in 1953, and Holloman4 in 1946. Recent work by Low, Stein, Turkalo, and LaForce5 has done much in separating the alloy and

Jan 1, 1970

By W. R. Kanne, P. R. Strutt, R. A. Dodd

A study has been made of the creep behavior of ß-NiAl of stoichiometric composition in the temperature range 475" to 775°C. Single crystal tensile specimens were deformed under a constant applied load. From slip line studies and tensile axis rotations it was concluded that the crystals deformed by pencil-glide on (100) and (110) planes with a (100) slip direction. Electron microscope thin-film studies showed evidence for profuse cross-slip, and the dislocation Burgers vector was determined to be (100). There was no tendency for the dislocations to lie in definite slip planes, although a strong alignment of segments of edge dislocations was frequently seen. The activation energy for creep in the temperature range 475" and 775°C was judged to be much lower than that for creep at temperatures above 775°C. It is possible that the rate-controlling process is the thermally activated cross-slip of screw dislocations. In recent years considerable interest has developed in the possible use of high-melting-point intermediate phases for high-temperature applications necessitating good creep resistance. Ordered alloys such as Ni3A1, modified by alloying additions, have received particular attention, culminating in the recent development by Pratt and Whitney of single crystal turbine blades.' The intermediate phase NiAl has considerable theoretical interest from a creep standpoint because not only is it ordered up to the melting point (-1650°C at stoichiometry) but it contains a high concentration of structural vacancies on the aluminum-rich side of stoichiometry. These vacancies are known to exert a strengthening effect under some conditions,' but in addition they might be expected to affect high-temperature creep rates through dislocation climb. The present paper deals with the slip line and dislocation structures developed during creep of stoichiometric NiAl between 475" and 775C, and with possible attendant creep mechanisms. MATERIALS AND TEST TECHNIQUES NiAl ingots of stoichiometric composition were prepared by induction melting 99.996 pct A1 and 99.98 pct Ni (kindly provided by the Kaiser Aluminum Co. and the International Nickel Co., respectively) in 100 cc pure alumina crucibles in a helium atmosphere. No chemical melting flux was used in order to avoid con- tamination of the alloy. Each ingot was slowly direc-tionally solidified to avoid porosity and to produce very large grains up to 2 in. in length. In this way, ingots were obtained which were suitable for sectioning into single crystal creep specimens. Chemical analysis indicated that all alloys were within the range 49.6 0.3 at. pct Ni. For the present investigation, identical rectangular single crystal blanks were cut vertically from one particularly large crystal in an ingot using a series of three diamond cut-off wheels with appropriate spacers. Thus, all sliced crystals had the same orientation with the tensile axis parallel to the long side of the rectangle; the initial orientation of the tensile axis is shown as S, in Fig. 1. The blanks were homogenized at 1250 to 1300°C for 48 hr and subsequently cooled slowly to room temperature. A gage length of rectangular cross section and about 0.75 in. in length was prepared on each specimen using an electrolytic lathe and a dilute nitric/phosphoric acid electrolyte. The gage length cross section was 0.250 0.0005 in. by 0.040 ± 0.0005 in. Holes to accommodate tensile grips were electrolytically machined using a rotating acid jet. After creep testing, this same technique was used to cut discs for transmission electron microscopy. Thus, all shaping was done electrolytically, the only exception being that (122) sections were spark-machined from some speci-

Jan 1, 1970

By Thomas Adair

Moderator-Thomas Adair is now a tunnel consultant with Perini Corp., Spring Lake, N.J. He has had 40 years experience in tunnel and shaft-sinking work in both soft and hard rock, as well as subaqueous rock. He has used moles in various locations and has traveled around the world studying the problems. SOME BRIEF COMMENTS ON "MOLES" by Thomas Adair We of the Perini Corp. have been, over the past 15 years, in the forefront of the battle to develop the mechanized miner. We have contributed much to pioneer, develop, and promote the use of the mining machine. Our money and talent have not been spared in this effort. However, we are sorry to say that as of the present time (1968), at least from the economic stand- point, this effort has not been very rewarding. But, I must say to those who are presently involved in the work of building mining machines, do not be discouraged. There is money in it. We of Perini Corp. know because we put it in there. It has been estimated that during the next 15 years, some $20 billion will be spent on underground excavation; more than 13 thousand miles of sub- surface tunnels will be excavated throughout the nation. An aggressive, properly structured research and development effort would produce, within the next five or ten years, a better excavation technology and improved boring system capable of reducing present costs drastically, with a resultant great saving. The time for this effort is now, but where the enabling money for this effort will come from, I have no idea. Machine builders should be encouraged to design and develop a shield- type boring machine capable of continuous mining through varying types of ground or rock by incorporating the possibility of making minor modifications such as change of bit type, power package, etc. Such a machine could

