Search Documents

By C. A. Hope, H. B. Wishart

THE number and severity of surface imperfections on rolled slabs, assuming the reception of uniformly good quality heats from the open hearths, depend upon a number of conditions associated with heating and rolling of steel in the primary mills. While there are other elements that have an effect on surface quality, rather than make this paper too lengthy the discussion of mill processing variables will be limited to three factors in order to illustrate their effect on slab surface quality: 1—amount of reduction between ingot and slab, 2—slab finishing temperatures, and 3—influence of roll changes. Measurement of the percentage of surface removed by scarfing on the flat surfaces of the slabs was used for evaluating quality in this study. A study of this nature must be made on slabs that are inspected and conditioned under uniform conditions and standards. In order to be certain that steel of the best possible steelmaking quality was received at the rolling mills, a low carbon deep drawing grade of rimmed steel, made for sheet mill application and manufactured under carefully controlled open hearth practices, was selected. Use of this particular steel thereby reduced the steel quality factor as a possible source of variation. The measure of slab surface quality is the amount of surface removed by scarfing during yard conditioning and is expressed as percentage of surface removal. This percentage was estimated by experienced personnel to uniform standards and it should be noted that these percentage figures are representative only for the grade selected and under the rigid inspection standards to which the slabs were subjected. Surface removal is a matter of concern because the imperfections, if undetected, often are the cause of poor surface quality in the finished product and their removal, by conditioning, add to the total plant costs. The data was collected at various times over a period of six months and, with normal weekly fluctuation in the level of quality, it is to be expected that for any period of sampling there will be some variation in the plotted results. The type of defect that is responsible for most slab conditioning at Gary Steel Works is a light angular surface break. This defect is usually interconnected to form large defective areas and occurs mainly on the bottom half of the slab on both sides. This type of defect is illustrated in Fig. 1, showing a bottom portion of a slab; while a close-up of an area of the same slab where the surface breaks were found is given in Fig. 2. The large dark areas are heat patterns, results of hot stacking and cooling. Independent of these light breaks, but sometimes associated with them, are larger and deeper isolated breaks. However, most of the surface removal occurs from conditioning the large areas of small breaks. There are also occasional scabs of varying degrees of severity but these are relatively infrequent. The slabs are generally free of rolled-in scale. Ingot to Slab Reduction vs Quality Some ten years ago at Gary Steel Works, the minimum slab ingot thickness was 30 in. Subsequent operating and other quality features indicated the desirability of using an ingot of reduced thickness with the result that a series of molds that would produce a 22 in. thick ingot with various widths was adopted as standard. A minimum number of the thicker mold sets are still used. From the standpoint of quality difficulties from pipe and segregation, the smaller ingots are an improvement. From a quality surface viewpoint, the slab product from the thin molds requires approximately twice the surface removal as the slab product from the thick molds. This is shown in Fig. 3 where the percentage of surface removal is plotted against slab product rolled from

Jan 1, 1956

By P. W. Bakarian, C. H. Mathewson

THE greater part of the literature on the plastic behavior of magnesium dates back to that active period of research in crystal mechanics immediately following the widespread preparation of isolated metallic crystals large enough for the application of conventional methods of mechanical testing. These investigations, performed on single crystals, revealed an analogy between zinc and magnesium with respect to their fundamental mode of deformation, in the operation of glide and twinning, respectively, on crystallographically similar planes. Mathewson and Phillips (1928)1 by geometrical analysis identified the {102} ? plane in magnesium as the twinning plane, Schiebold and Siebel (1931)2 confirmed this twinning plane, established the basal plane as the plane of slip, and a digonal axis I as the slip direction. They also reported twin formation in a secondary role on the {101} plane. Schmid (1931)3 summarized and discussed the earlier evidence and presented the results of his own experiments on the effect of temperature and small amounts of soluble elements. From X-ray studies on extended wire single crystals, he concluded that slip along the basal plane in the direction of the digonal axis I closest to the stress direction was the sole slip system operating at atmospheric temperature. This conclusion was based on experiments with crystals of many different orientations relative to the stress axis. Special attention was directed to the basal plane and the digonal axis I, as the plane and direction of greatest atomic density. Determinations of resolved shear stress at the onset of plastic yielding-i.e., the critical resolved shear stress-were also made; the average of these calculations showing 82.9 grams per sq. mm. This value varied only slightly up to 300°C., at which temperature it was found to decrease to 70.5 grams per sq. mm. The extension of his crystals at temperatures above 225°C. further disclosed the presence of new slip systems. After the original specimens of circular section had been

