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By D. E. Stone

Solid and liquid impurities must be removed almost completely from synthesis gas for the production of synthetic liquid fuels because of their effect on the synthesis catalyst and turbocompressors. The maximum permissible concentration of dust has been set at 0.05 grain per 100 cubic feet.5/ This is one part per million by weight, or about the same concentration as in average city air. The cost of synthesis gas is estimated to constitute 60 to 70 percent of the total cost of the synthetic liquid fuel. For this reason this station is developing processes using coal instead of the more valuable coke as raw material, which promises reduction in cost of the synthesis gas. This, however, increases the difficulty of attaining the above dust value. As failure of the dust-removing equipment to produce high-purity gas may ruin valuable equipment within a few minutes, it is imperative that a reliable and continuous method be obtained for determining such extremely low concentrations .of dust in the purified gas. A suitable device must also instantly sound an alarm and, if necessary, automatically actuate the proper valves to prevent damage. The Ess Instrument Co. designed and built an instrument which they believed might fulfill these specifications. It' continually compared, by means of photoelectric cells, the intensity of a light beam passing through the gas and a similar beam passing through clean air. For maximum sensitivity, the photocells were connected back to back, i.e., anode to cathode and cathode to anode. The difference in voltage produced by the two cells was amplified and operated an indicator.

Jan 1, 1951

By C. Díaz, M. Barati

Prof. Torstein Utigard's untimely death, in the spring of 2012, put an abrupt end to a meritorious career in the field of high temperature chemical process metallurgy. As an academic in the Department of Materials Science and Engineering of the University of Toronto, Torstein made solid contributions to the advancement of knowledge pertaining to production and refining of both nonferrous and light metals, and to the development of inquisitive and innovative young people in extractive metallurgy. In this profile, the authors highlight aspects of Torstein's rich personality and of his contributions to his field of expertise.

Jan 1, 2015

By J. W. Carson

Introduction Many bulk solids such as coal, limestone, and fine moist ores often flow unpredictably out of bins, hoppers, and boreholes. Vast amounts of time and money are spent-with or without success-on flow promoting devices. In addition, many solids segregate in storage, feed erratically, flood, arch, rathole, and stick to bin walls reducing the live capacity. This article discusses bulk solids flow properties and provides guidelines for designing storage bins, hoppers, and feeders to provide reliable flow. Bulk Solids A bulk solid is a granular material consisting of discrete solid particles-submicron to several inches in size-that is handled in bulk form (for example, in a bin or silo). The gas filling the voids is generally insufficient to fluidize the material and the liquid (usually water) content is assumed to be less than saturation. Types of Flow Problems To design an efficient storage system, an engineer must be aware of problems that can arise during storage and flow of bulk solids: • No flow. A stable arch or pipe (rathole) develops within the solid, stopping flow. • Erratic flow. Momentary arches form within the solid, (ratholes), partly or completely empty out, and then collapse. • Flushing. Powders become fluidized, aerate, and flush uncontrollably through the bin outlet. • Lack of design capacity. A large part of the stored material remains stable around a rathole. Manual prodding, severe vibration, and even explosives may be used to restore flow. • Segregation. Smaller particles tend to sift through the voids between larger particles causing accumulations of fines and coarse in various areas of the bin. • Product degradation. Some materials spoil, cake, or oxidize if they remain in a bin too long. This is usually caused by a first-in-last-out flow sequence. • Level control. Measuring the volume of material left in a bin is difficult if a rathole develops. In one portion of the bin the level control device may indicate the bin is full; in another portion it may indicate it is empty. Eliminating Flow Problems All flow problems can be minimized or prevented by suitable design of the bin/feeder unit. This involves knowing the flow properties of the solid, then choosing the appropriate type of bin and feeder to establish the desired flow pattern. There are three types of flow patterns that may occur in a bin: funnel flow, mass flow, and expanded flow. Funnel flow occurs when some of the material in the bin is stationary while the rest is in motion. Funnel flow bins, shown in Fig. 1, are characterized by: • Low head room. A flat bottom or shallow hopper bin has large storage capacity with minimum height. Unfortunately, all this storage capacity may not be usable ("live"). • First-in-last-out flow sequence. The first material put into a funnel flow bin is the last material withdrawn because the flowing material is concentrated in the region directly above the outlet. • Ratholes. Because of the flow channel that forms, a stable rathole develops if the material has sufficient cohesive strength. • Erratic flow. Once a rathole becomes partially or completely empty, it may collapse creating a stable arch and erratic flow. • Flushing. Collapsing ratholes cause flushing and flooding of fine material. • Segregation. If a bulk solid has a tendency to segregate, this tendency will be accentuated as the material is discharged from a funnel flow bin. Funnel flow bins are suitable for coarse, free flowing, nondegrading solids, when segregation is not important. Mass flow occurs when all the material in a bin is in motion whenever any is withdrawn. Char-