Jan 1, 1970

By D. Hartley

United States Steel Corp's. Minntac mine is located at Mt. Iron, Minn. on the Mesabi Iron range. The taconite pit is two miles wide, with a maximum depth of 170 ft. Millions of tons of crude ore, waste rock, and surface overburden are handled annually at the mine. All crude ore plus some of the lower-grade rock are rail-hauled; other materials are trucked. Length of rail haul averages 3.5 mi, with a lift of 140 ft. The maximum grade against the load is 1 ½ %. Nine 1200 hp diesel-electric locomotives handle trains of 40-and 50-cu yd side dump cars in crude ore and lower-grade rock service. In addition to this continuous operation, locomotives handle coarse tailings disposal and switching duties on an intermittent basis. All railroad equipment operates under the supervision of a mine control foreman through voice radio communication. The pit foreman also has this frequency available, quickly accommodating any changes in operation that may be required.

Jan 1, 1970

By Robert Walker

The win theme of this session is Unique Material Handing Systems. The theme was selected because of two major factors. 1. Accomplishments of unique character manage to attract interest regardless of their age. 2. There is much to be learned from pioneering efforts of the past as they are the stepping stones to technological development. Thus, 2-1/2 years after completion, the engineering feat of Oroville Dam still looms large let us take a close look at this project to see what made it unique. To begin with, it established a number of firsts: At 770 feet it was the highest earth fill dam in the world. At $121 million dollars, it was the largest ever United States construction project (Civil). At 80 million cubic yards it had the largest earth volume of any dam in the world. The extensive use of belt conveyors for this application had never before been tried. The use of a high capacity bucket wheel-excavator with shiftable belt conveyors had never before been utilized as a con¬tractor's tool. The principal of the "integral train" was applied most effectively whereby up to 220,000 tons of material-was transported daily some 14 miles. To achieve optimum economics a number of technical breakthroughs were necessary. The suppliers of major commercial components worked hand-in-hand with system engineers to develop new machinery necessary for the highly mobile characteristics of the systems, viz., single pulley drives delivering 2000 horsepower, 1000 horsepower right-angle shaft-mounted reducers, across the line starting of 1000 horsepower squirrel cage motors, 10 miles of steel chord conveyor belts with belt tensions up to 150,000 pounds, aircraft-type disc brakes, hydraulic take-ups, train loading at a rate of 25,000 tons per hour, automatic train indexing for rotary dumping at 10,000 tons per hour, roll-over car dumping without uncoupling cars, shifting 7500 ft. long conveyors up to 300 feet laterally without disassembly. These are some of the superlatives that have made the Oroville Dam project unique. The measure of its success is demonstrated by the results.

Jan 1, 1970

By T. T. Gronfors

The excavation process and equipment used for excavation join firmly each other. By changing the process or method, the construction of equipment may be altered essentially. It has been possible to develop a wholy new type of hydraulic boom for tunnelling, when only parallel drilling instead of V-cut is used. The utilization of controlled blasting has made small holes more desirable. So the controlled blasting has had an influence on the selection of drill steel equipment and in this way also influenced the construction of the equipment.

