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By John F. Brass

INTRODUCTION The Jim Walter Corporation is a Florida based organization with diverse interests. They have operations in many states and overseas, but the heart of the company is in the southeast. The major part of the corporation's business is home building and everything that is related to it. In 1969, the Jim Walter Corporation gained an interest in coal mining through the acquisition of the U. S. Pipe & Foundry Company which had two slope mines to supply its requirement of metallurgical coal. In the early 1970's it was decided to enlarge the coal mining activities and work was started on the Blue Creek project. This involved sinking four new deep mines (originally there were to have been five but it was later decided that the property could be satisfactorily worked by four mines). They are all located in west central Alabama between Tuscaloosa and Birmingham. They have a combined projected output of 7314 million tons of very high grade metallurgical coal per year to be reached by the mid 1980's. These new mines are all to work the Blue Creek seam which is a very gassy seam and in the area to be mined is found at between 45m (1500 ft.) and 731m (2400 ft.) below the surface. Longwall is the only practicable method of mining to produce the planned outputs in the conditions prevailing and each mine is planned to have three longwalls as the primary production system. Continuous miners will be used just to do the development work for the longwalls. No. 3 Mine is the most advanced of the mines and started the first longwall early in 1979. The second unit started in the middle of 1980 and the third is scheduled for mid 1981. The first longwall at No. 4 Mine is expected to commence production early in 1982. This paper attempts to relate some of the problems that have been encountered and the lessons that have been learned.

Jan 1, 1981

By E. Swartzman

THE free-swelling index, a numerical value for the free-swelling properties of coal, is being used to an increasing extent in specifying coal for burning in various types of equipment. The empirical standard ASTM method for determining this index uses, as a source of heat, a gas burner which requires frequent calibration because gas pressures are not constant, relatively small changes in gas pressure resulting in rather wide variations in the temperature attained in a crucible and thus in the resultant size of the coke button. Furthermore, the quartz crucibles specified for the test are not standard equipment, and relatively small variations in dimension and wall thickness from those specified often result in rather wide variations in the resultant size of the button.

Jan 10, 1951

By J. W. Cunningham, W. A. Tiller, D. H. Lane

The effect of ultrasonic vibrations on ingot solidification has been considered both theoretically and experimentally. The theoretical section elucidates the mechanisms by which the ultrasonic vibrations might refine the ingot structure. The experimental section describes a very efficient means of introducing the ultrasonic vibrations to the freezing interface. The application of this technique to the consumable-electrode arc melting process shows that the columnar mode of freezing may be effectively suppressed yielding an ingot structure consisting predominantly of equiaxed grains. The results support the contention that the ultrasonic vibrations increase the nucleation frequency in the layer of liquid adjacent to the freezing interface. CERTAIN structural characteristics of as-cast ingots are undesirable since they create considerable difficulty for subsequent processing and often produce defects in the finished product. These structural defects are illustrated in Fig. 1(a), and are: 1) planes of weakness where columnar grains growing from the different mold faces meet, 2) strength anisotropy due to the preferred orientation of the columnar grains and 3) inhomogeneity due to segregation at dendrite boundaries within the columnar grains and at the columnar grain boundaries. The type of ingot structure that eliminates 1) and 2) and diminishes 3) is the fine-grained equiaxed structure illustrated in Fig. 1(c). Many attempts have been made to produce the desirable ingot structure illustrated in Fig. 1(c) by inoculating, casting with varying superheats, vibrating or stirring, or by irradiation with ultrasonic vibrations. These attempts have met with various degrees of success, the ingots generally having the structure illustrated in Fig. 1(b). All four methods have been the subject of numerous investigations,1"4 the latter producing the most erratic behavior and inconsistent success. The method of ultrasonic irradiation during ingot solidification has shown considerable promise on small-scale ingots (diam 2 in.) but has not yet been successfully adapted to large-scale operation. The present paper considers the application of ultrasonic radiation to ingot solidification both theoretically and experimentally. The purpose of the paper is to elucidate the mechanism by which ultrasonic energy refines the ingot structure and to describe a method for producing the desirable ingot structure in both laboratory scale experiments and in ingots of commercial size. THEORY Conventional Casting—Before discussing the possible effects of ultrasonic radiation upon ingot structure let us first briefly review the reasons for the breakdown of columnar crystallization to equiaxed crystallization during ingot solidification. The following is a slightly oversimplified description. In the conventional method of casting, the alloy having a certain degree of superheat, T, is poured to fill a cold mold which is at room temperature, Tc,. Due to conduction of heat through the mold wall the outer rim of liquid metal cools rapidly to the liquidus temperature and begins to supercool. At some degree of supercooling, nuclei of solid form at random in this supercooled layer at the mold surface. The grains in this chill layer begin to grow inwards producing a solute build-up, thus lowering the freezing temperature at the interface as illustrated in Fig. 2. As growth proceeds, the temperature gradient in the solid conducts away not only the latent heat of fusion evolved during growth but it also conducts away some of the superheat of the melt so that the temperature

