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By J. R. Dawson, A. B. Kinzel

THE purpose of testing is to determine whether the material in question is identical in all essential respects with similar material which has given satisfactory service. The most common method of securing such information is to select samples as representative of the entire material and subject them to destructive tests. As the welding industry grew, service data were accumulated and tests of welds took on new significance. New tests were devised and old tests modified so as to be more pertinent to welding. Moreover, in some cases the generally accepted procedure of testing by sampling is not accorded the same degree of confidence when applied to welds as in the usual applications. Thus, in instances where great hazard would be involved should the material fail, means of non-destructive testing have been sought with favorable results. Accordingly, tests used today may be divided into two groups, destructive and non-destructive tests.

Jan 1, 1930

By Saluja, Sunder S.

Man had to learn to break rocks as early as the Stone Age, when they formed his main source of raw material. He started with chipping and over the years has reached a stage where he can employ atomic blasts and break, with one blast, millions of tons of rock. In between these two extremes there have been several stages of development including fire setting, use of the expansion of water on freezing in chipped cracks in cold climates, the use of low or deflagrating explosive black powder in about the 17th century, the use of high explosives with the discovery of nitroglycerine in 1846 by Sobrero, followed by the monumental discoveries of the great Swedish scientist Alfred Nobel in the latter half of the nineteenth century.

Jan 1, 1968

By Ernest A. Hersam

IN every commercial establishment,' it is customary and necessary to take inventory, periodically, and to account for profits and detect losses, to achieve productiveness and enhance efficiency. So, too, in the ordered life of every individual, there is the need of periodic introspection. The exercise of the Sabbath for rational thought, the utilization of pause, or rest, from the technique of daily occupation, orient the efforts. These are the constructive opportunities by which we grow always better than we were. Thus, also, there' is need of a periodic analysis of the organizations to which we belong and toward which we con- tribute. So we find' reason for the fitness of our loyalty. There seems to be no half-ground for the engineer. Whatever presumes to bear his name demands either the crushing pressure of his heel or the supporting pressure of his hand.

Jan 1, 1929

By Harlowe Hardinge

AN extensive recent trip throughout the mining districts of the Southwest, Central West, an Northwest,' reveals a numbes of interesting conditions that have influenced operators, in both large and small mills, to modify their flow sheets insofar as they pertain to crushing and grinding. The changes made and planned for the future should be of interest. It is interesting to note when traveling through the country, how ideas change and practice is modified, and it is rather amusing to see how milling methods seem to run, more or less, in cycles. New ideas and developments are brought about which run through the industry and are taken up by many of the best and most well informed operators. Some of them will change, sooner or later, back to their old practice; for, like everything .else, what will work well in one place will not necessarily be suited to another. On the other hand, it is often difficult to establish. other practices known to be of value, owing to the natural resistance to make a change, but on the whole, the western mill men seem to be more alive to possible benefits of various modifications than any other engineers with whom I have come in contact in all parts of the world. Mill men in other parts of the world always keep in con- tact with what is being done in the western part of the United States, but it does not necessarily follow that those in the western part of the United States are always right. Some of these changes that have been made and afterward abandoned will be referred to later.

Jan 1, 1929

By C. S. Harloff, Frank R. Corwin

THE Nichols Copper Co., associated with the Phelps Dodge Corp. and the Calumet & Arizona Mining Co., has constructed at El Paso, Tex., and is now operating a copper refinery with a yearly capacity of 100,000 tons of anodes. Transportation facilities were perhaps the most important of the considerations that led to the selection of this site. The rapid industrial development of the Middle and Far West has increased the consumption of copper there. The advantage of local refining as against shipping the copper to the Atlantic sea- board is apparent. Copper refined in the Southwest is equally competitive for export shipment, either from the Gulf or the Pacific Coast ports. The tonnage of copper produced in the Southwest not only justifies the construction of this plant, but may warrant considerable expansion in years to come.

