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By R. L. Manegold

This paper outlines the reasons for and the application of suspended magnets above belt conveyors for the purpose of removing tramp iron to protect equipment. The design of a magnet strong enough to extract iron through a distance of 24 in. is described along with the proper method of application in the field. Advantages of the suspended magnet in contrast to the conventional magnetic pulley are also discussed. IN RECENT years there has been a decided trend toward bringing ores and coal out of open-pit and underground mines by long, sloping single-stage belt conveyors. Because the high investment cost of haulage conveyors dictates maximum speed and full loading for economy, conveyor belts are running faster than ever before, with a greater burden on the belts. In addition, larger blocks of ore are being mined and conveyed. Rougher use of large mining equipment generates more tramp iron; mechanical loading rejects nothing. Therefore the extraction of tramp iron and other deleterious materials for the protection of haulage conveyors at transfer points, chutes, and idlers is becoming an increasingly difficult job. In our experience, the best method of protecting long haulage conveyor belts is to extract the tramp iron, at least the large tramp iron, ahead of the main haulage conveyor or series of conveyors. It is most practical to collect the tramp iron at the earliest source possible, usually directly after the primary car unloading dump or after the primary crushers, which are ordinarily not affected by tramp iron, see Fig. 1. The coal or ore from its primary source is fed by chutes or feeders onto a buffer or shock belt conveyor, a short, ruggedly built conveyor system that can be considered somewhat expendable. Its primary function is to bring the ore up to speed for transmission to the haulage conveyor. There is no assured method of protecting this conveyor from tramp iron damage at its feed end. Likewise, there is a possibility, although remote if the magnet applied to this belt is installed correctly, that the tramp iron extraction process will damage the shock belt, which is, however, short and comparatively inexpensive. Magnetic head pulleys with their maximum effective range of about 8 or 10 in. cannot be considered for large installations, even though they are desirable because of the continuous and automatic tramp iron removal feature. Further, the most dangerous form of tramp iron with respect to potential damage to a haulage conveyor is the long rod, roof bolt, or rail segment, which is not extracted satisfactorily because of the limited tangential contact of such an iron shape with the magnet. Magnetic head pulleys are also undesirable because the dribble or fines from the head pulley discharge at the same point as the tramp iron. Screens must be used to separate the fines from the magnetics, resulting in additional expense and loss of head room. Magnetic detectors have been used with success, but they only indicate the presence of iron, and the conveyor belt must be stopped for its manual removal. The stoppage of any conveyor means that all preceding equipment must be stopped or a cascade of material on the idle conveyor will result. Occasionally combinations of detectors and magnetic head pulleys are used. The detector precedes the magnetic head pulley and detects only large pieces of tramp iron, while the magnetic pulley subsequently takes out the smaller ferrous metals. Suspended magnets overcome the disadvantages of magnetic head pulleys, detectors or a combination of both. There are several magnetic extraction problems involved in applying a suspended magnet at this

Jan 1, 1953

By R. L. Manegold

This paper outlines the reasons for and the application of suspended magnets above belt conveyors for the purpose of removing tramp iron to protect equipment. The design of a magnet strong enough to extract iron through a distance of 24 in. is described along with the proper method of application in the field. Advantages of the suspended magnet in contrast to the conventional magnetic pulley are also discussed. IN RECENT years there has been a decided trend toward bringing ores and coal out of open-pit and underground mines by long, sloping single-stage belt conveyors. Because the high investment cost of haulage conveyors dictates maximum speed and full loading for economy, conveyor belts are running faster than ever before, with a greater burden on the belts. In addition, larger blocks of ore are being mined and conveyed. Rougher use of large mining equipment generates more tramp iron; mechanical loading rejects nothing. Therefore the extraction of tramp iron and other deleterious materials for the protection of haulage conveyors at transfer points, chutes, and idlers is becoming an increasingly difficult job. In our experience, the best method of protecting long haulage conveyor belts is to extract the tramp iron, at least the large tramp iron, ahead of the main haulage conveyor or series of conveyors. It is most practical to collect the tramp iron at the earliest source possible, usually directly after the primary car unloading dump or after the primary crushers, which are ordinarily not affected by tramp iron, see Fig. 1. The coal or ore from its primary source is fed by chutes or feeders onto a buffer or shock belt conveyor, a short, ruggedly built conveyor system that can be considered somewhat expendable. Its primary function is to bring the ore up to speed for transmission to the haulage conveyor. There is no assured method of protecting this conveyor from tramp iron damage at its feed end. Likewise, there is a possibility, although remote if the magnet applied to this belt is installed correctly, that the tramp iron extraction process will damage the shock belt, which is, however, short and comparatively inexpensive. Magnetic head pulleys with their maximum effective range of about 8 or 10 in. cannot be considered for large installations, even though they are desirable because of the continuous and automatic tramp iron removal feature. Further, the most dangerous form of tramp iron with respect to potential damage to a haulage conveyor is the long rod, roof bolt, or rail segment, which is not extracted satisfactorily because of the limited tangential contact of such an iron shape with the magnet. Magnetic head pulleys are also undesirable because the dribble or fines from the head pulley discharge at the same point as the tramp iron. Screens must be used to separate the fines from the magnetics, resulting in additional expense and loss of head room. Magnetic detectors have been used with success, but they only indicate the presence of iron, and the conveyor belt must be stopped for its manual removal. The stoppage of any conveyor means that all preceding equipment must be stopped or a cascade of material on the idle conveyor will result. Occasionally combinations of detectors and magnetic head pulleys are used. The detector precedes the magnetic head pulley and detects only large pieces of tramp iron, while the magnetic pulley subsequently takes out the smaller ferrous metals. Suspended magnets overcome the disadvantages of magnetic head pulleys, detectors or a combination of both. There are several magnetic extraction problems involved in applying a suspended magnet at this

