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By J. B. Austin

In considering so complex a process as the smelting of iron in the blast furnace, there is obviously no single method of calculating efficiency that gives a complete appraisal of the performance of the furnace in all its several functions; such a comprehensive view as is required to evaluate producing ability and manufacturing costs for a given furnace is obtained only by considering a group of efficiencies, each of which measures the performance of the furnace from a specific point of view. For instance, there is the rate of consumption of coke per ton of iron produced, which is probably the most frequently considered, and is certainly one of the most important of the group; there is the efficiency of recovery of iron charged; and there is the efficiency of utilization of energy, both chemical and thermal, in some respects related to the former two yet in other ways independent of either. In each of these cases, the calculation can be made on the basis of the actual input of material or energy, or it may be based upon a comparison with the minimum amount of material or energy that would be required by a "perfect" furnace; that is, an imaginary ideal furnace analogous to the perfect steam engine used in thermodynamic calculations, when this furnace is operating under optimum conditions. Moreover, the furnace itself can be considered either as an apparatus for smelting iron or, taking a somewhat less common point of view, as a gas producer yielding iron and slag as by-products. Some of these efficiencies are more useful than others, yet all are instructive; for a knowledge of them not only leads to good engineering practice from the standpoint of control but also discloses limits to possible improvement in performance and indicates the lines along which improvement is most likely to be profitable. Estimates of some of these efficiencies have appeared from time to time in the literature, but many of them are open to objection because they are based on data of uncertain accuracy or because they have been caleulated without due regard to the thermodynamic principles involved. Moreover, so far as the author is aware. no general survey of the blast furnace comparing its performance in all the aspects mentioned has been made.

Jan 1, 1938

By Ralph H. Sweetser

At the joint session of Blast Furnace and Open Hearth Committees, April 7, 1937, at Birmingham, the subject of the quality of basic open-hearth pig iron was so well presented and discussed from so many different viewpoints that it was the general opinion that progress had been made and that such meetings were conducive to the advancement of the art of making pig iron of the right quality for the open-hearth man to produce the most satisfactory quality of steel. It was agreed that there is a decided differentiation between the chemical analysis of pig iron and the "quality" of pig iron. Paul J. McKim said that open-hearth furnace operators frequently make reference to certain types of iron as "bad iron," "dirty iron," "cold metal," etc., claiming that when using these irons, although they are within specified chemical analysis, it is impossible to produce quality steel. Mr. McKim gave a list of the suggested causes of those "certain types" of bad irons that have a thoroughly respectable analysis but a thoroughly disreputable character. Another open-hearth man, P. A. MacIsaac, of Nova Scotia, said that: The effects of iron that is below standard in analysis or in that mysterious property called quality, are well known to all open-hearth operators. It has been shown that iron of this type results in the production of steels on which the rcjections of finished product run high. What is to be done about it? I would say that the burden of producing high-quality iron should be placed squarely on the shoulders of the blastfurnace man, even as that of making good steel is shouldered by the open-hearth man. It is the purpose of this paper to bring out into the open this "mysterious property called quality"; that is, in those "certain types" of basic pig iron that make it impossible to produce quality steels; and at the same time to point the way for the blast-furnace man to be able to shoulder the burden that Mr. MacIsaac and all other open-hearth men and foundry-men have placed upon him. Silicon, sulphur, phosphorus and manganese are not the guilty elements because these are known, specified and usually kept within the