Jan 1, 1930

By T. H. Weldon, L. V. Whiton, R. R. McNaughton, J. H. Hargrave

Oxygen enriched air is being used quite extensively in the metallurgical plants of The Consolidated Mining and Smelting Co. of Canada, Limited, at Trail, B.C. The oxygen used for this purpose is a by-product from the Company's chemical plants located in the area. Most of the ore treated in the Trail metallurgical plants comes from Com-inco's Sullivan Mine at Kimberley, B.C. At Kimberley the ore is milled to produce lead and zinc concentrates which are shipped to Trail for further treatment to metal. One section of this paper deals with the use of oxygen enriched air in the suspension roasting of the zinc concentrates. In this process the concentrate is calcined for leaching preparatory to electrolytic recovery of the zinc. A second section of the paper describes the use of oxygen enriched air in operations at the lead smelter. There oxygen enriched air is used in the blast to the lead blast furnaces and in the slag fuming furnace which recovers the lead and zinc contained in lead blast furnace slag. The final section of the paper outlines the precautions necessary for the safe use of oxygen enriched air in any plant operation. The Use of Oxygen Enriched Air in the Suspension Zinc Roasters The suspension roasting of zinc concentrate developed at Trail, B.C., has been described in AIME Vol. 121, "The Electrolytic Zinc Plant of The Consolidated Mining and Smelting Company of Canada, Limited" by B. A. Stimmel, W. 11. Hannay and K. D. McBean. Since the publication of that paper, the use of oxygen enriched air in suspension roasting has been introduced as regular practice with marked advantage. The relative importance of a specific advantage may vary with changing conditions, but, in general, it may be stated that improved operation has been achieved at increased capacities. Suspension roasting is carried out at Trail in converted standard 25 ft diam Wedge roasters. The 2nd, 3rd, 4th and 5th roasting hearths have been removed and the drying hearth covered over. Drying of the concentrate is done on the drying hearth and the 1st roasting hearth. The dried concentrate, after any lump's have been broken up in a ball mill, is fed to a single burner located in the upper part of the combustion chamber. Oxygen is introduced at the burner fan along with the gases from drying, returned combustion gases from the waste heat boiler outlet and the required amount of new air. Up to 60 pct of the concentrate settles out on the 6th roasting hearth, the rest passilig out of the roaster. The product collected in the waste heat boiler is finished calcine, but the dust collected in the cyclones after the boilers is returned to the base of the combustion chamber where the sulphate is decomposed. Gases from the c'yclones go to a Cottrell precipitator. The discharges from the 7th roasting hearth and the waste heat boiler are combined with the Cottrell dust to give the finished calcine. Following small scale tests started in 1933, oxygen enriched air has been used continuously in the suspension roasting of zinc concentrate in Trail, beginning in 1937. A significant factor in promoting its use in this operation was the availability of by-product oxygen from the Company's near-by Chemical and Fertilizer Division. To-day it is standard practice at Trail to use oxygen enriched air for zinc concentrate roasting. The most important requirement in roasting a zinc concentrate for an electrolytic plant is that the zinc in the calcine should have maximum solubility. It is also desirable at Trail that the gas produced for the manufacture of suhhuric acid should have a ~naximum concentration of SO2 and that a substantial recovery of waste heat from the gas be achieved. High solubility of zinc requires that the sulphide sulphur and zinc ferrite in the calcine be kept low. These are both functions of temperature and time, with formation of zinc ferrite also dependent on contact between the iron and zinc particles. One of the inherent advantages of suspension roasting is that minimum time and contact are achieved. The limit on temperature is imposed by the fusion point of the concentrate and not by the need to control zinc ferrite formation. Operating temperatures are normally maintained within the limits of 1725" and 1850°F. A relatively low zinc sulphate in the calcine is required at Trail, and this results from discharging the calcine from the high sulphur dioxide atmosphere at a temperature above 1600°F.

