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The 1963 Lignite Symposium was held on the University of North Dakota campus, Grand Forks, N. Dak., April 30-May 1, 1963, under the cosponsorship of the University of North Dakota and the Bureau of Mines. This symposium, the third in a series, had as a general objective the dissemination of information concerning advances in technology and utilization of solid fuels, with emphasis on lignitic coals. Approximately 150 representatives of industry, government, and educational institutions from 21 states and 3 Canadian provinces were present at the symposium. Those attending were welcomed by Marling J. Ankeny, Director of the Bureau of Mines, representing the Bureau, and Dean T. H. Clifford, Vice President of the University, representing the University.

Jan 1, 1964

By Sidney Katell

This report covers the period January 1963 through December 1963; it is a continuation of the series that began with the publication of Information Circular 7516 in October 1949. Also, it is the fifth in a series of reports prepared under a cooperative agreement between the Bureau of Mines and the American Association of Cost Engineers. The agreement provides for the publication of an annual cost bibliography with the work load involved in the preparation shared equally. The abstracted articles, concerned with all facets of cost engineering in the field of chemical and petroleum plants and related subjects, are from the following sources:

Jan 1, 1964

By Joel N. Van Sant

An investigation was conducted to study possible sources of Utah refractory and structural clays that could be used for the manufacture of refractories and light or buff burning heavy-clay products. A field study was made and the clay samples tested to determine their firing characteristics. Results of the Bureau's work indicate many small noncommercial deposits of hypogenic clay occur in igneous rocks. Commercial hypogenic deposits are mostly halloysite clay developed by hydrothermal replacement of limestone. The high firing shrinkage of halloysite precludes its use as a refractory, however, halloysite produced at the Dragon Mine south of Eureka, is used fur making oil catalysts. Clays and shales suitable for low heat duty refractory products are found in the Manning Canyon shale, in shales associated with coal bearing rocks, and in the Dakota formation. Some of the clays from the Dakota formation are also suitable for high-duty refractory products.

Jan 1, 1964

The editorial expenses for the preparation of the manuscript of the second edition, as for the first, were provided by grants of the Engineering Foundation and the Open Hearth Steel Committee of the Iron and Steel Division, AIME ; the Seeley W. Mudd Memorial Fund again sponsored the publication of this volume. The companies and research or educational institutions with which the authors, reviewers, and editors are connected also contributed much to the writing and editing of this book through their generous donations of time and travel and office expenses. And finally, the authors and others have given countless hours of their own time with no recompense but the satisfaction of a job well done. In order to give credit to the companies or educational institutions which made it possible for the members of the Editorial Board to devote considerable time to the revision of this book, the names of these members and their affiliations are recorded here as follows : W. O. Philbrook, Carnegie Institute of Technology M. B. Bever, Massachusetts Institute of Technology H. B. Emerick, Jones and Laughlin Steel Corporation B. M. Larsen, United States Steel Company A number of individuals suggested desirable changes in the book before rewriting was started. Almost all manuscripts were gone over critically by reviewers, and the resulting criticisms led to the correction of errors and omissions and greatly contributed to the accuracy and completeness of the text. Other people have supplied additional data or illustrations or assisted in other ways. While some of these contributors must remain anonymous because they are not known to the Editors, the cooperation of the following individuals is gratefully acknowledged : R. D. Allen, Republic Steel Corporation, Chicago Isadore Amdur, Massachusetts Institute of Technology Mary Baeyertz, Armour Research Foundation S. P. Bahmer, Republic Steel Corporation, Massillon E. C. Bain and Associates, United States Steel Company, Pittsburgh C. W. Briggs, Steel Founders' Society of America H. W. Briske, Wisconsin Steel Works

Jan 1, 1964

By A. D. McMahon

This survey is one of a series of Bureau of Mines publications designed to serve the needs of Government and industry for comprehensive information on mineral commodities and activities. Copper, a versatile metal, has been vital to all civilizations from pre-historic times to the present. Its essential value in antiquity and until the nineteenth century arose from its malleability and ease of working, its corrosion resistance and durability, its attractive colors in alloyed and unalloyed forms, and, of course, its availability. The principal uses were for tools, utensils, vessels, weapons, pipe, statuary and other objects of art, and for building and architectural purposes where formability, permanence, and beauty were necessary qualities. Utilization of copper based on these physical and mechanical properties has grown tremendously for commercial, structural, mechanical, architectural, and art items; and its capacity for forming numerous alloys has led to a myriad of applications from miniature copper and brass eyelets to huge bronze battleship propellers. The early nineteenth century marks the epoch of the greatest use of copper, transmitting electrical energy. This particular property of copper is fundamental to the spectacular growth of the electrical industry and all associated industries relying on electricity for power, light, and heat. More than half of all copper produced is used for transmission of electricity.

