Search Documents

By Roscoe E. Bell

BETWEEN 1945 and 1948 the author made studies of the western phosphate industry and its potentialities. These included an appraisal of the opportunities for western development of the industry, studies of production costs, of market potentials, of transportation economics, and of industry location. This paper will be directed toward pointing up the factors which have an important bearing on the establishment of fertilizer plants in the western area. Industry Location Factors: There are, of course, an infinite number of possible organizational setups which might require consideration. However, the phosphate industry is simple enough so that studies of the most probable alternatives can be made conveniently. The salient factors which require special consideration in such a study are: (I) the location of the raw materials, (2) the location, size, and character of the present and potential markets, (3) the location of energy sources and materials required for fertilizer processing, (4) the location and capacity of present manufacturing facilities, (5) the cost of assembling the materials and energy needed in manufacturing, and (6) the cost of distributing the manufactured product. Raw Material Supplies: Rock phosphate is the raw material for the manufacturing of phosphate fertilizer. In the United States the important known deposits of this material are located in three general areas (fig. 1). The western deposits, comprising about 60 pct of the nation's supply, are in the four-state area—Idaho, Wyoming, Utah, and Montana. The Florida deposits comprise roughly 38 pct of the national supply. The Tennessee deposits, comprising about 2 pct of the national supply, have been the most important source until recent years. The western deposits, which are virtually undeveloped, have not been used to any extent to meet the nation's need for phosphate rock and phosphate fertilizer. Fertilizer Markets: The large national markets for fertilizer are in the midwestern and eastern United States (fig. 2). The principal far-western markets are along the Pacific Coast, especially in California. Until recent years the western markets have been extremely limited, whereas the markets in the eastern United States have long been established and manufacturing facilities have been provided to meet these needs (fig. 3). In recent years the western markets have expanded very rapidly, continuing to grow throughout the war years and postwar period at a similar rate. The question always arises as to whether this is a temporary war-swollen market which will shrink back to its original size as soon as the present agricultural price levels drop. In order to answer this question consideration must be given to the character of the market (fig. 4). I have considered seventeen western and midwestern states in the western market area where transportation costs from the western deposits are equal to or lower than those from Florida. They include all states west of a line drawn through Chicago, Kansas City and the western boundary of New Mexico. In the mewar period this was a small market totaling only 37,000 tons of P,O, annually. The 1946 total for this same area was approximately 200,000 tons. Considerably more fertilizer would have been used in 1946 had adequate supplies been available. Estimates of future markets are difficult to make, but we do have some indices that are useful. The

Jan 1, 1951

By J. M. Hassler

NOWHERE can there be found a more misleading statement than the old one that "Iron can be manufactured cheaper in the South." During the past decade ironmakers and users of iron have heard varied and sundry stories of the wonderful resources of the Birmingham district, including abundant ore and coal fields, cheap labor, a wonderful climate and similar industrial Utopian statements. Birmingham represents the major portion of the iron business in the South, acid as Birmingham fares so goes the iron business of the South. The intent of this paper is to shed some light on the actual conditions surrounding ironmaking in the South, especially in the Birmingham, or North Alabama, district. By a presentation of facts it is desired to point out that the "cheap iron" of the industrial South is a thing of the past, primarily because of increased labor cost and because labor is radically different in performance to what it was years ago. Also, because most of the raw materials needed in ironmaking that would be classed better than inferior are gone.

Jan 1, 1937

In situ mining techniques have become prominent in recent years due to declining ore grades, rising costs, and increasing concern for miners' health and safety. Current practices depend heavily on the effective and uniform fragmentation of the ore zone of interest, which not only provides for proper media flow but also exposes additional surface areas to react with the processing system. Specifically, current applications have focused on blasting to a mined-out opening or, in the case of shallow de- posits, blasting to the surface void. In the former case, several obstacles are encountered, including proper initiation, uniform fragmentation, and a lack of swell space for the blast, which tend to produce less desirable results in the zone of' interest.