Jan 1, 1953

By H. Baldauf, H. Schubert

The structure of flotation reagents is important for their adsorption on mineral surfaces and thus for their flotation effectiveness. The influence of the structure of organic depressants on the flotation of fluorite and barite with anionic and cationic collectors was investigated using a modified Hallimond microflotation cell. In addition, adsorption, desorption, and electrokinetic results were employed to further elucidate the role and the correlation of the structural parameters for adsorption and the depressing effect. As hydrophilic reagents, different aliphatic and aromatic compounds capable of forming chelates with alkaline earth materials were used. For the depressing effect, the kind, number, and position of the polar groups in the molecule, as well as the structure of the reagent films play decisive roles.

Jan 1, 1980

By Sam Tour

SOME years ago, the writer described heat checks or thermal. cracks that occur in die-casting dies.1 The life of dies was considered in relation to the casting temperature, the material used for the die, and the heat to be absorbed by the die per unit volume of casting made. The mech-anism of the action that results in thermal failure of dies was described. In the present paper the writer proposes to describe some additional observations in regard to heat checking, make one or two suggestions as to the method or methods for further attack of the problem, and give the results obtained on some work carried out along these lines.

Jan 1, 1934

By L. A. Pursell

Environmental constraints can both delay and raise the cost of a major plant addition, often requiring a complete reevaluation of the plant site and the proposed project. In this case history, steps are presented which were followed in applying for environmental permits for a major addition to a lime plant. Methods are described for determining expected emission increases and for selecting the best control technology for each source. The description progresses through pre-application conferences with control agencies, the formal application procedure, computer modeling the air quality impact, and the methods followed in obtaining a favorable determination.

Jan 1, 1983

By Bryan Denby

The curvilinear nature of shear strength envelopes for rock discontinuities may be simply and precisely represented by a power curve. The development of shear strength criteria applicable to rock discontinuities is reviewed and related to a theoretical basis for curvilinearity. An approach is reported to enable the quantification of the two power curve indices using a nomogram based on empirical studies. Using a knowledge of discontinuity basic friction angle and peak dilation angle the relevant indices ranges may be predicted for mine slope studies.

Jan 1, 1984

By Irving B. Cadoff, Ernest Levine

The crack formation and propagation in the single -phase Cu-4 pct Ag alloys were studied. The alloys were loaded in mercury to various stress levels, the mercury was removed, and the specimen examined for cracks. Cracks were found to develop below the fracture stress; the frequency of such cracks increased with increasing stress level. Some cracks were nmpropagative. Fracture in mercury was found to occur by the link-up of cracks formed at various stress levels rather than by the growth and propagation of a single crack. If the mercury environment is removed prior to a critical amount of crack formation, then continued loading results in ductile fracture. The appearance of the cracks at selected grain boundaries is related to the relative orientation of the boundaries, as are the propaga-tive characteristics of the crack. The mercury interaction appears to be one of lowering the strength of the metal-metal bonds in the high-stress area of the grain boundary. GRIFFITH'S microcrack theory1 proposed a critical crack size above which a crack in an elastic material grows with decreasing energy at a stress of From his theory it was proposed that the presence of a liquid tends to lower the surface energy of the microcrack faces2 leading to a decrease in the critical crack size necessary for spontaneous fracture propagation. stroh3 proposed that the stress concentration at a grain boundary due to pile-up may initiate a microcrack at the grain boundary. petch4 and Stroh5 evaluated the stress distribution at the head of a pile-up in a polycrystal-line material and deduced that the critical crack size and hence of is dependent on the grain size. Experimental verification of this dependence was found by petch6 for hydrogen embrittlement of steel. Studies in stress-corrosion cracking7 have provided a picture of fracture which shows that initial separations occur in a scattered, independent fashion in regions of high tensile stress. A minimum or threshold stress is necessary to produce a sufficient stress concentration to initiate frac- ture. These separations join up to form a crack. The extension of fracture is largely discontinuous and consists of a joining up of cracks. In recent worka evidence of this scattered crack network was found in a Cu-Ag alloy embrittled by mercury. For the Cu alloy-Hg couple, the crack path has also been found to be dependent on the orientation of adjacent grains, and with the addition of zinc to mercury a reduction in embrittlement along with a change in fracture morphology was found.9 In this present study, a mercury-dewetting method was used to observe crack initiation and fracture morphology when a Cu-4 pct Ag alloy is deformed in mercury and Hg-Zn solutions. PROCEDURE Specimens of Cu-4 pct Ag were prepared as in previous crack-path studies.' The specimens were heated at 770°C for 24 hr and water-quenched Tension tests using a table-model Instron were carried out in mercury and in various concentrations of Hg-Zn. Loading was in steps up to the fracture stress, with the load being removed and the specimen examined for surface cracks at each step. The specimens were dewetted after each load to permit examination of the surface structure and rewetted prior to continued loading. The specimens were wetted by electro polish ing in phosphoric acid, rinsing in alcohol, and then immersing in a pool of mercury. Dewetting was accomplished by flame heating the specimen for 30 sec in a vacuum. Some surface contamination was found, but not enough to obscure crack configurations and grain boundaries. RESULTS Fracture Characteristics in Mercury. Fig. 1 is a stress-strain curve showing the progressive step-wise loading of the specimen. As may be seen from the graph, the first position stopped at a is at a stress 5000 psi below the expected fracture stress of 25,000 psi. Examination of the specimen after removal of mercury showed only one crack. The appearance of this crack at a stress far below the fracture stress of this alloy in mercury did not affect the stress-strain curve in any manner. The specimen was then recoated with mercury and deformation was continued (curve b, Fig. 1) raising the stress by 4000 psi, and the same procedure re~eated. The initial crack was located and appeared as in Fig. 2 (crack lb). In this figure the crack is

