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By R. H. Winn

A method for the selection of the most suitable corrosion inhibitor for a particular system is given. The method involves the evaluation of surface passivity by means of copper ion displacement after the metal surface has been subjected to the corrosive atmosphere. The application of the method to the selection of suitable inhibitors for use in producing wells is described. Correlation with recognized laboratory tests has beet1 found to be good within the limitations of the test. The use of the test to evaluate inhibitor persistencc is described. INTRODUCTION Corrosion as it is associated with the industry shows wide variations in its qualitative as well as its quantitative aspects. This complicates the work of the corrosion engineer. In the past few years the efforts of the corrosion engineer have been further taxed by the large numbers of products being marketed as corrosion inhibitors by various manufacturers. These products are submitted to him together with a limited amount of data to support their use as inhibitors. The data are usually authentic and reliable yet all too often when these products are applied to an actual corrosive system the results are disappointing due to the ineffectiveness of the inhibitor and the corrosive system. The corrosion engineer must select a comparatively limited number of inhibitors for field trial from the large number available. The selection is usually made on the basis of a standardized laboratory test such as that adopted by the National Association of Corrosion Engineers or by field experience in an area; however, testing of this type is discouraging on large numbers of compounds, particularly in view of the specificity of environment. It has been an object of this work to devise a method which will allow the corrosion engineer to select the best inhibitor for a specific environment under field conditions. The test would of necessity be rapid and inexpensive. It would preferably eliminate the need for expensive and delicate instruments. STATEMENT OF THEORY The test as developed makes use of the fact that metal ions will be displaced from solution by metals having a more positive electrode potential. Thus, if an active iron surface is exposed to a solution of a copper salt, free copper will plate spontaneously on the iron surface as it is displaced from the salt solution by iron ions. If the iron surface is passified, as by coating with an insulating-type organic corrosion inhibitor, it is no longer capable of displacing the copper ions due to its own limited ionization. The result will be a change in the amount of copper plated upon exposure to a neutral copper salt solution. In practice it has been found possible to measure the magnitude of the alteration of the cell potential by determining the copper deposited on a standard iron surface under controlled conditions. This means that, as the film builds up, the resulting shift in the electrode potential tends to cause the iron surface to act more like a noble metal, resulting in a reduction in the cell potential to a point that copper will no longer plate spontaneously. Obviously, the salts of other metals such as silver, gold or platinum might be used for this operation; however, copper was selected because of the color difference of the plate, the comparatively low cost of copper salts and the ease of evaluation of the plated copper. Furthermore, its high cell potential provides a substantial driving energy. The determination of the copper is readily done colorimetrically by dissolving it in 5 per cent ammonium hydroxide solution containing 2 per cent potassium per-sulfate. The blue color of the copper ammonic complex ion so developed may be compared with standards prepared by dissolving known quantities of copper powder in the same reagent. In routine screening it is seldom desirable to determine the amount of copper plated. It is usually more important to determine the concentration of inhibitor required to prevent the plating of copper.

By James C. Cawley

A summary is presented of existing leaky feeder communications systems currently in operation in North America. Background information pertaining to previous use of leaky feeder technology is discussed along with the survey methodology. A review of some pertinent facts concerning propagation in tunnels and specific reference to mine tunnel propagation is presented. A summary of the characteristics of each mine visited is presented in tabular form, and methods of procurement and maintenance are discussed. The role of user training in efficient system use is presented. Seven sites representing eight mines are included in the survey. Economic and technical topics are considered.