Jan 3, 1983

By Kenneth Eilerts, Vincent Smith

"INTRODUCTION Knowledge of the Phase relations of fluids produced from combination wells 4/ at the pressures and temperatures characteristic of production from natural reservoirs is essential to efficient recovery and refining practice. An accurate sample of the fluid from such wells may be prepared by mixing (in the proportions of the measured gas:liquid ratio) gas and liquid taken from the separator conditions of steady flow; and physical properties of the sample, at significant pressures and temperatures, may be determined with suitable laboratory apparatus for use in the solution of engineering problems. The results of study of sample so obtained and of mixtures of gas and liquid from the separator combined in other proportions are presented in this report. Attention was given in the study to the relationship between the physical properties of what may be regarded as the constituent materials - the gas and liquid taken from the separator - and the properties of mixtures of these constituents. Data obtained for the complete range of mixture Proportions are expected to provide a reference scale for the study of other combination-well fluids produced at different liquid:gas ratios."

Apr 1, 1942

By Robert F. Chaiken

More than 500 fires are now burning in abandoned coal waste banks and coal deposits in the United States. Once established, such fires can burn for decades, and extinguishing them by conventional methods such as surface sealing to exclude air, excavation to remove fuel, or flushing to cool the fire zone is usually difficult and always expensive. Burnout Control, a technique developed by the Bureau of Mines for the control of abandoned fires, involves the accelerated combustion of coal in place with total management of the heat and fumes produced. A burning waste bank or mine is placed under negative pressure relative to the atmosphere, and heat and combustion products are drawn from the combustion zone through an exhaust ventilation system. Heat produced appears as sensible heat in the exhaust, at temperatures as high as 1,000° C (1,832° F), and can be recovered for the production of steam, hot water, process heat, or electricity. The Bureau's first field demonstration of Burnout Control was at Calamity Hollow in Allegheny County, PA (near Pittsburgh). Calamity Hollow was the site of an underground mine in the 1900's and was surface mined in the 1940's. In the winter of 1961-62, a fire of undetermined origin was discovered in the exposed coal. In 1963, the Bureau constructed a trench barrier around the fire and a surface seal over the affected area. The fire was isolated, but not completely extinguished. In 1979, when the Bureau began work on the Calamity Hollow Mine Fire Project, to demonstrate controlled burnout, the fire was still smoldering on the hot side of the trench barrier. The project, which was begun in December 1979 and ended in July 1982, consisted of the design, construction, operation, and subsequent dismantling of a Burnout Control ventilation system. This report is the fourth in a five-part series that describes the Calamity Hollow Mine Fire Project. The first report, part 1, describes the design and construction of the field installation. Part 2 will present the results of a continuous 4-month burnout operation. (Because part 2 involves the analysis of a substantial body of data, it will not be published until after publication of parts 3, 4, and 5). Part 3 describes the instrumentation used to control and monitor the progress of the burnout operation. This part (part 4) and part 5 both deal with the closeout phase of the field demonstration. The quenching of the fire is described in this report, and part 5 will describe the final excavation and backfilling of the heated zones. The reports in this series document the Calamity Hollow controlled burnout demonstration, which showed that (1) controlled in situ combustion is a feasible method for controlling underground fires in abandoned mines, (2) the resultant thermal exhaust output is sufficient for energy utilization, and (3) water injection with fume exhaustion is a potentially effective method for cooling large underground fire zones. Further trials of both Burnout Control and water injection with fume exhaustion are planned.

