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Jan 1, 1967

By G. C. Gambs

The electric utility industry is the largest customer of the coal industry and consumes nearly 50% of the present coal production in the United States. The byproduct of the burning of coal in utilities is ash in several forms including fly ash, bottom ash and bottom slag. At present, very little of the coal ash produced is being used and must be disposed of as waste. The coal industry should look upon this waste material as a valuable by-product which, if it can be sold for $2 to $4 per ton, will have the net effect of reducing the cost of coal to the utility by 1¢ to 2¢ per million Btu. There are many ways to use coal ash and thus benefit both the coal industry and the electric utility industry by reducing the cost of coal as burned. The solutions to the problems are obvious and all we have to do is apply them. The electric utility industry is the largest customer of the United States coal industry, consuming nearly 50% of present coal production. By 1980, the electric utilities are expected to burn over 500 million tpy of coal or 75% of total coal production. When coal is burned in electric utility plants, ash is produced in one of several forms. These include fly ash, bottom ash and bottom slag. At the present time, approximately 20 million tons of these ashes are produced and must be disposed of by the utilities at a cost of 50¢ to $2 per ton. In 15 years, more than double this quantity will be produced. Only a small quantity of this ash is put to any practical use. Much remains to be done about expanding uses for fly ash and bottom slag. It is well known that fly ash, when used to replace a portion of the cement in a concrete mix, will produce highest quality concrete. The Corps of Engineers and the Bureau of Reclamation have constructed dams and other concrete structures for years with fly ash as a partial replacement for cement. However, many construction firms do not use it. This can become an opportunity for the coal industry to reduce the cost of coal delivered to utilities. Any fly ash, or other ash or slag, which is sold by the utilities, reduces the cost of coal burned by the utility. As much as 1¢ to 2¢ per million Btu could be taken from the fuel cost for each ton of ash sold which otherwise must be disposed of at a cost.

Jan 1, 1967

In his account of the Thackaringa sulphide ore, Lawrence (p. 92) reports the presence of valleriite as a minor accessory in chalcopyrite. He says that it is readily identified by its intensive anisotrophy and reflection pleochroism. He also gives (p. 87) the chemical formula as Cu8Fe4S7 Recent work by Evans et al. (1964), Chamberlain and Delabio (1965), and Schidlowski and Otteman (1966) suggests that most material identified as valleriite is, in fact, mackinawite. Mackinawite and valleriite are both extremely anisotropic and strongly reflection pleochroic, and so with fine-grained material it would be hard to distinguish them optically.Mackinawite, according to Evans et al. (p. D66) is a copper-free iron sulphide (PeS) with small quantities of nickel, whereas valleriite is considered to be a dimorph of chalcopyrite (CuPeS2 ). They found that mackinawite is much more widespread than valleriite, and, unlike the latter mineral, is commonly included in other sulphides, particularly chalcopyrite.Lawrence (p. 92) states that the valleriite inclusions are up to 0·01 mm long, so that an electron probe microanalysis should be quite feasible and provide a ready answer to this query.L. J. Lawrence: I thank Dr Townend for his comments on the occurrence of a valleriite-like mineral embedded in chalcopyrite from Thackaringa. The problem of distinguishing valleriite from mackina...

Jan 1, 1967

By R. C. Hickman

Preliminary evidence indicated that the Chattanooga Shale might constitute a potential vast low-grade source of uranium. Investigation by core drilling indicated that while the Chattanooga Shale may constitute a resource for the future, the very low (0.006 percent) average uranium content is not economic when compared with the relatively higher grade western ores. A total of approximately 12,000 feet of test drilling was done in 72 drillholes, and large samples were mined for extractive and metallurgical testing. An experimental mine site was selected on the basis of the drilling project.

Jan 1, 1967

The need to hoist increasing loads from great depths is leading to the more general adoption of winders of the Koepe and Blair types. The trend has introduced a number of new problems in winding ropes, more particularly in the Koepe system where regular destructive tests during the life of a rope are not possible. Consequently, the importance of introducing non-destructive tests is much greater, especially so in the case of Koepe ropes used for deep winding where there are three major destructive fatiguing influences. These are rotational effects when a vertical rope is changed end-for- end each trip, the much greater range of stress to which the rope is subjected each trip as compared with drum winding, and the destructive effect of a high coefficient of friction between wheel and rope. A plea for a lower coefficient in the interest of better rope and tread life, substantiated by analysis, is made for Koepe winders operating at depth.Co-ordination of rope testing with general hoisting problems is stressed and the active participation of the Wire Rope Committee of the Australian Mineral Industries Research Association Ltd. in the promotion ofthe project is noted.The general introduction of a rope testing programme in Australia, personnel requirements and some local basic research in the subject to cope with future demands are considered.