By M. A. Trevits, J. E. Urosek, A. C. Smith, M. P. Valoski

Unlike other types of mining accidents, where an incident generally involves only a few workers, the danger of a mine fire extends to every person working in the underground environment. Mine fires can trap or kill those working underground by blocking avenues of escape and rapidly creating heat, asphyxiating gases and toxic fire products that can quickly spread throughout the mine. The National Institute for Occupational Safety and Health (NIOSH), in partnership with the Mine Safety and Health Administration (MSHA), is conducting research to test, evaluate and improve or modify coal mine fire-fighting strategies and methodologies through large-scale tests. Because wood is the second most abundant fuel available during a coal mine fire, it was decided that a series of large-scale wood crib fire tests was needed to measure the products of combustion and to observe the capability of commonly available direct application fire suppression equipment, namely, fire extinguishers, water and gas-enhanced foam. This paper discusses the wood crib fire tests, provides insight into the products of combustion and describes observations made during the application of the fire suppression agents.1

By R. E. Zinkham, R. J. Goodwin

A mathematical study has been made of the amount of support a cement sheath could provide to casing cemented into the earth. Several assumptions were required to make the analysis, but only two of them are limiting: (I) the pipe must be completely surrounded with cement, and (2) any mud filter cake between the cement and formation has the same physical properties as either the cement or formation. The calculations showed that little support would be provided to the pipe before an unsupported cement sheath failed in tension; however, when the cement is confined between the pipe and wellbore and is loaded in compression, the pipe could receive a considerable amount of support. In fact, the theoretical results indicate the lower grades and larger sizes of pipe could have their working pressures doubled when reasonable compressive loads were applied to a surrounding cement sheath. These data are shown in six charts. Other down-hole conditions such as setting the cement under pressure, increased temperature and cement confinement all tend to increase the potential usefulness of the sheath. Because of size limitations, a laboratory program to verify the most important results of this mathematical study would be very difficult. However, small-scale field tests would be practicable. This paper shows that, if a solid cement sheath can be obtained in the field by either primary cementing or by repair after detection of flaws by surveys such as the new cement-bond logs, the use of this approach to reducing pipe costs merits further consideration. INTRODUCTION A modification in casing design practices is proposed which may either reduce the amount and grade of steel required to contain a specified internal pressure or permit the working pressure to be increased for a specified weight and grade of pipe. One of the more important considerations in casing design is its resistance to collapse; however, Bowers' and, more recently, O'Brien and Goins' have shown many casing programs are unnecessarily conservative in this respect, and they have indicated how savings can be made by designing for more realistic down-hole conditions. Earlier, Saye and Richardson howed that pipe costs could be reduced by considering the cement sheath as a part of the casing string when collapse resistance was being calculated. More recently, Rogers4 has raised the question as to whether a cement sheath might be considered in the design for burst resistance of the cemented casing. Calculations have been made for the increased burst resistance a cement sheath would provide for casing in a wellbore, and the results show that a sizable amount of support could be obtained in some instances. These data are presented in addition to a discussion of several other factors that are considered to affect the burst strength of pipe supported by cement. Two types of support are treated: Case I for tensile loading of the unconfined cement sheath, and Case for compressive loading of the confined cement sheath. ANALYTICAL TREATMENT AND RESULTS CASE I—TENSILE STRESSES IN AN UNCONFINED CEMENT SHEATH Conditions like this would most likely occur in a greatly enlarged portion of the hole where the cement was not in immediate contact with either the formation or a thin and hard mud cake. The mathematical analysis for this condition, as shown in the Appendix, rests on the following concepts. Pressure inside a unit length of pipe causes: (1) a tensile or tangential stress to be exerted over the longitudinal cross-sectional areas of the pipe and cement; and (2) an equal amount of strain in both the pipe and cement that is uniformly distributed over the wall thickness of each. This analysis was then used to make several calculations for a cement sheath around 51/2-in. OD pipe. The results are illustrated in Fig. 1, which shows that a tensile stress of 500 psi is imposed on a 5-in. thick sheath when the casing contains a pressure of only 1,450 psi. It also shows that a 10-in. thick sheath would be stressed to 500 psi in tension when the pipe contained a pressure of only 2,350 psi. Alternatively, if the stress analysis is made by means of the Lame thick-wall cylinder theory, the inner fibers of the 10-in. thick sheath will be stressed to 500 psi in tension when the pressure in the pipe is only 990 psi. This, of course, reveals that an unconfined sheath is of little support to the pipe in burst; however, an entirely different result is obtained when the cement is confined between the pipe and formation.

