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By Donald H. Dowlin

The design of a preparation plant for minimum maintenance and clean up requires both the skills of the Engineer and the practical experience of the Operator. From the initial flow sheet and preliminary design until the plant is completed and operating, each phase of the work must be thoroughly explored for simplicity, workability and high efficiency. It is the responsibility of the Designing Engineer to develop the plant around the basic flow sheet, selecting equipment and materials not only with regards to Initial cost but also required upkeep and repair.

Jan 1, 1962

By T. W. Smoot

Bentonites are composed chiefly of montmorillonites which are clay minerals generally distinguished from other clay minerals by their surface activity and extremely fine particle sizes. The uses of bentonite are many and varied, depending principally on one or more of the following characteristics: 1) Thixotropy, 2) Dispersion, 3) Plasticity, 4) Swelling, 5) Surface area, activity, ab- and adsorbtive properties. Some of the major uses of bentonite are briefly reviewed as are the mineralogical and physical properties. The uses of X-ray diffraction, differential thermal analysis and other tests for physical properties are reviewed as to their uses in evaluation. In the past 40 years, the industrial uses of bentonite have grown to include many applications. The physical and chemical properties of bentonites are such that they can be used as catalysts, adsorbants, plasticizers, binders, drilling muds, and pelletizers. Not all bentonites, however, can be used for all of these purposes and some are probably of little or no value for any use. The purpose of this paper is to briefly review the mineralogical, physical, and chemical characteristics and variations of bentonites. The determination of these characteristics and their uses in industry are also reviewed so that these determinations can be used as guides for evaluation. DEFINITION OF BENTONITE The word bentonite, as used in this paper, refers to a clay material, usually (but not necessarily) the result of the in-place-weathering of volcanic ash. Its mineralogical composition is dominated by the clay mineral montmorillonite and generally carries other clay minerals and silica minerals as the major 'impurities'. For this discussion, such a definition is justified since most of the economic uses of bentonite~ depend upon the physical and chemical characteristics of the montmorillonite minerals involved. The terms montmorillonite and bentonite have been used almost interchangeably in industry although the latter is much more commonly used. Therefore, where montmorillonite is discussed, it should be understood that the major feature of a bentonite is the subject. STRUCTIJRE OF MONTMORILLONlTE The economic importance of bentonites is generally based on one or more of the following characteristics of montmorillonite: 1) high-thixotropy and easy dispersion in water, 2) high-plasticity, 3) swelling properties, 4) large surface area/unit mass, 5) high surface activity, and 6) adsorptive properties. To understand these properties, an appreciation of the structural scheme of montmorillonite is helpful. Montmorillonite IS one of the three-layer clay minerals composed essentially of hydrous aluminum silicates. The essential building blocks of these layered silicate:; are: 1) silica tetrahedron composed of a silicon atom surrounded by four oxygen atoms, and 2) aluminun (iron, magnesium, etc.) octahedral unit that, ideally, has one of these atoms surrounded by six hydroxal units. Fig. 1 is a diagrammatic sketch of the montmorillonite structure. In the montmorillonite structure, the tetrahedron are pointed inward and attached to the octahedral units so that the O= atoms replace the hydroxal units where they are bonded; hence two-thirds of the hydroxal units

Jan 1, 1962

By Eugene A. Hickok

Seismic surveys utilizing the MD-1 have been performed by Geophysical Specialties Company since 1957 in many parts of the, U. S. and Canada and in several foreign countries. These surveys have proven the refraction seismic technique to be applicable to a wide variety of engineering problems. The best known applications of the instrument have been in the, construction industry, where it is used for the delineation of material and mineral deposits and for bedrock depth determinations. Fast on-the-site depth determinations give reliable subsurface' information even in boulder-strewn soils. A widely publicized use of the MD-1 is to make rippability studies in which the instrument is used to determine the seismic velocity of the materials to be excavated. By use of special tables which correlate rippability with seismic velocities, such as those prepared by the Caterpillar Tractor Company using the MD-1, the rippability of-a specific material may be determined.