Jan 1, 1964

By Paul E. Bennett, James S. Browning, Thomas L. McVay

Continuous 1.0- to 1.5 - ton - per - hour pilot plant flotation tests were made to determine the technical and economic feasibility of recovering beryl from flotation tailing being produced at the spodumene concentrator of the Foote Mineral Company , Kings Mountain , N.C. Best results were obtained when using an acid circuit and amine - type cationic reagents to float a bulk beryl - feldspar concentrate and then selectively floating the beryl away from the feldspar , using a petroleum sulfonate collector . About 77 percent of the beryllium in the pilot plant feed was recovered in a concentrate containing 6.42 percent BeO . The capital cost of an integrated flotation plant capable of treating 500 dry tons of spodumene mill tailing per day for recovery of beryl and feldspar is estimated at $ 210,000 . Indicated direct operating costs for the plant were $ 1.52 per ton of dry spodumene flotation tailing treated . This approximated the value of beryl recovered , but potential profits of about the same magnitude lie in concurrent recovery of marketable spodumene and feldspar byproducts .

Jan 1, 1964

By Paul W. Johnson, Ralph C. Kirby, Frank A. Peters

Alumina can be recovered from clay , using 30 percent nitric acid for digestion . Calcined clay is crushed and then digested at 325 ° F and 85 psig pressure with less than stoichiometric nitric acid required to form normal aluminum nitrate . In this way , a solution containing both normal aluminum nitrate , Al ( NO3 ) 3 , and basic aluminum nitrate , assumed to be Al ( OH ) ( NO3 ) 2 , is formed , and in which iron is virtually insoluble . The solution is filtered and then concentrated in vacuum evaporators to crystallize normal aluminum nonahydrate . The crystals are washed with 50 percent nitric acid and then decomposed to alumina and nitrogen oxides . The design that has been developed for this process is based on published work . For a plant producing 1,000 tons of alumina a day , the estimated operating cost is $60.69 per ton of alumina , and the estimated fixed capital cost is $ 76 million using a Marshall and Stevens chemical equipment index basis of 240.0 . This process is not competitive under current economic conditions with the production of alumina from bauxite via the Bayer process . For lowering costs , future research should include study of leaching at lower temperatures under atmospheric pressure and alternate aluminum nitrate decomposition methods .

Jan 1, 1964

By D. A. Elkins

Design plans and detailed cost estimates of mining and treating ore from Maggie Canyon deposit by two alternative methods which can be used in the event of a sudden need to exploit this resource are given . Lower costs are estimated for the operation employing oil - emulsion flotation . The total capital investment required for this operation is estimated at $ 11,750,000 . Assuming an 85 percent recovery in mining , 55.6 pct of the manganese in the ore reserve would report in 153,333 tons of ferromanganese containing 75 pct manganese . The production cost for the 5 - year operation would be about $ 245 per ton of ferromanganese . The total annual operating cost would be approximately $ 7.5 million , distributed , in pct , as follows : Mining 11.9 , milling 24.4 , sintering 9.9 , smelting 47.2 , hauling ore and sinter 2.8 , and general offices 3.8 . Recovery and costs are both higher for the operation employing dithionate leaching . In this operation the required investment is about $ 17,220,000 . Manganese recovery would be 67.6 pct in 186,160 tons of ferromanganese . Production cost would be about $ 284 per ton of ferromanganese . The total annual operating cost would be about $ 10,575,000 , distributed , in pct , as follows : Mining 8.4 , milling 44.4 , sintering 7.4 , smelting 34.7 , hauling ore and sinter 1.3 , and general offices 3.8 . Potential process modifications might reduce the operating cost of the first operation by as much as 7 pct and that of the second operation by as much as 9.5 pct , but exploitation of the deposit by the techniques studied is not economical today .