Jan 1, 1938

By H. J. Hand

Statistical methods are becoming increasingly important for interpreting routine reports, or for analyzing special test data in industrial plants, such as steel plants. They have already become practically a necessity to the plant metallurgist. A paper by Chancellor, 1 written in 1933, gives many examples of the benefits the plant metallurgist can derive from the use of these methods. The present paper discusses applications of importance to many others who must analyze reports in the steel plant, as well as other examples of interest to metallurgists. Statistical Methods Logically Suited to Plant Problems.—Statistical methods are not new as a branch of mathematics. Until comparatively recently, however, practical applications were confined mainly to actuarial science, biology, and economics; fields in which an observed result is obviously influenced (and often determined) by a complicated set of variables more or less constantly tending to affect it. As pointed out by Daeves,2 a decade or more ago, problems in industry are basically similar to those in these other fields in that a given result is at least partly due to that chance combination of causes happening to be present at the time. When trying to do the same thing repeatedly, constant results are never attained; they vary about the desired result with more or less well defined mathematical regularity. Such a condition arises out of the great number of factors tending to affect the final result. If statistical methods are so valuable to the biologist or economist, why then should they not also be of great value to plant managers and engineers, and to all who must interpret reports from various sources in the industrial plant? Within the last few years, industry has become conscious of this situation, and the use of these methods has been rapidly expanding in such p1ants. Many Useful Statistical Devices Available.—Many statistical methods of attack are available for the analysis of plant data. It is the object of

Jan 1, 1938

By M. L. Samuels

In a recent paper the authors1 discussed the reactions to tempering of hypereutectoid steels quenched from 1000' C., as revealed by studies on changes in hardness, electrical resistivity, coercive force and metallo-graphic charaeteristics. The data, which related specifically to tempering temperatures of 550°, 650" and 710" C., for varying periods up to 125 hr., permitted the following important conclusions: 1. The rate of softening of the steels at the temperatures examined differed markedly although the steels were of "similar" general chemical composition. 2. The temperature of maximum softening spread over a range from about 650" C, to the eutectoid inversion. 3. The divergence in behavior was ascribed, at least in part, to a profound difference in tendency to graphitization on annealing at sub-eutectoid temperatures. 4. The mode of spheroidization of the cementite, as revealed by metallographic studies, also varied considerably in the different steels. The purpose of the present investigation is to pursue further the study of the difference in behavior of the steels on tempering over a wider range of temperature. To this end the following features have received particular attention: 1. Comparison of temperatures of maximum softening of the various steels when the quenched samples were tempered for 5 hi. and for 75 hr. followed by furnace cooling and by quenching in water. 2. Deterrnirlation of the effect of quenching temperature, prior to tempering, on the rate of softening. Quenching temperatures of 1000" and 850" C. were used in the investigations. 3. Examination of the microstructures obtained with the various heat-treatments employed.

Jan 1, 1938

By B. S. Norris, Charles R. Austin

The stresses which initiate deformation processes in metals are fundamentally important in the study of the mechanical properties of metals. A point of inflection in the load-elongation curves obtained for single crystals' has been rather too readily interpreted as a true yield point, and the critical resolved shearing stress on the plane of slip taken as a material constant. Even early work showed that the stress at this point varies with rate of loading, but it has not been generally appreciated that creep tests under static loads alone are suited for determining the existence or nonexistence of a yield point.* It has now been shown by Miller that single crystals of zinc3 when loaded statically begin to yield at loads too small to measure; as a result there is no case now known, apart from that cited in the present paper, in which a true critical stress for yielding has been demonstrated for single crystals of metals. The case of iron has especial interest: the existence of an upper and lower yield point and of an elongation at the yield point in ordinary iron and steel marks this substance as unusual, though the effects have been found to a very minor degree in other metals and alloys. $ Most alloys do not show such marked phenomena when appreciable yielding begins, and accordingly modern practice is to speak of the yield strength of such materials, a stress read from the load-elongation curve after elongation has begun, rather than yield point. The special behavior of iron suggests that it is more likely that single crystals of iron should have a true yield point than other metals. The study of the mechanical properties of metals and alloys requires a determination of the crystallographic mechanism of deformation, wlletller deformation proceeds by slip, twinning, or cleavage, or a combination of these, and a determination of the stresses that induce these modes of deformation. With this information, a study of the rates of work-

