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By Milton H. Fies

EARLY in 1945 the laboratories of the Southern Research Institute will begin active research investigations on behalf of industrial clients. This achievement has come after four years of planning by a group of Alabama businessmen, and is in partialanswer to an urgent need in the South. Those who conceived the Institute have long realized that a marked relationship exists between scientific research and the economic well-being of the several regions of the country. Clearly, technological research, generally absent in the South, is the medium through which are created new finished goods industries, and the increase of technological research is perhaps the most important long-range project in the South.

Jan 1, 1945

By Robert W. Elayer

In August 1973, Fluor Utah, Inc. was awarded a contract by the Office of Coal Research (now part of the Energy Research and Development Administration), Department of the Interior, for the examination of the unique problems of large-scale surface coal mining to supply coal conversion complexes. The project consists of two phases: (I) data base development and organization and the formulation of a mathematical computer modeling system for surface mining; and (II) computer manipulation of the data base in accordance with the model to formulate several typical preliminary mine and preparation plant designs. Phase I is scheduled for completion by the end of July 1975 and Phase II is scheduled to be complete by the end of January 1977. This paper briefly discusses the effort for only one aspect of this project-the foundation for geologic modeling developed in Phase I. The Phase I task of geologic modeling can be broken down into two subtasks: (1) identify areas containing sufficient resources of surface-minable coal to support at least one large-scale mining complex, and (2) characterize the coal deposits in these areas for computer storage and retrieval. Identification of Resource Regions The basic production design criteria for large-scale surface mining, as stated in the contract, is the production of 75,000 tpd, or more, of bituminous coal. Based on a constant total Btu delivered to the preparation plant, daily production requirements for the different coals are as follows: Bituminous Coal 75,000 tons Subbituminous Coal 99,500 tons Lignite 143,500 tons Although surface mining on this scale is presently non-existent, it is deemed that future operations, in order to meet the increased energy demands, will have to look forward to much larger scale mining complexes. These tonnage requirements are meant to be used only for the delineation of general areas suitable for large-scale surface mining, termed "Strippable Coal Resource Regions." They were determined largely from the latest complete detailed coal resource estimates of the U.S. Bureau of Mines. Nine strippable coal resource regions, containing over 100 billion tons of strippable coal resources, were identified [(see Fig. 1)]. The delineation of these regions was based entirely upon estimates of surface-minable coal resources and the production design criteria for large-scale surface mining. If surface-mined coal was combined with underground production, or if smaller production rates were specified, then other areas which were omitted here would be included in the regions. Changing the outline of the regions, however, would not add any new mining situations to be studied in Phase II. Characterization of Coal Deposits The second subtask involved the general characterization of the coal deposits contained in the strippable coal resource regions. The geological information gathered

Jan 1, 1976

By R. Schuhmann

PROBLEMS in expressing, interpreting, and using size-distribution data recur in many phases of mineral dressing; therefore it is desirable that size analyses be expressed in such a form, either numerically or graphically, that comparisons can be made readily. The size distribution of comminuted material is a result of a specific physical operation on the material and therefore should be governed by some definite physical principle, or cause-effect relation. Although this principle has not been discovered, it has been found that the size distribution of comminuted, homogeneous solids may be expressed by relatively simple mathematical equations. Two equations in particular, proposed by Gaudin1 and by Rosin and Rammler,2 respectively, have stood out, both having wide demonstrated ranges of application. The form and the method of application of the two appear almost irreconcilably different on the surface, but, as will be shown, they are asymptotic in the fine sizes when expressed in the same units. This paper gives the results of a further study of the Gaudin and Rosin-Rammler relations, made with the object of developing a form of size-distribution equation that will be more usable and more significant-particularly in comminution studies, both for interpreting the nature of size distribution and for evaluating surface. The work is summarized in the following: I. An equation relating cumulative per cent finer to particle size in the fine sizes is derived from Gaudin's original equation. That equation relates weight per cent retained on one size and through the next larger size in a geometric series of sizes to size (of the retaining screen, for example). 2. Comparisons with Gaudin's equation and with the Rosin-Rammler equation show that the cumulative equation applies to the fine sizes of all size distributions that fit either of these earlier relations, and, furthermore, has some advantages over each. 3. A simple graphical method of surface calculation based on the cumulative-equation plot is evolved and illustrated. 4. Additional confirmation of the cumulative equation was obtained in the more severe test of sizing down to the limit of a sedimentation balance a sample of jaw-crushed quartz. The equation was closely followed over a 20o-fold range in size, from approximately 0.4 mm. (35 mesh) down to 0.0023 mm. (2.3 microns), the lower limit of the size analysis made. There is no indication that the equation will not hold further to well below 2.3 microns. 5. Calculations of the surface produced in the jaw-crushing test mentioned above showed that at least 8o per cent of the total new surface was on particles finer than 35 mesh (about ½ 5 of the crusher setting). The minus 35-mesh portion was only