Jan 1, 1984

By W. J. Dolinar

The U.S. Bureau of Mines implemented the Fe2+ /Fe3+-SO2 anode reaction in a Cu electrowinning cell with full-size electrodes. Electrowinning was conducted using industrial electrolyte at 258 A/m2 (24 A/ft2) and 40 'C. Manifold injection of electrolyte provided circulation between the electrodes. Five-day operation using an optimized manifold gave an average cell voltage of 0.94 V at 89% current efficiency, which amounted to an energy savings of 2.82 MJ/kg (0.355 kW-hr/lb) compared to conventional electrowinning. Acid misting was completely eliminated, and SO2 concentration 23 cm (9 in.) above the cell averaged 0.06 ppm.

Jan 1, 1995

By N. Careddu

In recent years, slabs with a rough surface have captured a large share of the ornamental stone market. However, the main technologies used for this type of treatment are based on mechanical shock (bush-hammering) or thermal treatment (flaming or flame-finishing). These traditional technologies are widely used, but have many limitations that decrease their usefulness. The purpose of this study was to develop a technology that enhances the natural colors of the rock and produces a rough surface without compromising its mechanical characteristics, in contrast to traditional technologies. This report shows the technical, economic and aesthetic results obtained with a new water-jet treatment and compares it with competing technologies.

Jul 1, 2010

By Michael J. Beus

The National Institute of Occupational Safety and Health-Spokane Research Laboratory (NIOSH-SRL) have developed a Shaft Conveyance Monitoring System (SCMS). Assessment of current hoisting technology has shown that monitoring wire rope tension and conveyance position and load directly from the skip or cage top offers several significant safety, production, and maintenance advantages. The SCMS consists of conveyance position and guide displacement sensors, a battery power supply and charging system, and a new sensor to measure hoist rope tension. This device provides a warning of the occurrence of ?slack rope? a particularly dangerous condition. A 2.4 GHz radio link transmits data to the hoistroom. A reduced scale hoisting test facility has been constructed to test these components prior to field trials. The advantages of monitoring wire rope tension and conveyance position and load directly from a skip or cage top will be discussed. Field tests are underway in full-size shafts to refine the concept and evaluate long-term reliability and maintenance requirements. Application of this technology may result in decreased maintenance costs as well as safer, more productive hoisting operations.

May 1, 2001

By G. P. Gu

The in-service 90/10 cupro-nickel tubes in a water-chiller system suffered from severe corrosion damage during their relatively short service life causing unexpected down time. In addition to downtime, the environmental risk associated with losing refrigerant was also a concern that initiated this investigation, Microstructural investigation using SEM and electron microprobe indicated that pitting corrosion had resulted in local nickel depletion, During the corrosion process, copper appeared to have re-deposited around the corrosion pits accelerating the local corrosion.