Jan 1, 1961

By W. A. Clark

THE production of sand in an oil well increases operating costs because of abnormal wear in subsurface equipment, the necessity for frequent cleanouts, and the need for a means of disposing of the sand. Moreover, removal of sand from the zone can bring about the creation of cavities from which bodies of formation, sand or shale, may slough into the hole, endangering the shutoff, impeding production or collapsing the liner. The procedure known as gravel packing is attracting attention as a means of controlling these factors and contributing to the productive life of a well. That gravel packing is now substantially beyond the preliminary stage on the Pacific Coast is reflected in the 191,000 bbl, of oil produced monthly by the 66 gravel-packed wells in 11 different producing sectors. REASONS FOR GRAVEL-PACKING Gravel packing, if properly carried out, can be expected to provide the following benefits: 1. Prevent the movement of sand and thus eliminate sand production and sand fills, and prevent the formation of cavities. 2. Provide a practical, relatively inexpensive, large-diameter hole, which will provide well-known theoretical advantages. 3. Support the walls of the hole by completely filling the space between the liner and the formation, regardless of its irregularities, and afford a support for liners. 4. Provide for more efficient pumping operations in wells by: (a) possibly utilizing the gravel as a gas trap in pumping gaseous fluids, (b). allowing deep submergence of the pump into the oil zone.

Jan 1, 1939

By T. M. Chance

THe necessity of adopting improved methods of bituminous-coal cleaning at many collieries is recognized by all familiar with the requirements of the various bituminous markets, the approaching exhaustion of the relatively small areas of inherently high-grade coal, and the difficulties encountered in maintaining a uniform grade of shipped coal. Many coals lose much of their market value by degradation in size, and, in any event, if the cleaning .process is to contemplate wetting the coal the minimum amount of fines should be produced to prevent sludge losses and the difficulties resulting from the moisture content of the wet fines. Hence, it is desirable to bypass the finer coal dry, if this can be done without too great increase in impurities in the final product. This procedure has given excellent results at washeries at Steelton and in the Birmingham district. If the raw fines are too impure to permit admixture with the washed coal, it may be desirable to use dry methods, such as the pneumatic table, rather than to wet an excessive amount of such fine material. The bituminous-coal cleaning plant should therefore: (1) Treat the raw coal in as large lump as possible and without sizing; (2) eliminate degradation of pure coal in the washing process; (3) avoid wetting the fines, if possible; (4) produce washed coal practically free from mechanically included impurities; (5) crush the refuse and retreat, if much intergrown coal and refuse are present, rather than precrush the entire feed. Ordinary gravimetric methods of concentration, whether hydraulic or pneumatic, will not meet all of these requirements, as the large lump includes those sizes now sent to the picking tables, if it is desired to treat material of such size. I do not know of any prior commercial method, based on the falling velocity, coefficient of friction or resistance to fracture, that permits the production of clean coal varying in size from, say, 10-in. lump to 1/16-in. mesh. The effect on the specific gravity of any given coal as a result of variations in ash and pyritic sulfur content is well known; in fact, it has been made use of in commercially ascertaining ash content by deter-