Jan 1, 1938

By T. W. Guy

During the past three years the Surface Preparation Committee of the American Mining Congress Coal Operators' Committees has been collecting data on dewatering and drying washed coal, and on screening coal in representative plants in the Eastern and Central bituminous fields. Because of wide variations in bed moisture, such data can be compared only after deducting the bed moisture. It was found that practically every company used a different routine for moisture sampling and determinations. Some reported the moistures as total moistures, others as surface moistures, air-dried moistures, or oven-dried moistures. For most of the reports it was necessary to estimate, from a consideration of the bed moisture and other data available in a given case, corrections to be made in order to obtain surface-moisture figures as a common basis for comparison. At any plant, and regardless of bed moisture, the percentage of surface moisture remaining in a product when the dewatering, or a given stage of the dewatering, has been completed, is the real measure of what has been accomplished. The descriptions and data given with Fig. 1 show that surface-moisture figures show relationships that would not be shown by total moistures. Therefore bed moisture should be deducted, or, if more practicable, the surface moisture of the products should be measured direct. A preparation engineer finds one per cent, or even a part of one per cent, of surface moisture a very important consideration in the results of his efforts to find the most effective and economical methods of reducing and controlling the surface moisture in his products within the required limits. Therefore it is important for him to have accurate measurements of surface moisture with minimum uncertainty as to whether they sometimes include less than the surface moisture and at others all of the surface moisture plus an unknown part of the bed moisture. The Problem We know that pieces of coal have a capacity for holding water: (1) inside themselves, which is a natural characteristic of the bed from

Jan 1, 1938

By H. F. Yancey, M. R. Geer

The importance of the size composition of coal is reflected in the difference in price of the various sizes of the same coal and in the large number of primary sizes and mixtures of sizes produced by the modern preparation plant to meet the demands of a market that in late years has grown increasingly conscious of coal size. The importance of size in the industrial and domestic uses of coal has its counterpart in the role played by size composition in the laboratory examination of coal. Investigation of many of the physical properties of coal in their relation to its uses requires an evaluation of size composition. In fact, the Standards on Coal and Coke issued by the American Socaiety for Testing Materials in 1936 contains 12 standard methods of testing that involve some use of size composition. The screen analysis is, of course, the standard method of determining size composition, whether the material is coarse run-of-mine coal or fine pulverized fuel. Custorriarily, the analysis is reported as the weight percentages retained on or passing each of a series of testing screens, the number of which may range from only two or three to as many as 20. When more than two or three sieves are used, which is usual, the number of weight percentages obtained is so great as to make the analysis difficult to comprehend. Direct comparison of analyses made 011 the same sieves is hard, and comparison of analyses covering the same range of sizes but made on different sieves is next to impossible. Consequently, a frequent purpose of sizing tests-—-correlation of size with properties and charactcristics related to size-—is rendered difficult. Less cumbersome means of expressing size composition have been attempted with various degrees of success. An average particle size, calculated by any of several formulas, is useful for some purposes, also the weight percentage retained on a single sieve finds some application as a

Jan 1, 1938

By L. E. Young

The purpose of this paper is to start a discussion on: (I) methods of supporting the immediate roof, particularly of local areas of poor roof, during the mechanical loading of coal; (2) methods of increasing the rapidity of the movement of the mining faces so that, without the use of cribs, jacks, park walls, and filling, there will be no danger to men, equipment, and working places from the subsidence of the overlying strata. In the Pittsburgh district the application of mechanical loading devices in mines working in the Pittsburgh seam has been retarded by the difficulties of holding and handling the draw slate. Normally the thickness of this slate averages about 8 in. but the hardness varies, and a cut of coal cannot always be loaded without placing posts or crossbars to support the slate. Locally, the slate may be thicker and special methods of support may be required. If crossbars are placed to hold the slate when the coal averages 5 ft. in thickness, the standard methods of transporting the coal cannot be followed, and the use of conveyors may be desirable. Very little information is available on the effect of increasing the rate of movement of advancing or retreating break lines or longwall faces. A few British publications have presented some data but all such data relate to longwall faces that have moved not more than 6 ft. a day. The most rapid rate of movemerit of longwall faces in Germany is 6 ft. per day. In the ordinary hand-loading mine in western Pennsylvania break lines on full retreat will move about 2 ft. per day. If loading machines are used under similar conditions the rate of retreat may reach 4 ft. per day. In a mine where coal is loaded by hand on conveyors three shifts per day, the rate of retreat has ranged from 11 to 16 ft. per day, with an average of 13 ft. If mobile loading machines could be used to load on conveyors on break lines, the rate of retreat should be increased substantially During 1935 and 1936, the United States Bureau of Mines, under a cooperative agreement with the Pittsburgh Coal Co., carried on studies of roof movement at Montour To. 10 mine. The work war done urider the direction of Mr. H. P. Greenwald, Supervising En neer, Experi-