Jan 3, 1979

AT the fall meeting of the Iron and Steel Division, Oct. 4, 1934, in New York, a symposium was held on Slag Control in the Making of Iron and Steel. The chairman was J. H. Nead and the vice chairman, G. B. Waterhouse. The latter presided at both morning and afternoon sessions. The papers and discussions were presented in the order in which they appear on the following pages. To meet space requirements, much of this material has been considerably condensed. CONTENTS [ ]

Jan 1, 1935

By Theodore Barry

The task of developing controls in the mining and manufacturing industries to give them a tighter grip on operating costs has afforded this author an interesting vantage point for observing certain practices common to both industries. Of course, each of these industries has problems unique to itself, but all industries have many common problems. After all, every industry is a business and every business is concerned with the task of producing its wares as profitably as possible. While many differences between businesses in different industries are known, the author is convinced through experience that the mining industry has much more in common with the manufacturing industry than is generally acknowledged. Four principal questions come to mind in the comparison of mining with manufacturing: How different are the management control methods in these two worlds? How do both industries go about the task of controlling costs? How does the mining industry compare in terms of the effectiveness of its workers? And perhaps most important, what can the mining industry learn from what the manufacturing industry is doing?

Jan 11, 1962

By S. S. Clarke

THE opening of sheet-ground mines in which the ore beds are only from 7 to 9 ft. thick led the Commerce Mining and Royalty Co. to con-sider mechanical loading, in order to avoid the high cost of hand shovel-ing in such mines. Scraper loaders were chosen because the capital investment would be comparatively low; because they are small enough to be used in low working faces, and because they can be mounted on a mobile carrier.

Jan 1, 1939

By J. C. Bartlett

As American students of mining, philosophy, philology, music, history, or art have found it necessary or highly advantageous to supplement their course of study at home by a residence of some years at a foreign university, so, ever since mining has been practiced in this country in any other than a rude and wasteful manner, many American students of mining have sought in London or Paris, but chiefly in the Academy of Freiberg, Clausthal, or Berlin, such infor-

By August Wendel

It is a well-known fact to all Bessemer steel manufacturers using a blooming mill, that ingots show large cracks in the first few passes of the rolls, which, in the following ones, do not always roll up satisfactorily. This deficiency in the quality of the product is generally called "red-shortness," though, in the writer's opinion, mostly unjustly so. Different explanations for the said peculiarity are given by the leading authorities, each works selecting one element as a special scapegoat for the inferior quality of the ingot. The sulphur is generally first charged as being the principal cause of all mischief in this direction ; then, after ascertaining that sulphur is not higher than the average, and sometimes lower in the very worst heats, silicon has to bear its share of abuse. How and why silicon should affect the working qualities of the metal, the writer could never precisely learn, but is convinced that the doctrine of its pernicious influence is an established one with many. In cases where silicon failed to explain everything, resort was taken to calcium, aluminum, and some other known or unknown elements, without settling the difficulty; and lastly, when the skill of the chemist became exhausted, " practical men " came to the same conclusion, which many leading blast-furnace managers had arrived

CLARENCE M. HAIGHT, Franklin, N., J. (communication to the Secretary*).-In that hart of Mr. Wilson's paper describing the Gilman cut-and-fill system, a few features do not appear to be fully explained. In what way is the waste used for filling obtained? The text mentions that, if waste is encountered when driving the filling raises, these raises are stopped until the fill is needed; that seems to suggest mining the capping for fill, which might make the backs of the stopes had as the stopes approach the top of the ore. If, on the other hand, the fill is brought to the raises in cars, are the crosscuts that are necessary in ore or waste? Is the cost of this fill included in the stoping costs given?