Jan 1, 1940

By J. W. Taylor, E. G. Zukas

THE results of shock-loading studies on copper were reported several years ago by smith. In his experiments, Smith found that there was a correlation between the shock direction and the orientation of twins which the shock produced. By using free-surface-type shots in which the free surface of the specimen was not normal to the shock direction, he showed conclusively that twinning of copper in impulsive loading was caused by the rarefaction wave. Similar tests with iron, however, showed that it twinned during compression. More recent studies of iron2 and on Fe-Si single crystals3 have shown that twinning can be suppressed in these materials by shock loading at pressures high enough so that the velocity of the shock wave exceeds the elastic-wave velocity. From these observations, it appeared that twinning was caused by the shear stresses present in the zone undergoing adjustment from one-dimensional to three-dimensional loading. At high pressures, such a zone becomes so thin that there is insufficient time for the relatively ordered motion of atoms involved in twinning to occur. Twinning in copper, therefore, cannot be produced by a single compressive shock wave because resolved shear stress large enough to create twins exists only for a very short time (0.01 psec or less) before the pressure increases suddenly and loading becomes essentially hydrostatic. (A typical pressure vs time record for a copper shot, illustrating the short rise time of the compression wave, is shown in Fig. 1.) If, on the other hand, a second shock wave can be created in a precompressed sample, then the new elastic limit is several kilobars,4 and a resolved shear stress sufficient to cause twinning should be maintained for an adequate time period (0.1 psec or more). This experimental situation can, in fact, be realized. The experimental arrangement used to do so is shown in Fig. 2. By utilizing the pressure transformation in Fe-V alloys, it was possible to shock-load the copper in compression while the copper was already precompressed. In the first test, an 8 wt pct V-Fe sample was used as a driver for loading the copper, and the copper was exposed to the following series of compressive shocks: 1) an elastic wave of about 8 kbars, which is usually ignored in shock studies; 2) the pressure transformation wave for the driver of 200 kbars; and 3) the driving shock wave of 270 kbars pressure. Metallurgical determination of the angular twin distribution, shown in Fig. 3, with respect to the shock direction and the shock rarefaction direction (which was 23 deg from the shock direction) showed that twinning took place

Jan 1, 1965

By Howard Clarke, Cyril Stanley Smith, Clarence Zener

THE importance of cold-working in the fabrication of metals is in marked contrast with our ignorance as to the nature of the accompanying internal changes. The failure of the usual methods of testing to provide a consistent picture of these internal changes has given the incentive for the present program of investigating the effect of cold-working upon the internal friction of metals measured at small strain amplitudes. It has previously been shown1,2,3, that the internal friction introduced by cold-work is removed by annealing at comparatively low temperatures. In the present paper the following additional factors are investigated: (I) frequency of measurement, (2) amount of cold-work, (3) temperature of measurement. Special care was taken to minimize the internal friction due to causes other than cold-work. The present paper is purely experimental, the authors believing that any conclusions drawn from this work as to the nature of the internal changes accompanying cold-work would be premature." PREPARATIONS OF SPECIMENS In this study of cold-work it was desirable to eliminate as far as possible all other sources of internal friction. One disturbing source is the lack of temperature equilibrium between adjacent crystallites of a vibrating specimen.4 Temperature equilibrium is aided by small grain size and by the use of low-frequency vibrations. Unless unduly long specimens are used, low frequencies can be obtained only in transverse vibrations. But in transverse vibrations a second source of internal frictions is present, that arising from transverse thermal currents.5 The effect of these may be reduced by increasing the transverse dimensions. The grain size and transverse dimensions of the specimens were thus so chosen as to render the vibrations simultaneously nearly isothermal with respect to intercrystalline thermal currents, and nearly adiabatic with respect to transverse thermal currents. The material for this investigation was a 70-30 brass, part of the same lot of material that was used for some earlier studies on the effect of strain on proportional limit.10 It had the following composition: copper, 70.59 per cent; zinc, 29.39; lead, 0.01; iron, 0.01. This material was received from the brass mill in the form of 3/4-in. rod, cold-drawn to final size by a 65 per cent reduction of area from material that had been annealed to give a grain size of 0.060 mm. Rods of appropriate length were annealed for 2 hr. at 400°C. and cooled in air. The annealed rods (grain size, 0.012 mm.) were then stretched in a tensiontesting machine, using special grips10 to ensure axial application of the load. The rate

Jan 1, 1941

E. P. Pfleider, University of Minnesota I would like to ask Bob Merrill whether he considers that horizontal concave curvature of a slope has any stabilizing effect, such as Jenike 1 suggested several years ago. R. H. Merrill, U. S. Bureau of Mines, Denver Federal Center The stabilizing effect is due to the restraint offered to radial movement by the curvature. We found in laboratory tests that if we constrained the rock with the same stresses as those measured in the pit then it would sustain a maximum stress about two or four times greater than when the same rock type was unconstrained. We are therefore definitely of the opinion that a constrained situation in a slope is favorable towards stability. G. A. Leonards, Purdue University I was interested in Mr. Lane's observations concerning the correspondence between rate of slide movement with rise of reservoir. Perhaps the most interesting feature is that the rate of movement at the time the rock slope failed was less than the rate at an earlier time when it did not fail. This is difficult to explain from current slope stability theory. K. S. Lane, U. S. Army Corps of Engineers I believe that reduced rate of movement is the result of the progressive type of failure, such as described by Patton and Deere. which occurs along the sliding surfaces. It is difficult to analytically define the progressive failure condition for inclusion in slope stability conditions, but its existence should be recognized in design. We should also realize that many apparently stable slopes undoubtedly contain overstressed regions. To design a slope with no overstressed region would be uneconomical and conservative. D. H. Deere I would pose the question-"What is the meaning of a factor of safety of one?" We were involved in the design of a large, irregularly shaped, underground cavity with an unsupported span of several hundreds of feet. Tests on rock specimens indicated a strength of 1300 lb per sq in. The RQD would have been between 90 to 100 percent indicating excellent structural continuity. In-situ stress determinations indicated an approximately hydrostatic state of stress at a level of 1400 lb per sq in. Calculation of stress concentrations at the walls indicated that the stresses there would be about 3000 to 4000 lb per sq in. Admittedly the rock is in a confined condition everywhere except at the very skin of the wall and the rock walls would thus on the average be somewhat stronger. Allowing for the effect of restraint the factor of safety was found to be less than 0.5 over a region several feet into the wall. Construction was started, using rockbolts only to support the walls. Failure around the immediate skin occurred after each