Jan 1, 1943

By T. E. Leontis, R. S. Busk

WORK was initiated several years ago at The Dow Chemical Company to determine the applicability of powder metallurgy processes to magnesium and its alloys. Although it was found possible to apply the normal techniques of compacting and sintering, it was discovered early that the technique of extrusion offered special promise. This technique and the alloys produced were therefore studied extensively, and the present paper is a partial report of those studies. It is expected that a second paper will discuss more extensively some of the alloy systems simply mentioned here. Although the literature on powder metallurgy is very extensive, there are only two articles dealing with magnesium13,14 and there is no reference to the direct extrusion of the powder of any metal without the preliminary step of compacting. Furthermore, no mention has been made of the possibility of designing alloys by the technique of powder extrusion, particularly alloys that cannot be made in any other way. Sauerwaldl3 discusses the extrusion of magnesium and aluminum powder to produce alloys containing nonequilibrium phases, but again he emphasizes the importance of pre-compacting before extrusion. There seems to be general agreement that some form of hot-pressing is essential to obtain in a compact the full theoretical density of the metal used.'-" The nearest approach to the technique of direct powder extrusion is that of extrusion of pre-sintered compacts,'-" for which the best review through 1944 is that by Kieffer and Hotop.11 Ensign* discussed a specialized technique of "extruding" already compacted and sintered gears for the purpose of sizing. Sauerwa1d13 discussed the compacting and extrusion of magnesium and magnesium-aluminum alloy band-saw chips. The properties of the extruded compacts were found to be comparable with those of extrusions prepared from solid billets. He also extruded a compacted mixture of magnesium and aluminum powder and found the properties to be somewhat different from those obtained on an extrusion made from a cast billet of the same composition. The second reference dealing specifically with the powder metallurgy of magnesium is Stern's patent," in which is described the extrusion of scrap chips and turnings following a hot-pressing and sintering step. Considerable emphasis in most of these articles is placed on the necessity of atmospheric protection to minimize the danger of oxidation. Experimental Procedure The first experiments were made with the small extrusion press shown in fig. 1. With this press, billets of about 1/2 in. diam are used to produce wire

Jan 1, 1951

By John V. Beall

They let the whole world know again that not only could we do it, but we make it look easy. The great crews before Scott, Irwin and Worden of Apollo 15 have all blended warm humor, informality and dexterity to put on a good show: but it keeps getting better and the last one was the best. Scott's rendition of Galileo's experiment using a hammer and a feather--not just any feather, but a falcon feather after the name of the LEM-was priceless. One generation of school kids will never forget that lesson. The final touch was in the "would-you-believe''" category, Now if English astronauts had been performing the mission, the sign-off would have been typically low key. Something like; "well its tea time, chaps; we'll have to toddle along." Apollo 15 surprised and thrilled spectators by blasting off to the Air Force song "Off we go into the wild blue yonder" and leaving a camera behind to photograph their own ascent. Now that is what we call showmanship. There is another aspect to our space show and that is that it cost billions of dollars to put on. With that kind of backing, the world for an audience and in the face of grave personal risk, one would expect the space explorers to be all business. Instead they did their jobs with limpid buoyancy. Our older readers will recall and contrast a movie of the thirties and the tense atmosphere when they had to talk that kid up there (Franchot Tone) down through the zero ceiling. A feat of considerably less difficulty than docking LEM. but nevertheless the gut tightening drama was absent in the latter event. In another example, few of us can visualize reporting back after a business mission to one of the old barons such as J. P. Morgan in any but the most sedate and business-like terms. In fact we don't have to go that far back, as we can think of a few pepper-pot bosses we have had to whom one always played it straight.

Jan 1, 1971

By John Johnston

WHEN I was honored by being invited to give the Howe Memorial Lecture, I decided to read Howe's book, "The Metallography of Steel and Cast Iron," published in 1916-that is, about 25 years ago-in search of a text. I found the book written in fine, clear, attractive, yet precise style, as I expected, knowing that his father ¬Dr. Samuel Gridley Howe, his mother-Julia Ward Howe, and all of his four brothers and sisters had lived in a New England literary atmosphere and had written books. This leads me to suggest that many authors of metallurgical papers and books could well study Howe's writings with a view to the improvement of their own. I failed to find a specific text, but did find a subject, for in reading his book I was struck by the few instances in which time is considered explicitly as a factor in the phenomena examined, and by the fact that many of the hottest arguments would have been settled had time been taken properly into account. Indeed, Howe hardly mentions time except in a rather incidental way, as in a few references to lag; for instance: The lowering of temperature at which the transformation occurs by rapid cooling . . . is a phenomenon of undercooling or lag. It is in part explained by the fact that the transformation itself is a time-consuming reaction which, setting in during a rapid fall of temperature. is naturally protracted till the temperature has sunk far below that at which it is due. He does discuss, quite fully, the iron-carbon equilibrium diagram, as known at that time, introducing it by stating: As he is a reasonable man who is not deterred from using a hand truck for moving his trunk by the consideration that he has thus to move a trunk plus a truck, so am I reasonable in putting into your hands this useful, indeed indispensable, tool for mastering the ABC of iron metallurgy. Somewhat later, in introducing a discussion of the phase rule, which "it would be hardly proper to pass . . . by without an attempt to outline its meaning," for "a clear exposition of its applicability or jurisdiction is needed to restrain the half-initiated from misusing it and the uninitiated from being misled by these misuses," he writes-and I quote his statement because we cannot properly discuss the influence of time on a process until we know the state of equilibrium which would ultimately be reached by the system under consideration It is a most remarkable and valuable generalization, its conceptions help greatly toward getting a broad outlook on metallography, but its misconception has brought out a flood of obscuring writings. It tells us about the constitution towards which alloys tend, that which they reach when equilibrium is complete, when all tendencies have corrected themselves and have been complied with completely. Its application, in absence of true equilibrium, is like determining density with a telescope or even with a tuning fork; it is like the mad tea party at which the butter put into the works "f the watch was the best butter. If the reader learns no more than to beware of attempts to decipher the conditions of inequilibrium by a law which touches only the conditions of exact