Jan 1, 1964

By W. P. Haynes, J. W. Mulvihill, G. B. Taylor, S. Katell

Capital and operating costs have been estimated for separating methane and hydrogen in gas - separating plants designed to produce 90 million scf per day of product gas containing a minimum of 90 percent methane . After a preliminary literature review of various separation techniques , three different processes --moving - bed adsorption using active carbon , oil absorption , and liquefaction -- were chosen for the cost estimates . Three different methane feed gas concentrations , 5 , 20 , and 50 percent ( cases 1 , 2 , and 3 , respectively ) , were chosen as representative methane concentrations for the separation estimates . Capital and operating costs were lowest for the moving - bed adsorption process in all three cases investigated . Operating costs declined from $ 0.24 to $ 0.06 per 1,000 cu ft of product gas , and capital costs declined from $47,490,800 to $7,411,200 as the percentage of methane in the feed gas increased from 5 to 50 percent .

Jan 1, 1964

By J. A. Ruppert, P. M. Sullivan

A study was made of filtration techniques for recovering the major part of the tin contained in iron - tin alloys known as hardhead . Special smallscale filtering apparatus and a three - stage cyclic process were developed . Eighty- seven percent of the tin contained in an alloy of 82 percent tin and 17 percent iron was recovered as pure metal by pressing at 975° C followed by a second pressing at 800 ° C and a final filtering at 250 ° C. Small amounts of Sb , Cu , and Fe impurities were removed by adding Al to the molten product and performing another filtration at 250 ° C.

Jan 1, 1964

By F. D. Everett

Thermoelectric and metal alloying applications have changed the status of tellurium from oversupply to under supply . In a search for new sources of this element in Arizona , Colorado , New Mexico , Utah , and neighboring states , the Bureau of Mines analyzed more than 200 samples and obtained the results of tellurium determinations by private companies on more than 500 samples from a wide variety of mineral - bearing deposits . The About 40 minerals containing tellurium have been reported , mainly tellu- rides of gold , silver , bismuth , mercury , lead , copper , iron , and nickel . minerals usually occur in small quantities and identification in ores is extremely difficult . Samples containing more than 0.1 percent tellurium were taken from the Hilltop and Memphis properties in Dona Ana County , N. Mex . , and the Silver King property in White Pine County , Nev . , where development was chiefly for base metals . The Lone Pine mine in Catron County , N. Mex . , and the Bambolla mine near Moctezuma , Sonora , Mexico are potential sources of native tellurium occurring in small but high- grade pods . Much of the production of tellurium has come as a byproduct of electro- lytic refining of copper and lead- zinc ores in Arizona , Colorado , New Mexico , and Utah . Base -metal ore deposits will continue to be the most important pri- mary source of tellurium , although the concentration in ores is nearly always less than 10 parts per million . Any significant increase in output of tellu- rium probably will be related to production and improved efficiency in smelt- ing and refining base - metal ores .

Jan 1, 1964

By Raymond W. Hiteshue, Sam Friedman, Robert Madden

Experiments were made in a semicontinuous unit to provide engineering data for designing experimental continuous systems . These systems would be used to study the hydrogasification of hvab coal and char (from lowtemperature carbonization ) to high - Btu gas . In experiments at 800 ° C and with a coal residence time of several seconds , yields of hydrocarbon gases increased from about 2,000 scf / ton of maf coal at 250 psig to 7,000 scf at 1,000 psig . With 15 minutes residence time , yields increased from 8,000 scf/ton of maf coal at 250 psig to 17,500 cubic feet at 1,000 psig . In all cases , small quantities of heavy oils were produced along with the gaseous hydrocarbons . Production of oils could be minimized with a corresponding increase in gaseous hydrocarbons by increasing the retention time of the volatiles within the hot zone . Yields of gaseous hydrocarbons from char were slightly greater than from coal under similar conditions . Although the hydrogasification reaction is very pressure dependent , substantial quantities of coal (40 to 60 percent ) could be reacted to gaseous hydrocarbons at pressures as low as 50 psig provided reaction temperatures were increased to 1,200 ° C. It was also demonstrated that a hvab coal could be hydrogasified continuously without incurring agglomeration . This was achieved by dispersing coal in a relatively large reactor with concurrent flow of hydrogen . At 1,000 psig and 800 ° C , it was possible to react about 35 percent of the coal and to produce a gas containing up to 52 percent methane .