Jan 1, 2005

By Chas Kemsley

NO. 6 shaft at Dome Mines, Limited, is an internal shaft going down vertically from the sixteenth, or 2,000-ft., level to the twenty-ninth, or 4,000-ft., level, with loading station and sump below this. It is located approximately 4,600 feet east of No. 3 shaft, the latter being Dome's main shaft through which ail ore, men, and material are handled. The decision to sink this shaft was made in May, 1935, and work was commenced almost immediately. To reach the site of the new shaft, 3,100 feet of cross-cutting, and 1,400 feet of slashing to widen existing cross-cuts, was necessary. On account of the long haul and the large amount of material to be handled, trolley haulage was decided upon and installed as soon as possible to facilitate the removal of waste rock from the crosscut and other necessary excavations. Figure 1 shows a cross-section of the cross cut and the manner in which the trolley wire is supported and guarded. For hanging each individual cross-piece, two holes are drilled into the roof and filled with snug-fitting wooden plugs. Into these, %-in. ragged hanger bolts arc driven by means of a stoper. The bolts are of various lengths to allow for irregularities in the face of the rock, and they have sufficient thread to permit several inches of adjustment for proper alignment of the cross-pieces. These hangers are spaced at 8-ft. intervals except at the curves, where 5-ft. spacing is used. A 2 in. by 6 in. cedar plank is fastened to the cross-pieces directly over the centre of the track. To this the trolley-wire supports are bolted, and 1 in. by 10 in. cedar boards are nailed on each side to act as guards. Two power-supply cables, one telephone cable, and one .Y2-in. conduit lighting circuit are also supported on the trolley-wire hangers, as shown in Figure 1. A 20-in. ventilating pipe and a 10-in. air line are placed as shown, thus acting as a guard to prevent workmen from walking on the track.

Jan 1, 1938

By C. E. Reistle

The generation of steam for drilling operations has visually been accomplished in the past by the use of portable locomotive-type boilers without the aid of auxiliary equipment or advanced for economizing fuel or water consumption. This has been due primarily to the fact that the steam-generating plant of a drilling well must necessarily be of temporary and portable design, and the amount of steam generated has not been considered sufficient to justify the additional expense necessary to obtain more economical operation. However, with the constantly increasing depth to which oil wells are being drilled and the use of larger and heavier equipment, the steam requirements have reached a point where equipment and methods that were previously considered as applicable only to permanent plant installation can be and are being used to a decided advantage by the more progressive operators. As an example of the present-day requirements and the rapidly increasing steam consumption in rotary drilling, a comparison between the requirements during the intensive drilling period in the Seminole end Oklahoma City fields of Oklahoma is of interest. In the Seminole field. There the approximate depth of rotary drilling was 3,500 feet, the general practice was to use three 85 to 90 or 100 horsepower A. P. I. code boilers operating at a working pressure of 175 to 200 pounds per square inch. The fuel end water consumption was approximately 450 to 500 thousand cubic feet of gas and 700 to 750 barrels of water per day. In the Oklahoma City field, where the average drilling depth is approximately 6,500 feet, the general practice is to use either four 100 or 116 horsepower or three 123 horsepower A.P.I. code boilers, operating at a pressure of 250 pounds per square inch. The fuel and water consumption varies from 550 to 750 thousand cubic feet of gas and from 1,000 to 1,500 barrels of water per day.