Jan 1, 1942

By T. T. Field, M. Gell

MUCH has been learned about plastic deformation behavior in crystals through the use of dislocation and slip band etchants. Slip in nickel and nickel-base alloys has previously been revealed by various etching techniques.l-5 The techniques for nickel-base super-alloys4,5 were successful only in the Udimet 700 composition in specific heat-treated conditions. The objective of this work was to develop a more generally applicable slip-band etching procedure. The nominal compositions of the alloys used in this study are listed in Table I. The low carbon Mar-M2OO alloy referred to in the text is the same as listed in Table I with the exception that the carbon content is less than 100 ppm. Mar-M200 and Udimet 700 were solutionized at 2250" and 2150°F, respectively. The aging treatment for both cast alloys was 32 hr at 1600°F and for wrought Udimet 700 was 4 hr at 1975"F, 24 hr at 1550°F, and 16 hr at 1400°F. The new slip-band etching technique consists of a chemical etch followed by a short electropolish, Table 11. Fig. l(a) shows the best result obtained on an internal section of a plastically deformed single crystal of Mar-M2OO when using a conventional slip-band etching procedure which consists of electropolishing followed by etching. Ghostlike traces corresponding to planar slip bands are observed, but the contrast between the bands and the background is weak. Fig. l(b) shows the same field using the new slip-band etching technique. After the etching step of this technique, the same ghostlike traces of Fig. l(a) are observed, but the subsequent electropolishing accentuates the slip bands and the subgrain boundaries while the rest of the matrix is being polished. Longer electropolishing obliterates the slip bands. The new slip-band etching technique makes use of the etchants and electrolytes that are normally used for a given material. Because of this, it should be possible to slip-band etch other nickel-base superal-loys by using existing etchants and electrolytes for a material and following the procedures outlined in the "Comments" section of Table 11. All the illustrative examples given below show internal plastic deformation in single crystals of regular and low carbon Mar-M200 in the solutionized and

Jan 1, 1970

By Russell G. Haworth

Three companies, United States Potash Company, Potash Company of America, and International Minerals and Chemical Corporation, are now operating potash mines and reGneries in the Carlsbad, New Mexico, area. The three mines are located approximately twenty miles east of Car1sbad. The deposits have been found ideal for mechanized mining methods. This summary has been compiled from information made available by the three operating companies. Prospecting Since outcrops of potash are nonexistent, prospecting is accomplished by drilling and coring of the salt section to establish the grade, thickness, and outline of the potash beds contained in the salt deposits. Information regarding the nature of the formations in the cover of 400 to 600 ft thick over the salt and potash beds is also obtained from drill cuttings in the same operation. By proper interpretation of assembled data the best location for shafts may be determined. The overburden varies in character but consists in general of interbedded shales, sand, gravels, limestones, and anhydrite beds. Water, in unpleasant quantities, especially in the sands and limestones, often completes the geologic section. Some of the shaftas in the area have been sunk without undue difficulties, others have been delayed by flows of water. Most of the shafts are concreted from the surface to the salt section. Each of the three mines in the Carlsbad area has one shaft for hoisting ore and one for hoisting men and supplies. Mining Methods Information acquired from initial drilling and prospecting affected the choice of mining methods. Since the tabular, slightly rolling deposits were similar to coal seams, the room-and-pillar system used in coal mining was adopted by all the companies. Pillars have not been removed in any of the mines on a large scale. One company has conducted experimental robbing of pillars in one restricted area. Where it is known that overlying strata contain water in large amounts, it is not considered practical to risk flooding of the mines by removing pillars without fill. Some thought is now being directed toward development of economical methods of filling for pillar recovery. The problem is not identical at the three mines and local conditions will govern the methods employed for eventual pillar recovery. The important point is that, with large reserves, it has not been necessary to resort to mining of pillars for adequate production. The ore deposits are laterally extensive but are irregular in shape and lie at a depth of 700 to 1100 ft below the surface. The major operations of all mines are on the same bed strati-graphically, except for the langbeinite level at International Minerals and Chemical Corporation. The deposits are apparently not connected and in many parts of the deposits being mined, "salt horses" or barren zones occur. From 400 to 700 ft of salt with minor beds of polyhalite and anhydrite lie immediately above the ore horizon. The ore differs from the salt only in the potassium chloride content and color due to small amounts of iron associated with the sylvite, giving the ore a somewhat mottled red and white cast. Thickness of the ore varies from 5 to 14 ft. Rooms and break-throughs in the mines vary from 24 to 40 ft in width, the overlying salt forming an excellent roof and providing safe mining conditions. Almost no timber is used in any of the mines for roof support. Drilling is normally the first step in mining the face of a room. Electric motor driven auger drills are used in the area. Jack hammers were used to some extent when the mines were first opened but the ore is easily drilled if bits are sharp and the coal type

Jan 1, 1950

ENGINEERS AVAILABLE (Under this heading will be published notes sent to the Secretary of the Institute by members or other persons introduced by members.) A member of the Institute who has had many years' experience in office management for prominent mining engineering and metallurgical companies, and who is now located in the West, would like to secure an executive position with a firm or company engaged in mining or metallurgy, located in the East, and preferably in New York. No. 139. Member, aged 36, married, graduate mining engineer, 14 years' active experience as engineer, superintendent, and manager of large coal-mining operations. Wide experience in development and operation of