Jan 1, 1924

By Richard H. Sibson

Changes in seismic style along the San Andreas fault system appear to correlate with strike-parallel variations in regional heat flow. Large earthquake ruptures are associated with colder segments of the fault zone, while comparatively high levels of microearthquake activity and small to moderate shocks occur along the hotter segments, often in association with aseismic creep. Such behavior is consistent with geotherm and strain rate dependent profiles of shear resistance versus depth, constructed for quartz-bearing rocks. These profiles suggest that the transition from frictional to quasi-plastic behavior with depth should increase by a few kilometers passing from the hotter to the colder portions of the fault zone, giving rise to long-wavelength concentrations of distortional strain energy near the base of the seismogenic zone in the cold segments. Some support for this hypothesis comes from the observed deepening of microseismic activity passing northwest and southeast from the central Californian active region to the currently locked, ~400 Ian segments of the San Andreas fault that ruptured in 1906 and 1857.

Jan 1, 1982

Jan 1, 1934

Jan 1, 1931

THE bellows are important and necessary agents in most melting processes. In addition to seeing that these have sufficient soft cloth, extend far and wide, and are of good design, including good valves and good long tubes, and that they cannot break and lose the air received, it is very important to give attention to their installation so that they may easily effect their purpose. Therefore I now wish to proceed by noting some common devices for moving them, both with water and with man power, so that you may make use of them as the need arises.

Jan 1, 1942

By Lawrence H. Van Vlack, Otto K. Riegger, Gerald I. Madden

The microstructural variations of periclase (MgO) in the presence of oxide liquids are examined under the steelmaking variables of: 1) temperature, 2) liquid composition, and 3) FeO additions under different oxidation levels. Attention is given to the distribution of the phases, both liquid and solid, and to the growth of individual crystalline grains. Silicate liquids penetrate more extensively between individual periclase grains than do liquids containing high percentages of Fe2O3 Higher MgO solubilities in the liquid and lower MgO contents of the solid favor more rapid grain growth. The presence of a second solid phase reduces the periclase grain growth rate and increases the amount of the solid-to-solid contact within the oxide microstructures at high temperatures. The service suitability of a refractory depends on many factors. Two are of major importance and include 1) the thermal resistance to melting, and 2) the mechanical resistance to loads at service temperatures. Neither is a simple consequence of the service temperatures because service conditions will alter compositions, produce partial melting, and induee phase changes. Consequently, the equilibrium phase relationships have been rather thoroughly studied and give a knowledge of the thermal resistance to melting, but do not give full information about the mechanical properties because two refractories with the same types and quantities of phase may have different microstructures. Although variations of microstructures with time, temperature, and composition have been subjects for extensive investigation in metals, only a limited amount of comparable microstructural work has been performed for refractory materials.' This study was an attempt to evaluate some of the consequences of service parameters upon the microstructures of refractories so that bases may be established for the analyzing of high temperature mechanical properties. Periclase (MgO) was chosen as the refractory oxide; variables included those which are encountered under steelmaking conditions such as 1) temperature, 2) liquid composition, and 3) FeO additions under various oxidation levels. Specific attention was given to the distribution of the phases, both liquid and solid, and to the growth of individual crystalline grains. The most closely related work on microstructures of polyphase materials is that of Van Vlack and Rieg-ger2 on the microstructure of magnesiowüstite [(Mg,Fe)O] in the presence of silica. In that work which pertained to solid solutions with less than 40 pct MgO, most of the quantitative work was performed on FeO microstructures. The chief conclusions concerning these relatively low-melting oxide solids were as follows: 1) the rate of crystalline grain growth is inversely proportional to the grain diameter, 2) grain growth proceeds more rapidly at higher temperatures but is slightly retarded by additional liquid content, and 3) a Silicate-containing liquid penetrates as a film between the individual magnesiowüstite grains independent of time, temperature, amount of liquid, or the MgO/ FeO ratio. The above observations are in contrast to prior work3 on the microstructure of silica in the presence of iron oxide-containing liquids where the liquid does not penetrate as a complete film between solid grains. The phase relationships for the compositions of the present work are shown in Fig. 1 which is a summary of the work of several investigators.4 Of importance is the fact that CaO forms a more stable structure with SiO2 and Al2O3 than do either MgO or FeO. The oxygen potential has little effect on periclase unless iron oxide is also present. The iron oxide is ferrous at moderately low oxygen levels, changing to ferric as the Oxygen potential is increased so the spinels, magnetite, and magesioferrite are formed.5 These two phases are relatively stable in air at steelmaking temperatures. I) EXPERIMENTAL PROCEDURE ractory were made with reagent grade Oxides. The magnesium oxide used was 99 pct MgO after ignition, and the iron oxide raw material had a minimum content of 99 pet Fe2O3. The CaO, SiO2, and A12O3 were also reagent grade raw materials. After mixing, the required compositions were pressed into pellets at a minimum pressure of 5000 psi to insure compaction of the raw materials and prevent excess void content. A silicon carbide element tube furnace was used with thermocouple control for sin-