Jan 1, 1964

By H. Brindel

The paper point out the importance of a maintenance program at Toquepala, as to the effect that any changes in the above may have on the program and organization. The Southern Peru Copper Corporation carry out a training program in operation with a appropiate peruvian staff, as it has been established the basics for a sound, preventative maintenance and repair organization. In consecuence, this company decided to expand a two -fold program of training and maintenance so that the Peruvian personnel will not only be an aid to the Company but a national as set to Perú as well.

Aug 20, 1963

By G. N. Maniar

G. W. Healy (union Carbide Metals Co.)-The author's paper is a useful contribution to the store of maps of chemical activities of oxides in multi-component slag systems. It is also a good example of the utility of the Gibbs-Schuhmann technique for calculating activities in a system where that of one of the components has been measured. This paper Koh and Caugherty. This plot is reproduced by alor in X-ray Metallography. Because of this nonlinearity, preparation cf suitable standards and/or correction for absorption and enhancement are essential in microanalysis. However, our objection is not the conclusion that Dr. Aaronson has arrived at nor the technique he has used; but only to the foot-note credited to V. Macres. The level of chromium that he was concerned with (less than 3 pet) is so low that the deviation of uncorrected Cr-curve will be negligible. Besides Dr. Aaronson has used chromium intensity from martensite and set it equal the bulk chromium content of the alloy. Using this chromium-intensity as a reference, he has calculated the amount of chromium in the ferrite. This amounts to the same as using an internal standard. Since the chromium content in austenite and ferrite are almost the same, enhancement due to iron in both will be the same and therefore does not need to be corrected. together with the author's recently published one1 on the CaO-FeO-Fezo3 system will be most helpful to others learning to apply Schuhmann's method, which merits a far wider application than it has received to date and should greatly aid our understanding of equilibria between metal and oxide phases. As shown by okcen" its use may even be extended to sections of systems with any number of oxides. I have some questions as to the selection of equilibrium constants made by Dr. Turkdogan. He has chosen one for the formation of Fe2O3 from FeO and oxygen which gives Fea3 activities 50 pct higher

Jan 1, 1963

By G. W. Healy

G. W. Healy (union Carbide Metals 0.)-The author's paper is a useful contribution to the store of maps of chemical activities of oxides in multi-component slag systems. It is also a good example of the utility of the Gibbs-Schuhmann technique for calculating activities in a system where that of one of the components has been measured. This paper Koh and Caugherty. This plot is reproduced by alor in X-ray Metallography. Because of this nonlinearity, preparation cf suitable standards and/or correction for absorption and enhancement are essential in microanalysis. However, our objection is not the conclusion that Dr. Aaronson has arrived at nor the technique he has used; but only to the foot-note credited to V. Macres. The level of chromium that he was concerned with (less than 3 pet) is so low that the deviation of uncorrected Cr-curve will be negligible. Besides Dr. Aaronson has used chromium intensity from martensite and set it equal the bulk chromium content of the alloy. Using this chromium-intensity as a reference, he has calculated the amount of chromium in the ferrite. This amounts to the same as using an internal standard. Since the chromium content in austenite and ferrite are almost the same, enhancement due to iron in both will be the same and therefore does not need to be corrected. together with the author's recently published one1 on the CaO-FeO-Fe2O3 system will be most helpful to others learning to apply Schuhmann's method, which merits a far wider application than it has received to date and should greatly aid our understanding of equilibria between metal and oxide phases. As shown by okcen" its use may even be extended to sections of systems with any number of oxides. I have some questions as to the selection of equilibrium constants made by Dr. Turkdogan. He has chosen one for the formation of Fez03 from FeO and oxygen which gives Fea3 activities 50 pct higher

Jan 1, 1963

By Frank A. Peters

A series of evaluations is being made to determine the relative processing costs of producing metallurgical-grade alumina from low-grade aluminous materials. These evaluations include the estimated operating and capital costs as well as recommendations for additional research and development to improve the processes and to lower their costs. The design for each process is based on published work. The three processes considered in this evaluation are designed to leach alumina as aluminum sulfate from calcined clay with sulfuric acid and to remove the silica residue by filtration. The filtrate from leaching is then purified by one of the following methods: Removal of iron in electrolytic cells using mercury cathodes; removal of iron by chemical precipitation through the formation of an iron-manganese complex; or precipitation of the alumina from an aqueous-ethanol solution, leaving iron in solution. Both the operating and capital costs for these processes are higher than those for the Bayer process. For plants producing 1,000 tons of alumina a day, the estimated operating costs per ton of alumina are: Electrolytic iron-removal process........... $81.35 Chemical iron-.removal process............... 82.08 Ethanol purification process............... 86.17 The investment in mercury is not part of the operating cost since this cost is considered equivalent to catalyst cost which would not be shown. The estimated capital investments for 1,000- ton-per- day plants on a Marshall and Stevens chemical equipment index basis of 240.0 are: Electrolytic iron-removal process...... $116,775,500 Chemical iron-removal process............... 99,418,900 Ethanol purification process................ 94,210,200 These investments include the working capital but not the land for each of the processes. Included in the electrolytic iron-removal process is an investment of $4,859,400 for mercury. Investigation of other methods for removing iron, of the decomposition operation, and of the leaching operation could reduce these costs.