Jan 1, 1967

By J. H. Westbrook

IT is always of interest to document the origin of real microstructures which closely approach various idealized morphologies. Such instances constitute excellent bases for experimental studies of the effect of microstructure on properties. Typical examples include the eutectoid steels (lamellae) used by many investigators and the two phase Cu-Cr alloys (spheres) recently employed by Hibbard and Hart The present note describes a structure with cylindrical particles. In a study of certain alloys in the Cr-C system, an alloy was arc melted whose composition was very close to the aCr-Cr,C, eutectic (3.2 wt pct C, according to the latest phase diagram published by Bloom and Grant2). The alloy was not analyzed but previous experience with the melting technique employed indicates good correspondence between intended and analyzed compositions with negligible tungsten contamination from the electrode. The phases present in the alloy were identified by X-ray powder patterns as a chromium and Cr,C,. Typical micrographs, presented in Fig. 1, show unmistakable evidence of the cylindrical geometry of the carbide phase. The eutectic grains are randomly oriented and, consequently, only a few show the true fibrous nature of the carbide particles, most being cut so as to show slightly elliptical cross sections. Within any particular grain, remarkable uniformity is to be observed with respect to the size, shape, spacing, and orientation of the carbide particles. Length to diameter ratios have been estimated from the micrographs to be at least 250:1, with diameters of about lp. This alloy may be of further interest from different viewpoints. On the one hand, it might be used to check the applicability of the equations derived by Fullman3 for computing true particle dimensions of cylindrical particles from opaque random sections. On the other hand, it might be possible to extract the carbide particles from this alloy and repack them in a ductile matrix to form a synthetic structure of the type discussed by Metcalfe et al.4 With the large l:d ratio and the small diameter of the carbide fibers, it is likely that the interdefect distance in each fiber is sufficiently great to permit realization of a large fraction of the presumed high strength of the carbide. References 1W. R. Hibbard, Jr. and E. W. Hart: Dispersion Hardening of Copper-Chromium Alloys. AIME Trans., 1955, vol. 203, p. 200; Joun-nal of Metals, January 1955. 2D. S. Bloom and N. J. Grant: The System Chromium-Carbon. AIME Trans.. 1950. vol. 188. p. 41; JouRnal of Metals, January 1950. aR. L. Fullman: Measurement of Approximately Cylindrical Particles in Ooaaue Samples. AIME Trans.. 1953, vol. 197, p. 1267; Journal of Metals. ~ebtember 1953 4 A. G. Metcalfe, C. H. Sump, and W. C. Troy: Fiber Metallurgy. Metal Progress, 1955, vol. 67, p. 81.

Jan 1, 1958

Copper ores from small mines in the area south of Tucson, where the Twin Buttes mine is located, were first operated in the 1880's. Today this area is one of the great copper mining centers of the world. In 1963, Anaconda Company acquired the property from Banner Mining Company and in recent years joined with AMAX in a 50/50 partnership to work the Twin Buttes property. From the beginning, Anaconda had relied on conveyors to remove overburden, oxide material for eventual leaching, and ore from the open pit. In the large st preproduction stripping program in mining history, Anaconda in a four-year period (1965 to 1969) removed 266 million tons of overburden of an average depth of 500 ft (152 m) lying over the ore body. The alluvium overburden was stripped by scrapers carrying 70 to 80 tons and push-loaded by two D9 tractors operating in tandem. The scrapers delivered their loads to bins which fed a 60 in. (1.52 m) conveyor having a capacity of 8500 tph. The 25% slope belt conveyor, which was 2100 ft (640 m) long, transported the material to the brow of the pit, where it was transferred to an 8300 ft (2530 m) surface belt to a 1000 ton loadout bin. At this point, the overburden was trucked to the sites of the tailings ponds, where it was used for dam construction. During 1976, the one billionth ton of overburden was removed from the Twin Buttes mine. The Twin Buttes quartz monzonite porphyry contains only scattered mineralization of which chalcopyrite is the most abundant mineral, associated with chalcocite, covellite, minor bornite, and several oxide minerals. Oxidation has progressed to variable depths of up to several hundred feet below the base of the alluvium. Because of the depth of the sulfide and oxide ores and hard rock waste, two in-pit crushers and conveyor systems were also installed for their transport out of the pit; and in 1976 a third crusher and conveyor system was installed lower in the pit for waste rock only. The two initial crushing and conveying systems were designed to handle any of three functions: crushing waste to be disposed of by a rail-mounted stacker -conveyor, crushing oxide ore for conveyor and then truck transport to stockpiles for future leaching, and primary crushing of sulfide ore for conveyor transport to the two 30 in. by 70 in. (0.76 by 1.78 m) secondary crushers and the two 7 ft (2. 13 m) standards and four 7 ft shortheads in the third and fourth stage crushing plant. A third standard crusher has been in- stalled recently. Mining is done by 15 yd (11.5 cum) shovels which load 100- and 150-ton