Jan 1, 1963

By Carl H. Beal, E. D. Nolan

In February, 1918, the conclusion was published by Lewis and Beal "that wells of equal output on the average will produce equal amounts of oil in the future, regardless of the ages of the wells." This conclusion was based upon the study of data collected principally in Oklahoma and was not known at that time to be true for other oil fields. An abundance of statistical proof was later collected by the senior author of the present paper, which showed that the conclusion was undoubtedly well founded and that it applied to other fields as well. Accordingly, it was later restated2 as the "law of equal expectations" as follows: "If two wells under similar conditions produce equal amounts during any given year, the amounts they will produce thereafter, on the average, will be approximately equal, regardless of their relative ages." Although only scanty data from the California oil fields were available at the time this publication was prepared, sufficient information was analyzed upon which to base the insert on Fig. 80, which showed beyond a doubt that the law held at least for a part of the Midway oil field in California. Recently the authors have collected more complete data in California, and it is the purpose of this paper to explain the method used in demonstrating the truth of the law and, in addition, to give several methods by which curves constructed in accordance with this law can be used in a practical way with ease and accuracy. The Family Curve The law of equal expectations means that each individual of a group of wells producing under similar conditions will decline along approximately the same type of curve, the rapidity of decline varying with the output

Jan 1, 1921

Jan 1, 1938

C. M. GARLAND,§ Chicago, Ill. (written discussion 11).-7--In the development of Mr. Traer's method for the low-temperature coking of Illinois coals, after the principles laid clown by Prof. Parr, it was soon demon-strated that, in order to yield a product of uniform volatile content, the coal must be coked in thin layers, and consequently must be handled in comparatively small volumes. This means, in the first place, that great care must he observed in the design of the coking chambers to prevent the loss of the products of distillation, and, in the-second place, that labor-saving devices must be utilized to the greatest possible extent in order to reduce the cost of handling.

Jan 12, 1918

Jan 1, 1928

Jan 1, 1942

By E. W. Steele

In the copper-casting department of a modern electrolytic copper refinery there are two kinds of casting furnaces: the anode, for casting crude copper into anodes for electrolysis; the refined-copper, for casting the cathodes resulting from electrolysis into market shapes, such as ingots, wire bars, and cakes. Both furnaces are reverberatories of practically the same general design and are operated intermittently, putting through a charge normally in 24 hr. The treatment of the copper in the two furnaces is similar, in that oxidation followed by skimming and reduction (poling) is carried on in both; but in the refined-copper furnace, the work must be done with greater care and it is of extreme importance that not the slightest trace of impurity be introduced into the copper. The furnaces usually hold from 150 to 300 tons of molten copper, which constitutes the daily charge. Except in the case of furnaces in the Lake district, where the concentrates from native-copper ores are charged through the roof, the furnaces are charged through the side doors by charging machines similar to those used in open-hearth steel practice. In 1916, at the Perth Amboy plant, of the American Smelting & Refining Co., located at Maurer, N. J., a study was made of the possibility of firing the copper refinery furnaces with pulverized coal instead of by hand. The proposed method possessed obvious advantages over hand firing and coal was a much cheaper fuel than oil at that time. However, there were several objections to its use, the principal ones being the possibility of increasing the sulfur content of the refined copper and the additional slag that might be produced from the ash. The increase of the sulfur content of the refined copper was the more serious, as more than 0.002 per cent. sulfur is objectionable. Any increase of the slag would be expensive as the copper in this slag would have to pass again through the entire smelting and refining process. It was thought that certain modifications in operations and furnace conditions, which will be described later, would overcome these objections SO the proposition was discussed with a manufacturer of coal-pulverizing equipment. He was uncertain concerning the use of pulverized coal