Jan 1, 1970

By N. S. Bornstein, M. A. DeCrescente

ThE nickel and cobalt base superalloys employed in gas turbine engines under some conditions' oxidize at an accelerated rate when exposed at elevated temperatures to atmospheres containing minor quantities of sea salt. It is generally agreed by investigators in the field that the major steps comprising this phenomena of accelerated oxidation, also called hot corrosion or more commonly, sulfidation, are a) a slag composed primarily of Na2S04 is formed on turbine components, b) the protective oxide scale is rendered ineffectual, c) the slag reacts with. the substrate to form metal sulfides, and d) the substrate is rapidly oxidized. Sodium sulfate, a minor constituent of sea salt, is formed within the gas turbine engine from the reactions between NaC1, the major constituent of sea salt, and the oxides of sulfur.' Depending upon concentration, engine compression ratio, and temperature, the Na2S04 will be present in the gaseous or condensed state. It has been determined that in order for sulfi-dation to occur the Na2S04 must be present in the condensed state.' Although a number of sulfidation mechanisms have been postulated, there is no consistent explanation of oxide scale breakdown and subsequent catastrophic oxidation. Some investigators believe that after oxide scale breakdown, the Na2SO4 reacts with the substrate to form lower-valent sulfur compounds. The accelerated rate of oxidation is due to oxidation of a nickel-sulfide phase." Other investigators believe that sulfur from the fused salt reacts with chromium in the alloy to form chromium-rich sulfides; thereby depleting the alloy of an element which imparts oxidation resistance.3,4 This publication will demonstrate that the accelerated rate of oxidation associated with sul-fidation is due to interactions between Na20, a con-stituent of NazSO.,, ancl the substrate. The aim of this study was to separate and determine the effect of compounds of sulfur and sodium on the oxidation kinetics of various nickel-base superalloys, in order to elucidate the sulfidation mechanism. The work reported herein is sponsored in part by the Naval Ship and Development Center-Investigation of EXPERIMENTAL PROCEDURE The nickel base alloys B-1900, U-700, and Waspaloy were chosen for this study. The nominal compositions are presented in Table I. The specimens, approximately 1 in. by 1 in. by 0.060 in. received in the "as cast" condition were polished with 600 grit emery, washed, and rinsed with acetone immediately prior to oxidation experiments. Sulfida-tion attack was duplicated in the laboratory by apply-ing a saturated aqueous solution of Na2S04 onto the al loy substrate and subsequently exposing the specimens in oxygen at elevated temperature. The method of Na2S04 application is described elsewhere in detail.6 In another set of experiments the affected substrate microstructure associated with sulfidation was reproduced free of the normal oxide scale, by reacting and diffusing elemental sulfur into the alloy. The experimental procedure is also described elsewhere in detail. All oxidation studies were performed using an Ainsworth thermobalance type RV-AU-1, which is readable to 0.01 mg and is reproducible to ±0.03 mg. The specimens, introduced into a heated furnace, were exposed in the temperature range 800" to 1000°C

Jan 1, 1970

By R. H. Adams, A. M. Khan

The Huntington Beach oil field is on the Pacific Coast, southeast of the City of Los Angeles (Fig. 1). It lies both onshore and offshore. Most of the onshore section is operated by Standard Oil Co. of California, WOI. The Tar reservoir is of upper Pliocene age, about 200 ft thick, and consists principally of fine-grained, unconsolidated, somewhat shaly sand, with thin inter-bedded shale stringers throughout (Fig. 2). The reservoir is a broad, highly faulted, elongated anticline, with an areal extent of about 370 acres. Most of the faults bisecting the structure are normal, trend north-south, and are the main cause of reservoir discontinuity (Figs. 3 and 4). From 1964 to Dec., 1967, 259 steam stimulations were performed on a total of 125 Tar sand wells. Eighty-six new wells were drilled and steam stimulated. Of the total, 96 have been stimulated twice, 34 three times and 3 four times. During this same period, a two-injector steam drive pilot has been in progress. The response obtained from this project has been compared with the response to cyclic stimulation. This paper presents an analysis of the field observations for the two methods of thermal recovery. History of Development Drilling to the Tar pool commenced in 1924 with an initial well production of 40 to 50 B/D of 12o API gravity oil. Complete primary development of the pool has been spread over several years. Approxi- mately 40 wells were drilled during the first phase of development, which was completed in 1945. The subsequent primary development started in 1960 with initial well productions of 30 to 40 B/D oil. Thirty-seven wells were completed in the Tar pool during this phase. For the most part, slotted, gravel flow packed liners have been used in the wells in this pool. A cyclic steam stimulation pilot was initiated in March, 1964. Based on the very successful stimulation in the pilot area, the cyclic stimulation project was expanded to include all of the Tar pool wells producing at the end of 1965 (Fig. 5). Also, a development drilling program was begun at this time. To date, 86 new wells have been drilled under this program. The number of wells drilled each year in this secondary phase of development is also shown in Fig. 5. New Well Completion Practices Most of the new wells have been completed to produce from both the Upper and Lower Tar zones. Generally, a casing stub is cemented from the top of Lower Tar to the base of clean Upper Tar sands to exclude intermediate water-bearing sands. The water string is then cemented from the top of Upper Tar to about 1,500 ft with neat cement and 30 percent silica flour. The annulus from 1,500 ft to surface is then filled with a petroleum-based gel through a high-temperature port collar. Once again, a history of sand-free production dictated the use of 60-mesh gravel flow packed liners. The Upper and Lower Tar