By E. R. Atkins, G. H. Smith

Results of laboratory tests are presented to show that lire value of "m", in the Archie expression dernlined by the shapes of the particles in the system. Tile value of m "the shape factor", is constant for a system of particles of a given shape for a range of F - + values. Applying this concept, one can predict F - + relationships for mixtures of particles with different shapes, and these predicted relationships are useful in electric log interpretation. It is suggested that an equation of the form 1/F -10mcan be used to describe the properties of natural formations containing varying amounts of sand and clay. From this work and values of "a" and "m" reported in the literature, it appears that in many cases rocks in the same geological horizon have a common primary porosity but contain varying amounts of a particular clay. It is concluded that the equation can be applied to a rock-water system only when values of "a" and "m" have been established for the particular system. INTRODUCTION The petroleum literature contains many reports of the results obtained by determining formation resistivity factor F and porosity + of rock samples from oil fields all over the world. The usual practice is to use data from a large number of samples from a number of fields to find an average relationship between F and +. Several such average relationships have been advanced. In the absence of data on a particular formation or field, it has been the practice to use the average relationships to give a rough approximation of the F - + relationship. The purpose of this paper is to report on basic relationships that exist between F and + for naturally occurring particles in water solutions. Other workers' have found the same relationships apply to the diffusion of hydrogen through packed beds of dry particles. In the work discussed here, relationships for application to unconsolidated sands or shales containing mix- tures of particle shapes are derived. These relationships, developed for unconsolidated formations, may apply to consolidated formations. EXPERIMENTAL To evaluate F- relationships for unconsolidated rocks, the results of laboratory measurements on simple slurries of clay or sand will be used. Such laboratory studies are concerned with the electrical behavior of water-containing rocks. The wet rock constituents are electrically similar in slurries and in rocks. Archie2 defined formation resistivity factor as All resistance measurements were made using a 1,000-cycle impedance bridge with an oscilloscope as the null detector." The accuracy of this bridge was better than * 0.15 per cent. For the particular apparatus employed, no additional reactance was required to achieve balance for samples with resistances between

By A. Whillier

Recommendations are given for the design of vertical cooling towers for use underground in mines and a method is given for predicting the entering and leaving water temperatures when a given amount of heat has to be dissipated.

By David C. Oyler, Dennis R. Dolinar, Christopher Mark, Craig S. Compton

Fully-grouted roof bolts comprise more than 80% of the primary roof supports used in U.S. coal mines. However, nearly 1,500 MSHA reportable, non-injury roof falls occur each year, and most of these are attributable to failure of the roof bolt system. Anchorage failure is one failure mechanism for fully-grouted bolts. As roof deformation works its way upward, the bolts can become heavily loaded near their upper ends. If the applied load exceeds the anchorage, the bolts will simply pull out. Research dating back 30 yrs indicates that this type of anchorage failure is most likely when the roof rock is weak, just where roof support is most critical. In soft shale or coal roof, the small amount of data available in the literature indicates that 20-30 in of resin anchorage may be required to achieve the full capacity of the bolt. In other words, the “full resistance zone” of a 60 in bolt may actually be just 30-40 in. Despite its potential importance, there is no widely accepted anchorage test for fully grouted bolts. Standard pull tests have sometimes been employed, but they provide no information on the anchorage near the top of the bolt. An alternative, first described more than 25 yrs ago in the U.S., is the short-encapsulation pull test (SEPT). With this test, the bolt is installed with only a short (1 ft or less) tube of resin. In recent years variations of this test have become international standards. v