Jan 1, 1925

By D. R. Miller

The use of fully grouted cables for ground reinforcement in underground mining is becoming widespread. Reinforcement design for this application has tended to be empirical although some two- dimensional design techniques have been developed. This paper describes a technique based on a model of the behaviour of cables placed across planes moving in shear. The model is three- dimensional and includes a simple model of the 'dowel' effect which arises from the bending of the cables. The model determines the shear resistance developed at a particular shear displacement assuming joint friction and cable parameters. Using data for twin 15.2mm dim. steel strand cables, and a concept of reinforcement efficiency, the application of the model to design wall support in open stopes is demonstrated. The examples consider the cases where major planar structures are known in location and orientation and where, as is more common is open stope development, mapping has indicated that a distribution of potential shear failure structures may be present. The actual location and orientation of potential shear planes is not known. These two cases highlight the underdesign of reinforcement that may arise if the distribution of orientation of potential shear planes is not considered.

Jan 1, 1984

By William H. Hamilton

Tunnel-driving capabilities in terms of feet per hour have advanced several hundred percent in the last century. Indications are that this capacity will double each decade for the next three decades. These future improvements will be made possible by a greatly increased need for underground excavation and the awareness of industry of its own latent capabilities. The factors of most interest to any potential user of a tunneling machine are those making possible an increase in production. The first and most obvious factor, and probably the one that has created the excitement and interest of most people, is the increase in boring rate through faster rock fracture and improved support systems. Boring rate can be increased by more horsepower in the form of increased thrust, torque, and cutterhead speed, and by better cutters and cutting methods, better material-handling systems, and better ground-control systems. All of these items are extremely important and are the basis of much discussion and effort by everyone concerned with the excavation of tunnels by machine. The second factor, just as obvious and equally important as an increase in boring rates, is "increase in production through better utilization of the tunneling machine and related equipment," which means a reduction in downtime through greater reliability of equipment. Mechanical rock attack is presently capable of cutting hard rock at 5 fph and soft rock at more than 20 fph. In current practice, however, this advance rate is maintained for less than 50% of the shift time. I predict that tunnel-driving contractors and their supporting manufacturers of tunnel-boring equipment will provide machinery that will maintain these advance rates for more than 90% of the shift time. This increase in effective production will be due to the increase in reliability of the tunneling machine and tunneling system components. Such a percentage increase in utilization of the tunneling equipment is just

Jan 1, 1970

By E. A. Stevens

IT has been ascertained in recent years that certain rocktypes, geological formations and structural conditions may be used as fairly reliable guides, when prospecting in recognized mineral belts or mining districts, with a reasonable certainty of discovering "pay-ore;" and that such is considered as a practically established conclusion may be inferred from a perusal of the recent reports of the U. S. Geological Survey and the literature of the several scientific societies discussing minim, geology, and kindred subjects. Cripple Creek is no exception to this conclusion, and the rock-type or association, rather than the structural condition, is the most infallible guide.† These guides consist of four, possibly five, dike-rocks, three of which are extremely basic, while the fourth is an acid rock of an entirely dissimilar character. The basic rocks are nepheline-basalt, limburgite, feldspar-basalt and tephrite. There are grounds, however, for believing that the two latter are subdivisions of one type, and therefore will be described under one head. The acid rock is quartz-porphyry. Nepheline-basalt is-a rock encountered in but few localities elsewhere on this continent, and occurs in narrow dikes cutting various formations. When typical‡ it is composed of

Jan 1, 1913

By John E. Conley, John A. Ruppert

W. B. Mather—A minor recommendation that may be offered to improve the paper is the inclusion of a map of Oregon showing the general location of the various deposits. This is of especial importance to persons like myself who are not familiar with the various areas and counties mentioned. N. S. Wagner and R. S. Mason (authors' reply)—We agree that an index map of Oregon showing the location of the various nonmetallic deposits would add to the paper (fig. 1).

Jan 1, 1951