Jan 1, 1938

By George Watkin Evans

The need for mechanization in coal mining wherever it can be successfully introduced is evident when we take into account the fact that during recent years the coal-mine employee's wages have increased and his hours have been shortened. Coal is no longer King, and a brief study of statistics covering the production of coal, petroleum and natural gas and the development of water power will convince anyone that coal has had very powerful competitors during the past 10 years. Petroleum production in the United States between 1918 and 1936 increased from 100 per cent to 309 per cent. Water power increased from 100 per cent in 1918 to 270 per cent in 1936. Bituminous coal slipped from 100 per cent in 1918 to 75 per cent in 1936. The anthracite industry slipped from 100 per cent in 1918 to 50 per cent in 1932, but climbed to 55 per cent in 1936. In 1918, the State of Washington produced a little over four million tons of coal and the production of California oil, at that time, was a little less than one hundred million barrels per year. By 1929 the production of California oil had increased to a little over 292,000,000 bbl. or nearly 300 per cent as compared with 1918. By 1934 the production of coal in the state of Washington had dropped to about 1 1/3 millions of tons per year. Our neighbors in British Columbia had their coal production reduced from a little over 2 1/2 million tons in 1920 to less than 1 1/3 million in 1933. The North western Improvement Co., a subsidiary of the Northern Pacific Railroad Co., owns coal properties in various parts of Washington and Montana. The Northern Pacific is one of the very few railroads using any considerable quantity of coal in its operations. Practically all of the American railroads in the Pacific Northwest, except the Northern Pacific, are using cheap California fuel oil or electricity. This problem, of course, is not a new one in coal mining, and all of the progressive coal companies in the country have tried to meet competition from an overproduction of petroleum and an overproduction of natural gas as well as enlarged developments of hydroelectric plants.

Jan 1, 1938

By Charles T. Holland

Miners have observed for many years that as pillars are removed in mining operations the pillar adjacent to those mined out frequently shows evidence of being compressed. Although this has been known for a long time, little or no information is available concerning how far from the mining area the pillars are affected in this manner, or how great is the magnitude of the compression, or concerning the manner or characteristic way in which the compression acts, as the mined-out area approaches the pillar under consideration. The writer made a study of pillar action in the Mona mine of the Arkwright Coal Co., partly to get some quantitative data on the deformation of coal-mine pillars. The study was not completed but it seems best to present the information that was obtained. Method of Measurement Fig. 1 shows the details of the apparatus used for measuring the deformation. This is permanently attached to the pillar. Fig. 2 shows the details of the gauge that records the deformation. This gauge is removable and was used to measure the deformation at all the stations. The recording dial is graduated in thousandths of an inch and records measurements up to one inch. Fig. 3 shows how the removable gauge is placed in the instrument. When installing the instrument in the side of the pillar, all loose coal near by was removed and a trench 4 to 6 in. deep, and approximately 1 ft. wide, was dug in the pillar. In this trench near the top and the floor, the holes holding the instrument were bored. These holes were then partly filled with thin cement and the rods were inserted. The remaining space in the holes was tamped full of cement. At this time, by carefully manipulating the permanent rods and clamps and adjustable pin, it was possible to adjust the instrument so that the removable gauge would stand true and measure any vertical deformation between the top and bottom rods. Fig. 4 is a photograph of one of the instruments installed, showing the removable gauge in place.