Jan 1, 1964

By S. N. Singh, M. C. Flemings

Results are presented of a study on the combined influences of ingot dendrite am spacing and thermo-mechanical treatments on the fracture behavior and mechanical properties of high purity 7075 aluminum alloy. The most important single variable influencing mechanical properties was found to be undissolved alloy second Phase (microsegregation inherited from the original ingot). Ultimate and yield strengths were found to increase linearly with decreasing amount of alloy second phase while ductility increased markedly. At low amounts of second phase, transverse properties were approximately equal to longitudinal properties. In tensile testing, microcracks and holes were invariably found to originate in or around second phase particles. Fracture occurred both by propagation of cracks and coalescence of holes, depending on the distribution and amount of second phase. IN most commercial wrought alloys, second phase particles are present that are inherited from the original cast ingot. These include, for example, non-equilibrium alloy second phases such as CuAl2 and impurity second phases such as FeA13 and Cr2A1, in aluminum alloys. A previous paper1 has dealt with the morphology of these second phases in cast and wrought aluminum 7075 alloy, and with their behavior during various thermomechanical treatments. In this paper we discuss the influence of the particles on mechanical properties and fracture behavior of the alloy. Previous experimental work indicating a direct and major effect of second phase particles on mechanical properties (especially on ductility) includes the work of Edelson and Baldwin on pure copper.' Also relevant are the many studies demonstrating the important effect of nonmetallic inclusions on the fracture of. steel.3'4 Work on aluminum includes that of Antes, Lipson, and Rosenthal5 who showed that a dramatic improvement in ductility of wrought aluminum alloys of the 7000 series is achieved by eliminating second phases. It now seems well established that included second phases play a dominant role in controlling ductility (as measured, for example, by reduction in area in a tensile test) of a variety of materials. There is, therefore, considerable current interest in the mechanisms by which second phase particles affect ductile fracture. Experiments done by various workers have shown that second phase particles or discontinuities in the microstructure are potential sites for nuclea-tion of microcracks and of holes,6-l3 which then grow and cause premature fracture and the loss of ductility. Theoretical attempts have been made to explain the observed phenomena; most are able to explain observations qualitatively, but lack quantitative agreement. Much experimental work needs to be done to aid extension of theoretical models. A recent review article by Rosenfield summarizes work in this general area.14 PROCEDURE Material used in the previously described study on solution kinetics of cast and wrought 7075 alloy1 was also used in this study. Procedures for ingot casting, solution treating, and working were described in detail in that paper. Test bars were obtained for material of 76 initial dendrite arm spacing (11/2 in. from the ingot base) and 95 µ initial dendrite arm spacing (51/2 in. from the ingot base) for the following thermomechanical treatments (solution temperature 860°F; reduction by cold rolling). a) Solution treated 12 hr, reduced 2/1, 4/1, and 16/1. b) Solution treated 12 hr, reduced 16/1, solution treated approximately 5 hr after reduction. c) Same as a) except solution treated 24 hr prior to reduction. d) Same as b) except solution treated 24 hr prior to reduction. e) Same as d) except solution treated 20 hr after reduction. Test bars were taken both longitudinally and transverse to the rolling direction. Transverse properties are in the long transverse direction; since the final product was sheet (0.030 in. thick), properties in the short transverse direction could not be obtained. Test bars were flat specimens, of gage cross section1/-| in. by 0.030 in. and 1/2 in. gage length. After machining the test bars, they were given an additional 1/2 hr solution treatment of 860°F and aged 24 hr at 250°F. Three bars were tested for each location and thermomechanical treatment, after rejection of mechanically flawed bars. The average results of these three bars are reported. Elongation was measured using a $ in. extensometer and reduction in area was determined using a profilometer to measure the area after fracture. INFLUENCE OF THERMOMECHANICAL TREATMENTS AND SECOND PHASE ON MECHANICAL PROPERTIES Results of mechanical testing are presented in Figs. 1 to 4 and in tabular form in the Appendix. A general conclusion from results obtained is that details of the thermomechanical treatments studied were important only insofar as they influenced the amount of residual second phase. Figs. 1 and 4 show the longitudinal properties obtained (regardless of thermomechanical