Jan 1, 1978

By Clarence Zener, Howard Clarke, Cyril Stanley Smith

The importance of cold-working in the fabrication of metals is in marked contrast with our ignorance as to the nature of the accompanying internal changes. The failure of the usual methods of testing to provide a consistent picture of these internal changes has given the incentive for the present program of investigating the effect of cold-working upon the internal friction of metals measured at small strain amplitudes. It has previously been shown1,2,3, that the internal friction introduced by cold-work is removed by annealing at comparatively low temperatures. In the present paper the following additional factors are investigated: (I) frequency of measurement, (2) amount of cold-work, (3) temperature of measurement. Special care was taken to minimize the internal friction due to causes other than cold-work. The present paper is purely experimental, the authors believing that any conclusions drawn from this work as to the nature of the internal changes accompanying cold-work would be premature.'l PrEpaRations oF Specimens In this study of cold-work it was desirable to eliminate as far as possible all other sources of internal friction. One disturbing source is the lack of temperature equilibrium between adjacent crystallites of a vibrating specimen.4 Temperature equilibrium is aided by small grain size and by the use of low-frequency vibrations. Unless unduly long specimens are used, low frequencies can be obtained only in transverse vibrations. But in transverse vibrations a second source of internal friction is present, that arising from transverse thermal currents.5 The effect of these may be reduced by increasing the transverse dimensions. The grain size and transverse dimensions of the specimens were thus so chosen as to render the vibrations simultaneously nearly isothermal with respect to intercrystalline thermal currents, and nearly adiabatic with respect to transverse thermal currents. The material for this investigation was a 70-30 brass, part of the same lot of material that was used for some earlier studies on the effect of strain on proportional limit.10 It had the following composition: copper, 70.59 per cent; zinc, 29.39; lead, 0.01; iron, 0.01. This material was received from the brass mill in the form of 3/4-in. rod, cold-drawn to final size by a 65 per cent reduction of area from material that had been annealed to give a grain size of 0.060 mm, Rods of appropriate length were annealed for 2 hr. at 400°C. and cooled in air. The annealed rods (grain size, 0.012 mm.) were then stretched in a tension-testing machine, using special grips1' to ensure axial application of the load. The rate

Jan 1, 1942

By H. E. Stauss

THE time-to-fracture test has been applied to pure platinum and to two alloys of platinum under the special conditions of small cross-sectional area of the specimens and of a test temperature above the annealing temperature. While the results are similar in character to those secured with large specimens of steel at temperatures below the annealing temperatures, two differences are noted: (I) an upward inflection in the curves for log stress vs. log time for the alloys, and (2) a sharp break in the curve for log stress vs. log time for pure platinum when single crystals filled the wire. The experiments showed that: (I) platinum and 10 per cent rhodium-platinum maintained their strengths at 1100°C. better than did 10 per cent iridium- platinum, and (2) the rhodium-platinum after a time exceeded the iridium-platinum in strength at 1100°C. Platinum alloys in their service at high temperatures encounter conditions some- what similar to those that exist in the usual form of the time-to-fracture "l test with steel. This paper is intended primarily to present results obtained by a "time-to- fracture" test under conditions approximating actual service for platinum (at the temperature 1100°C. under oxidizing conditions) with three materials, pure platinum (99.99 per cent), a platinum alloy with lo per cent iridium, and a platinum alloy with 10 per cent rhodium. The experimental procedure differed from that previously used in this type of measurement in that the samples were of small diameter (0.010 in.), were fully annealed, and were tested at a temperature definitely above their annealing points (600°C., 1000°C. and 1050°C., respectively, for 60 per cent cold reduction and 15 min. heating time2,3). The experimental arrangement was similar to that previously described,4 using as heating unit a small, horizontal, platinum- wound furnace, ½ by 12 in., maintained at constant temperature by an automatic controller. The samples were 0.010-in. wires, which had been annealed at 1200°C. by drawing them slowly through the furnace. The time-to-fracture was measured electrically. Elongation was not determined because of the difficulties inherent in the experimental arrangement. Life-that is, the time-to-fracture-was considered the important property in these first tests. No attempt was made to measure the reduction in area, but the types of fracture were noted qualitatively; in the text they are referred to as (I) the normal, plastic, or necked fracture, (2) the knife-edge fracture, and (3) the brittle or intercrystalline fracture with small reduction of area. Results for different constant applied stresses are plotted in Fig. I. In all cases at least two trials were made for each stress, although they cannot always be indicated separately on the curves. The breaking stresses drop very rapidly to a small frac-