Jan 1, 1970

By W. A. McKinney

In conventional dump leaching of porphyry mine strip wastes, many years are required to extract up to 20 percent of the copper from the contained sulfide minerals. Furthermore, none of the molybdenum, gold, or silver in the strip wastes is recovered by current leaching practices. Because mineralization occurs predominately along fracture planes, breaking of the rock during mining operations liberates and concentrates some of the metal values in the fines. Research shows that upgraded fines can be screened from mine wastes and froth floated for early recovery of copper, molybdenum, gold, and silver. For example, screening a dump sample assaying 0.35 percent copper as chalcopyrite removed about 20 percent of the copper as minus 1/4-inch material that analyzed 0.6 percent copper. About 35 percent of the molybdenum and 20 percent of the gold and silver also reported in the fines. Crushing the mine dump sample to minus 3 inch before screening increased the distribution of copper and molybdenum in the minus 1/4-inch screen fraction to 28 and 50 percent, respectively. Similar results were obtained by screening fines from two other large samples of mine waste dump materials. Flotation studies established that the enriched minus 1/4-inch fines from the three dump samples could be effectively concentrated. Comparative testing revealed that the combination of froth flotation of fines and acid-ferric sulfate leaching of the coarser fraction enabled doubling the recovery of copper over direct leaching of the samples. In addition, significant amounts of molybdenum, gold, arid silver were recovered by flotation.

Jan 1, 1970

By Carl L. Bieniewski

U.S. molybdenum production increased fivefold from 18.2 million pounds in 1946 to 90.5 million pounds in 1966, and constituted 87.3 percent of the total free world supply in the 1946-66 period. Mining development in other free world countries in the next few years may reduce the magnitude of the U.S. position, although similar development planned for the United States may counteract some of the relative gains by those countries. In 1966 two-thirds of the reported molybdenum consumption in the United States by end uses was as an alloying element in steel. Molybdenum also has important use as an alloying element in iron and high-temperature alloys. Consumption of molybdenum metal for making fabricated parts has increased in the past few years, especially in the space and nuclear industries. Molybdenum compounds are used mainly for making pigment, catalysts, and lubricants. Based on producer reports of shipments of primary products to domestic customers, U.S. consumption of molybdenum increased from 16.5 million pounds of molybdenum in 1946 to 65.6 million pounds in 1966. U.S. molybdenum reserves are now estimated to be 5.9 billion pounds of recoverable molybdenum, an increase of 2.1 billion pounds above previous estimates. Molybdenum ores account for 71.4 percent of the reserves, copper ores for 22.3 percent and copper-molybdenum, tungsten, and uranium ores for 6.3 percent. Several methods for predicting future demand are illustrated and estimates of demand using these methods were made for 1975. Based on present capacities and announced company plans for future developments, estimates of annual production were made for 1967 through 1975 for the United States, Canada. Chile, Peru, and the free world. These data indicate that molybdenum production in 1975 for the free world is expected to be 246 million pounds with the United States producing 68.2 percent and Canada, Chile, and Peru 30.3 percent.

Jan 1, 1970

By Alfred E. Schwaneke

A new high-temperature soft soldering system has been developed by the Bureau of Mines for use on copper, copper alloys, and low-carbon steel; the method is applicable to automobile radiators and home appliances. The system uses a unique sacrificial metal coating method to promote spontaneous wetting and spreading of zinc and zinc alloy solder: on metallic substrates. The 10-5 to 10-6 cm thick, electroplated or sputtered, sacrificial nickel coating is absorbed by the molten filler alloy during soldering and produces a direct solder-substrate metallic bond. Preliminary measurements on butt joints with copper members give tensile strengths up to 22,000 psi at room temperature using 95 Zn-5 Al alloy as solder. Spontaneous wetting, spreading, and capillary penetration are extremely rapid and produce joints as easily as 50-50 tin-lead solders. Recrystallization or annealing of the wrought copper joint members is negligible at the soldering temperatures of 450° to 490° C and lower. A list of fluxes and solder alloys is included in the report.