Jan 10, 1914

By H. Brevers, Maurice Rey

Through circumstances connected with the war, the senior author lost his records, therefore it has been impossible to include numerical data in this paper. The arsenical quicksilver ore investigated had been roasted, with poor metallurgical results. The vapor-tension temperature curves of mercury and arsenious trioxide are similar, and the arsenical compound hampers the coalescence of mercury drops in the condenser and is the cause of large stack losses. The ore was a gray limestone carrying small amounts of carbon and mineralized with cinnabar and two arsenic minerals, realgar (As2S2) and arsenopyrite (FeAsS). The proportion of realgar often exceeded that of cinnabar; the proportion of arsenopyrite was smaller. The grade of the ore varied between 0.8 and 4 per cent Hg. The problem was to make a high-grade mercury concentrate, as free from arsenic as possible. The water used throughout the testing was hard, having a pH of about 8. Flotation of Realgar Realgar showed a very strong tendency to float. It formed a film at the surface of the pulp and floated in abundance with only pine oil. Therefore an attempt was made to float the realgar before the cinnabar, but this was not very successful; the percentage of mercury in the realgar concentrate could never be brought below 2 or 3 per cent. Cinnabar slimed easily and floated with pine oil, so that some of it always accompanied the realgar. There was also the question of the cinnabar-arseno-pyrite separation. On further investigation it was found that realgar can be floated not only with pine oil but even better with a combination of hydrocarbons and pine oil. Washing the ore with ether revealed that it contained hydrocarbons, which helped to float the realgar. In this connection it belongs to the same class as carbon, sulphur and talc. It can be floated also with a xanthate, when activated by a heavy-metal salt. The conditions favoring the two types of flotation are opposed, as activation by a copper salt facilitates xanthate flotation (in fact, is even necessary to it), whereas it hinders pine oil and petroleum flotation. One type of flotation can be termed non-polar and the other polar, a distinction that has been stressed in a previous paper.' Depression of Realgar and Flotation of Cinnabar Many chemicals were tested in an attempt to float the cinnabar and depress the realgar. Finally starch rendered soluble with caustic soda was tried, also several grades of commercial soluble starch, and dextrin was found to be the best and the most convenient reagent. Several of these starch preparations have a strong flocculating effect on the pulp, which is a distinct disadvantage. Dextrin, with its low flocculating power, is excellent. It is noteworthy that starch preparations are also depressants for carbon and talc, so that the fact apparently has a general

Jan 1, 1943

By Maurice Rey, H. Brevers

Through circumstances connected with the war, the senior author lost his records, therefore it has been impossible to include numerical data in this paper. The arsenical quicksilver ore investigated had been roasted, with poor metallurgical results. The vapor-tension temperature curves of mercury and arsenious trioxide are similar, and the arsenical compound hampers the coalescence of mercury drops in the condenser and is the cause of large stack losses. The ore was a gray limestone carrying small amounts of carbon and mineralized with cinnabar and two arsenic minerals, realgar (As2S2) and arsenopyrite (FeAsS). The proportion of realgar often exceeded that of cinnabar; the proportion of arsenopyrite was smaller. The grade of the ore varied between 0.8 and 4 per cent Hg. The problem was to make a high-grade mercury concentrate, as free from arsenic as possible. The water used throughout the testing was hard, having a pH of about 8. Flotation of Realgar Realgar showed a very strong tendency to float. It formed a film at the surface of the pulp and floated in abundance with only pine oil. Therefore an attempt was made to float the realgar before the cinnabar, but this was not very successful; the percentage of mercury in the realgar concentrate could never be brought below 2 or 3 per cent. Cinnabar slimed easily and floated with pine oil, so that some of it always accompanied the realgar. There was also the question of the cinnabar-arseno-pyrite separation. On further investigation it was found that realgar can be floated not only with pine oil but even better with a combination of hydrocarbons and pine oil. Washing the ore with ether revealed that it contained hydrocarbons, which helped to float the realgar. In this connection it belongs to the same class as carbon, sulphur and talc. It can be floated also with a xanthate, when activated by a heavy-metal salt. The conditions favoring the two types of flotation are opposed, as activation by a copper salt facilitates xanthate flotation (in fact, is even necessary to it), whereas it hinders pine oil and petroleum flotation. One type of flotation can be termed non-polar and the other polar, a distinction that has been stressed in a previous paper.' Depression of Realgar and Flotation of Cinnabar Many chemicals were tested in an attempt to float the cinnabar and depress the realgar. Finally starch rendered soluble with caustic soda was tried, also several grades of commercial soluble starch, and dextrin was found to be the best and the most convenient reagent. Several of these starch preparations have a strong flocculating effect on the pulp, which is a distinct disadvantage. Dextrin, with its low flocculating power, is excellent. It is noteworthy that starch preparations are also depressants for carbon and talc, so that the fact apparently has a general