Jan 1, 1967

By W. A. Haley

Wheel loaders were first introduced shortly after World War II as small machines designed for handling loose materials in various industrial and processing applications. It was not until the early 1950?s, however, that machine size permitted widespread loading of loose or stockpiled material into on-highway type trucks. An ever increasing number of machines continue to be used for this purpose today. In fact, it is by far the major use for wheel loaders in mining and quarrying. Many of these loaders were working at mines or quarries handling in-process or finished material and some were doing shovel clean-up. It was quite natural then, when the primary pit loading shovel was down, to attempt to maintain some production by replacing it temporarily with the wheel loaders. Most of these attempts were not very successful, however, until the really large wheel loaders, 4- to 6-yd. size were introduced in the early 1960's. Since that time these machines have proven they can be productive and economical primary pit loading tools, a job that was once the exclusive domain of the power shovel. To be competitive with the shovel however, conditions must exist or be made to exist, that will be favorable for the wheel loader.

Jan 1, 1967

By Raul A. Deju

A theoretical and experimental study was made of the surface phenomena occurring in a silicate - sulfonate system and a silicate -amine system, Experiments were conducted varying the collector concentration to examine its effect both on the total surface sorption and the rate of sorption. The results were compared to a theoretical model based on a Langmuir-type isotherm, Finally, the flotation behavior of selected silicate minerals was predicted from the sorption results and an explanation for the flotation of silicates postulated on the basis of both the theoretical predictions and experimental data.

Jan 1, 1967

By J. G. Walters

This report presents the results of an investigation in Which the chloroform solubilities of coals and chars are related to rank, temperature of thermal treatment, time at a given temperature, vacuum thermal treatment, plasticity, oxidation, blending, and mass spectral analyses and molecular weights of the extracts. It was found that the quantity of chloroform extract obtained from chars can be altered by creating a vacuum above the charge during preparation of the char, increasing the time at temperatures within the plastic temperature range, and by utilizing different rates of heating to attain a given temperature. Relationships found between the chloroform solubilities of chars produced at temperatures within the plastic temperature range and the relative fluidities in this temperature range indicate that the chloroform-soluble portion of the char is a significant component of the plastic mass. Chloroform-extract yields from chars made from blends of coals cannot be calculated from chloroform-extract yields obtained from chars made from the component coals.

Jan 1, 1967

By Alexander E. McHugh

A study of some variables affecting the recovery of molybdenum from oxidized molybdenum minerals was made. The effects of variations in contact time, temperature, pulp density, particle size, and solvent concentration on the recovery of molybdenum using acid and alkaline solvents were investigated. Chemical analyses, screen analyses and microscopic examinations were made and the presence of important elements determined. A hydrometallurgical method was developed to recover the molybdenum from the oxidized molybdenum ore by simultaneous dissolution of the molybdenum with sulfuric acid, adsorption on activated charcoal and flotation of the charcoal. The molybdenum was extracted from the activated charcoal with sodium hydroxide, precipitated with calcium hydroxide as calcium molybdate and this regenerated sodium hydroxide for additional stripping. A solvent extraction method, using mines, was also studied to recover molybdenum from both alkaline and acid molybdenum solutions. Satisfactory results were obtained.

Jan 1, 1967

Jan 1, 1967

By R. D. Hagni

The following is a case study illustrating the use of thin sections and polished sections of crude ore to predict metallurgical response. By examining polished sections of the metallurgical products, the textural and mineralogical reasons for unsatisfactory separation can be explained. An area of oxidized Negaunee Iron-Formation located south of Negaunee, Michigan, in the Marquette Iron Range, has been considered for roast reduction-magnetic separation. Preliminary metallurgical studies and subsequent pilot plant testing produced varied results. These results prompted this microscopic study which began with an examination of 126 thin sections and 82 polished sections prepared from 126