By J. H. Henderson, J. Naar

The displacement of a wetting fluid from a porous medium by a non-wetting fluid (drainage) is now reasonably well understood. A complete explanation has yet to be found for the analogous case of a wetting fluid being spontaneously imbibed and the non-wetting phase displaced (imbibition). During the displacement of oil or gas by water in a water-wet sand, the porous medium ordinarily imbibes water. The amount of oil recovered, the cost of recovery and the production history seem then to be controlled mainly by pore geometry. The influence of pore geometry is reflected in drainage and imbibition capillary-pressure curves and relative permeability curves. Relative permeability curves for a particular consolidated sand show that at any given saturation the permeability to oil during imbibition is smaller than during drainage. ' Low imbibition permeabilities suggest that the non-wetting phase, oil or gas, is gradually trapped by the advancing water. This paper describes a mathematical image (model) of consolidated porous rock based on the concept of the trapping of the non-wetting phase during the imbibition process. The following items have been derived from the model. 1. A direct relation between the relative permeability characteristics during imbibition and those observed during drainage. 2. A theoretical limit for the fractional amount of oil or gas recoverable by imbibition. 3. An expression for the resistivity index which can be used in connection with the formula for wetting-phase relative permeability to check the consistency of the model. 4. The Iimits of flow performance for a given rock dictated by complete wetting by either oil or water. 5. The factors controlling oil recovery by imbibition in the presence of free gas. The complexity of a porous medium is such that drastic simplifications must be introduced to obtain a model amenable to mathematical treatment. Many parameters have been introduced by others in Iprogressing" from the parallel-capillary model to the randomly interconnected capillary models independently proposed by Wyllie and Gardner3 and Marshall4. To these a further complication must be added since an imbibition model must trap part of the non-wetting phase during imbibition of the wetting phase. Like so many of the previously introduced complications, this fluid-block was introduced to make the model performance fit the observed imbibition flow behavior. THE IMBIBITION MODEL ASSUMPTIONS The following assumptions are common to many two-phase models previously described. 1. The wetting characteristics of the medium are clearly defined. 2. When two fluids co-exist in the medium, the wetting phase will fill the smaller pores and the non-wetting fluid the bigger ones. 3. The pores have a circular cross section. 4. Apparent pore radii are related to the capillary pressure (drainage) by

Measurements of the rates of penetration at various throttle air pressures are presented as a function of thrust for three different rockdrills when drilling quartzites with strengths of 45 000 lb/in2 and 39 000 lb/in2, The rate of penetration at optimum thrust is shown to agree well with the predictions of theory and curves of air consumption as a function of throttle air pressure are presented. Man-held machines are shown to be under-thrusted at throttle air pressures above 40 lb/in2g. Measurements of bit wear as a function of distance drilled are presented graphically and discussed in terms of the theory developed in Part 1.

By Christopher Mark, Gregory M. Molinda, Timothy M. Barton

The Coal Mine Roof Rating (CMRR) was first presented at this Conference nine years ago. Since its introduction, the CMRR has been incorporated into many aspects of mine planning, including longwall pillar design, roof support selection, feasibility studies, and extended cut evaluation. It has also become truly international, with involvement in mine designs and funded research projects in South Africa, Canada, and Australia. The purpose of this paper is to bring the mining community up to date with recent improvements and applications of the CMRR. The most important new development is a streamlined process for determining the CMRR from exploratory drill core. Just three types of information are now required: •Fracture spacing (or RQD) •Uniaxial compressive strength (or axial Point Load Testing) •Diametral Point Load Testing The moisture sensitivity adjustment has also been changed, and new research has related the immersion test to slake durability. Most recently, the CMRR has been implemented in a computer program, which can be obtained from NIOSH free of charge. The program facilitates calculation of the CMRR from either underground or drill core data. Values from many locations can be saved in a single file, and an interface with Autocad allows CMRR contour plots to be integrated into mine planning.