Jan 5, 1917

By Thomas MacFarlane

IN smelting copper, lead, and silver ores, it is scarcely possible in every case to make analyses of the various parcels of ore, with the view of combining these and the fluxes so accurately as to yield, in the furnace, slags of exactly the most favorable composition. This is even more difficult with ores which require previous calcination, or with mattes which have been roasted in heaps. Even in cases where the greatest pains have been taken and the most elaborate calculations made beforehand, it frequently happens that variations in the working of the furnace interfere with the result so much desired. Generally, the practical metallurgist must be content with ascertaining the average composition of his ores and fluxes, making a calculation once for all as to the most advantageous mixture, and leaving slight changes in its composition to be taken care of as it is passing through the furnace. The various products then afford him the best material whereon to base his judgment as to the manner in which his smelting mixture is working. Of course the character of the slag is one of his chief guides, but it is not always possible from its outward characters alone to form a correct judgment as to its composition. Neither would it be possible or practicable to apply chemical analysis for this purpose, as it would be impossible to wait for its results while working a furnace. Abich was, I believe, the first to point out the relation existing between the composition of volcanic rocks and their densities, and to show that, the latter being ascertained, very correct conclusions

Jan 1, 1880

By H. E. N. Stone, B. L. Daniell

This paper examines the cracking behavior on chemical reduction of three types of ore/oxide briquette mixtures. The complex sintering/hardening atmosphere was replaced by 100% oxygen and the blast furnace atmosphere by a 5/95 hydrogedsteam mixture which was used isothermally at 700°C for a constant, arbitrary time. Cracking has been assessed by measurement of reduction expansion or increase in specimen diameter as a result of chemical reduction and a subjective index based on appearance and friability. Oxidized briquettes of iron ore concentrate crack on reduction'-3 in a manner which parallels the degradation of sinter in the Linder test. In the present work, the cracking behavior on chemical reduction of three types of ore/oxide briquette mixture has been studied. Firstly, LD converter fume with additions of silica; secondly, Oxfordshire ore with ferric oxide; thirdly, ferric oxide with separate additions of silica, alumina and lime. Motivation for the first-mentioned experiments lay in the improvement of the fume as furnace feed; for the second, in assessing the tolerance of a finely divided ferric oxide as a base for low melting point additions. The third series provided additional information. In this work, the complex sintering/hardening atmosphere is replaced by 100% oxygen and the blast furnace atmosphere is replaced by a 5/95 hydrogen/ steam mixture used isothermally at 700°C for a constant arbitrary time. The particular reduction conditions were known from previous experience3 to be capable of disclosing any tendency to cracking. Cracking has been assessed by measurement of reduction expansion (i.e., increases in specimen diameter as a result of chemical reduction) and a subjective index based on appearance and friability. Generally

Jan 1, 1970

E. S. MOORE (author's reply to discussion*).-I have read with much interest Dr. W. F. Smeeth's criticism' of my article on the air blasts in the Kolar Gold Field, India. However, before answering the questions he asked, I should like to suggest that possibly the phrase "difference of opinion" might be substituted for the word "misapprehension" when applied to my statement that the matrix of the conglomerate resembles a hornblende schist. This conglomerate is certainly regarded as a metamorphosed sediment. Dr. Evans, who has had wide experience with metamorphic rocks, has regarded this as a clastic rather than an autoclastic rock and mentions it as a probable glacial deposit2 and similar to the Lower Huronian conglomerate of North America. I was greatly impressed by the similarity between this rock and the bands of Huronian conglomerate in the United States and Canada where metamorphism has rendered the matrix of the rock schistose. It was scarcely intended that the word basal, as used in my text, should be extended to the Kolar field, although possibly it may be equally applicable there. The word is so frequently used on this continent for the Lower Huronian conglomerate, which in many places is the basal formation of the predominantly sedimentary Proterozoic group, overlying the more largely igneous Archeozoic rocks, that it was inadvertently used without special stratigraphic significance for the Kolar area. In reply to Dr. Smeeth's question as to how the conglomerate indicates a syncline, it would seem that if there is present in a closely folded area a band of sediment that is younger than the surrounding rocks, it must be in a syncline in those rocks. As to an apparent contradiction in the statement on page 693 regarding the compressive stress, it does not seem that such contradiction exists; I think every one will take the same meaning as Dr. Smeeth has taken, which is exactly what was intended.