Jan 1, 1967

By A. H. Larson, T. P. McNulty

RECENTLY, an investigation of the absorption of sulfur dioxide gas in molten binary copper alloys was conducted. A Sieverts-type apparatus, consisting of a mercury-filled gas dispensing buret and a mercury manometer, was used initially for determining the volume of gas absorbed as a function of pressure. The equilibration behavior of the alloys studied indicated that the mercury in the gas measuring system was absorbing sulfur dioxide. Owing to the widespread use of mercury as a displacement medium in absorption studies, an investigation was made to determine the nature and magnitude of the mercury - sulfur dioxide absorption effect. The gas measuring system was modified by substituting a Worden Quartz Products Type PDHV fused-quartz-spiral pressure gage for the mercury-filled dispenser and manometer. The dispensed gas volume at known temperature and atmospheric pressure was measured by evacuating a Pyrex vessel of known volume and by admitting sulfur dioxide into the vessel until the attached quartz pressure gage registered atmospheric pressure. Atmospheric pressure was measured concurrently with a separate mercury barometer. The volume of the empty sample chamber and its attendant apparatus was determined by measuring the equilibrium pressure accompanying the addition of a measured volume of sulfur dioxide into the initially evacuated system. The volume of the mercury sample was calculated from the density of mercury at the temperature of the study (25°C). Measured volumes of sulfur dioxide were then dispensed into the system and the equilibrium pressure accompanying each gas addition was determined. From the difference between the system volume and the mercury volume, the number of moles of gaseous sulfur dioxide remaining in the system at each pressure was calculated. The difference between the number of moles of gas dispensed into the system, denoted Enso2: and the number of moles of gas remaining in the system after absorption equilibrium had been attained, denoted nso2(g), was equal to the number of moles of absorbed gas, denoted nSO2. The number of moles of absorbed gas was then converted to absorbed volume, denoted VSo2, in cu cm at stp conditions of (PC and 760 mm Hg. Table I contains calculated values of Snso2, nSo2(g), and VSo2 for different sulfur dioxide pressures. In the original system, denoted Run I, volume limitations of the gas dispensing system prevented absorption studies at equilibrium pressures near atmospheric pressure, so a different gas dispensing system, denoted Run 11, was used for determining the last pressure reading in Table I. The data in Table I are expressed in terms of the absorption of sulfur dioxide in 49.68 cu cm of mercury. In Fig. 1, these data are expressed in terms of the absorption of sulfur dioxide in 100 cu cm of mercury. Since the absorption data plotted in Fig. 1 show a linear relationship, the volume of sulfur dioxide absorbed in mercury is a function of the first power of pressure. The absorption reaction is So2(gas) = SO2 (in Hg) The first-power pressure dependence, coupled with the fact that the sulfur dioxide could be removed from the mercury by applying vacuum, indicated reversible

Jan 1, 1967

By Robert W. Ageton

The Bureau of Mines investigated the in situ vertical component of the rock stress in the rib of the haulage drift on the 6100-level of the Star mine, Burke, Idaho, using the flatjack and borehole deformation methods. The estimate of the vertical component of stress about 2 feet into the rib at a station along the haulage drift on the 6100-level of the Star mine by the flatjack method is approximately 5,875 psi, whereas the borehole deformation procedure at this station yielded a value of 5,500 psi for the same depth into the rib. The test zone is approximately 5,625 feet below the surface.No attempt was made to extrapolate stress estimates beyond the depth of the flatjack installation.

Jan 1, 1967

By D. W. Agers

This paper is an extension of previous work evaluating a new extractant, LIX®-64, for recovery of copper from dilute acidic solutions. Large scale pilot plant operations have confirmed the technical and economic feasibility of the process and, with minor exceptions, scale up parameters obtained by previous laboratory work. Operating problems encountered in the pilot plants are discussed. Design parameters for-scale-up to commercial plants are presented and discussed along with a revised capital cost estimate. The future pilot program is discussed, including minor design changes and the effect of entrained organic on dump leaching efficiency.

Jan 1, 1967

By F. A. Loving

This paper describes experiments which represent an effort to measure preciscly the pressure-time history in detonating condensed commercial explosives. The performance of explosives in mining has been a favorite subject for experimentalists and theorists for many decades. Much useful empirical information has been developed; but it has not yet been possible to predict, or even to account for, the behavior of explosives in mining on the basis of fundamental physical principals. A basic piece of information that would appear necessary for any rigorous analysis is the pressure-time history in the detonating condensed explosive. The experiments described here represent an effort to measure this relationship precisely in commercial explosives. THE EXPERIMENTAL METHOD The experimental method, first described by Cowan and Jacksonl has been extensively evaluated by Cowan and Balchan for relatively simple explosives. The experimental procedure involves the detonation of a layer of explosive between metal plates whose external surfaces are polished to a mirror finish (Fig. 1). Precise measurements of the deflection of

Jan 1, 1967

By R. B. Tippin, J. S. Browning

Inasmuch as the higher grade potash deposits are rapidly being depleted, it is important that economic beneficiation techniques be developed for recovering potassium compounds from lower grade sylvite ores and deposits containing clay materials. The Federal Bureau of Mines has conducted research to develop processes for heavy liquid concentration of potash ores, This method of concentration is discussed, and results of tests made on potash ores from New Mexico are presented. The tests demonstrated the technical feasibility of producing near commercial-grade potash concentrates, with a high recovery of the contained sylvite. The concentration of minerals based on their differences in specific gravity dates back to the very beginning of mineral dressing, and the use of heavy liquids in the laboratory to achieve optimum mineral separations has been utilized for many years. With the advent of froth flotation and its success, the incentive to develop new processes has remained relatively dormant. However, flotation refinements in the nonmetallic ores have not progressed as rapidly as in metallic (sulfide) ores because of the complexity of the deposits and the chemical similarities of the minerals.