Jan 1, 1970

By Mayumi Someno, Kazuhiro Goto, Masahiro Kawakami

The apparent rates of decarburization of liquid alloys of Fe-C, Fe-C-S, Ni-C, and Co-C systems and the rate of oxidation of solid graphite with pure carbon dioxide gas and with gas mixtures of carbon monoxide and carbon dioxide have been measured in the temperature range of 1000° to 1600°C. The cotnposition of carbon dioxide and carbon monoxide gas at the reaction surface has been measured by oxygen concentration cells with the ZrO,-CaO solid electrolyte. 1) The apparent rates of the carbon removal are essentially the same for all the cases of solid graphite, Fe-C, Fe-C-S, Ni-C, and Co-C systems under the same experimental conditions. 2) The apparent rates are independent of the carbon content in the high carbon concentration range but very much affected by the flow rate and the gas composition of the CO-CO2 reactant gas mixture. The ratio of the gas consumed by the reaction to the total quantity of the supplied gas is very large under the present experi~nental conditions. 3) There is a concentration gradient of' carbon dioxide in the vicinity of the reaction surface and the content of CO, becomes extremely small at the reaction surface. 4) A large time fluc-tuation of the gas composition was observed. This jluctuation implies the presence of unstable flow in the gas phase in the vicinity of the reaction surface. THE decarburization of molten steel by an oxidizing gas or by slag may be one of the most important chemical reactions in steelmaking processes. Nevertheless, the kinetics of this heterogeneous chemical reaction do not seem to be well-solved even with the previous studies. Although the conditions for the reaction in steelmaking processes are quite different from those in the laboratory scale, some critical experiments may give information on the mechanism of the decarburization. From the previous work,'-' it is known that the rate of the decarburization is independent of the carbon content in liquid iron with more than about 0.2 wt pct C when the oxidizing gases are supplied to the surface of liquid Fe-C alloys on a laboratory scale. Two rate-controlling steps have been proposed for the decarburization of liquid iron with the high carbon content: one is the surface reaction control proposed by Swisher and Turkdogan;' the other is that the rate is controlled by the gaseous diffusion through the gaseous stagnant layer. proposed by Baker. Warner, and Jenkins.7 and also by .Ito and Sano.2 In the present study, some experiments have been carried out for the evaluation of these rate-controlling steps in the decarburization of liquid iron with high carbon content. The apparent rate of decarburization of liquid iron has been compared with the rates of carbon removal of liquid Ni-C, Co-C, and solid graphite under the same experimental conditions. The composition of carbon dioxide and carbon monoxide gas at the reaction surface has been measured by oxygen concentration cells. I) EXPERIMENTAL PROCEDURE Fig. 1 shows the schematic diagram of the reaction chamber. Solid graphite and liquid metals were contained in an alumina or magnesia crucible of 32 mm ID and 35 mm in height. The samples were heated by high-frequency induction and the temperature was measured by the calibrated optical pyrometer. The temperature was held constant to within 10°C. The re-actant gases were supplied to the surface of the samples through the quartz tube of 8.0 mm ID. The distance from the end of the quartz tube to the surface was 20 mm. The block of high-purity graphite was cut and shaped to the inner profile of the crucible. The height of the shaped graphite was 18 mm, which corresponded to the depth of the liquid iron of 100 g. About 100 g of Fe-C alloy (4.20 to 4.40 pct C), Ni-C alloy (1.84 pct C), Co-C alloy (1.85 pct C), and Fe-C-s alloy (4.35 pct c, 0.5 or 1.0 pct S) were melted in the crucible. The reactant gases were pure CO, and gas mixtures of CO-CO,: the flow rates were controlled by capillary flowmeters with bleeders.