By H. L. Overton, J. B. Lipson

The concept of sodium single-ion equivalent activity as developed by Gondouin, Tixier and Simard,' was used to determine the filtrate resistivity-activity relationships for 150 laboratory and 49 field drilling muds. With the exception of the native and phosphate high-resistivity muds and the calcium-treated muds, the filtrate resistivity-activity relationships were found to be within 20 per cent of that for pure sodium-chloride solutions. Gondouin, et al,* previously suggested a method of treating the high-resistivity muds in quantitative electrical log analysis. A new treatment is presented which uses the P-alkalinity of the filtrate as a correlating parameter in handling the calcium-treated muds in quantitative electrical log analysis. INTRODUCTION Gondouin, Tixier, and Simard in 1957 introduced new interpretive procedures for analyzing the self-potential curve of electric logging. They re-emphasized the previous work of the Schlumberger brothers, Wyllie and others, and re-defined the activity concept in terms of a number which they termed the effective resistivity. Their procedures are particuarly effective when the connate-water resistivities are less than 0.08 ohm-m or greater than 0.3 ohm-m. For gyp muds where the calcium content is known, a procedure was presented which allows calculation of the connate-water resistivity with improved accuracy. These procedures assume that one of the fluids in the system is a pure sodium-chloride solution, but they are not limited by the assumptions. For the fresh and saline connate waters, for instance, it is assumed that the drilling mud filtrate is a pure sodium-chloride solution. For the gyp mud interpretive procedure, it is assumed that the connate water is a pure sodium-chloride solution. Brown,' on the other hand, has suggested that it would be extremely fortuitous if drilling mud filtrates could all be treated electrochemically as sodium-chloride solutions, and he cites some examples where discrepancies exist. A study has been made of the deviations of sodium single-ion equivalent activities, an of drilling mud filtrates from that of pure sodium-chloride solutions. Drilling fluids in common use on the Texas and Louisiana Gulf Coast and laboratory-controlled muds were investigated. Using a cell patterned after Gondouin, et al, (Fig. I), the equivalent activities were measured. It should be remembered here that the activity measured is merely an index which uses numbers that represent the sodium single-ion equivalent activity a,., of the mud filtrate. The membrane potential developed across the cell was determined with a null-type potentiometer. The resistivities of the solutions were measured by the four-electrode method. The resistivity system was calibrated by using saturated KC1 solution as a standard. Chemical properties of the drilling fluids studied were measured with standard API-approved equipment for the particular property in question. For the activity measurements, two shale discs were chosen to serve as cationic membranes. These two discs were both 1 1/4 in. in diameter and, respectively, 1/4 and 1/8 in. in thickness. The membrane potential, Em, was determined using the shale discs as cationic selective membranes separating two standard sodium-chloride solutions of known mean activity. Then by comparing the constant Km in the following equation, with the theoretical value of — 59 mv at 75OF, the perfection of the membrane was determined. The variation of Km for the two membranes used in this experimental work, as well as one of the many unsuitable membranes, is shown in Fig. 2. The measurement of the activity of mud filtrate involves the balancing of its combined individual activities against a standard solution of known mean activity. At the point where there exists zero potential across the membrane cell, the activity effects may be assumed equal for all practical purposes. The mechanics of making a null reading of this sort requires having a large number of different mean activity solutions. A more practical method involves

By Jami M. Girard, Ed Mchugh

Slope stability accidents are one of the leading causes of fatalities at U.S. surface mining operations. The Spokane Research Laboratory of the National Institute for Occupational Safety and Health (NIOSH) is currently conducting research to reduce the fatalities associated with slope failures. The purpose of this paper to discuss some of this research and to present potential new technologies for slope monitoring and design. The paper also briefly discusses various warning signs of slope instability, introduces the most common slope monitoring methods, describes the limitations of various slope monitoring systems, and presents some field results using some of this new technology.

By Mark S. Redfern, Kim M. Corneliusa, Christopher A. Hamrick, Sean Gallaghera

Coal miners often handle heavy electrical power cables, weighing up to 10 kg per meter. These cables are manually lifted and attached to the mine roof to prevent damage from mobile underground equipment. Data suggest that workers who commonly perform cable handling tasks experience a high rate of lost time back injuries. In this study, six male underground miners performed a total of 12 cable-hanging tasks in standing, stooping, and kneeling postures, during which kinematic and ground reaction force data were collected. Reductions in vertical work space were found to result in a linear increase in the peak moment experienced by the lumbarspine (p<0.05). In restricted postures, peak moments were not significantly different in stooping vs. kneeling postures (p>0.05). Average lumbopelvic flexion during the tasks was highest in stooping conditions, followed by standing and kneeling exertions (p<0.05). Implications of this data with respect to design of cable handling tasks are presented and discussed. Keywords: Biomechanics, posture, low back pain, restricted workspace, mining