Jan 1, 1950

By Galen H., Clevenger

THE first and most important thing that affects the majority of lead producers in the Rocky Mountains and the western mining regions is that zinc in an ever-increasing degree is inseparably associated with the lead. The Sullivan mine in British Columbia is not only a great lead mine, but also a great zinc producer. This mine could not reach its full measure of productiveness, nor was its great value established, until a reasonably good physical method was developed for separating the lead from the zinc prior to the recovery of each metal by an appropriate process. The western metallurgists and also metallurgists in other parts of the world have long faced the lead-zinc problem. This for many years stimulated a great deal of experimental work looking toward the development of a physical or chemical method of separating lead and zinc in concentrated form from complex ores. Space will not permit of going into this work in detail, but it is sufficient to say that with but few exceptions the western lead smelter continued smelting charges many times too high in zinc for the most efficient operation of lead furnaces. The zinc was not only lost, as the zinc content of many a western slag dump bears mute testimony, but the cost of lead smelting was increased by reason of the presence of the zinc. The owner of the ore under these circumstances could be paid nothing for the zinc and, indeed, he was penalized for it

Jan 1, 1926

By F. Twyman, D. M. Smith

THOSE chemists (they are still greatly in the minority) who use the spectroscope, use it very often, and find it almost indispensable. As a means of detecting minute quantities of the metals it is unrivalled. A metal can be readily distinguished in the presence of any other element, compound, or mixture without the necessity of separation. The qualitative analysis of the metallic constituents of a substance, which the spectroscope gives so easily, is a sure basis for planning a chemical analysis. As the determination of each element proceeds the purity of precipitates may be checked as often as desired. If, possessing these advantages, the spectroscope has been neglected in general chemistry, it is not surprising that it was neglected in metallurgical chemistry; for many of the impurities which are of industrial interest, even when they are present in a metal or alloy in small quantities, are not then always easily detected by the examination of their visible spectrum. The history of the development of the art has been given in Bureau of Standards Scientific Paper No. 444.

Jan 1, 1928

By E. C. Bitzer

The primary object of the work described in the following pages was to simplify the equipment in the separating circuit of the heavy-media process by substituting a spiral classifier for the separatory cone. Mechanical considerations were the leading attraction and the best that was hoped for on metallurgical performance was that the new vessel would give results equal to those obtained by conventional equipment. Tests have demonstrated in commercial operation on iron ore that the mechanical advantages of the spiral separator are about as predicted; also, the metallurgical performance is superior to the cone on the ores treated. Treatment of iron ore involves the separation of two products: a concentrate that sinks and a float product that contains true float material plus a controlled division of interfering middling. The middling material is heavier than the average specific gravity of the separating medium. Recent work with the spiral separator on Tri-State zinc ore showed that the middling material had to be recovered as concentrate because this fraction contained the bulk of the zinc in the ore. It has been demonstrated that it is possible to make three products with the new separator on an ore such as this: a float tailing, a float middling, and a high- grade heavy sink product. It appears from this last work that the new separator has definite mechanical and metalluigical advantages over any type of separating cone for treating feed that contains large amounts of material of a specific gravity close to that of the separating medium. However, either type of separator should perform equally well, metallurgically, on feed that is free of middlings. Each series of experiments with the spiral separator has required additional work to fully develop the possibilities of the machine. For this reason the paper is divided into chronological parts. History of Development A drag-type classifier was first proposed as a substitute for the cone separator by Butler Brothers technicians during the initial tests with galena medium at Crosby, Minn., in 1937. The desire for finding a substitute for the cone arose from trouble with interfering middlings and certain operating disadvantages of the cone. The possibility of using a spiral classifier was also suggested at this time by Emmett Butler and C. J. Abrams. However, inability to satisfactorily recover fine galena, which was used as a medium, terminated all development work at Crosby. During the winter of 1937--1938 investigation started on magnetic medium with concurrent development of the inverted or closed-top cone, which was found necessary to eliminate iron-ore middlings with the float product. About

Jan 1, 1949

By AIME AIME

IT IS impossible in this short sketch to give a detailed description of each part of the plant at Bethlehem, therefore, only such facts will be touched on as are necessary to give a general idea of the works. The extent of the plant, and the fact that the units making up the various departments are located in different parts of the works, make it impracticable to mention the departments in any regular order with regard to their location. They are, therefore, mentioned approximately in the order of their relation to each other with reference to their functions in the making of the various products.