Jan 1, 1967

By Robert E. Green, T. Hinton

Expressions are derived for tke orientation factors appearing in the Grana to -Lucke theory of dislocation damping, for fcc crystals. The factors are given as functions of the elastic constants, the direction cosines of the specimen axis, atld the direction cosines of the particle displacemeizts, for darnping due to dislocation motion on each of the twelve possible slip systems as ixell as lor simultaneous dislocation rnotion on all twelve systems. RECENTLY Green' has outlined the general procedure for calculation of the modes of wave propagation in a single crystal possessing a given crystallo-graphic orientation. In addition he has suggested how the results of such calculations along with calculations of the resolved shear-stress factors for slip enable the orientation-dependent factors (orientation factors) appearing in the Granato-Lucke theory of dislocation damping to be calculated. However, reen' assumed that the maximum stress on dislocations was in the direction of the particle displacement of the elastic wave giving rise to the dislocation damping. The present cal'culations show that this is an oversimplified approach appropriate only to special cases of high crystallographic symmetry. The exact calculation of stress on the dislocations can only be obtained by resolving the nine components of stress associated with the elastic wave into the appropriate slip direction and then summing. In this paper the general expressions for orientation factors are derived for fcc crystals in terms of the elastic constants, the direction cosines of the particle displacements, and the direction cosines of the specimen axis, bearing in mind the point mentioned above. Equations are presented which give the orientation factors for damping due to dislocation motion on each of the twelve possible slip systems as well as for simultaneous dislocation motion on all twelve systems arising from elastic-wave propagation. These orientation factors are appropriate to attenuation measurements made by the pulse-echo technique, where the elastic wave is a traveling wave. They will be compared with those for the case of a standing wave as derived by Granato and Lucke which are appropriate to measurements of internal friction by the resonance technique. The expressions for the orientation factors are compared with the five values given by insruch,' based on unpublished work of Granato and Liicke, for positions of highest symmetry in the stereographic triangle. The various equations derived for modes of wave propagation and orientation factors have been evaluated for the case of aluminum crystals at 1-deg intervals throughout the stereographic triangle. These results will be presented in the form of contour diagrams in a subsequent paper3 and their relevance to ultrasonic measurements discussed. ORIENTATION FACTORS The coordinate system used for the calculations is shown in Fig. 1 and all specimen axes are taken to lie in the shaded standard triangle. The twelve slip systems are indexed according to Table I. Following the suggestion of lers, we may define the orientation factor Ok in the Granato-Liicke theory5 by the equation

Jan 1, 1967

By D. A. Keyes

International Minerals & Chemical Corp. (Canada) Ltd. is presently exploiting by underground mining a potash-rich zone in the middle Devonian Prairie Evaporite formation near Esterhazy, Saskatchewan. Of the three main potash-bearing horizons denoted by Goudie as zones 1, 2 and 3 only the 1ower. two are present at Esterhazy and mining is confined to the lower or zone 1 horizon. The area in which the evaporites were deposited, although flanked on the west by a zone of geosynclinal deposition and tectonic activity, has been subjected to only very gentle epeirogenic activity. The sylvinite ore is coarsely crystalline and occurs in well-defined beds. The halite, sylvite and insoluble content of the ore bears a direct relationship to the lithological units, but the carnallite cuts across the beds. Local concentrations of salt produce blank spots in the ore horizon. Some of these appear to be salt-filled, post-ore channels and cracks while others have been formed by brines emanating upward from below the ore. INTRODUCTION International Minerals & Chemical Corporation (Canada) Ltd. is operating an underground potash mine near the town of Esterhazy in eastern Saskatchewan. The deposit was discovered by IMC in 1955. Subsequent drilling outlined extensive high-grade reserves, and in 1957 shaft sinking and plant construction began. Production from Yarbo No. 1 Shaft commenced in September, 1962 and quickly reached the initial capacity of one million tons of muriate product per year. Production is currently being expanded to 1.6 million tpy. The single mining level is 3140 ft below the surface at No. 1 Shaft. GENERAL GEOLOGY The Esterhazy district lies within the Interior Plains region of Canada and on the northeast rim of the Williston Basin (Fig. 1). Average dip of the rock formations in this area is about 40 ft per mile to the southwest. The potash ore occurs in the Prairie Evaporite formation of the Middle-Devonian Elk Point Group. The Prairie Evaporites are overlain by 3000 ft of Paleozoic shales and limestones and by Jurassic and Cretaceous sandstones and shales (Fig. 2).