By C. Laughton

The Deep Underground Science and Engineering Laboratory (DUSEL) is to be constructed at the defunct Homestake Mine, in South Dakota. As a cornerstone of DUSEL?s research program, it is intended to conduct experiments into the fundamental nature of neutrino and proton particles. The experimental apparatus required to con-duct these experiments will be housed in large rock cavern(s) sited at depths of over a kilometer. As conceived, these cavern(s) are planned to have mined volumes of up to half a million cubic meters, and spans of approximately 50 meters. The paper will describe key end-user requirements, and outline the in situ rock conditions and mine site constraints that are likely to play determinant roles in identifying candidate sites and developing cost-effective design options(s).

By Martin Coryell

This coal area, and the coal from a limited portion of it, has been known for a long time. In 1817, McClure prepared a geological map to represent the boundaries, and they are not controverted at the present date. In 1834, Richard C. Taylor made a survey and report on portions of the basin. In 1835, Prof. W. B. Rogers was appointed by the State of Virginia to make a geological survey, and made six annual reports in which this area was included; but the reports and maps were not published. R. C. Taylor&apos;s Statistics of Coal, published in 1855, gave to the public the details of exploration and production, to date, very perfectly and completely. Daddorw and Bannan&apos;s work, Coal, Iron, and Oil, published in 1866, repeated the details before given, and advanced some vague theories respecting the coal-field, but gave no new facts. Macfarlane&apos;s work, Coal Regions of America, published in 1873, under the head of " Triassic Coal," chapter 27, gives what is known from existing publications of the position, geology, and production of the field, making

The sessions of the Institute were opened on Tuesday evening, October 26th, at Garrett&apos;s Hall, by Mr. Charles A. Otis, Chairman of the Local Committee of Arrangements, who welcomed the Institute to Cleveland, and introduced Col. Charles Whittlesey, who addressed the Institute briefly on the coal deposits of Ohio. Col. Whittlesey described the situation and character of the coalbeds of the State, and gave a short history of the use of raw coal in the manufacture of pig-iron, and spoke of the excellent quality of metal produced. The aid that a body of scientific miners and metallurgists were capable of giving in the development of coal and other mineral resources was dwelt upon, and the hope expressed that the visit of the Institute to Cleveland might be profitable as well to its members as to the citizens of the State. The President, Mr. A. L. Holley, responded to the welcome of Mr. Otis and of Col. Whittlesey, and read an introductory address on Some Pressing Needs in the Iron and Steel Manufacture. The following members and associates, duly proposed and indorsed by the Council, were then elected MEMBERS. Alfred S. Bertolet,.. .. . Youngstown, Ohio. Henry Binnse,. Chicago, Ill. John Birkinbine,.. .. . Philadelphia. Andrew A. Blair,. .. .. Watertown Arsenal, Mass. Ogden Bolton,. .. .. Canton, Ohio. Lloyd Booth,..Youngstown, Ohio. E. Borda,..Philadelphia. N. P. Bowler,.. .. . Cleveland, Ohio. Alexander E. Brown,.... Cleveland, Ohio. C. F. Brush,.. .. .Cleveland, Ohio. S. M. Carpenter,.. .. . Cleveland, Ohio. James Cartwright,.. .. . Youngstown, Ohio. Henry Chisholm,.. .. . Cleveland, Ohio. Wilson B. Chisholm,.. .. . Newburgh, Ohio. W. H. Clarke,.. .. . Millertown, Pa. James E. Clayton,. .. .. Ore Knob, N..C.