Jan 1, 1924

By Robert W. Thomas

LEACHING of mined-out areas at the Arizona property of the Ray Mines Division, Kennecott Copper Corp., was started on Jan. 20, 1.937, and by July 1, 1938, 10,000,000 lb. of copper had been produced by this method. Leaching operations at present are confined to the western portion of the ore body and over an area of approximately ten acres. The ore in this area was extremely high in pyrite and the copper content, which averaged slightly in excess of 1 per cent, was the result of incomplete secondary enrichment by solutions which apparently worked laterally from the main ore body. Above the ore was an unaltered zone of primary or protore averaging 125 ft. in thickness and containing approximately 0.6 per cent copper. Above this was the capping or leached zone averaging 50 ft. thick.

Jan 1, 1938

By R. E. Grant

THE Cerro de Pasco Railway Co., owned and operated by the Corporation, is a common carrier whose chief functions are transportation of ore and concentrates from the mines at Cerro de Pasco to the smelter in Oroya, and haulage of coal from the coal mines at Goyllarisquisga to the coal washery at Fundicion. Connecting with the Peruvian Central Railway at Oroya, the C. de P. Railway maintains joint, daily freight and passenger service from Lima and the port of Callao to Cerro de Pasco, terminal of the C. de P. main line and gateway to the Huanuco Valley. Extending from Oroya to Cerro de Pasco the main line is a standard-gauge roadbed of 70-lb. rail, 132 km. long with a maximum compensated grade of 2.25 per cent and a curvature of 16°, climbing from an elevation of 12,272 ft. above sea level at Oroya, lowest station on the line, to 14,208 ft. at Cerro de Pasco. The highest point reached by the C. de P. is on the coal branch at Alcacocha where the rails are 14,385 ft. above the sea.

Jan 1, 1945

By E. W. Davis

DURING late years, the proportion of beileficiated iron ore shipped from the Lake Superior District has increased very rapidly. By benefication is meant washing, screening, drying, sintering or any process by which the grade or structure of the crude ore is improved before shipment. In 1915, only 3,000,- 000 tons, or 9 per cent, of t6e total Minnesota shipment was beneficiated ore, compared with 13,500,000 tons, or 35 per cent, of the total Minnesota shipment in 1925. This increase is, of course, due to the fact that iron and steel can be made more cheaply after beneficiating these ores than they could have been had these ores not been so treated. Fundamentally, however, several causes contribute to the necessity for beneficiating iron ores, such as depletion of the reserves of high-grade ores, the iron ore leasing systems and taxation methods and, at the smelting plants, a better understanding of blast-furnace operations, increased operating costs and increased sulfur content of blast-furnace coke. As economic conditions change, it is by no means certain that the proportion of beneficiated ore shipped each year is going to continue to increase. Undoubtedly some of the beneficiation operations are not economically sound at the present time and what the future has in store for the iron ore industry is problematical. Generally speaking, the cost of fuel for blast-furnace operations will increase as time goes on and in order to continue to produce cheap iron and steel, some of the other costs must be lowered. Freight and labor rates probably can- not be reduced. The cost of producing iron ore cannot be reduced much below the present price. It therefore appears that the best opportunity for maintaining iron and steel prices at their present level in spite of in- creased costs of labor and raw materials is to use. less or cheaper raw materials. This, of course, contemplates an improvement in metallurgical processes all along the line and, as a matter of fact, we can confidently expect these improvements because scientific investigations will undoubtedly be even more productive in the future than they have been in the past.