Jan 1, 1970

By Allan D. Taylor, Robert S. Shoemaker

Adopting as a principle the phrase "the mill of yesterday should not be built with the high cost money of today," the authors have designed a hypothetical concentrator which could be built for a typical southwestern United States (or other similar area) copper ore. Many of the design features could also be used for other ores in other climates. Functional design, large equipment, and outdoor type of construction have been combined in a concentrator (which includes all ancilliary facilities such as truck and maintenance shops, offices, warehouse, nominal tailings disposal, and water supply) which could be built today for substantially less than the cost of comparable but conventional plants.

Jan 1, 1973

By K. V. S. Sastry

First attempts to apply computers for the modeling, simulation and analysis of mineral processing unit operations date back to almost twenty years. Since then substantial efforts have been directed to the development of computer software for mineral processing. Current literature indicates considerable activities in the development of computer packages for interactive and batch simulation of individual unit operations and integrated plant operations. This paper presents a comprehensive review of various simulation systems that have been described in the literature along with a discussion of present trends in the development of mineral processing simulation software. Finally, the paper includes a detailed discussion of the desirable features in future simulation packages.

Jan 1, 1984

By W. F. Dietrich

Mineral fillers are relatively inert chemically under the conditions of use but have physical properties* that modify those of the materials • The properties. uses, and other data on 15 classes of important *The pro listed in the second edition of Industrial Minerals and Rocks.l A third edition of this reference is in preparation. in which they are incorporated. The mineral fillers considered in this article are asbestos, barite, clays, diatomite, crushed limestone, limestone whiting and lime, mica, silica, talc and soapstone, and pyrophyllite. Slate and stone, other than limestone and its derivatives, are excluded because, even though used in large quantities, they are exceptionally low-cost materials generally produced close to the area where they are used. Carbon black is excluded because it is manufactured from natural gas and more than 90 pct of the output is used in rubber; hence the factors for estimating requirements are easily evaluated. OVERALL GROWTH FACTORS Table I gives the population, retail sales, and value added by manufactures in the U. S. and in the eleven western states in 1954. These data are rough guides to the proportionate part of total U. S. markets for products containing mineral fillers that may be expected in a given area. For example, the population of the eight Mountain states in 1954 was 3.6 pct, and retail sales in these states were 3.8 pct of the U. S. total, but the value added by manufactures was only 1.3 pct of the U. S. total. On the other hand, the three Pacific Coast states, with 10.3 pct of the total population, had 12.0 pct of the retail sales and produced 9.6 pct of the value added by manufactures. On an industry-by-industry basis the correlation between the three guideposts will not be as close as shown in the 1954 data for the Pacific Coast states, but in the long-term view the continuing rapid population growth in the western states is certain to result in expanded industrial production at an even more accelerated pace, which will shorten the gap between local consumption and production in most major groups of manufactured consumer goods. Of course, there will always remain favorable areas for production of specific products. Such special situations must be individually analyzed. Fig. 1 compares the population trends in the U. S., the western states, and California with Real Gross National Product from 1910 to 1957, with forecasts to 1970. It is estimated' that the U. S. Real Gross National Product, as measured by the value of goods and

Jan 1, 1960

By J. W. Leonard

One of the more obvious phenomena which relate to coke formation is that soft coals of low volatile matter content tend to yield hard or high strength cokes while hard coals of high volatile matter content tend to yield soft or low strength cokes. This observation led researchers of the Coal Research Bureau of West Virginia Univ. to study the possibility of using Hardgrove grindability as a supplemental rank indicator for coking properties. Grindability has been used for many years as a means to measure the resistance of coal to comminution but it has rarely if ever been considered for evaluating coals for carbonization. The coal proper- ties which are measured by grindability are complex, but recent work with the difficult-to-correlate high volatile coals has demonstrated that a 93% correlation exists between grindability and the total petrographic rnicrinites, exinites, and resinites. This work demonstrated that inherent ash had no apparent effect on the grindability of high volatile coals, suggesting that the coal substance is apparently harder than the associated ash. These observations, together with the patented Burstlein process," indicate that the distribution of hard and soft components in the individual high volatile coals and blends of coals may be quantitatively interrelated to coke stability through selected ranges of coal volatile matter. The objective of this progress report is 1) to demonstrate the statistical relationships which exist between coal grindability and the numerous coal petrographic entities and 2) to present the results of initial studies concerning the correlation of the coke physical strength index of stability with coal volatile matter and grindability.