Jan 1, 1930

By M C. Ackland

The Grande Côte Mineral Sands Deposit (GCMSP) is located on a coastal mobile dune system in Senegal on the west coast of Africa. Senegal is a stable, democratic republic, having gained its independence from France in 1960. It has a population of about 12.5 million people. The dunes begin about 25 km north-east of Dakar, the capital city of Senegal, and extend northwards for more than 140 km. The mineralised dune system averages about 2 km wide with some areas extending to up to 4.5 km wide.Mineral Deposits limited (MDL), a Melbourne-based company with over 60 years operational experience in mineral sand mining in Australia, holds, through its Senegalese subsidiary MDL Senegal SARL (MDLS), a 25-year Mining Concession covering the deposits. The main heavy mineral (HM) areas identified to date are, from south to north, Mboro, Fass Boye, Diogo and Lompoul. Within the Mining Concession there is potential to identify additional resources beyond the limits of present drilling. The dunes are mobile or semi fixed, pale yellow in colour and overlie older white marine sands. The dunes range between 5 m and 30 m in height and the mineralised zones, which are essentially flat-lying, average around 15 m in thickness. The mineralisation consists, principally of ilmenite with accessory zircon, rutile and leucoxene. Zircon and ilmenite are the main commodities of interest.Independent consultants AMC estimated mineral resources for the four main deposits in 2006 of 1330 Mt of sand averaging 2.0 per cent HM at a cut-off grade of 1.5 per cent HM. At a cut-off grade of one per cent the resources were 3200 Mt averaging 1.5 per cent HM. All of the estimate was classified as Inferred Resources under the 2004 Australasian Code for Reporting of Exploration Results, Mineral Resources and Ore Reserves (JORC, 2004).Subsequent completion of infill drilling, sampling and assaying of the initial mining area, centred at Diogo, was completed in 2008, enabling a final dredge path to be designed and ore reserves estimated, based on a JORC compliant Measured and Indicated Mineral Resource. Infill drilling is continuing in the Lompoul and the results of this campaign will be included in the JORC compliant data base by AMC in April 2010 to enable the 15 per cent year dredge path and mine plan to be finalised.Development studies have shown that the project can be optimised as a dredging operation, with mineralised sand being treated in a conventional floating spiral preconcentrator, wet concentrator and dry mineral separation plant. Engineering work now substantially completed by Ausenco Limited (Ausenco) has developed the combination of some existing plant from MDL’s past operations, and new plant for the complete process from dredging to final product separation and grading. Testwork on a series of bulk samples has determined that the project can yield a high quality zircon product and an ilmenite product along with minor rutile and leucoxene.Work to date indicates a likely output of around 80 000 t of zircon in various quality streams (Primary, Secondary, Standard and Foundry Grades), around 550 000 t of ilmenite plus around 15000 t of rutile and around 12 000 t of leucoxene/secondary ilmenite. Planned zircon output would represent around 7per cent of the total world production, which would make the GCZ&IP a significant producer on a world scale.The studies have indicated capital costs to be in the range of US$400 M total operating cost (after completion of ramp-up) of around US$50 M - $55 M/a. Revenue is expected to be in the range $127 M - $157 M/a.

Oct 5, 2011

By J. H. Fulton

Summary Considerable test work has been done with the detachable type of carbide bit. In general, these bits improved drilling operations, but at a bit cost .greater than was compensated for by the reduction in man-hours of labour. Too few bits continued in service for the possible drilling life of the carbide inserts, and technical improvements or lowered first cost, preferably .both, are indicated ?in order that the bits can be generally acceptable as an economical drilling tool. In ?preliminary test work, the drill rods .with ?one insert of the chisel-bit type appear to be more trouble-free, to have a longer life, and to give a somewhat lower bit cost per foot drilled, than other types. INTRODUCTION The object of this paper is to outline briefly the 'methods used and the results obtained in test work with tungsten carbide bits used in combination with the smaller bore, lighter weight rock drills. As various articles have appeared in the past few years giving the historical background ?and early development of carbide ?bits, this information will not be repeated. Table I lists the equipment used in the test work. The stopers weigh about 95 pounds and the jackhammers with airleg from 97 to 110pounds. The smaller rock drills are stated to deliver about 2,200 blows per minute at 1 to 30 rotation and to require 85 to 95 cubic feet of air at around 100 pounds pressure.

Jan 1, 1950

By D. C. Treilhard

After a brief history of the mining and smelting operations of Kilembe Mines Limited, this paper outlines the smelter layout and describes . the. daily operations at the Jinja plant. Particular attention 1s paid to the details of the furnace and converter operation. A subsequent section of the paper deals with the significant developments in plant metallurgical practice, covering both smelting and converting.