Jan 1, 1938

By Martin A. Mayers

It has long been recognized that it would be highly desirable to be able to predict the temperatures at various points in a burning fuel bed and their variations with changes of the properties of the fuel and the rate of air supply. Experimenta1 investigations of fuel-bed temperature1-4 have not been lacking, but the absence of any theoretical background has made it impossible to use the results of these tests as a basis for prediction, except in a very general may. A mathematical analysis", based on a somewhat simplified theory of the distribution of lieat in a fuel bed, lias recently been completed by the author. Even though numerical values of some of the coefficients are not known, the calculations result in some conclusions of general significance. Thus, for example, it appears that when the temperatures throughout the fuel bed can be calculated, the rate at which ignition of the fuel by underfeed action can be maintained can also be calcu1ated. The uncertainty concerning the values of the coefficients referred to above is serious limitation on the use of that method. The following paper presents a discussion of these coefficients and includes estimates of their values based on the data now available. A brief description of the theory on which the analysis is based, and some results of the calculations showing their degree of agreement with experimental results, are presented by way of introduction to the discussion of the coefficients. For a more. extended discussion of the theory, see the A.S.M.E. paper5. Theory and Comparison with Experiment The theoretical analysis is similar to that used in the calculation of the stationary temperatures in a conducting solid in the classical theory of heat concluction. The fuel bed is pictured as a uniform, continuous, porous solid through the interstices of which air can be blown and ill which combustion can take place. The solid lias a finite thermal conductivity, so that heat may be transported in any direction, against the flow of air as well as in the same direction. While it is true that nothing

Jan 1, 1938

By T. T. Quirke, L. C. McCabe

The object of the present investigation was to discover a physical basis for rank differentiation of coals, particularly the coals of the Illinois basin. Vitrainl was selected as the most appropriate coal material to use in the investigation, because of its homogeneity and ease of acquisition and handling. Previous Investigations.—Hoffman and Jenker2 have shown that their index of reflection is a characteristic of coal rank and that the Leitz slit microphotometer may be used in determining the different intensities of reflection. Zhemchuzhnikov3 measured the luster of several Russian coals with a color analyzer and found that the degree of luster was indicative of rank. Luster-volatile matter curves based on data from Sucan and Donetz coals were satisfactorily used for determining the rank or volatile content of other coals after the luster strength was determined. In 1934 Fisher4 reported refractive indices of 1.76 for bituminous vitrain and 1.87 for semibituminous vitrain. Investigation of Angle of Polarization.—Early in the present investigation several determinations of the refractive indices of the vitrains were made by immersing the minus 150 plus 200-mesh powder in oils. It was found that all the samples fell within the range 1.6 to 1.8. However, difficulty was encountered in securing oils in this high index range that were closely enough spaced to separate some of the coals. The writers made a number of determinations of the angle of maximum polarization from the polished surfaces of the vitrains and derived their refractive indices by the procedure described in the following paragraphs. Johannsen5 states the fundamental concepts underlying this procedure as follows: In general, in an isotropic medium light vibrates in all directions at right angles to the direction of propagation, and when it meets with another isotropic medium at an angle, part of the light is reflected and part refracted. It has been found that after reflection or refraction, the vibrations do not move with the same freedom in every

Jan 1, 1938

By Eugene McAuliffe

It is not possible to include in this paper, limited as it is in scope, the many diverse steps toward the reduction of mine accidents that are taken in the mines that produce the nation's coal. Every coal-producing state has enacted laws covering proper mining practices, and the major portion of these are directly related to the safety of the mine employees. The United States Bureau of Mines, the American Institute of Mining and Metallurgical Engineers, The American Mining Congress, a number of national, regional and state organizations, as well as the coal technical press, have covered time and time again all of the '(do" and "don't" phases of mine operation that bear on the important question of mine and employee safety. Within the past 15 years The Union Pacific Coal Co, has attempted to put into practice in its mines in southern Wyoming these many good recommendations, finding some value in all, and yet, to secure substantial results, the management found it necessary to resort in the end to what might be referred to as i'extra-territorial" methods. It is the writer's purpose to show in this paper that marked and even extraordinary betterment, can be brought about when employer and employee work together with due sincerity. In presenting our own experience, one that has been duplicated in so far as results are concerned on numerous other properties, no theory of perfection of management exists; on the other hand, our organization feels that as long as our record of accidents remains as shown by even our latest and best performance we still have far to go. Safety work in some form has been carried on in and about the mining properties of The Union Pacific Coal Co. since the first mine was opened at the now long-abandoned town of Carbon, Wyo., in 1868. On June 30, 1903, an explosion and subsequent mine fire occurred in mine No. 1 at Hanna, taking 169 lives, and a second explosion occurred in the same mine on March 28, 1908, in which 59 additional lives were lost. Looking back with impartiality on the causes leading up to these two unfortunate disasters, we can only conclude that shooting from the solid, the absence of adequate ventilation, rock dusting, the use of water at the face to allay