Jan 3, 1964

By N. E. Rogen, N. J. Grant

WHILE direct measurements of the growth of precipitate particles during aging is of fundamental value, few such measurements have been made. Direct measurements by means of optical or electron-microscopy and X-ray techniques are preferred, however, many of the aging studies have been based on indirect methods such as electrical resistivity and hardness. Because of the minute size of most precipitate particles (less than 1000A) the light microscope is of limited use while electron microscopy is subject to slowness, etching problems and consequent resolution problems. It is fortunate that alloys of the Nimonic type, based on Ni-Cr-Ti-Al, lend themselves to accurate and relatively easy particle size measurements. With proper balance of titanium and aluminum, the only aging precipitate is the gamma prime (r') Ni3,(Al, Ti)2 phase and this phase is the basis of the high-temperature strength of these allos.3-6 The Ni3(Al, Ti) phase is a face-centered-cubic, ordered structure with nickel atoms occupying the cube faces. Titanium atoms can replace three out of every five aluminum atoms and when substituting do so preferentially.2 Electron microscopy has shown that during aging of most of the commercial alloys of this type, precipitate particles are unusually uniform in size and distribution, and that the volume of (r') phase is large (20 pct).4,7 The aim of this investigation was to measure the growth of (y') phase during aging. In so doing, it was hoped that a clearer understanding of the aging process would be attained. X-ray line broadening was used as the measure of precipitate particle size. This technique was selected because it can measure and average the diameter of thousands of particles in one operation. The variations in hardness and matrix lattice parameter with aging were also studied and related to the particle size. EXPERIMENTAL PROCEDURE An alloy of the following composition was studied: Cr Ti A1 C Ni Wt pct 20.71 2.98 1.43 0.04 bal. At. pct 22.06 3.47 2.95 0.18 bal. The alloy, a 15- lb vacuum melt, was forged to 1/2-in. diam at a temperature of 1900" to 2200°F; was solution heat treated for 4 hr at 2000°F and water quenched; and was then aged in various ways. The ASTM grain size was 4 to 5. No (7') phase could be detected by X-ray analysis after solution treatment and electrolytic extraction. Aging was performed on 2-in. long specimens at 1400°, 1500°, and 1600°F for increasing times. One-half inch sections were removed after each time increment and were then electropolished in a solution of H3P04 saturated with chromium trioxide at a potential of 30 v and rectified with a tantalum electrode. Rockwell hardness measurements were taken using one side of the polished specimen. Matrix lattice parameter determinations were made on the other side using filtered chromium radiation references with the position of the (220) line of a silicon standard. To enable the precipitate particles of the (y') phase to be measured using X-ray line broadening techniques, it is first necessary to separate and concentrate this phase by electrolytic extraction. Extraction is necessary because the difference between matrix and precipitate lattice parameters is only approximately 0.5 pct and intensities of.the (y') phase lines are very weak relative to those of the matrix. The extraction techniques employed have been described before and found to produce a reasonably quantitative separation.398 A water solution of 15 pct H3Po4 is used at a current density of 0.5 amp per sq in. at 6 v. The precipitate particles are separated from the liquor by centrifuging and decanting and are then washed, dried and repowdered. A plot of the X-ray intensity vs diffraction angle for the (111) line of the precipitate particles was used as a measure of particle size. The intensity curve approximated the shape of Gaussian distribution function and its breadth was measured at the half height. The (220) line of a silicon standard was used to correct the measured line breadth for instrumental and other broadening errors. The Scherrer formula was used to calculate particle

Jan 1, 1961

By M. R. Tek

General equations relating the pressure drop necessary to sustain the flow of a fluid through a porous matrix at a given rate have been developed. The results indicate that at high values of flow rate the pressure-flow behavior may not necessarily satisfy the usual Darcy equation. The mathematical analysis, carried through the micro-pore geometry and extended through the macro-reservoir scale, indicate that Darcy's law, of limited applicability to certain ranges of Reynolds numbers, can be generalized through the inclusion of some additional parameters. The "generalized Darcy equation" has also been formulated in dimen-sionless form permitting the evaluation of its predictive accuracy with regard to literature data. A comparison between predicted and experimental values indicates that the generalized Darcy equation predicts the pressure drops with good agreement over all possible ranges of Reynolds numbers. INTRODUCTION The limits and the nature of validity of Darcy's law' has been a subject of every-day interest to the industry for many years. It is well known that as the Reynolds number, characteristic of the fluid flow through porous media, becomes large, Darcy's law gradually loses its predictive accuracy and ultimately becomes completely void. For the last 20 years much has been said and written on this subject. Unfortunately little has been accomplished to bring about a satisfactory agreement, at least on the nature of the threshold of validity of Darcy.'s law. Fluid dynamists, geo-physicists, and engineers all had their individual views, explanations, interpretations and concepts on the subject. To some, a mechanistic analogy with pipe-flow proved a satisfactory explanation.' To others,' turbulence, in its random character, was incompatible with the geometric structure of consolidated porous systems. To some,4 turbulence merely represented a factor influencing the permeability measurements and again to others5,6,7 em-pirical or semi-empirical correlations proved satisfactory from an engineering viewpoint. Deviations from Darcy's law at high flow rates have been studied by systematic experiments by Fancher, Lewis, and Barnes.' In an article on the flow of gases through porous metals, Green and Duwezs conclude that the onset of turbulence within the pores appears unsatisfactory to explain deviations from Darcy's law. This view is held by many others. While the subject remained controversial for many years, the development of vast natural gas reserves throughout recent years further justified considerable interest on this problem from the standpoint of gas reservoir behavior. As large amounts of field data became available from the operation of many gas fields, it became evident that the steady-state behavior of gas wells was not, in general, in agreement or compatible with Darcy's law. This suggested a careful reconsideration of all mechanisms which may account for pressure drops in addition to viscous shear. In a series of articles9,10 . Hou-peurt indicated that deviations from Darcy's law may be explained on the basis of kinetic energy variations and jetting effects without resorting to assumptions on turbulent flow conditions. Another article by Schneebeli11 indicates that special experiments by Lindquist clearly demonstrated that the onset of turbulence does not necessarily coincide with conditions of deviation from Darcy's law. This view is also held by M. King Hubbert.12 Starting with the basic pressure-flow relations suggested by Houpeurt, the derivation, development and extension of analytical expressions to -supplement and generalize Darcy's law has been the objective of this work. MATHEMATICAL ANALYSIS Derivation of Dimensionless Pressure-drop, Flow-rate Relations In considering the flow of a fluid through a porous matrix geometrically represented by a succession of capillary passages in the shape of truncated cones,810 an approximate expression may be derived relating viscous and inertial, i.e., total pressure drop to the physical properties of the fluid, geometric properties of the rock matrix and the rate of flow: ?P/?r = µ/k V [ 1 + c(m4 - 1) p V/16n" mµ w] ..........(1) Let us formally set: c (m4 - 1) / 16n" m = a d ......(2) Such a representation is equivalent to assert that the term [c(m4 — 1)/ 16n"m], variable with various porous media and probably highly variable within a given porous medium, may be macroscopically defined as equal to a lithology factor times the aver-age grain diameter d. In view of the usual grain and pore size distribu-