Jan 1, 1943

By W. H. Herrnstein, F. H. Beck, M. G. Fontana

Sulfur solubility in a iron was measured in the 750 to 890°C temperature range and was found to be insensitive to ferrite purity within a limited composition range. The permeability of sulfur in ferrite was determined from the internal sulfidation of Fe-Mn alloys. From the solubility and permeability results, the diffusivity of sulfur in ferrite could be calculated. These results are summarized as follows: Dissolved sulfur decreased the lattice parameter of ferrite. The effect of dissolved sulfur on the tensile properties of ferrite at low temperatures was also determined. SINCE sulfur is an important residual impurity in commercial irons and steels, effects associated with the presence of sulfur as a solute in iron are of considerable practical interest. Unfortunately, certain basic information relative to the Fe-S system appears to be lacking in the literature, e.g., the effect of dissolved sulfur on the lattice parameter and mechanical properties of ferrite. In addition, discrepancies exist in previously reported results for the solubility of sulfur in ferrite. These discrepancies raise questions regarding the sensitivity of sulfur solubility to the purity and microstructure of iron. This study was undertaken primarily in an effort to obtain reliable data on the solubility of sulfur in ferrite. Additional objectives included determination of the permeability and diffusivity of sulfur in ferrite by the internal sulfidation method and determination of the effect of dissolved sulfur on the lattice parameter and tensile properties of ferrite. EXPERIMENTAL METHOD Three grades of iron, encompassing a range of impurity levels, were employed in the study. The grades were designated VME (vacuum-melted electrolytic), SPZR (single-pass zone-refined), and MPZR (multipass zone-refined). The composition of each grade is given in Table I. Poly crystalline and single-crystal strip specimens were employed in the solubility experiments. Uniform grain size strip (ASTM 3 to 5) of 0.005 to 0.020 in. thickness was obtained by alternate cold reductions of 60 thickness 60 to 80 pct and recrystallization at 650°C for i hr in pure, dry argon. Single-crystal specimens were produced in 0.010-in.-thick SPZR iron strip by the strain-gradient anneal technique. Recrystallized strip 0.25 in. wide was strained until a Luders band or bands had propagated over the length of the strip; the strip was then annealed by drawing it through a 150°C per in. gradient (890°C peak temperature) at 1 in. per hr in an atmosphere of pure, dry argon. Laue photographs of the crystals produced exhibited no discernible asterism. Specimens were equilibrated with H-H, atmospheres at temperatures between 750" and 890" by one of two methods, each of which makes use of the reaction: The encapsulation sulfurization method was employed in the majority of the solubility experiments. A strip

Jan 1, 1969

By Roland D. Parks

CORUNDUM, little publicized as an industrial abrasive, has, in its small way, contributed greatly to the production of many specialized items vital to our war program and to our allies. Optical elements of the highest quality for range finders, bombsights, and scientific instruments; precision metal parts for torpedoes and airplane engines; quartz crystal plates for military radios; armorplate and malleable castings for tanks and guns; and eyeglasses for everyone; these are some of the products that corundum has helped to produce in the quantities needed and on time. Unlike metals and many other raw materials, corundum is not incorporated into any of these finished products. It is simply a grinding medium used to produce the desired finish or precision; an operating supply or tool, so to speak. With a Mohs' scale index of o, corundum ranks next to the diamond in hardness among the natural minerals and is superior to emery and garnet. The gem varieties of corundum, including the Oriental ruby and sapphire, are frequently more highly prized as jewels than the diamond. It is the intent of this paper to deal only with a description of the corundum industry, the administration of wartime control, and certain economic aspects as seen by the author. Several references are listed to assist anyone who wishes further information on the geological occurrence of the mineral. ORE PRODUCTION AND CONSUMPTION For the past two decades, South Africa has been the world's sole producer of corundum ore. A possible exception is Russia, where, it is understood, there was considerable production during the thirties for domestic consumption but for which statistics are lacking. The United States is the world's principal consumer of corundum ore; imports for the period 1934 through 1940 averaging 3000 short tons per year. The years 1935 and 1936 were close to the 5000-ton mark, and imports during 1941, the last prewar year for which statistics have been released, were approximately 6000 short tons. Again lacking statistics on Russia, the United Kingdom ranks second, but far below the United States in consumption of ore. Historically, corundum has been found in some 35 countries throughout the world, but the principal deposits are in South Africa, Canada, Madagascar, Russia and the United States. Deposits are generally small and subject to rapid exhaustion. Thus, the United States was the principal world producer for the period 1870 to 1900, when operations ceased except for two years during World War I. India was a producer of ore from 1898 through 1921, with peak output in 1916 through 1918. Canada came into production in 1901 with substantial output of ore and finished grain until 1914; the production thereafter was smaller until 1921. Madagascar has produced ore since 1910 but has had important output in only a few scattered years. South African production started in 1912,

Jan 1, 1945

By Wilford S. Wright

FOR the past four years the management of the Black Hawk Consolidated Mines plant at Mogollon has conscientiously kept accurate records pertaining to cost of operation and the performance of certain equipment. These records have been valuable in coordinating the work in the mine, mill and power plant. Also, as to quantity and kind of equipment and supplies most suitable from the standpoint of economy and dependable operation, they have served as a guide. Through comparison with records at other mines, where the same things are being done in a different way, they have pointed out mistakes to be avoided. No outstanding accomplishments, either in costs or performances, are revealed; in fact, some of the results are perhaps quite inferior to those obtained at similar plants, but it is with the thought that more records should be published for the benefit of the mining profession that the author presents these data. To other operators and to mining engineers who are called upon to make estimates for prospective operations, the information herein should be helpful. GENERAL CONDITIONS Mogollon is in the southern part of Catron County, southwestern New Mexico. It lies near the western border of the Mogollon Range, 14 miles east of the Arizona line. Silver City, 80 miles to the southeast, is the nearest railroad point. The connecting road, over which supplies are hauled into camp by trucks, is an improved highway for about 50 miles; the remainder consists of graveled roads and unimproved steep mountain grades. One general supply truck and one tank truck make daily round trips. Hauling of supplies to the mine has cost at the rate of $0.08 per ton-mile; or, on the basis of ore production, $0.30 per ton mined. Lumber, hauled in from local mills, has cost an average of $30.00 per 1000 board feet, $8.50 of which has been for hauling. The annual consumption averages 108,000 board feet. Lime, hauled from a plant in Arizona, is about the only other item not brought out from Silver City. Fuel oil for the generation of power is the item of greatest hauling expense, the f.o.b. Mogollon cost of approximately $0.06 per gal. being nearly twice the f.o.b. refinery price. Water for power plant, mill and camp use flows to camp storage tanks through a 4-in. pipe line from a spring and intake 3 miles up Silver Creek Canyon. A few times, particularly in the month of June, mill operations have been suspended for two or three days because of water shortage. MINING CONDITIONS During the years 1938, 1939, 1940 and 1941, the mine produced 230,059 dry tons