Jan 12, 1918

By H. C. Fowler

No exact demarcation can be made between producfion engineering and engineering research projects which interest production engineers because the results of today's engineering research make possible many of the applied production engineering methods of tomorrow. A corollary of the development of fundamental research is that so-called practical research becomes necessary. Assuming engineering research to include all subjects related to oil and gas production on which knowledge is being increased through experimentation and through analyses of data obtained from both the laboratory and the field, a review of the work of 1932 shows that the fundamental concepts of at least three major problems have become better understood—bottom-hole pressures, solubility of gas in oil, and fluid movement—and that the established data on the relationships of oil and gas have been applied to obtain more efficient and more economic production of both. Engineers no longer are concerned primarily with the initial development of devices for obtaining the pressures at the bottom of wells. Advancement in the technique of obtaining reliable pressure readings in wells has been rapid. One of the first public suggestions regarding apparatus for obtaining precise information at the bottom of oil wells was made before the Petroleum Division of the A.I.M.E. in 1928. Even during the early development stages in East Texas, reservoir pressures were estimated from well-head observations. Soon, however, a number of proved devices and methods were available, and today bottom-hole pressures in many fields are being recorded and studied as an essential part of the production programs. The research now turns to interpretations of data, obtained with these devices, in terms of reservoir energy and to the development of methods whereby the oil and gas will be withdrawn in accordance with rational and equitable programs based on oil-gas-energy relationships. The term ((bottom-hole pressures" should not be interpreted as indicating the full scope of all research on this problem. By using pressure (and temperature) data obtained in related vertical-flow studies,

Jan 1, 1933

By B. Amadei

INTRODUCTION Laboratory studies on the deformability and strength of intact rocks generally involve the uniaxial compression test, the standard triaxial compression test and direct or indirect tension tests. If [al ,a2 ,a3] are principal stresses [(al>a2>a3)] with compression taken as positive and tension taken as negative, the applied stress field for each one of these tests can be represented as shown in Fig. 1. However, for most in-situ conditions, such as those that exist at any point around an underground excavation, the stress field is truly three-dimensional or multiaxial [(al+ a2+a3)] and none of the tests shown in Fig. 1 can be used to predict the mechanical behavior of the rock. There are special cases for which one of the three principal stresses vanishes. Biaxial loading of rocks in-situ takes place, for instance, when rocks deform and fail in plane stress conditions. This can occur in a free unloaded surface of a rock structure such as in the wall of an underground excavation or a rock slope. Parallel to the free surface, the stress field components can be both compressive [(al>a2>0)], both tensile [(O>a2>a3)], or mixed, one component being compressive and the other one tensile [(U~>O>U~)]. The purpose of this paper is to present the results of 25 true biaxial tests that have been conducted on cubical specimens of Indiana Limestone using the multiaxial cell available at the University of Colorado at Boulder. The tests include uniaxial compression and tension, biaxial compression and combined biaxil compression- tension. Flexible fluid cushions and brush bearing platens were used for compressive and tensile loading respectively in order to minimize loading end effects on the test specimens. The paper begins with a review of previous investigations on the multiaxial behavior of rock. Then, test results are presented in terms of

Jan 1, 1984

By J. Morgan Clements

The manufacture of coke in Peru, as practiced at the coalmines of the Quishuarcancha and Goyllarisquisca districts, is intermediate between the primitive coke-heap and the bee-hive oven. The method of coking is quite simple. In constructing the coal-heap, preparatory to burning, the ground is first leveled, and a simple stack of stone and clay is built, giving the bottom, to a height of 6 ft., approximately 6 ft. of external diameter. The size of the stack varies in different districts, but is generally 9 ft. high, and slightly smaller at the top than at the bottom. The walls of the heap are from 12 to 14 in. thick, which allows an inside diameter of from 3.75 to 4 ft. These walls are pierced at intervals by three or more tiers of openings or flues, connected with the central flue. The radial flues have a diameter of about 5 in. and are built with a gentle upward slope. The stack (shown in Fig. 1) is permanent; and in this respect the practice in Peru differs from other primitive practices in which nothing is permanent except the yard. Above the permanent 6-ft. portion of the stack there is added a cap of clay, about 3 ft. high, which contracts toward the top, where it has an inside diameter of about 2 ft. This clay cap is temporary, and frequently has to be renewed after each burning. Before charging the coal, there are first built, from the lowest tier of flues upon the ground, a number of temporary flues, leading from the central stack out to the edge of the coal-heap, and constructed of blocks of coal for the greater part of the distauce, the outer edge alone being of rough stoue. The coal is then piled up over these flues and around the stack to a height of about 6 ft. The bottom flues are the only ones that