Jan 1, 1958

By R. D. Boddorff, R. L. Ash, C. T. Butler, W. W. Kay

DRILLING and blasting in anthracite open-pit mines is a continuous problem to contractors and explosive engineers because of the diverse conditions caused by the nature of the geological formations, the extensive mining of the portions of coal beds near the surface, and the proximity of many strip pits to populated areas. Pennsylvania anthracite occurs in four separate long and narrow fields totaling only 480 sq miles. The coal measures are rock strata and coal beds that are considerably folded and faulted. The crests of the anticlines are eroded extensively. The beds outcrop on the mountain sides and dip under the valleys. At first only the upper portions of the synclines could be stripped. Now stripping to increasingly greater depths is economically possible, as is indicated by the fact that the proportion of freshly mined anthracite produced by strip mining has increased from 3.7 pct of the total tonnage in 1930 to 29.6 pct in 1950. Much of the rock overlying the deeper beds now being stripped is so extensively broken that considerable difficulty is experienced in drilling satisfactory blast holes and in using explosives in such manner as to insure a uniformly broken material easily removed by the excavating machinery. Such breaking of rock strata has occurred because the bed now being stripped has been mined extensively in former years by underground methods, and tops of gangways and chambers have subsequently failed. Draglines are used to uncover coal where the overburden can be moved with little or no rehandling. These machines range in size from those having a 2 cu yd capacity bucket on a 60-ft boom to those handling a 25 cu yd bucket on a 200-ft boom. Draglines are also used to strip to the bottom of the coal basins if the depth and the distance between the crops are not too great. For this type of operation blast holes are drilled full depth to the bed. These holes are commonly 30 to 90 ft deep; however, in exceptional cases, holes may be as shallow as 12 ft or as deep as 130 ft. Drilling is normally done for blasts of 12,000 to 60,000 cu yd of overburden, 30,000 cu yd being considered an average blast if vibration is not the controlling factor. Where the stripping of wide basins or the exposure of a moderately pitching vein makes the use of draglines impractical, dipper front shovels equipped with 4 to 6 1/2 cu yd buckets load into trucks. Overburden is removed in benches of 25 to 30 ft with blast holes drilled 4 or 5 ft deeper than the planned floor of the bench. For shovels under 5 cu yd bucket capacity the volume blasted varies from 8000 to 12,000 cu yd, whereas a volume of 30,000 to 50,000 cu yd of overburden is frequently blasted at one time for the larger shovels where vibration is not an important factor. During the past decade the churn drill, generally the Model 42-T Bucyrus-Erie blast hole drill equipped for drilling 9-in. diam holes, has become the most common blast hole drilling machine. Electricity powers half the churn drills in use and is preferred on the large strippings where electric shovels are operated and the working area is concentrated. On these operations the cost of additional electricity for the drills is less than the cost of fuel to operate diesel units because of the existing large demand load of the excavating equipment. Moreover, electric motors start more easily in cold weather and generally are less expensive to maintain. Diesel driven units are employed where a higher degree of mobility. is required. The average drilling speed is 8 ft per hr, although in softer rocks a rate of 15 ft per hr is attained. Where rock is hard and strata is badly broken, drill speeds may ' be less than 2 ft per hr. Low drilling production results under these circumstances when loose material falling from the upper portion of the drill holes causes drill stems to be jammed. Rock formations vary so greatly in the region that a 9-in. diam churn drill bit may become dull after drilling only 2 ft or may drill satisfactorily for 56 ft; however, an average of 35 ft is usual in sandstone of medium hardness. Dull bits are hoisted to flat bed trucks by the sand line of the drill and are usually sharpened in the contractor's bit shop adjacent to the job. Care is generally taken to cover the thread end of the bit with a cap. To facilitate handling of bits around the drill, a heavy thread protector having an eye top is becoming more popular than the flat-top rubber or metal cap furnished with new bits. The 9-in. diam blast holes for a 25 to 30 ft bench are normally on 18x18 ft to 20x20 ft spacings, depending on the character of the overburden, although in broken ground 15x18 ft centers may be used to obtain better breakage and a more even bottom for the bench. The patterns of holes for shots