Jan 1, 1943

By Granville S. Borden

MANY complaints have been filed by mine prospectors, explorers and producers about inequities in mining taxation. They have insisted upon improvement, and in the past 35 years there has been some progress. Many of the best taxation provisions made to date are those contained in the Revenue Act of 1951. Mining economics presents special problems, a fact even recognized by many textbooks. Certain provisions have been made to take care of mining taxation rights, but these have been made by Congressional act and do not represent basic, constitutional, guarantees. Despite special provision, in the form of depletion allowances, there remain injustices. The industry faces the problem of gaining adequate income tax allowances for exploration and development expenditures, operating losses, and bonus and subsidy payments. Problems in mine taxation arose soon after the adoption of the 16th Amendment. This amendment gave Congress the power to impose income taxes. Supreme Court decisions against a number of mining companies held that Congress, under its power to tax income, could tax net operating revenue before depletion allowance was deducted. The court also ruled that the right to deduct depletion is a matter of Congressional permission. There is no statute provision permitting mining stockholders to recover their investment out of dividends while the mine is being operated. The Supreme Court did not recognize that part of mining proceeds are actually amortization of the cost of mineral rights. Both these omissions stem from failure to recognize that by its very nature mining consumes its mineral rights and therefore that a part of gross proceeds are not income but recovery of capital. Suppose a Congress unfriendly to mining interests repeals the provisions that allow deductions for depletion. Under such a situation assume that a corporation buys a mineral deposit for $300,000. They mine the deposit and earn an operating profit of $500,000. At the current rates they would pay a Federal Income tax of in excess of $250,000. This venture results in a loss of $50,000 as shown in the table below. For the example given the absence of depletion provisions in income tax law would turn ore into waste rock, because the word "ore" connotes commercially mineable rock. [ ] In retrospect the conclusion is clear: If the Supreme Court had recognized that a part of mining proceeds represent in reality sales proceeds of mineral rights, then profits derived from such sales would have been taxed at the favorable long-term capital rates, instead of being taxed at the high normal, surtax and excess profits rates. It is a question whether percentage depletion allowances offset this tax situation. History The history of depletion allowances has been one of general improvement. The original act did not include depletion, but an allowance at the rate of 5 pct of gross proceeds was provided in 1913. The Acts of 1916 and 1917 allowed depletion upon cost of property, and in 1918 the law was further changed to permit depletion upon cost, or market value as of date of discovery. In 1932 metal, coal and sulphur properties were permitted to elect depletion in percentages of gross income, limited to 50 pct of net income, in lieu of cost depletion. Shortly thereafter the rule was changed and percentage depletion is now allowable in any case where it is higher than cost depletion. Since 1942 percentage depletion allowances have been extended to cover many nonmetals, and in 1951 the rate for coal mines was increased from 5 to 10 pct of gross income. It is interesting to note that these allowances have been retained, and even

Jan 1, 1952

By Strathmore R. B. Cooke

That calcium will activate quartz for flotation with anionic collectors such as soaps has been known for a number of years,1 2 3 and the method has been applied to the concentration of various iron ore 4 5 6 as well as to other materials. Clemmer gives the permissible pH range for the activation of quartz by calcium as between 9.5 and 12.5 with an optimum value of 11.0, and Hertzog7 has determined the calcium abstraction of iron ores and of Ottawa sand, but otherwise little quantitative data are available. The purpose of the present investigation was to determine those conditions under which dilute solutions of calcium chloride will activate quartz for anionic flotation and to determine the amount of calcium ion adsorbed by quartz. Those variables, the influence of which was primary, such as calcium, sodium, and hydrogen ion concentrations, were studied. Other factors which influenced the results are discussed in the description of the experiments. Three different experimental methods were used to determine the activation of the quartz. The first method was to treat a sample of ground, deslimed quartz with solutions of calcium chloride and sodium hydroxide, and to determine the calcium adsorbed by chemical analysis of the solution. Ad- vantages are that a direct value for the

Jan 1, 1949

By Linn Bradley, W. W. Strong, H. D. Egbert

A hot-dry method of cleaning the gas from blast furnaces has been shown1 to conserve the sensible heat energy of the gas, and in general it thus permits of a higher flame temperature. The electrical method of cleaning gases removes from 98 to 99 per cent. of the suspended matter in one operation when operating properly, thus making possible the use of a very clean gas for burning in the stoves. The use of such clean gas thus makes feasible a different type of hot-blast stove construction from that being used at present. It therefore seems advisable to construct the stoves from the viewpoint of getting the maximum amount of heat energy into the products of combustion. By preheating the air added to the top gas and obtaining a better mixture of the air and top gas, less excess air will be required and a higher flame temperature obtained from the combustion of the top gas. The interior of the stove should be provided with a kind of brick that will withstand a high flame temperature, will conduct the heat energy along certain directions, insulate the flow of heat along other directions and at the same time store heat energy so as to make the flow of such energy more uniform. It is quite likely that these results can be best obtained by using several kinds of bricks: one type which is a good insulator of heat energy to be used for lining the stove and for making partitions through the stove to restrain the flow of heat; another type of brick or material with high refractory qualities; and a third type which will be a good conductor of heat energy. The surface of the stove exposed to the atmosphere should be a minimum in comparison to the mass of checkerwork which it is possible to obtain, due regard being paid to other conditions. With clean and hot furnace top gas it will be advisable to consider a rearrangement of the checker work in the stoves. One season for the present size and shape of checker openings is to provide facility for