Jan 1, 1943

By G. M. Wiles

The increasing number of problems of the modem mine manager has led the author to discuss the art of management. He lists the principles concerning selection of personnel, exploitation and development, new equipment, process improvements, new processes, maintenance, operating cost data and public relations. Application of the principles to problems of mine startup, operation and rehabilitation are described. Since D. C. Jackling was famous for his adeptness at organizing and training teams of operating personnel, the subject of mine management is particularly appropriate for a Jackling Lecture. In fact, it is doubly appropriate because in very basic ways Jackling's career changed the nature of the tasks and challenges facing a mine manager. Management of mines, of course, is the art of finding and winning minerals economically from the earth's crust, and it involves the use of all the engineering sciences. But also of prime importance is a skill which is not yet a science - the area of management often referred to as human engineering. Since expenditures on staff and labor may well involve more than 50% of the direct costs of operating a mine, ability at human engineering is just as important as the ability to plan and put into effect the most efficient operating procedures. In addition to his ability to select and train operating personnel, Jackling possessed, to a degree unmatched by many of his contemporaries, broad, analytical powers covering both the economics and operating phases of large scale mineral extraction. His breadth of vision found its greatest expression at the time he analyzed the Utah copper deposit. Fortunately, Messrs. Penrose and Gemmell had enough faith in his analyses to furnish the capital needed to begin operations. The result, as is well known to all of you, was Kennecott's lucrative Utah copper mine — and the beginning of the open pit porphyry copper era. The Utah copper mine, and Jackling's subsequent similar successes in Arizona, New Mexico and Nevada, had one thing in common —all of these large porphyry deposits were worthless until open pit, large daily tonnage schemes were developed for their exploitation. The successful development of such schemes made vast new mineral resources available for economic exploitation. But at the same time, the trend away from smaller high grade operations in favor of the far more complicated operations required to handle large deposits of low grade ore have greatly altered a mine manager's problems. We are all familiar with the saying "mines make managers." There is still some truth in this statement, but far less than there used to be in the days when high grade properties were the rule rather than the exception. When high grade orebodies prevailed, many managers, superficially at least, could not make a mistake because the profits of their mines

Jan 1, 1962

By H. J. Modi, P. L. De Bruyn

IN recent years interest has been aroused in flotation rate studies both from a technical and a more practical aspect. With increasing fineness of grind becoming a necessity in treatment of low grade ores, difference:; in flotation rates of various size ranges will assume importance in the evaluation of overall recovery results. Theoretical analysis of flotation kinetics was initiated by Schuhmann,' who sought to define flotation rate of a given mineral and specified size range in terms of certain physical variables of the flotation system. Using as a basis for his analysis the bubble-particle encounter hypothesis previously advanced by Gaudin,' Schuhmann writes for the rate of flotation (R,.) of particles of average size x, Rx = PcPa(x) V F. [1] In this relation Pc and Pa represent, respectively, the probability of collision between particle and gas bubble in a given time interval and the probability of adhesion of particle to the bubble after collision. Rigorously speaking, the term PC does not have the significance of a probability factor, since it depends on the time interval and therefore can be numerically greater than unity. The term c(x) expresses the concentration of particles of an average size x in the flotation cell in weight per unit volume of pulp, and V denotes the total volume of pulp in the cell. The product, P,c(x)V, defines the frequency of particle-bubble collisl.on, and when it is multiplied by P,, the number of collisions per unit time resulting in successful adherence is obtained. The factor, F, measures the froth stability and is introduced because after fruitful bubble-particle contact some particles may still riot reach the froth launder. Coalescence of bubbles in the froth column or too short a bubble life could account for this effect. Schuhmann also introduced the concept of "specific flotation rate" (Q) to allow for the relative abundance of different mineral species in the flotation pulp. The specific flotation rate, having the dimension of reciprocal time, is defined as Eq. 2: Qx =Rx/c(x)v [2] and it also follows from Eq. 1 that Qx = PcPaF. [31 The theoretical aspects of flotation kinetics were also considered by Sutherland,3 who tried to improve Eq. 1 by expressing the probability factors in terms of such physical variables as particle radius (x), bubble radius (X), velocity of bubble relative to particle (v), the number of bubbles per unit volume of pulp (N) and the induction period (A) necessary for air-mineral adhesion. According to Sutherland's treatment, the rate equation, Eq. 1, transforms to R, = [3pX x v N] [sech2 (3 v ?/4 X) ] ?c(x) V [4] where the first term in brackets on the right-hand