Jan 1, 1926

By NILS DANIELSEN

THE name of Swedish charcoal iron will probably bring to the memory of many old consumers an extremely tough and ductile iron which was formerly used in considerable quantities for common blacksmith purposes. To-day very little of this iron goes to such kind of work. Swedish charcoal iron is merely a speciality which is chosen whenever its remark¬able properties can be utilized. By giving a rough sketch of the manufacturing process of Swedish charcoal iron, the character of the iron, its weak as well as its strong points will more easily be understood. Swedish charcoal iron is a wrought iron also known in the United States under the name of Norway iron and Swedish Lancashire iron. The name Norway iron seems to have been attached to the product for the reason that in the earlier days it was generally brought into the States by Norwegian ships. However no iron of this kind is now made in Norway. The reason for the name Swedish Lancashire iron is that the manufac¬turing process emanated from Lancashier in England, the method being generally adopted in Sweden in the years 1831-1850. Today this iron is, with the exception of one plant in the United States, made in no place in the world outside of Sweden.

Jan 1, 1924

By M. J. Coolbaugh

Mining of potash more than 3000 ft beneath the water-bearing sediments in Saskatchewan presented the unique challenge of designing stable mine workings and assuring protection from overhead water in a material that was believed to flow plastically, but whose behavior as a plastic material was not sufficiently known. Under the stress conditions ordinarily encountered in mining most rocks behave as elastic materials; that is, they compress slightly under pressure, and rebound when the pressure is released. Salt and potash, however, are different. Even under the relatively low pressures encountered at shallow depths, these materials become slightly plastic and yield to stress by flowing.* The plastic properties become more pronounced at greater depth and pressure, and the question arises as to whether or not the plastic flow will be rapid enough and exert enough pressure to destroy underground structures or interrupt the mining process.

Jan 5, 1967

By M. G. Benz, J. F. Elliott

A new type of solution calorimeter has been constructed to measure heats of mixing, enthalpy increments, and heats of fusion, formation, and reaction at temperatures above 1000°C. With it, measurements hove been made of the partial molar heats of mixing joy tin in the Cu-Sn system from 0 to 13 at. pet Sn at 1127°C and fir nickel in the Cu-Ni system from 0 to 9 at, pet Ni at 1200°C. The integral molar heat of mixing for the Cu-Sn system is strongly negative with a calculated minimum value corresponding to the composition Cu3Sn. The integrnl molar heat of mixing for the Czi-Ni system is slightly positive at these temperatures. These integral molar values have been measured with a probable error less than 30 cal per g-atom at an atom fraction of nickel or tin equal to 0.1. The estimated probable error for the Cu-Sn system is approximately 450 cal for a measured heat of solution of approximately 9000 cal. For the Cu-Ni system it is approximately 700 cal for a measured heat of' solution of approximately 60 cal. A new type of heat of solution calorimeter was designed and constructed to provide a more accurate experimental method for determining heat effects at high temperatures, (T > 1000°C). With it, partial molar heats of mixing, enthalpy increments, heats of fusion, and heats of formation and reaction for metal systems can be measured directly. Previously it has been necessary to rely upon the use of the dropping calorimeter or the van't Hoff equation applied to equilibrium data for this information. For the most part equilibrium data are scarce and difficult to obtain in many cases, and it has been necessary to rely upon the "method of mixtures" for the desired enthalpy measurements. An earlier study1 provides a prototype for this work. The "method of mixtures" as outlined by K. K. kelley,2 "consists of dropping the substance under investigation from a furnace, with controlled and measured temperature, into a calorimeter operating at or near room temperature.'' In this manner the change in the total heat content (enthalpy) of the substance between the temperature of the furnace and that of the calorimeter is determined. In order to determine high-temperature heats of mixing, enthalpy increments, and heats of fusion, formation, and reaction, it is necessary to take the difference between two such measurements, one before and one after the occurrence of the enthalpy change being studied. The desired enthalpy change is then the small difference between two large numbers. Small errors in the large numbers are included as large errors in this small difference. It is this difficulty that must be avoided for accurate measurement of the desired functions. The procedure with the new solution calorimeter consists of dropping the substance under investigation from a furnace, with controlled and measured temperature, into a solution calorimeter operating in the temperature range of 1000o to 1200°C. Measurements in the range of 1200" to 1600°C are planned for the future. By selection of the composition and