By Edward L. McHugh, Stanley M. Miller, Jeffrey K. Whyatt

The point estimation method can be applied to the safety factor (SF) equation for any specified rock slope failure mode (such as plane shear, step path, or wedge) to obtain reliable estimates of the mean and standard deviation of the SF probability distribution. A gamma probability density function is recommended for modeling this probability distribution, because it allows only for positive values and is flexible enough to provide symmetrical shapes and right-skewed, exponential-type shapes for the SF distribution. The mean and standard deviation define this distribution, which then can be integrated numerically from 0 to 1 to obtain the probability of sliding, PS (portion of the SF distribution where SF < 1.0). The overall probability of failure, PF, for the potential slope failure mass is the joint probability that the rock discontinuities are long enough to allow kinematic failure (PL) and that sliding occurs along the rock discontinuities (PS); that is, PF = PSPL. This method for estimating the probability of sliding is extremely efficient computationally, and thus, expedites slope stability simulation routines used by NIOSH software to stochastically describe rock slope behavior and assist the engineer in designing catch benches for large rock slopes. Enhanced bench design translates into increased operational efficiency and safer working conditions in open pit mines and quarries.

By A. L. Holley

It has been customary at our opening sessions, for the presiding officer to address you on the general development of one or another of our several professions, or upon some important feature of Mining or Metallurgical Engineering. It is somewhat embarrassing to his successor that our former President, Dr. Raymond, expert as he is in every one of these professions, has been accustomed to keep them all, in their turn, prominently before yon. In selecting for this occasion a subject necessarily connected with iron and steel, I have thought that a review of these manufactures, with reference to some of their more pressing needs for improvement, will be more timely than a general or statistical paper. I shall endeavor to confine my remarks to a few specific defects of practice and management, and to their equally specific and more or less developed remedies. That serious defects exist; that they must be remedied ; that the manufacture is indeed already on the verge of transition, will be generally admitted. But it cannot be revolutionized all at once, however desirable the technical results might he, for that would bankrupt the business at large. We cannot afford to pull down and rebuild all our blast-furnaces that do not make a ton of pig iron with 25 cwt. of fuel; nor to replace all our hand-puddling furnaces with revolving ones, even if we could select the best revolver. Although the soft steels promise to supplant iron for most structural purposes, there are neither money nor present market to warrant all at once replacing our iron works, or half of them, with steel works. Since, then, these manufactures can neither stand still nor be suddenly metamorphosed, their managers are saying to one another: " We must feel our way into larger development; we must work gradually into better practice; we must improve a little at a time."

By Dominik Hofer

A broad spectrum of tantalum containing input materials can be processed for the production of synthetic tantalum concentrate (“SynCon”). The use of these low grade substances offers a secure alternative to mining of coltan in Central Africa. SynCon is produced in a multi-stage pyrometallurgical process, wherefore the melting behaviour of slags presents an important factor especially regarding the energy consumption and its optimisation. The characteristics of a slag comprising mostly Al2O3, CaO, SiO2 and MgO are influenced by the amount of other oxidic constituents which enfolds the main focus of this study. A hot stage microscope serves for the investigation of the slag behaviour in a temperature range from 1000 to 1600 °C under reducing atmosphere (CO/CO2 gas). The experimental results are compared with thermodynamic calculations (FactSage) to get a better understanding of the process.

By Emad Farouz

This paper presents a case history of a successful construction-phase pile load test program that optimized the pile design in challenging ground conditions at the Great Neck Wastewater Treatment Plant in the Town of North Hempstead in Nassau County, New York. The improvements and expansion of the wastewater treatment plant included the construction of several new structures to comply with new stringent nitrogen discharge requirements and new design flow. The challenging ground conditions included up to 20-ft thick organic deposits with weight of hammer blow counts and up to 14 percent organic content and tidal ground water that was near the ground surface. The foundation design evaluated various deep foundation alternatives and selected driven closed-ended pipe piles then filled with concrete as the most suitable foundation. The selection process included considerations of cost, risk, vibrations, noise, and schedule. The contract documents utilized an innovative approach of performing an optimization load test program that was implemented during construction to optimize pile lengths and reduce potential vibration and construction schedule. This paper discusses the details of the successful load test program including static testing, dynamic testing, and the innovative contracting approach utilized to implement the construction phase load test program. It also discusses the successful development and implementation of driving criteria for production piles and construction challenges. The successful load test program resulted in savings of several hundred thousand dollars, optimized schedule, and lower environmental impacts.