Jan 1, 1962

By Judson G. Brown

In order to filter small amounts of fine slimy solids the reversible cake-filtration process was developed. The filterable solids contents lion in feeds can range from less than 1 ppm up to about 5%. The relative advantages of this process, are usually the greatest in the range of 0.05% to 1.0% filterable solids. Filterable solids that average in particle size about 20 microns& are non-compressible are very easy for this filtration process. Some feeds have been all sub-micron in particle size. A 1/8 inch thick cake is considered to be very thick. The usual cake is between 13/2 and 1/16 inch thick. A new line of injection molded plastic filter plates were developed for use with the reversible cake filtration process. The first commercial sized installation of this system was made 3 years ago in the Wakefield Y.M.C.A. swimming pool. Over 70 filters ranging in size from one plate to 63 plates have been produced. In addition to the process advantages there are the low cost and corrosion resistance advantages of the plastic plates.

Jan 1, 1962

By Josh B. Taggart

Some twenty to twenty-five years ago we saw the beginning of mechanization in our coal mines, It has now progressed to the point Chat as instruments of production the pick and shovel are things of the past, They had to give way to better and more efficient methods--so mechanization, followed by and combined with automation, has become common-place in our mines. Our coal could not keep its competitive position without this progress Without it our industry could not look to the future with any degress of confidence. Today we lock back and see cases of regained and salvaged markets. We see better coal products being produced at decreasing costs. We see better utilization of manpower and a stronger, more confident industry, Our hats arc off to those mining men, equipment manufacturers, labor leaders, and others who had the foresight to work toward these ends and the ability to bring them about.

Jan 1, 1962

By C. K. Jankousky

The midwestern area referred to is the Illinois basin. The coals presently worked are mainly the No. 5 and No. 6 coal seams which vary in thickness from five to eleven feet. Present average of the more important No. 6 id about nine feet. The coal can vary considerably in toughness within the same mine with some coal perhaps rashing very easily and other coal being extremely difficult to cut. Top is generally well laminated shales with some fortunate areas having limestone roof. There are local areas with troublesome top of poorly laminated shales, shale with slickensides and shale intermingled with small partings and traces of coal. The bottoms are generally one to three feet of clay which softens readily on exposure to moisture. The mines are dry although some water is released and collects from rapid penetration of the seam by continuous miners. However, there are locally wet areas. Most of this material refers to mines of the Freeman Coal Mining Corporation. The mining operations written about are underground mines in southern and central Illinois.

Jan 1, 1962

By Floyd G. Anderson

This report reviews and summarizes information on prevention and suppression of dust in mining, tunneling, and quarrying published in the United States during the years 1958 through 1960. Unpublished pertinent data developed or assembled by the Bureau of Mines during this period also are included. Silicosis statistics reported by the U.S. Public Health Service indicate a sizable silicotic population in the United States and suggest a need for greater dust-control effort. A joint medical-environmental survey was begun by the U.S. Public Health Service and the Bureau of Mines to evaluate the magnitude of the silicosis problem in the metal mining industry in the United States.

Jan 1, 1962

By William J. Campbell

Evaluation by the Bureau of Mines of published expansion values for magnesium oxide shows significant variation in values, which may be attributed to sample variables, experimental errors, or systematic differences between measuring techniques. To eliminate the sample variable in measuring expansion, thermal expansion characteristics of a high-purity polycrystalline magnesium oxide were determined by 21 cooperating laboratories using one or more of the following techniques; X-ray camera, X-ray diffractometer, dilatometer, interferometer, and telemicroscope. All expansion values were corrected by the author to a single reference temperature of 25° C. Linear expansion was expressed as a power series in the form of the following equation. Expansion (percent) = [[ A + B (?t) + C (?t)2] ?t 104] The constants, A, B, and C, were determined by least square techniques for X-ray camera, X-ray diffractometer, and dilatometer data separately, and for combined data of all five techniques. Expansion values are tabulated from 26° C. to 1,400° C. in 2° C. intervals using constants derived from X-ray camera data. Below approximately 500° C., expansion values obtained by dilatometric and interferometric methods are significantly lower than those by X-ray methods; above 500° C., this bias decreases rapidly. Comparison of results within methods showed the least variance for X-ray camera results; dilatometer and X-ray diffractometer results have about the same variance. The average deviations, in percent, between observed and calculated expansion values among methods were approximately 10 percent from 100°C. to 300°C., 5 percent from 300°C. to 500°C., and 2 percent from 500°C. to 1,400°C. Maximum deviations were approximately twice as large in most instances.