Jan 1, 1966

By J. T. Birkholzer, M. Rutenberg, K. -H. Lux, R. Wolters, J. Rutqvist, L. Blanco Martin

In this paper, we present numerical results corresponding to the Thermal Simulation for Drift Emplacement (TSDE) test, conducted in the Asse salt mine (Germany) between 1990 and 1999 to simulate reference repository conditions for spent nuclear fuel in rock salt. This test is of significant relevance for nuclear waste disposal in salt because extensive research and measurement programs were set up for the experiment. In our numerical study, we use two sequential simulators, TOUGH-FLAC and FLAC-TOUGH, and we investigate two-way coupled processes, focusing on thermo-mechanical analyses due to the main effect of heating. The two simulators used have recently been updated and are able to deal with large strains and creep processes. Moreover, specific constitutive relationships and coupling functions for rock salt and crushed salt under repository conditions are available. Within the framework of a benchmark exercise between Lawrence Berkeley National Laboratory and Clausthal University of Technology, the same scenario has been modeled in three dimensions using the two simulators mentioned. The main objective of the current, first stage of the benchmark is to evaluate the capabilities of these two simulators to predict relevant processes under repository conditions for high-level nuclear waste in saliniferous media. The comparison of the numerical predictions between them is very satisfactory, leading to a successful code-to-code verification. The comparison between measurements and numerical results shows that the most important processes are captured by the codes and constitutive models used. However, some differences exist between measurements and numerical results. These differences will be addressed in the next stage of the benchmark exercise, in which a parameter fitting effort will be undertaken. Overall, from the results obtained it can be concluded that TOUGH-FLAC and FLAC-TOUGH have the necessary capabilities to reproduce relevant processes under repository conditions for high-level nuclear waste in saliniferous formations.

Jan 1, 2015

By R. R. Lowery

An analysis of three 1-1/4-diam manufactured wire ropes of 6x19 classification was done to identify and describe reference conditions of new rope. Reference condition is of value when examining tested or retired ropes. Measurements of strand and rope pitch and of wire and rope diameter confirmed adherence of all ropes to those construction specifications. Mechanical properties of strength and ductility were determined by accepted methods for the ropes and wires from the ropes. Individual wires from one rope failed to meet minimum wire ductility values. Wire chemical composition varied in average carbon levels, from 0.70 to 0.78 wt pct, and in manganese content, from 0.45 to 0.80 wt pct. One manufacturer's product contained 1 to 3 wt pct Ni and Cr. Heavily wrought pearlitic steel microstructures were porous and contained inclusions. Cold work variations were evidenced by wrought grain width. Recorded anomalies reflected the condition of the manu-factured products. The report provides data that compare the three wire ropes studied, but cannot verify the effects that these conditions or anomalies have on rope service life.

Jan 1, 1983

By Satu Jyrkönen

A single-particle laminar-flow technique was used to study oxidation of four synthetic nickel mattes, which were screened into three size fractions, Experimental conditions were: reaction gas from N2 - 21 to 75 vol-% O2; gas preheating temperatures ranging from 500 to I 100'C. The four mattes were synthesized so that Ni/Cu ratios of I and 10 were obtained with high and low iron contents. Chemical analysis of the particles was used to determine the oxidation degree of the materials, and optical and scanning electron microscopy were used to detect their morphology, internal composition and structure. The best sulfur removal from the synthetic nickel mattes was achieved under the most oxidizing conditions with the finest size fraction. The matte with Ni/Cu = 1 and high iron content was found to be most reactive. The least reactive matte was with Ni/Cu = 10 and low iron content; the coarse fraction particles did not react at all under the conditions studied.