Jan 1, 1963

By H. C. Carpenter

This literature study of methods for desulfurizing residual fuel oil was conducted by the Bureau of Mines at the request of the Department of Health, Education, and Welfare. The sulfur compounds in residual fuels are believed to consist chiefly of condensed thiophenes and other polycyclic sulfur compounds. Hydrodesulfurization appears to be the most promising method for desulfurizing these oils and is the only method applicable to all types of sulfur compounds. There are indications in the literature that hydrodesulfurization without hydrocracking of residual oils may require higher pressures than used in present desulfurization processes, but no cost data and little experimental data are available on the higher pressure operation. Literature proposals for hydrogenating residual oils and heavy crude oils are exclusively for hydrocracking the oils to lower boiling products with accompanying partial desulfurization of the residual fuel fraction. Costs of the hydrocracking operations appear the closest available to probable costs of hydrodesulfurizing the oils, and have been reported (in 1955 to 1957) as $500 to $840 investment cost per daily barrel of capacity, with total operating costs of 70 cents to $1.10 per barrel.

Jan 1, 1963

By W J. Dyck

Past attempts to establish an integrated steel industry on the West Coast of Canada have been unsuccessful for at least three reasons: (a) insufficient reserves of a suit-able iron ore supply; (b) a relatively small local market for iron and steel; and (c) the non-availability of an economical process to produce primary iron on a small scale. Today, the reserves of economically mineable ore deposits are ample to support a steel production of 100,000 to 200,-000 tons per annum. The local market has increased so as to be able to absorb most of this capacity. With-in the next few years, a small integrated steel plant, including the "H-Iron" direct iron ore reduction process for electric furnace charge stock production, will be able to show a profitable operation. Introduction

Jan 1, 1963

By H. C. Carpenter

This literature study of methods for desulfurizing residual fuel oil was conducted by the Bureau of Mines at the request of the Department of Health, Education, and Welfare. The sulfur compounds in residual fuels are believed to consist chiefly of condensed thiophenes and other polycyclic sulfur compounds. Hydrodesulfurization appears to be the most promising method for desulfurizing these oils and is the only method applicable to all types of sulfur compounds. There are indications in the literature that hydrodesulfurization without hydrocracking of residual oils may require higher pressures than used in present desulfurization processes, but no cost data and little experimental data are available on the higher pressure operation. Literature proposals for hydrogenating residual oils and heavy crude oils are exclusively for hydrocracking the oils to lower boiling products with accompanying partial desulfurization of the residual fuel fraction. Costs of the hydrocracking operations appear the closest available to probable costs of hydrodesulfurizing the oils, and have been reported (in 1955 to 1957) as $500 to $840 investment cost per daily barrel of capacity, with total operating costs of 70 cents to $1.10 per barrel.

Jan 1, 1963

Mineral engineering is defined as those engineering activities that relate to the discovery, development and utilization of mineral resources. Using petroleum engineering as an example, it is shown that the breadth of the field to be studied is a major educational problem. Breadth of field is aggravated by the rapidity with which technological demands may change. At present, special short courses serve to update engineering education. Recent experience suggests an increased rate of change for the future. The fact that engineers have typically human needs and goals, and the fact that engineers respond to these in our free society, introduces a third class of problems. One approach to the solution of these problems is the unified engineering curriculum based on a core of subject mat-ter common to all engineering. Experience suggests that the unified curriculum is an effective method to minimize the importance of the first two problem areas presented, and shows a degree of success in handling some problems within the third area. Perhaps, for the good of all segments of society, it is best to have both career-oriented and unified curricula represented by educational institutions of high quality.

Jan 1, 1963