Jan 1, 1967

By Stewart W. Daniel

"Increasing labour costs, the trend to larger mills, the processing of lower grade ores and a diminishing sup-ply of well-trained and experienced mill operators contribute to the necessity of automating a grinding circuit. With sophisticated process control techniques, supervision of the mill line is reduced to an occasional inspection by the shift supervisor. Process operating decisions and/or adjustments are quickly and accurately performed by the electronic devices to be described. When the variables in the grinding circuit are stabilized using the sensors and controllers as discussed, the over-all grinding circuit is maintained at its optimum grinding load level, with ample protection against under-and overloading."

Jan 1, 1967

By G. G. Hancock, H. H. Johnson

Hydrogen gas at atmospheric pressure is shown to cause substantial embrittlement in a martettsitic high-stretzgth steel. Subcritical crack growth is observed at very lom stresses and with high growth rates. It is suggested that an adsorbed layer of hydrogen atoms at the crack-tip surface provides the damaging hydrogen. Oxygen in small quantity, as little as O.7 pct by volume, is shown to eliminate subcritical crack growth in gas environments caused by hydrogen or water vapor. However, dissolved oxygen in water has little or no influence upon crack-growth rates. Oxygen-stopped cracks may be restarted by water, or by hydvogen or water vapor if oxygen is removed from the environment. These observations are interpreted in terms of preferential adsorption of oxygen at the crack tip and the formation of an oxide barrier. RECENT investigations1-3 have demonstrated that environmental factors are frequently responsible for delayed failure in martensitic high-strength steels. The environment causes crack initiation from preexisting cracklike flaws at unexpectedly low stresses, often far below the uniaxial yield strength. The crack then propagates at a rate controlled by the environment and the crack-tip stress-field intensity; during this period crack propagation will cease if either the stress or the aggressive environment is removed, and this may be considered a definition of subcritical crack growth. Fracture occurs when the crack has grown to a critical length, such that the fracture toughness of the steel is exceeded. Several liquids are known to cause delayed failure, but water and water vapor are the most severely damaging of the environments investigated to date.'-3 It has been suggested that hydrogen produced during corrosion reactions may be the actual embrittling agent2 The severe embrittlement caused by water vapor inevitably raises the question as to whether other gas environments are damaging. Previous work4'5 has demonstrated that high-pressure hydrogen (2250 psi or greater) is an effective embrittling medium, as measured by such criteria as reduction in area, notch tensile strength, and time to failure. Moreover, the embrittlement was eliminated by the addition of small quantities of air or oxygen to the high-pressure hydrogen, but it was not influenced by additions of nitrogen or argon.4 In the present study attention is focused upon gas environments at atmospheric pressure, in particular hydrogen and oxygen. The influence of these constituents upon the initiation and growth of a crack from a pre-existing cracklike flaw in a high-strength steel was determined directly by the electric-potential method of monitoring crack growth. MATERIALS AND PROCEDURE The H-11 steel was supplied by the U.S. Naval Research Laboratory as 3 by 12 by 0.065 in. sheet specimens with 1-in. transverse center slots. The slot tips were finished by Elox machining to a radius of 0.001 in. or less. The yield strength was 230,000 psi; chemical composition and heat-treatment schedule are given in Table I. The experimental apparatus, precracking procedure, and incremental loading sequence have been described previously.3 In the only significant change, precracking was sometimes carried out by a hydrogen embrittlement and baking technique. All experiments were conducted at room temperature; the hydrogen gas environment was purified by a commercial palladium purifier. Crack initiation and propagation were followed by the electric-potential method,'-3 using a calibration that has been recently dicussed. Stress-field intensities at the crack tip were computed by the conventional Irwin frmula; the plasticity correction was negligible and therefore not included. EXPERIMENTAL RESULTS A striking brittleness associated with molecular hydrogen at atmospheric pressure is demonstrated by the data in Table I1 and Fig. 1, which indicate that subcritical cracks in hydrogen initiate at lower stress-field intensities and propagate more rapidly than in fully humid argon. Ki and Kf are the crack-tip stress-field intensities at initiation and termination of subcritical crack growth, respectively. Termination, of course, corresponds to fracture. In both hydrogen and humid argon Ki is less than Kf

Jan 1, 1967