Jan 1, 1962

By A. M. Gaudin

In the first place, let me thank you for inviting me to appear before you today to speak to you on "Mineral Industry Problems - Present and Future". It is a distinguished honor for me to have this opportunity, and I am highly appreciative of this distinction. The beautiful surroundings of Gatlinburg and the pleasantness of a summer occasion are a wonderful tonic for all of us, yet they should not blind us to the seriousness of our Industry's problems No doubt, because of my past appearances before members of the Society of Mining Engineers, at which I discussed wholly scientific topics, or research in the Applied Sciences, you may be expecting me to revert to these subjects. But I intend to venture in a field that is new to me, yet old to all of us, the field of Economics.

Jan 1, 1962

By Joachim J. Hauser

William F. Hosford, Jr. (Massachusetts Institute of Technology)—Dr. Hauser has used a very interesting method to study the interaction of dislocations on different slip systems, but it should be pointed out that the analysis of the experiments is subject to a serious criticism. He states that "the effect of the compression can be adequately described by one slip system." The effect of frictional constraint during the compression makes this quite unlikely. When a block of metal is compressed its lateral expansion requires a sliding of the metal over the compression platens. The role of friction in the interface between the deforming metal and the platens is to increase the normal force required for the compression. Analyses1213 have shown that, in general, the additional force, p, required for the compression is a function of l/h where is the coefficient of friction, I is the length of the speci- men in contact with the platens. For a constant COefficient of friction, isho' shows that P should increase exponentially with pl/h for both plane strain and axially symmetric compression. For a compression specimen, Fig. 7, whose cross section perpendicular to the compression axis is a rectangle whith one dimension L, much larger than the other W, a much larger force would be required for appreciable flow parallel to L than for flow parallel to U7. Therefore lateral strain in the W direction, EW, should be much greater than the lateral strain in the L direction EL. Since L/H = 14.5 for Dr. Hauser's crystals, and since no lubrication was used, it seems questionable that appreciable lengthening of the crystals could occur. Because the theories of frictional constraint have been derived for isotropic polycrystalline materials, it was decided to make experimental measurements on a single crystal. A section 3.590 in. long was sawed from an aluminum single crystal with a square section of 0.249 in., so that L/W= 14.4. This crystal was tested in compression between dry ground steel platens. Fig. 8 shows the orientation of the crystal and the axis of compression. The face for compression was chosen so that the operation of the single-slip system which would be predicted in the absence of friction would lead to a larger strain in the length direction than in the width direction. The dimensional changes of the width and length as well as the height were measured frequently during the compression with micrometers. Width strains were calculated from the average of readings near each end and at the center. A plot of the length strain, EL, against the width strain E w is given in Fig. 9. The slope indicates that the EL amounted to only 2.5 pct of cw. Other compression tests on similar crystals with shorter lengths also showed severely limited elongation. Even for a crystal with L/W = A.0, EL was only about 26 pct of cw. Because of the frequent interruptions of the tests for dimensional measurements should have decreased the frictional constraint by allowing a reseating of the platens, even smaller elongations under continuous testing seem probable. These tests on long narrow crystals show that essentially plane strain conditions prevailed. We may assume that Dr. Hauser's crystals deformed similarly. That the compression can be described by the

Jan 1, 1962

By F. L. Jackson

The large scale transportation and storage of sulphur in the liquid state is a relatively new development, but is really only a logical extension of old mining and processing techniques, It is not known who the first person was to win a relatively pure sulphur from ore by melting, but this method was commercially used at least two hundred years ago in Sicily and is still in use today. The Frasch process of mining was invented over sixty years ago, and the development and improvement of-liquid sulphur pumping and handling techniques has paralleled the growth in the Frasch mining industry. During the last fifty years, improvements in the technology of using sulphur have included the premelting of sulphur prior to its being burned for acid production or conversion into CS2 and other compounds. Yet, until fairly recent times, sulphur produced as liquid has been solidified into large blocks at the producing point, broken down by blasting or with mechanical equipment, and shipped in bulk form as a solid.