Jan 1, 1957

By R. M. Raymond

RECENTLY one of the Welsh coal companies, which has an excellent plant of up-to-date ma-chinery both on the surface and underground, operated under modern methods, sent one of its engi-neers to the United States to study actual operations in the mines. He visited several of the most important and best conducted collieries, went back, and reported that the greatest difference between operations in England and in the United States was. the closer con-tact between management and workmen. By manage-ment he meant management all the way through; close cooperation between office management, superintend-ents, foremen, shift-bosses, etc., and the workmen. A visit to some of the coal mines in that country by the writer made this fact rather impressive. The feel-ing on this side of the water that the methods in use in the coal mines in England are not up-to-date was found in many cases to be quite erroneous. Many mines, particularly those with very thin beds, in which profitable operations are doubtful under the best con-ditions, have necessarily had to adhere to old methods instead of making mechanical improvements. The Powell-Duffryn mines, in the center of the South Wales district, are certainly operating successfully, and have planned their business excellently. Sufficient areas of contiguous land have been leased for extended opera-tions. Mine plants are laid out in the valley, for work-ings on both sides, on a reasonable tonnage of 1500 to 3000 tons to each operation. The beds are from 30 to 48 in. thickness, and a 3-ft. seam is considered an ex-cellent thickness of coal; in fact, the miners prefer to work on the thinner beds rather than the thick ones, where they consider it more difficult to control the backs. This company is making use of its fine coal for produc-ing electric power, which is distributed to its own operations, and for use in the communities adjoining. For this purpose methods of cleaning the fine coal are being put into use. Compressed air is generated at the central power plant and is transmitted over long dis-tances to various mines in each valley. A byproduct coke plant uses more of the fine coal and gives further returns from non-commercial coal. The long-wall system applied in sections of limited size is popular in working the small seams, and me-chanical cutting is used, also handling either by shaking chutes or belt conveyors, or a combination of both. In some mines mechanical cutting is not necessary. The backs are so handled that in the softer or somewhat crushed seams hand cutting can be carried on effec-tively.

Jan 10, 1927

By A. G. Guy

IN the course of a research on steady-state diffusion it became necessary to make diffusion calculations for a finite solid. This problem was found to be sufficiently different from the corresponding problem for the semi-infinite solid for an entirely new approach to be necessary in obtaining a useful solution. The assumption of an exponential variation of the diffusion coefficient with concentration' was no longer a practical necessity, so that the new solution offered the possibility of handling diffusion in semi-infinite solids for arbitrary variations of the diffusion coefficient with concentration. In discussing the principle on which this method of calculation is based, it is convenient to consider the relatively simple problem of one dimensional diffusion into a matrix that initially contains none of the diffusing substance. The solution of the set- ond Fick Law,?C/?t=D0?2C/?x2, for diffusion into a semi-infinite solid is3 C/C=1-F(x/2vD0t [1] where C is the concentration of the diffusing substance at a depth x cm below the surface after dif- A. G. GUY, Member AIME, and M. GOLOMB are Professor of Metollurgicol Engineering and Professor of Mathematics, respectively, Purdue University, Lafayette, Ind., A. S. YUE, formerly with Purdue University, is now with the Research Laboratory, Dow Chemical Co., Midland, Mich. TP 4505E. Manuscript, July 18,1956. fusion has occurred for t seconds; C, is the concentration of the diffusing substance at the surface of the matrix; Do is the diffusion constant, expressed in sq cm per sec; and + represents the Gauss error function. The corresponding solution for diffusion into a finite solid of thickness, 1, is conveniently written for the change in concentration, C+, at a point midway through the matrix and for times, t, great enough for the following equation to be used4 c1/2/C1=(1/2-2/?e-?2D0t/l2) [2] In Eqs. 1 and 2 the diffusion coefficient is represented by the symbol Do (rather than by D) to emphasize that these equations are valid only for constant values of D. To understand how these equations can be modified to take account of actual variations of D, such as that shown in Fig. 1, first consider the fact that for a given time of diffusion theconcentration at a given point is determined, not by the D value alone, but by the ratio x/vD0 in Eq. 1 and by a similar ratio, l2/D0 in Eq. 2. Even though in fact D varies, it is possible to keep this ratio constant by using a special coordinate system, x,, that varies with D in the appropriate manner. The necessary character of this special coordinate system can be easily visualized by imagining that

Jan 1, 1958

By Howard Clarke, Cyril Stanley Smith, Clarence Zener

The importance of cold-working in the fabrication of metals is in marked contrast with our ignorance as to the nature of the accompanying internal changes. The failure of the usual methods of testing to provide a consistent picture of these internal changes has given the incentive for the present program of investigating the effect of cold-working upon the internal friction of metals measured at small strain amplitudes. It has previously been shown1,2,3, that the internal friction introduced by cold-work is removed by annealing at comparatively low temperatures. In the present paper the following additional factors are investigated: (I) frequency of measurement, (2) amount of cold-work, (3) temperature of measurement. Special care was taken to minimize the internal friction due to causes other than cold-work. The present paper is purely experimental, the authors believing that any conclusions drawn from this work as to the nature of the internal changes accompanying cold-work would be premature.'l PrEpaRations oF Specimens In this study of cold-work it was desirable to eliminate as far as possible all other sources of internal friction. One disturbing source is the lack of temperature equilibrium between adjacent crystallites of a vibrating specimen.4 Temperature equilibrium is aided by small grain size and by the use of low-frequency vibrations. Unless unduly long specimens are used, low frequencies can be obtained only in transverse vibrations. But in transverse vibrations a second source of internal friction is present, that arising from transverse thermal currents.5 The effect of these may be reduced by increasing the transverse dimensions. The grain size and transverse dimensions of the specimens were thus so chosen as to render the vibrations simultaneously nearly isothermal with respect to intercrystalline thermal currents, and nearly adiabatic with respect to transverse thermal currents. The material for this investigation was a 70-30 brass, part of the same lot of material that was used for some earlier studies on the effect of strain on proportional limit.10 It had the following composition: copper, 70.59 per cent; zinc, 29.39; lead, 0.01; iron, 0.01. This material was received from the brass mill in the form of 3/4-in. rod, cold-drawn to final size by a 65 per cent reduction of area from material that had been annealed to give a grain size of 0.060 mm, Rods of appropriate length were annealed for 2 hr. at 400°C. and cooled in air. The annealed rods (grain size, 0.012 mm.) were then stretched in a tension-testing machine, using special grips1' to ensure axial application of the load. The rate