Jan 1, 1917

By Reinhardt Thiessen

Under sulfur in coal, is usually understood that form of sulfur which is combined with iron and known as pyrite. It occurs in the form of balls, lenses, nodules, continuous layers, thin sheets, or flakes, both in horizontal planes and vertical cleavage fissures. But pyrites also occur as very fine microscopic particles, or nodules, disseminated through the compact coal. This form has had but very little consideration. Finally, there is sulfur in coal in an amicroscopic form (not visible with an ordinary microscope), probably combined with the organic matter that exists in the coal. This form has had considerable attention from a scientific standpoint, but has probably not been recognized enough on the economic side. One or the other, or both, of these two latter forms may comprise the larger part of the sulfur content of coal, especially after it has been washed or otllerwise prepared for use. Pyrites in Microscopic Particles All coals that have been examined by the author contained a varying amount of sulfur in very small globules, or particles, of pyrite. These particles are seen in a thin [section as roughly rounded opaque dots, Figs. 1 to 10. When isolated, they are generally shown to be approximately spherical in shape, with a rough outer surface. They vary in diameter from a few microns to a hundred microns, the majority messuring from 25 to 40 microns; relatively few exceed the latter diameter. They are, therefore, very small objects. Their size is best appreciated by comparing the illustrations, in which they are shown. at a magnifiea tion of 100 diameters, with some known area like the period used in the ordinary printed page. The period is about 0.6 mm. in diameter, and . when magnified 100 times, will cover a circular area of about 2 1/2 in. in diameter, or all but the corners of the illustrations. The illustrations, therefore, represent an area about as large as an ordinary period, and the pyrite globules form but a small part of the total area. Very frequently a number of these particles are joined together in horizontal rows; oc-

Jan 1, 1920

By AIME AIME

IN accordance with the custom of recent years, the Institute joined with the Western Division of the American Mining Congress in holding a joint meeting at Joplin on Sept. 28, 29 and 30. Actually the meeting might be said to have begun on the 27th, since the Engineering Education Committee held two sessions on that day, which are reported on another page. In addition to these sessions there were informal gatherings in the Hotel Conner, which was the headquarters, on the golf links and elsewhere of all those who had arrived by Sunday morning. The technical sessions were formally opened on Monday morning by Robert E. Tally who, after suitable preliminary remarks, introduced A. Scott Thompson, of Miami, Okla. Mr. Thompson in welcoming the visitors to the Tri-State district said that it had come to be known as a poor man's country and at the present price of zinc did not find it difficult to live up to its name. He also referred to the work Mr. Tally had done for the stabilization of the mineral industry. H. Foster Bain, in responding to this address for the Institute, said that mining men generally felt at home in Joplin, that the solutions of their problems and the general practice that had been developed in the district were not only of great interest to them, but that visitors could learn much

Jan 1, 1931

By AIME AIME

AT A meeting of the Boston Local Section of the Institute, on Oct. 3, approval was voted to the work done by its representatives on the Committee opposing the passage of a bill by the, Massachusetts Legislature to license engineers. The report is as follows: The Joint Committee on Licensing of Engineers, which included a Committee of the Boston Society of Civil Engineers and representatives of seven other societies,* submitted to the members of the respective societies, on Jan. 8, 1921, a report in which it was stated that on Jan. 4, 1921, a petition was filed in the Legislature of Massachusetts by the Boston Chapter of the American Association of Engineers accompanied by a bill to provide for the registration of professional engineers and land surveyors. This report also stated that at a meeting of this committee, held on Jan. 7, 1921, it was voted:

Jan 1, 1921

By R. R. Angel

Drilling rate is a parameter that should be considered in determining the volume requirements for air and gas drilling. The use of past methods which ignore the effects of the solids content upon the pressure and velocity of the annulus flow stream can result in undercalculation of the required volurne by as much as 50 per cent. A vertical-flow equation is presented for determining volume requirements. This equation includes the effect of the solids that are transported up the annulus in the flow stream by incorporating the drilling rate as one of the parameters. The effect of down-hole temperature on required circulation rates is also ana-lvzed. A simple approximate method of determining volume requirements is presented. This method is more accurate than the methods used in the past. Hole cleaning difficulties are analyzed for a recent air drilling job where past methods indicated that - excess air was being used. Sample curves of calculated boitom-hole pressures are presented for air and gas drilling in several hole sizes. INTRODUCTION In certain areas the use of air or natural gas as a circulating medium for drilling oil and gas wells is becoming a common practice. Large increases in penetration rate and bit life are achieved through the use of these media in preference to mud or water. Drilling rates as high as 90 ft/hr have been obtained in shales. The importance of maintaining adequate circulation rate is generally recognized; however, much disagreement exists among drilling operators as to what constitutes "adequate" circulation rate. In quarry drilling, where annular velocities can be accurately determined, an annular velocity of 3,000 ft/min of standard air is required for best results in rocks having approximately the same density as those commonly penetrated in drilling oil or gas wells'. Although this standard air velocity has proven satisfactory for quarry drilling, some oil and gas well drilling operators believe that an equivalent annular velocity of more than 4,000 ft/min is required; others believe that as little as 2,000 ft/min . is sufficient. Much of this disagreement results from determining the required circulation rates with methods which fail to incorporate the drilled solids in an equation which is applicable to vertical flow. Hughes Tool Co. Bulletins No. 23' and 23-A3 present data for determining circulation rates based on the Weymouth formula. These data do not include the drilling rate as a parameter and, therefore, neglect the effect of the solids being transported up the annulus. In spite of this apparent defect and the fact that the Weymouth formula is not applicable to vertical flow, the Hughes data have well served the drilling industry in many areas and are important and timely contributions to the science of air and gas drilling. The Hughes data purposely omit a correction for increasing down-hole temperature. At slow drilling rates this effectively compensates for the use of a formula which is not valid for vertical flow; however, volumes determined by the Hughes method are not sufficient to support rapid drilling rates at moderate and great depths. For example, Phillips Petroleum Co.'s Cauthorn "D" No. l in the Vinegarone field for Val Verde County, Tex., was air drilled from 1,500 to 9,300 ft using a compressor delivering 1,400 cu ft/min. The 8 3/4-in hole was drilled with 5-in. drill pipe, and drilling rates as high as 90 ft/hr were obtained between 7,000 and 9,300 ft. No water or caving hole was encountered. At 7,728 ft it was necessary to wash-out 60 ft of cuttings to reach bottom after a trip to change bits. At 8,130 ft a twist-off occurred and the drill col-lars were stuck in drill cuttings. These difficulties indicate that the 1,400 cu ft/min of air was not sufficient to keep the hole clean. Hughes data indicates that 1,180 cu ft/min is sufficient to produce an annular ve-