Jan 1, 1938

By A. C. Richardson

Troughs or launders are probably the oldest machines used for ore concentration, and their development was suggested no doubt by the natural segregation and stratification of materials that take place in the bed of a stream. Trough washers for coal cleaning were first used in France and Germany about one hundred years ago and have been used in some form or other ever since. The early launders were intermittent or batch machines, and only comparatively recent developments have made them continuous. The chief disadvantage of early launder systems as applied to coal has been that when a satisfactorily clean coal was produced the loss of good coal in the refuse was excessive. Other disadvantages have been the large quantities of water and the great lengths of troughs necessary to treat moderate tonnages of feed. One of the most widely used types of trough washers is the Rheolaveur, which has been developed in the last 25 years. Fig. 1 shows a more or less standard arrangement for fine coal. In this there are four trouglis placed one below the other and sloped a few degrees from the horizontal. Rheo-boxes or draws are provided at intervals in the bottom of the trough for the removal of material deposited from the stream. These draws are spaced substantial distances apart. Some of the rheo-boxes are provided with upward currents of water to modify the horizontal current stratification. In operation it is the function of the first two troughs to remove all refuse material and permit only clean coal to be discharged over the end. In order to accomplish this, large quantities of coal are drawn through the rheo-boxes. The third and fourth troughs are used to recover the coal discharged through the boxes of the first two troughs as a middling product and to discharge a clean refuse. The middlings are returned to the first launder and are usually about equal to 40 per cent of the raw coal being fed to the launder. In considering launder processes, one would reason that the conditions of extreme crowding under which stratification takes place in a flowing stream should effect complete separation in a single pass down a launder.

Jan 1, 1938

By William Reynolds

This paper deals with the results of a study of the application and development of mining machines for cutting out and removing dirt bands in bituminous coal beds. Face Preparation When one or more dirt bands1 occur in a seam of coal, the problem of elimination of impurities becomes manifest. The degree of completeness to which these impurities arc removed at the face has an important bearing upon labor costs, haulage costs and outside cleaning costs, and often the ash content of the product is markedly affected. Yet, because the present-day miller is paid for the number of tons he loads he often lacks interest in the quality of the coal. To insure a clean product, a system of penalties for dirty coal is enforced, but control of extraneous impurity content in the loaded coal is often inadequate and ineffectual when coal and banded impurity are shot as one. It seems only logical that to reduce the amount of impurities by proper face preparation before the men are permitted to load the coal is the most efficient method of preparation. Many mines with one or more bands of impurities in their seams are able to mine a desirable product with a comparatively small amount of surface preparation. In fact, three companies in West Virginia have recently changed their methods of fact* preparation, with most gratifying results. The first company (in the Kanawha field) after changing its cutting practice with the hope of relieving a sales problem, was rewarded by an approximate 3 per cent drop in ash in the product. Another company, operating in the same field, reduced its ash approximately 4 per cent by a change in cutting practice. The third company (in the Pocahontas field) found the wet washer inadequate in producing a marketable coal, and installed new cutting machines. Three cuts are now being made in each working place, and the results arc so satisfactory that the cleaning plant has been abandoned.