Jan 1, 1942

By E. Brunner, E. S. Mardock

A method of measuring oil saturations in cores or sand packs by neutron scattering is described. This method permits local SatUrations to be measured in a core enclosed in a steel pressure vessel without interrupting the flow. calibration data and a saturation distribution measurement obtained with the apparatus are included by way of illustration. Introduction In laboratory flow experiments designed to study the mechanism of oil production it is frequently necessary to measure the oil saturation in a core or sand pack containing Oil, gas, and perhaps brine. It is sometimes desirable that the saturation measurement refer to a relatively small portion of the core, so as to eliminate end effects; that it be made without interrupting the flow, and that it be applicable to a core enclosed in a steel Pressure vessel capable Of withstanding the Pressures encountered in petroleum reservoirs. None of the usual methods of measuring saturation meets all Of these requirements. To measure the gas saturation by observing the apparent compressibility of the gaseous Phase1 would require the interruption of the flow and would give an average saturation for the whole core. An electrical conductivity method is available for measuring brine saturations,2,3 but it is not applicable to oil. A radioactive tracer might be used if a suitable substance could be found that would dissolve in the oil, emit gamma radiation, and not be adsorbed on the sand, the steel core holder, or in an aqueous- phase. The large gamma-ray background from the mass of radioactive oil in other parts of the apparatus might, however, be undesirable. There remain for the saturation measurement methods involving the absorption or scattering of some penetrating radiation produced outside the apparatus. It might be possible to use X-rays or gamma rays; but these radiations would be so much less strongly absorbed and scattered by the oil than by the steel walls of the core holder and by the sand that it seems doubtful that much precision could be attained. In a beam of neutrons, however, there is a radiation that is very penetrating and, moreover, its scattering by substances containing hydrogen, such as oil, is qualitatively different from that occasioned by other materials. It would seem possible, and has proved to be quite practicable, to measure oil saturations accurately under the required conditions by means of neutron scattering. The first, to our knowledge, to suggest neutron scattering as a means of measuring oil saturation were F. Brans and ,. A. Bottema,4 of the Amsterdam laboratories of the Bataafache Petroleum Maatschappij, who made a few preliminary experiments to test the method while they were engaged in exploring the possibilities of neutrons for well-logging purposes. A comprehensive account of neutrons and their behavior will be found, together

Jan 1, 1946

By Roland D. Parks

Corundum, little publicized as an industrial abrasive, has, in its small way, contributed greatly to the production of many specialized items vital to our war program and to Our allies. Optical elements Of the highest quality for range finders, bombsights, and scientific instruments; precision metal parts for torpedoes and airplane engines; quartz crystal plates for military radios; armorplate and malleable castings for tanks and guns; and eyeglasses for everyone; these are some Of the products that corundum has helped to produce in the quantities needed and on time. Unlike metals and many other raw materials, corundum is not incorporated into any Of these finished products. It is simply a grinding medium used to produce the desired finish or precision; an operating supply or tool, so to speak. With a Mobs' scale index of 9, corundum ranks next to the diamond in hardness among the natural minerals and is superior to emery and garnet. The gem varieties of corundum, including the Oriental ruby and sapphire, are frequently more highly prized as jewels than the diamond. It is the intent Of this paper to deal Only with a description of the corundum industry, the administration of wartime control, and certain economic aspects as seen by the author. Several references are listed to assist anyone who wishes further information on the geological occurrence of the mineral. Ore Production and Consumption For the past two decades, south Africa has been the world's sole producer of corundum ore. A possible exception is Russia, where, it is understood, there was considerable production during the thirties for domestic consumption but for which statistics are lacking. The United States is the world's principal consumer of corundum ore; imports lor the period 1934 through 1940 averaging 3000 Short tons per year, The years 1935 and 1936 were close to the 5000-ton mark, and imports during 1941, the last prewar year for which statistics have been released, were approximately 6000 Short tons. Again lacking statistics on Russia, the United Kingdom ranks second, but far below the United States in consumption of ore. Historically, corundum has been found in some 35 countries throughout the world, but the principal deposits are in South Africa, Canada, Madagascar, Russia and the united States. Deposits are generally small and subject to rapid exhaustion. Thus, the United States was the principal world producer for the period 1870 to 1900, when operations ceased except for two years during World War I. India was a producer of ore from 1898 through 1921, with peak output in 1916 through 1918 Canada came into production in 1901 with substantial output of ore and finished grain until 1914; the production thereafter was smaller until 1921. Madagascar has produced ore since 1910 but has had important output in only a few scattered years. South African production started in 1912

Jan 1, 1948