Jan 1, 1970

By J. Howard Boyce

INTRODUCTION The Tsumeb Mine is situated in the northern part of South West Africa, approximately 335 air miles north-east of the port of Walvis Bay on the Atlantic Coast, and 240 air miles north of Windhoek, the capital of South west Africa. The mine came into operation in the early 1900's and has operated continuously since then except during the two world warm and the depression years of the thirties, Tsumeb Corporation purchased the property in 1947, installed a new plat, and ham built a modern tom. In addition to the concentrator which began operations in 1948, a copper smelter was started in 1962 and a lead smelter in 1963, Tonnage of ore treated in the concentrator has varied through the years, reaching a maximum of 70,000 tons per month with a current mined tonnage of approximately 50,000 tons per month. Copper concentrates, lead concentrates and zinc concentrates are produced, and for a number of years the production of a germanium enriched concentrate was an important feature of the operation, Both copper and lead concentrates are smelted in Tsumeb, while the zinc concentrates are shipped overseas. Ore change, and the installation of the smelters in Tsumeb have necessitated modifications in the concentrator operation. This paper will describe current plant practice in some detail and will touch briefly on the techniques used from 1954 to

Jan 1, 1970

By M. Duclos, A. Sawatzky

A simple model has been developed which describes the steady-state solute distribution in Ti-H type systems above the eutectoid temperature in the presence of a temperature gradient. The solute distribution is dependent on the shape of the phase boundaries. An interesting result, and one that is not observed at steady state in thermal diffusion below the eutectoid temperature, is the existence of a two-phase region. The heat of transport for hydrogen in a titanium, Q*a, over the temperature range 275" to 650.C is determined to be 4500 * 230 cal per mole. The heat of transport for hydrogen in B titanium, QB* over the temperature range 320" to 590.C is found to be 630 ± 200 cal per mole. It is also shown that thermal diffusion provides a method by which phase bounduries above the eutectoid may be determined in Ti-H type systems. IN modern technology materials are being used at constantly increasing temperatures under greater temperature gradients. Thus atomic migration in metal alloys due to a temperature gradient (thermal diffusion) may in some cases occur to an observable extent. The thermal diffusion of hydrogen in zirconium has in recent years received considerable attention1-' because of the use of zirconium alloys in nuclear power reactors. The thermal diffusion kinetics below the eutectoid (547°C) are fairly well understood. At steady state the solid solution, a, and hydride, 6, phases are completely separated with the hydride precipitating at the lower temperatures. No experimental work has been carried out in the a + B region although Droege4 suggested that a complete separation of the two phases, as observed at temperatures below the eutectoid, might not always occur. In the present investigation a simple model has been used to determine the steady-state solute distribution under a temperature gradient in Zr-H type systems heated above the eutectoid temperature. The solute distribution is shown to be dependent on the shape of the phase boundaries in the constitutional diagrams and several typical cases are discussed. The model has been applied to Ti-H. This system was chosen in preference to Zr-H because of its much lower eutectoid temperature (-300°C as compared with 547.C), thereby reducing experimental errors due to oxidation and hydriding. The heats of transport for hydrogen in the a and B phases of titanium also have been determined since they were required to compare the proposed thermal diffusion model with experiment. THEORY In the presence of a temperature gradient the atomic flux in a single-phase region of a two-com-ponent system of which the atoms of only one component are diffusing is given by:' J = - U\dx + RT3 dx) which can be written as: j-D(dn/dt +Q*n/RT2)dt/dx [11 J - -D\dT + RT2)dx [1] where D = diffusion coefficient, n = solute concentration, T = absolute temperature, R = gas constant, dT/dx = temperature gradient, and Q* = heat of transport. At steady state (J = 0) Eq. [I] leads to the solute distribution: n = noexp Q*/RT where no = a constant depending on total solute content. The heat of transport Q* can be experimentally determined from the steady-state distribution. In the present paper we shall determine the solute distribution in systems having the constitutional diagram exemplified by Ti-H shown in Fig. l.' As shown, N,(T) and NB(T) are the equilibrium solute concentrations in the a and 0 phases at temperature T. Lines AA' and CC' define the region of interest to us. The following assumptions are made: 1) Steady-state conditions prevail. 2) In a single-phase region all points on an isotherm have the same thermodynamic potential so that the composition over an isotherm is uniform. If a two-phase region exists, thermodynamic equilibrium is found only at phase interfaces. However, we assume the component of the concentration gradient along an isotherm to be small so that the composition in each phase is approximately the same as at the interface and is given by the constitutional diagram, Fig. 1. 3) There is appreciable diffusion of only one component. 4) We shall consider only the case where Qa*, QB*, and Qg*, the heats of transport for solute diffusion in the a, B, and 6 phases, respectively, are positive. This has been observed for the thermal diffusion of hydrogen in zirconium3 and titanium.10 We will show that the steady-state solute distribution above the eutectoid is primarily determined by the heats of transport and the temperature dependence of Na(T) and Np(T). It may be quite different from the steady-state distribution below the eutectoid. For example, we will see that, under certain conditions,