Jan 1, 1958

By E. Topanelian

In recent years considerable progress has been made in the development and application of mathematical techniques for the solution of certain problems involving economic "strategies". Such a problem might involve, for example, the scheduling of shipments of a commodity from a number of sources to a number of destinations. The object would be to schedule the shipments in a manner so as to satisfy the destination requirements and at the same time minimize the transportation costs. The solution to such a problem is not necessarily intuitively obvious. The "obvious" solution is frequently far from optimum. If the shipments are to be made from, for example, only two sources to four destinations, the optimum schedule is readily found. However, if shipments are to be made from, say, 10 sources to several hundred destinations, even a competent and experienced scheduler may spend considerable time in finding a reasonable answer. Even then he is not sure that he has the optimum solution. Furthermore, he has no way of knowing how far from optimum the answer is. Consequently, he does not know whether he should accept this solution or seek a better one. Prior to the advent of large high-speed digital computers, little more could be done with such problems because of their great size and multiplicity of possible solutions. A problem involving 20 sources and 50 destinations would require choosing, from a very large number of possible combinations, the optimum combination of 1,000 variables. The best one could do was to utilize intuition, extrapolation from past experience, and other non-exact approaches. With a high-speed computer, however, such problems can be solved providing a reasonable computational procedure (or algorithm) can be utilized. The purpose of this paper is to describe such a procedure (linear programming) and to apply this procedure to a production scheduling problem. THE RESERVOIR PROBLEM A simple reservoir model is used throughout this analysis to illustrate the use of linear programming. Even the simplest reservoir behavior problem is nonlinear in both space and time, but if the geometry is fixed for a particular study and the time variable is quantized, the resultant system may be described by linear constraints on the variable production rates. Crude oil is available from five separate sources and is delivered to a pipeline. Sources 1, 2, 3 and 4 are ideal reservoirs and therefore are subjected to reservoir flow restrictions. Source 5 is labeled "Outside Source" and crude oil from this source is assumed to be available in unlimited quantities without considering reservoir conditions. The general problem is to determine the schedule of crude oil production from five sources which, over an eight-year period and subject to certain restrictions, will result in maximum profit. "Profit" is defined to encompass all economic factors and expenses involved in producing and selling crude oil to a pipeline facility. Such economic factors are lumped to the extent that the term represents the dollars profit from one barrel of crude oil from any of the five sources entering the pipeline system. Table 1 presents the assumed profit per barrel for oil from any of the five sources over each of the four time periods. In this chart the eight years is broken into four equal intervals of two years. The selection of four time periods of two years each and the values representing the potential profit are completely arbitrary selections for the purpose of illustrating this idealized reservoir problem. In any practical application of this work a careful economic study would have to be made in order to estimate potential unit profits for time periods as far in the future as eight years. In this particular study it is assumed that all of the potential unit profits (C) are known and fixed before the production schedule is attempted. For each reservoir arbitrary values are assigned for