Jan 1, 1962

By A. R. Taylor

In recent years, thermodynamic data have been used to a greater degree than ever by the chemical and metallurgical engineer as a means of predicting and controlling chemical reactions. To satisfy the spiraling demand for basic physical data needed for the calculations, the Bureau of Mines is studying the heat capacities of a variety of chemical compounds at high and low temperatures. This paper is one of a series presenting such data. The heat capacities of two alkaline earth compounds, strontium bromide and strontium nitrate, were measured in a temperature range of 60° to 300° K. in an adiabatic calorimeter and at temperatures of 300° to about 1,200° K. in a Bunsen ice calorimeter. The construction and operation of the calorimeters are discussed in other reports.3 4 The heat-capacity data presented in this report were extrapolated to 0° K., and smooth values of heat capacity, entropy, enthalpy function, and free-energy function were calculated and tabulated at even 10-degree intervals. The enthalpy data were fitted with algebraic equations by applying the method of least squares; calculations a£ heat-capacity values, entropy, enthalpy function, and free-energy function were made at even 50-degree intervals. The heat and entropy of fusion of strontium bromide were calculated from the enthalpy measurements.

Jan 1, 1962

By Ruth F. Brinkley

This circular describes the activities and publications of the Bureau of Mines, Explosives Research Laboratory4 for the fiscal year 1960 (July 1, 1959 -June 30, 1960). Part 1 describes briefly the principal projects that were active during the report period, and presents some data not scheduled for publication elsewhere in the near future. Certain of the results are only preliminary and should be regarded as tentative, pending the findings of the completed investigation. Publications that appeared during the report period are listed and described briefly in part 2. In general, the research activities reported in these publications antedate fiscal year 1960. The published material relating to activities that are still current is indicated by references in part 1.

Jan 1, 1962

By William A. Beck

The Construction Aggregates Corp. operates a plant for processing sand and gravel from two deposits in Ottawa County, Mich. The bulk of the sand is obtained from a sand dune on the shore of Lake Michigan, and the gravel is dug from a glacial-drift deposit farther inland. Mining is done with draglines, and the material, both at the digging site and in the plant, is moved mainly by systems of conveyors. The Ferrysburg plant serves customers along the Great Lakes, which is unusual for a business normally local in character. Annual production exceeds 1-1/2 million tons of sand and gravel as concrete aggregate and 200,000 tons of core sand for foundry use.

Jan 1, 1962

By K. E. Doud

An unusually pure grade of rutile and several grades of aplite rock are produced in a unique mining and mineral dressing operation in Hanover County, Virginia. The ore body is an aplite rock of gnessic structure, having a sari ace exposure extending over several hundred acres, heavily leathered and containing rutile, ilmenite, and other titanium and iron minerals. The physical nature and mineral composition of the ore body has permitted the use of a relatively economical and unusual processing circuit. The flowsheet was designed to take full advantage of the remarkable liberation of the minerals at relatively coarse rinds. It permits flexibility in changing the product mix, and maintains high levels of purity in both rutile and aplite rack. The mineral processing is discussed in some detail below.

Jan 1, 1962

By K. K. Kelley

Thermodynamics data for silicates have applications in the fields of extractive metallurgy, ceramics, and geochemistry. To facilitate these applications, up-to-date tables of heats and free energies of formation are needed. It is the purpose of this report to supply such tables for anhydrous silicates. During the last 15 years the heats of formation of a substantial number of anhydrous silicates have been reliably determined at or near room temperature. This resulted from the development (first by the Bureau of Mines and later by the Geophysical Laboratory of the Carnegie Institution of Washington, by the Institute of Geology of the University of Helsinki, Finland, and by the Department of Geology of the University of Chicago) of accurate solution calorimeters, employing hydrofluoric acid as the reaction medium. Specific references to work of these laboratories will be made in the next section of this report. Also, entropy data at 298.150 K. and high-temperature heat-content values are available for many of these silicates, mainly owing to work of the Bureau of Mines. Most of these entropy and heat-content data have been compiled in Bureau of Mines Bulletins (13, 15).3