Jan 1, 1996

By Frank K. Cameron

"The DepositsThere are two large deposits or groups of deposits of potash salts which, at the breaking cut of the great world war in 1913 and for several decades preceding, were practically the only commercial sources of supply for the entire world. In both cases the origin of the deposits was sea water, the potassium salts being deposited by desiccation, but there were modifying factors which were not entirely the same in both cases so that well defined and important differences exist in these deposits. The larger and better known group, called the Stassfurt Deposits, are in Germany in the region about or adjacent to Magdeburg and Halberstadt. The general character of these deposits and the methods for recovering potash from them have been frequently described, not only in technical publi¬cations, but in the non-technical propaganda long maintained by the Kali Syndikat, an organization founded on a ""cartel"" with the supervision and support of the late Imperial German Government.Less well known are the smaller though nevertheless extensive deposits in the neighborhood of Mulhouse in Upper Alsatia, which were also under the control of the Kali Syndikat at the breaking out of the war but have now passed to French control, with the reentrance of Alsace into the French Republic.The Alsatiaa deposits, while less extensive than the German deposits, are, nevertheless of great magnitude. They occupy a large part of the area between the Vosges Mountains and the River Rhine, from Col¬mar on the North to Mulhouse on the South. Indeed a few borings on the East bank of the Rhine indicate that the deposits may extend under the river and to some distance beyond Buggingen Linken, Baden, though it has not been Shown as yet that this extension is of commercial significance.As is well known, the Stassfurt potash occurs as potassium chloride or potassium sulphate or both salts, intimately mixed with salts of sodium, magnesium eau& calcium (lime) and contaminated with substances. insoluble in water such as ferric oxide, clay etc. The potash salts are segregated in more or less extensive 'pockets' throughout the salt mass, these segregations departing usually from the horizontal. But the main ""potash region"" is a stratum varying from 30 to 150 feet in thickness and at a depth requiring shafts 5000 feet."

Jul 1, 1919

By R. R. Angel

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

Jan 1, 1958

By R. T. Swinderman

"Virtually every article you read on safety has a statement to the effect: “It’s obvious that safety pays”. If it is so obvious, why is it so hard to answer these questions? • How does the Maintenance or Operations Manager convince the Plant Manager to spend money from the annual budget for safety improvements? • How does the Plant Manager influence Corporate to prioritize safety improvements? • How does an engineering firm persuade the owner to spend more on design and equipment up front to reduce risk? There are many cultural and structural reasons why it is so difficult to prove the obvious. In my opinion the main culprits are: the almost universally used ‘Low Bid’ process, variations in reporting incident statistics between industries and countries, and, the Generally Accepted Accounting procedures (GAAP) [or International Financial Reporting Standards (IFRS)]. Conventional wisdom is it’s smart not to spend more than you need to meet the minimum regulations and maximize production. But buying on price alone often harms people, degrades the environment, and reduces the company’s bottom line. How can this be? You met the minimum safety requirements and saved money by buying on price. Don’t those savings go right to the bottom line? When you buy on price you get minimum quality, minimum compliance and are often backed corner with no reasonable options to rectify the problems that arise from buying on price instead of buying on long term life cycle cost. Culturally few companies actually ‘walk the talk’. It is trendy to have giant billboards at plant entrances proclaiming world class compliance with quality and safety standards. Annual reports are embellished with safety slogans and sustainability statements. Behind the front gates and the glossy annual reports the message is clear: produce or be replaced. Only a few companies go beyond the window dressing and actually endorse, from the top down, continuously improving their safety culture. Those that do embrace safety, show significant performance advantages over their competition that are reflected in their safety, productivity and environmental records and, ultimately their financial statements and share price. Current accounting (and reward) systems make it unlikely financial managers will accept non-conventional approaches to justifying expenditures on safety because they are driven to report “hard” numbers that can be documented and are within the “GAAP or IFRS Rules.” But in reality, accountants quantify soft or intangible costs all the time in their financial statements. Justifying safety investments is greatly enhanced by quantifying what most financial managers would call intangible costs. Government agencies have no problem assigning intangible costs to justify regulations to improve safety. How many times have you heard that the regulation is justified because the cost to industry is X while the benefit to the society is 2 or 3X? How can they say that without including intangible costs? We find it hard to believe these government claims of benefits to society because we have been trained to think about saving hard direct costs to justify investments."

Jan 1, 2017