By J. W. Snavely

A practical mathematical treatment is presented for the determination and control of conveyor belt acceleration, particularly for conditions of starting where vertical curves are involved. A typical sample problem is analyzed, with required calculations, to clarify the procedure. THE part that acceleration plays in starting a belt conveyor and its effect on belt conveyor design are well understood in a general way. Its practical importance is easily overlooked, however, and under some conditions, it is absolutely necessary to give the problem of acceleration detailed study. Most handbooks on conveyor belting design adequately present basic data for the determination of acceleration values. This paper will only attempt to present practical thinking and a convenient method of treatment of acceleration in belt conveyor design. Mathematical Analysis In working out the various problems of conveyor belt acceleration, the starting point, as presented by the handbooks, is the familiar formula of "force of acceleration is equal to the mass times acceleration." By expressing these fundamental quantities in terms of belt conveyor design, it is possible to arrive at the unsuspected conclusion that the acceleration time for horizontal belt conveyors is independent of the load, and instead, dependent upon the belt speed, the type of drive arrangement and drive pulley, and the idler coefficient of friction. The mathematics leading to this conclusion are shown in Table I, which has been prepared to show this derivation. While at first the conclusion just given may not seem to be reasonable, further reflection indicates that obviously the type of drive pulley and the type of drive do affect materially the tension in the conveyor belt, and thus, as clearly shown, the time of acceleration is dependent upon the factors mentioned. Inasmuch as all of the factors except time are predetermined by the belt conveyor design, it becomes relatively easy to establish the accelerating time and to reduce further this time determination to a simple graph from which the time in seconds can be read directly. Such a graph is given in Fig. 1. The table appearing on Fig. 1 should be explained further. For a given belt speed, the time of acceleration can be expressed as a percentage of the belt speed. The time of acceleration is also dependent on the drive arrangement, and changes in the drive arrangement consequently change the time of acceleration. It further follows that for a given belt speed, the time expressed as a percentage of that belt speed also changes with the type of drive. Obviously then, it becomes possible to graph the percentage of speed for .each type of drive against the belt speed and accelerating time, after which, for a given belt speed and type of drive, the time can be read directly in seconds. Two constants were established for Fig. 1, the first one being the limiting of the maximum acceleration tension to 35 pct of the full load operating tension in the belt. The purpose of this is to limit the total tension imposed upon the belt during the acceleration period to 135 pct of the full load operating tension, 'which is the amount required to start or breakaway the fully loaded belt conveyor from rest. The other constant is the friction factor used for the idler equipment, which has been established as 0.022. For installations where it is necessary to establish the values of acceleration, invariably high grade idler equipment is used, and it has been established from field experience that 0.022 for the idler friction factor is amply conservative. The use of this friction factor for idlers must be tempered with judgment, of course, for occasions will arise where more power than indicated is required to start, even with the very best of equipment, such as low temperature operations that tend to congeal the grease in the bearings and thus produce additional friction drag. An inspection of the table in Fig. 1 affords a convenient rule of thumb method for determining the acceleration time, which conveniently can be 5 pct of the belt speed in seconds. The 5 pct of belt speed figure is close to the average for most types of drives. In using Fig. 1 it must be emphasized that it applies accurately to horizontal belt conveyors only.

Jan 1, 1953

By J. W. Snavely

A practical mathematical treatment is presented for the determination and control of conveyor belt acceleration, particularly for conditions of starting where vertical curves are involved. A typical sample problem is analyzed, with required calculations, to clarify the procedure. THE part that acceleration plays in starting a belt conveyor and its effect on belt conveyor design are well understood in a general way. Its practical importance is easily overlooked, however, and under some conditions, it is absolutely necessary to give the problem of acceleration detailed study. Most handbooks on conveyor belting design adequately present basic data for the determination of acceleration values. This paper will only attempt to present practical thinking and a convenient method of treatment of acceleration in belt conveyor design. Mathematical Analysis In working out the various problems of conveyor belt acceleration, the starting point, as presented by the handbooks, is the familiar formula of "force of acceleration is equal to the mass times acceleration." By expressing these fundamental quantities in terms of belt conveyor design, it is possible to arrive at the unsuspected conclusion that the acceleration time for horizontal belt conveyors is independent of the load, and instead, dependent upon the belt speed, the type of drive arrangement and drive pulley, and the idler coefficient of friction. The mathematics leading to this conclusion are shown in Table I, which has been prepared to show this derivation. While at first the conclusion just given may not seem to be reasonable, further reflection indicates that obviously the type of drive pulley and the type of drive do affect materially the tension in the conveyor belt, and thus, as clearly shown, the time of acceleration is dependent upon the factors mentioned. Inasmuch as all of the factors except time are predetermined by the belt conveyor design, it becomes relatively easy to establish the accelerating time and to reduce further this time determination to a simple graph from which the time in seconds can be read directly. Such a graph is given in Fig. 1. The table appearing on Fig. 1 should be explained further. For a given belt speed, the time of acceleration can be expressed as a percentage of the belt speed. The time of acceleration is also dependent on the drive arrangement, and changes in the drive arrangement consequently change the time of acceleration. It further follows that for a given belt speed, the time expressed as a percentage of that belt speed also changes with the type of drive. Obviously then, it becomes possible to graph the percentage of speed for .each type of drive against the belt speed and accelerating time, after which, for a given belt speed and type of drive, the time can be read directly in seconds. Two constants were established for Fig. 1, the first one being the limiting of the maximum acceleration tension to 35 pct of the full load operating tension in the belt. The purpose of this is to limit the total tension imposed upon the belt during the acceleration period to 135 pct of the full load operating tension, 'which is the amount required to start or breakaway the fully loaded belt conveyor from rest. The other constant is the friction factor used for the idler equipment, which has been established as 0.022. For installations where it is necessary to establish the values of acceleration, invariably high grade idler equipment is used, and it has been established from field experience that 0.022 for the idler friction factor is amply conservative. The use of this friction factor for idlers must be tempered with judgment, of course, for occasions will arise where more power than indicated is required to start, even with the very best of equipment, such as low temperature operations that tend to congeal the grease in the bearings and thus produce additional friction drag. An inspection of the table in Fig. 1 affords a convenient rule of thumb method for determining the acceleration time, which conveniently can be 5 pct of the belt speed in seconds. The 5 pct of belt speed figure is close to the average for most types of drives. In using Fig. 1 it must be emphasized that it applies accurately to horizontal belt conveyors only.

Jan 1, 1953