Jan 1, 1938

By W. E. Curran

For years the geographical isolation of the Southern iron-ore district from the great producing centers in the North and East enabled it to meet its conditions and solve its own problems without regard to the practices and policies of other districts, but during the past few years distances have been shortened, practices and wages are being standardized, and these changing conditions have brought new problems to the South. Development of Pig Iron in the South The development of the pig-iron business in the South was very slow during its early years, gained speed rapidly in the latter part of the nineteenth century, reached its peak in 1918 and was on the decline before the depression that began in the latter part of 1929. The first blast furnace in Alabama was built at Cedar Creek in 1818, the year before the state was admitted to the union. In 1830, Daniel Hillman was sent from Tuscaloosa to found an iron works in Roupes Valley, where rich pockets of brown ore were numerous. He built a forge on the site of what later became Tannehill furnace and called it the Roupes Valley Iron Works. There pots, pans, plows, and horseshoes were made of metal from his Catalon forge; shaped by a large hammer operated by water power. Daniel Hillman died in 1832 and the ironworks lay idle until 1836, when Col. Ninion Tannehill bought the property, rebuilt the forge and, using slave labor from his plantation, operated and enlarged the works. By 1845 he had built two crude furnaces and did a flourishing business in ovens, skillets and kettles, which found a good market all over the South. In 1855, the plant was sold by Colonel Tannehill to Moses Stroup, an experienced ironmaster from Pennsylvania. He tore down the old furnaces and built a new plant, the ruins of which stand today (Fig. l). This furnace plant operated continuously until it was destroyed by Northern troops in 1865. It was never rebuilt, so that the shell in the picture is the same furnace that made many tons of guns and shells for the Confederacy during the war period.

Jan 1, 1938

By Mark Sheppard

DuRing the winter of 1937, the writer visited a West Virginia stone quarry at which the overburden is stripped hydraulically. The quarry is in a bed of limestone, about 200 ft. thick, which outcrops on a hillside above a small river; the quarry face is 175 ft. high. The top of the stone is cut in all directions by erosion channels, which are filled with a tough, red clay. Some of the larger channels are 30 ft. deep and 8 ft. wide. The thickness of the clay overburden ranges from a few inches to 10 ft., the average being estimated as less than 3 feet. The topography of the district is rugged, and the hillside above the quarry face is not suited to the use of the usual mechanical methods of moving dirt. Until hydraulicking was started 10 years ago, the overburden was dug by hand labor, dumped to the quarry floor and transported to the dump in quarry cars. Cleaning deep channels was a slow and expensive process. When hydraulicking was started, the top of the quarry face was over 200 ft. above the level of the river. The pipe line was carried in a semicircle around the top of the quarry about 200 ft. from the face and about 50 ft. above it. As there is no adequate supply of water above the quarry, the water must be pumped from the river. As quarrying progressed the pipe line was moved until the discharge points are now over 300 ft. above the river. Water is pumped from the river by a four-stage centrifugal pump having a 5-in. intake and a 4-in. discharge. It is direct-connected to a 200-hp., 2300-volt, 1760-r.p.m. induction motor. At 1760 r.p.m. the rated capacity of the pump is 750 gal. per minute under a head of 600 ft. The pump is installed in a house of frame construction on the river bank, about 10 ft. above normal water level, which also houses the pump for the mill-water supply. Above the pumps are hoisting bays into which the motors are raised whenever the river reaches flood stage. An 8-in. suction line, equipped with a strainer and a foot valve, takes the water from a concrete sump at the edge of the river. The pipe line from the pump consists of 1750 ft. of 8-in. spiral steel flanged pipe and

Jan 1, 1938

By Oliver Bowles

When a new type of equipment revolutionizes methods of quarrying one kind of stone, producers of other kinds focus their attention on its potentialities in their particular fields. The purpose of this paper is to discuss the accomplishments of the wire saw in slate, to show its more limited attainments in other kinds of stone, and to point out the possibilities of much wider application. A wire saw consists of a 3/16-in. or ji-in. three-strand wire cable that runs as a belt and cuts the rock by abrasion. (Fig. 1. The teeth of the saw are sand grains carried in the grooves between the strands. Accomplishments in Slate† Initial experiments with wire saws by the U. S. Bureau of Mines in the Colonial Slate Quarry, Wind Gap, Pa., in 1926, attained success so immediate and pronounced that within two years in virtually every quarry in the neighborhood of Wind Gap, Pen Argyl and Bangor, the most productive slate area in the United States, wire saws were substituted for channeling machines. An 80-ft. cut in slate is shown in Fig. 2. The technique of operation has been described in several reports (references at the end of the paper). The present purpose is to summarize the accomplishments in a large, typical slate quarry after nine. years of experience. Parsons Bros. Slate Co., at Pen Argyl, Pa., substituted two wire saws for six channeling machines in 1927. The following comparisons are made between the present method with wire saws and the former channel-ing-machine method. Rate of Sawing.—The average rate of cutting with a wire saw in the early days of its operation, as determined by the Bureau of Mines', wits 14 to 17 sq. ft. per hour. Parsons Bros. Slate Co. estimates the present rate of cutting at about 25 sq. ft. an hour, whereas the channeling-rnarhirle