Jan 1, 1970

By Thomas J. O’Neil

From the time of its emergence as an independent state until the late 1950's, the Republic of Ireland suffered from chronic unemployment, the lowest living standard in Northern Europe, and-most serious of all-an aggravated emigration problem which drained off most of its talented young people. In 1958, however, there was a drastic legislative reaction to these problems, and this in turn ignited the current mining boom in Ireland. Paving the Way to Prosperity In order to reverse the tide of emigration, the Irish government now realized, challenging domestic employment opportunities had to be increased and living standards had to be raised. It was also apparent that future industrial and economic growth in Ireland had to be based on producing goods for export. The home market could not sustain large-scale expansion, and consequently Ireland's chronic balance-of-payments deficit could best be minimized by producing export goods. These considerations, together with the limited amount of accumulated wealth in Ireland, combined to set the objectives of the country's First Program for Economic Expansion in 1958. The general objectives of this program were (1) to stimulate all segments of the economy, (2) to develop foreign trade and (3) to attract foreign capital.

Jan 1, 1970

By J. Vance Batty

The Permian Red Bed copper deposits of the South Central States are a potentially important resource. Only the higher grade, near-surface ores are now exploited because conventional froth flotation does not recover oxidized copper minerals which comprise 10 to 15 percent or more of the copper content of typical ore. Laboratory-scale beneficiation studies were initiated to devise a method capable of recovering both sulfide and oxidized copper mineral. Testing established that the high clay and gypsum content of typical ore prevented effective flotation of the oxide mineral using sulfidizing, fatty-acid, or oil emulsion techniques. A modified leach-precipitation-flotation (L-P-F) procedure recovered over 90 percent of the copper, compared to a recovery of 77 percent obtained by conventional sulfide flotation. The higher costs of the L-P-F method would reduce the increased revenue from higher copper recovery. An increase in copper price and/or an increase in oxide copper content of the ore would make the L-P-F process comparatively more attractive.

Jan 1, 1970

By T. Olrog

Dissemination of technical data on developments in rock-blasting techniques in Sweden initially takes place as personal contacts and contacts between companies. In addition to these informal contacts, contacts occur in Sweden in a somewhat more organized form. There exists an informal working group--the Rock Blasting Committee--which consists of a number of personal representatives from various companies that perform rock blasting on a large scale and from firms manufacturing the equipment that is used. This means that people from both mining and construction companies get together, plus the manufacturers of explosives, drill steel, drilling machines, and loading equipment. This working group has, so far, succeeded very well in ignoring the purely commercial interests of the companies concerned. Cooperation in this form was started in the 1940's when the tungsten-carbide drill steel was invented-the group originally concentrated entirely on the development of that product. Their activities have been broadened since that time and now a meeting is held every year, at which practical experiences are reported. Only in the past five years have subjects relating to blasting procedures to avoid rock damage been treated at such meetings. This, of course, does not mean that such techniques had been neglected previously. It does, however, reflect the fact that practice in this field is still under development. Why do we try to be careful about the rock surfaces? Obviously, it is a question of economic evaluation. An even rock surface provides, in certain cases, the conditions for more favorable maintainance costs later on, greater strength, and a diminished risk of slides. The economic connections in this field, however, are neither simple or clear. A well-controlled blasted rock surface limits the need for concrete when you later build the concrete constructions. In this respect, the connections are all the more clear. In certain situations, such as tunnels for hydroeletric power plants, a good rock surface that is not lined is hydraulically more favorable than a more coarsely blasted surface. This permits a gain in the height of fall, but the

Jan 1, 1970

By C. F. Swab

A relatively innocuous halocarbon was investigated as a substitute for the highly toxic carbon tetrachloride in the approval testing of chemical cartridges. The vapor effluent of 1,1,2-trichloro-1,2,2-trifluoroethane from chemical cartridges is continuously monitored by a nondispersive infrared analyzer. Breakthrough times for the cartridges, using the halocarbon, can be equated to those of carbon tetrachloride, if multiplied by the factor, 1.49.

Jan 1, 1970