Jan 1, 1905

By C. P. Proctor, J. B. Morrow

With numerous plans under consideration for coal classification, and with the advent of the Bituminous Coal Code, the intelligent sampling of coal has become increasingly important. To us it is rather significant that there have been very few fundamental studies of coal sampling in American technical literature since those of E. G. Bailey, which appeared in the Journal of Industrial and Engineering Chemistry in March, 1909. He covered the subject up to that time so thoroughly and in such an excellent manner that perhaps many other later students have felt that they could add very little to his findings. The recent studies of the British Engineering Standards Association have indicated the possibility of a somewhat different interpretation of Bailey's results, permitting the taking of smaller samples, and perhaps it will now be helpful to reopen this question. C. W. H. Holmes, in an informative series of articles on coal sampling recently published in Colliery Engineering, makes two rather interesting statements, as follows: It is scarcely surprising to find a lack of interest and knowledge regarding the sampling of coal not only in the mining industry itself but also among consumers of industrial fuel: at its best coal sampling is a dirty business, regarded as a nuisance and an expense by the commercial man, and usually as a nuisance and nothing else by the chemist. The writer can conceive only two classes of people who have never experienced any difficulty in obtaining representative samples of coal from wagons; those who have never tried to, and those who have never had the necessity or desire to check the accuracy of their work. The primary purpose of this paper is to present some tabulated data of the more significant results of a sampling investigation undertaken during the last four years to obtain certain fundamental data on the variables connected with coal sampling and to point out that often assumptions have been made that are not in accordance with the facts. One of the standard sampling methods states:

Jan 1, 1936

By C. P. Proctor, J. B. Morrow

With numerous plans under consideration for coal classification, and with the advent of the Bituminous Coal Code, the intelligent sampling of coal has become increasingly important. To us it is rather significant that there have been very few fundamental studies of coal sampling in American technical literature since those of E. G. Bailey, which appeared in the Journal of Industrial and Engineering Chemistry in March, 1909. He covered the subject up to that time so thoroughly and in such an excellent manner that perhaps many other later students have felt that they could add very little to his findings. The recent studies of the British Engineering Standards Association have indicated the possibility of a somewhat different interpretation of Bailey's results, permitting the taking of smaller samples, and perhaps it will now be helpful to reopen this question. C. W. H. Holmes, in an informative series of articles on coal sampling recently published in Colliery Engineering, makes two rather interesting statements, as follows: It is scarcely surprising to find a lack of interest and knowledge regarding the sampling of coal not only in the mining industry itself but also among consumers of industrial fuel: at its best coal sampling is a dirty business, regarded as a nuisance and an expense by the commercial man, and usually as a nuisance and nothing else by the chemist. The writer can conceive only two classes of people who have never experienced any difficulty in obtaining representative samples of coal from wagons; those who have never tried to, and those who have never had the necessity or desire to check the accuracy of their work. The primary purpose of this paper is to present some tabulated data of the more significant results of a sampling investigation undertaken during the last four years to obtain certain fundamental data on the variables connected with coal sampling and to point out that often assumptions have been made that are not in accordance with the facts. One of the standard sampling methods states:

Jan 1, 1936

By B. J. Harlan

The trying times experienced by the steel industry during the past four years have emphasized the necessity of producing pig iron at the lowest possible cost. The trend in both design and operation of blast furnaces has been toward this end rather than toward securing maximum production from a unit or group of units. In the following discussion the trend in design of stacks and auxiliary equipment will be taken up before operation is considered. Although few furnaces have been constructed in the past few years, the trend is definitely toward larger furnaces with a hearth diameter of 24 or 25 ft. Such a furnace is very flexible, being able to produce efficiently any desired daily tonnage between 500 and-1000 or more. The detail of the design of furnace stacks, with the exception of the top, has changed little in recent years. To decrease the velocity of gas through the throat of the furnaces, thereby reducing flue-dust losses, the stock-line areas are constantly being made larger. The top dimensions of the larger furnaces are usually as follows: Stock-line diameter, 19 to 20 ft.; large bell diameter, 14 to 15 ft.; straight section of throat, 5 to 10 ft. high; inwall batter, 1 to 11/4 in. Pe ft. The ratio between the area of the stock line and the area of the large. bell is usually about 1.85 to 1. The stock-line diameter of some smaller furnaces has been increased to that of the hearth diameter of the stack at the expense of the stack batter. Remarkable decreases in flue-dust production are claimed for the so-called " Venturi top," which is achieved by flaring the stock line, in the form of an inverted cone, from a diameter of 17 ft. at 10 ft. below the large bell closed to a diameter of 19 ft. 6 in. at 3 ft. below the large bell closed. Time alone will tell which of the two designs is the better. Because of differences in raw materials, one top may be better for some plants and the other top for other plants. In the search for lower costs and higher efficiencies all operators are, adopting stoves that will maintain maximum hot-blast temperatures with a minimum gas consumption. To meet these requirements, stove capacity of approximately 7 sq. ft. of heating surface and 1.8 cu. ft. of brick volume is required per cubic foot of wind blown per minute.

Jan 1, 1934

By O. Jay Myers

THE war effort has furnished the necessary impetus for better magnesium foundry practice. Four or five years ago, there were but a few formulas in general use for cores and mixtures for magnesium castings. Certain sands, binders, and inhibitors were specified and the proportions of these materials in each mixture were maintained between very narrow limits. As more and more war industries entered the field, much research was carried out and methods and practices were improved. Magnesium founding is still in a state of flux; therefore it is not uncommon to find one foundry spraying inhibitors on its cores, and another foundry using sand mixtures with incorporated protective agents. The basic core or dry-sand mold mixture for magnesium in use today is compounded with sand, core oil or resin binder, cereal, and moisture. Core oil or resin binder are added for baked strength while the cereal binder and moisture are for green strength. The normal mixtures (based on the weight of the sand) contain from 0.5 to 1.5 per cent of both cereal binder and core oil, and the moisture content varies between 1.5 and 5 per cent. The ratio of core oil to cereal binder varies from 60:40 to 40:60, while the correct amount of moisture depends upon the method of coremaking. PROTECTIVE AGENTS In all magnesium practice, protective agents are used in conjunction with the core and molding sands to prevent oxidation of the metal. The use of these inhibitors is not novel, but publications covering this field are not entirely adequate. Beck1 says Magnesium alloys decompose water to form magnesium oxide, hydrogen being liberated in the process (Mg + H20 -+ H21 + MgO). This reaction results in the blackening of the skin and the appearance of areas of porosity on the casting surface, the cavities of which are filled with a grey oxide powder (these are termed `burns'). Although sand cores for magnesium castings are thoroughly dried during the baking cycle, burning will take place on the castings unless the metal is protected properly. This type of burning is more difficult to define than the "water-magnesium" reaction cited by Beck. A possible explanation may lie in the following equation: 2Mg + 02 -s 2MgO Here, the source of the oxygen is not water, but the air in the mold cavity, together with the chemically combined oxygen in the core-binding media. Generally, two methods are used to prevent this reaction from taking place.

Jan 1, 1945

By H. Sadek

The accompanying table shows the available data pcrtaining to the Hurghada field, the major oil and gas field in Egypt. Operations in Abu Durba, a small field, amounted to almost nothing in 1935.

Jan 1, 1936