Jan 1, 1952

By Lillian Erskine

WHILE brass and other copper alloys have long been listed as offering health hazards to their workers, it is questionable if the metals involved are alone responsible for the trades' records of morbidity. The entire science of foundry sanitation is the product of the past two decades; and the best standards now operative would have been regarded as little short of revolutionary prior to 1910. The special handicap to the conservation of the health of the brass founder's employees has been the fact that, unlike the iron founder, his business could be profitably carried on in almost any small and unsanitary quarters. As a result, writers on occupational disease have accepted brass chills or brass founders' ague as an inevitable feature of the trade; and respiratory disabilities, as well as phthisis and disturbances of the nervous system, are also included as prevalent among those employed. While there can be no question as to the basic accuracy of past investigations, there is every reason to doubt the necessity for an undue percentage of ill health among brass molders and casters who are safeguarded by scientific ventilating standards and by improving personal habits of sobriety. There is, however, need for a campaign of education as to the most approved practices and equipment whereby the employer may safeguard the health of his workers, and thereby reduce his labor turnover and increase his productive efficiency. Broadly speaking, copper, tin, and aluminum carry negligible health hazards. The toxic qualities of lead, however, are a menace; especially if scrap lead is recovered or bought for foundry processes. The rapid volatilization of zinc renders its fumes and flocculent condensation the chief problems in conserving the health of the brass worker. The frequent presence in the foundry air of traces of arsenic compounds, lead

Jan 2, 1919

By A. B. Kinzel

THE demands of the petroleum and chemical industries for steels to be used in pressure vessels and similar structures at artificially low tempera-tures are continually increasing, and the writing of proper specifications with suitable tests becomes increasingly important. Likewise, the selec-tion of suitable steels for such applications is of increasing concern to the metallurgist. It is generally recognized that highly alloyed steels of the austenitic stainless type retain their properties even at very low tempera-tures and represent the best technological solution of the low-temperature steel problem. However, in many instances less expensive carbon or low-alloy steels suitable for service within limited temperature ranges are available. The problem thus becomes one of defining the various factors involved in the production and fabrication of these less expensive steels and determining the temperature ranges in which their properties justify engineering application. Most of the applications involve welded structures, and the heat effect of welding as well as the nature of the weld metal are matters of prime concern. The first problem that the metallurgist faces is the determination of the type of test to be used as a criterion of the performance of the steel in low-temperature service. It has been generally recognized that the static properties of steel as determined in the ordinary tensile test undergo a gradual and relatively slight change as the temperature of test is lowered in the range of current interest; i.e., from room temperature to minus 120° C. It is further generally recognized that the behavior of steel under impact involving notch sensitivity is definitely affected at the lower temperatures. While the major subject of this paper is the effect of grain-refining deoxidizers, of low-alloy additions and of welding on the low-temperature notched-bar impact properties, an inquiry into the general behavior of steel under low-temperature impact testing is included. This is a pertinent portion of the investigation and the results thereof are

Jan 1, 1937

By M. L. White, J. L. Shafer, C. L. Caenepeel

Often an in situ leach is the only practical economic method for copper recovery from small low grade oxide deposits. The decision to develop a copper property by an in situ blast and leach is strongly dependent on ore grade, tonnage, hydrology, and the copper extraction and acid consumption rates. The inherent leachability of the ore will in part determine the desired amount of fracturing of the ore deposit by the blast in order to obtain a copper extraction rate that is economical. For the last several years Occidental Research Corp. (ORC), has undertaken a modest effort to address the question of how to best identify and determine the information necessary to predict and control the operation of an in situ leach for the economic recovery of copper.

Jan 2, 1979

By M. A. Mahtab

When characterizing orientations of rock joints in an engineering site with respect to mean values of the existing clusters or joint sets, a need may arise for a similarity test that allows grouping of observations from several adjacent sampling stations. Subjective judgment, though based on experience, may not produce realistic groupings in the data. A similarity test is developed in this paper for objective grouping of samples of joint orientations in engineering sites. The test is applied to the data from a large, geologically complex site of a potential open pit mine.

Jan 1, 1984