Jan 1, 1938

By Ralph W. Smith

Development of the lime industry in Ste. Genevieve County began in a crude way in 1840. According to information furnished by the Missouri Bureau of Geology, in the early days small vertical kilns built of stone were used, and wood was the fuel. Modern development began in 1904 when one company introduced steel shells lined with firebrick. Within a few years two more companies erected similar plants, and in 1925 a fourth company began operations. Thus there arc today four lime companies at Ste. Genevieve, all operating at high capacity and with a gradually increasing production. Geology The limestone of Ste. Genevieve County, which has the chemical composition and purity required for lime burning, is the upper 80 or 90 ft, of Spergen formation. The Missouri Bureau of Geology, in its geological map of Ste. Genevieve County, gives the Spergen formation a total thickness of 160 ft., but only the upper portion is pure enough for lime burning, with an average raw-stone analysis of 98.7 per cent CaCo3; 0.35 SiO2; 0.3 R2O3; 0.35 MgCO3; 0.3 SO3. The Spergen, one member of the Meramac group, Iowa series, of the Mississippian system, underlies an area approximately 12 miles long north and south, by 5 miles wide east and west (Fig. 1) in Ste. Genevieve County. The entire eastern two-thirds of Ste. Genevieve County is sedimentary, the formations dipping gently toward the east on an average grade of about 4 per cent, or 2 1/2°. Thus the outcrops of the various sedimentaries run approximately north and south. A line running west from Ste. Genevievc crosses the outcrops of the sedimentaries, ranging from the top of the Mississippian to the Ozarkian geological system in a space of 12 miles. Thus with the gentle dip of 2 1/2° the 160-ft. thickness of the Spergen formation stretches out in its outcrop so that it is approximately one mile wide. The early quarry and lime developments at Ste. Genevieve mere in this easily obtained surface rock of the Spergen outcrop.

Jan 1, 1938

By E. L. Spain Jr. N. A. Rose

This study was undertaken primarily to determine the reasons for certain variations in the soundness of gravel aggregate taken from a number of widely separated points on the Tennessee River. Under laboratory tests, concrete made with these various aggregates in some cases exhibited marked differences in specific gravity. crushing strength and durability. Gravel was studied in detail from Chattanooga to the mouth of the river and to a lesser extent from Chattanooga to Knoxville. The causes of variation were determined, and variational curves were constructed, which accurately predict the composition of aggregate at any point on the river and therefore its relative suitability for use in concrete. The aggregate at any point is suited for making sound concrete; the variance of suitability is due to varying percentages of sandstone and weathered material, which are less sound than other constituents. Introduction When it is stated that the aggregate from one point is inferior to that from another, it must not be construed to mean that the gravel is unfit for use. The classification upon which such aggregate ratings are based is largely arbitrary, thus inferiority or superiority is merely relative. Samples of gravel were selected from stockpiles at the dams of the Tennessee Valley Authority under construction, from the stockpiles of private companies along the river, and from samples taken by the gravel-exploration barge of the T. V. A. One hundred or more gravels of each size studied were selected at random by taking small handfuls while walking around the piles. These were separated according to the different mineral or rock constituents present, and the percentage of each constituent was obtained by counting. At least three such samples were taken from each size, and all checked with one another within a few per cent. The results were then averaged. In order to check on the accuracy of such sampling, a whole sample was taken from one point after the gravel was thoroughly mixed. The two methods gave approximately identical results. Sources and Types of Materials The sources of gravel found in the Tennessee River are numerous and varied. The river itself traverses several geologic provinces, each

Jan 1, 1938