Jan 1, 1962

By B. K. Shibler

During a research program to develop improved methods for recovering elemental sulfur and useful sulfur compounds from secondary source materials, the technical literature was searched for pertinent articles on processing methods. This report summarizes results of the literature survey and describes the more important processes that have been used or suggested for recovering sulfur and sulfur compounds from all non-Frasch sources. The bibliography presented represents a survey of the available English language literature on the subject through 1958, with particular attention focused on the period 1950 through 1958. Engineering Index and Industrial Arts Index were the principal guides used in the survey of this period. Chemical Abstracts was used to a limited extent to identify a few key foreign articles and patents. The Sulfur Symposium (4)4 published in November 1950 by Industrial and Engineering Chemistry includes a broadly representative selection of the literature up to 1949. Therefore, this reference was used extensively to locate and list pertinent articles on processing methods reported in the period prior to 1950.

Jan 1, 1962

By J. M. Morkowitr

A. Sawatzky (Atomic Energy of Canada, Ltd.)—The detailed criticism by Markowitz of my simple treatment of the thermal diffusion of hydrogen in Zircaloy-2 indicates that my paper was not as lucidly written as it could have been. I would therefore like to reiterate several of the main points of my proposed mechanism and describe in more detail some of the features only implied in the original paper. The distribution equation derived in my paper was stated to hold only for the case where the volume taken up by the hydride was small compared to the volume taken up by the solid solution phase, subsequent work, mentioned below, having shown it to be out by only a few percent up to a hydrogen concentration of about 3000 ppm. Of course, hydrogen in the two-phase region alone is not conserved in my treatment as pointed out by Markowitz. On the contrary, one of the important features of my proposed mechanism is that in the presence of a temperature gradient a two-phase region cannot exist over the whole specimen. For example, if the specimen is entirely a + 6 initially, then on application of a temperature gradient, a single phase (a) region at the hot surface develops from time t = 0 onwards. As mentioned in my original paper, the interface between the a and a+d regions moves toward the colder surface of the specimen with a discontinuity in hydrogen concen- tration developing at the interface and increasing with time. This interface moves at such a rate that hydrogen in the specimen as a whole is conserved. It must be pointed out that my distribution equation (Eq. [5] in Markowitz's paper) holds only for linear geometry. It is easy to show that for the cylindrical geometry of Markowitz the assumptions used in my treatment lead to

Jan 1, 1962

By Edward P. Larsen

At our annual meeting in St, Louis, Mo. in February 1961, we presented a comprehensive paper (No. 61-B-22) on the subject of "Blending and Handling of Materials for Agglomeration". In that paper you will find a discussion on the difference between "blending" and "mixing". With regard to "blending" we brought out the facts of its usefulness for the preparation o materials in an agglomerated mass to attain controlled chemical and physical uniformity. "Mixing" was discredited as not being useful for the attainment of uniformity of any kind.

Jan 1, 1962

Why A Friction Hoist? B EFORE discussing the equipment, it would be instructive to review the factors that influenced the management of Opemiska Cop-per Mines to purchase a friction hoist rather than a conventional double drum hoist. The mine required that 250 tons per hour be hoisted from a depth of 2,100 feet. They also specified that the top speed should not exceed 1800 feet per minute. Eight ton capacity skips in balance and a maxi-mum hoisting speed of 1725 feet per minute would meet the required <Output on a duty cycle as follows: Loading time Creep away from loading pocket Accelerate (at 2.5 ft/sec2) 10 seconds 5 seconds 11.5 seconds Full speed run Decelerate (at 2.5 ft/sec2) Creep into dump Cycle time Trips per hour Tons per hour 72 seconds 11.5 seconds 5 seconds 115 seconds 31 31x8 = 248

Jan 1, 1962