Jan 1, 1964

By Russell C., Fleming

FOK, many years the officials of the Magma Copper Co. mine at Superior, Ariz., have had to contend with adverse conditions underground in the form of high rock temperatures, hot water, and high relative humidity. These conditions in the mine have been such that working the mine would have been impossible were it not for the constantly expanding and improved sys- tem of ventilation to produce bearable conditions in the working places. Results that have already been achieved make an interesting study of what can be done along those lines. From the time the mine was first opened in 1910 it has been hot. An idea of the conditions that have persistently been encountered can be obtained from parts of the mine that are not being worked at present or that do not yet have sufficient ventilation. Virgin rock temperatures as determined in drill holes at the faces range from 104° to 116°*. An observation made at the face of No. 5 West footwall drift on the 2800-ft. level.

Jan 1, 1930

By T. W. Guy

The increased moisture due to water-spraying for coal dust control is of interest even for mines from which the coal is to be wet-washed before screening, because in many cases wet coal dust materially de- 20-mesh X 0 sizes as pct ROM average ............................... 6.3 pct Range 2.3 to 9.5 pct 20-mesh X 0 sizes as pct 3/8 X 0 sizes average........'...................... 18.9 pct Range 12.7. to 23.9 pct creases the loading efficiency of men and equipment at the faces. It also causes a serious increase in the normal wear and deterioration of all equipment with which it comes in contact. It is important to the consumer if it increases his as-received moisture. No attempt will be made in this paper to cover the entire subject of water-spraying of coal for dust control. It will be confined to discussion and data on (I) percentages of dust in bituminous coals, (2) moisture increases due to spraying for dust control in mines or plants by methods which have proved satisfactory for periods of one to five or more years, and (3) a few suggestions for research. Size and Percentage or Coal Dust The U. S. Bureau of Mines1 classifies as coal dust all bituminous coal passing a 20-mesh sieve (0.0328 in. square opening). The percentage of such dust to be found in ROM coal, of course, varies widely with the characteristics of the seam, and with the methods used in the mining and in the preparation of the coal. ROM screen analyses of 12 U. S. coals selected at random from personal files given in Table I show: A few other screen analyses examined indicating 40 pct or more of 20-mesh X 0 dust in 3/8 in. X 0 sizes were not included because of uncertainty that they were representative. The number of results in Table I is not sufficient to give a reliable estimate of the average, or of the range to be expected, but it indicates that in every case the coal dust is a relatively large percentage of the total ROM coal, and, of course, a progressively larger percentage of resultants as the larger sizes are separated for marketing.

Jan 1, 1949

Low metal prices prevailing at the beginning of 1950 stimulated the search for improved mining methods. More experience was gained during the year with such new developments as the jackleg drill, millisecond delays as applied underground, trackless mining, and Diesel powered equipment. One of the outstanding innovations in mining practice was the starting of the Round Mountain "dry land gold dredging operation." The Government is now inviting the mining industry to open up every available source of new metal supply and this circumstance will undoubtedly speed the development of new machines. New methods will also result but it is doubtful if economic efficiency will be at its peak.

Jan 2, 1951

By Alfred H. Bell

Drilling activity in the eastern interior coal basin, which includes Illinois, southwestern Indiana and western Kentucky, decreased greatly in 1931. Only 521 wells were drilled as compared with 1438 in 1930.' The decline in oil production (Fig. 1) was due partly to the failure of new production to make up for the natural decline of the old wells and partly to artificial curtailment of production to meet a decreased demand. During the year prices trended sharply downward until July, after which they made a partial recovery (Fig. 2). The average price of Illinois crude, which is the same as that for southwestern Indiana, was $0.852 per barrel in 1931 as compared with $1.616 in 1930, or slightly more than one-half. The cost of drilling has declined only slightly. The 25 per cent curtailment of production which was adopted by agreement of the southeastern Illinois operators on Sept. 1, 1930, ended on June 3, 1931. It was effective for five months in 1931 as compared with four months in 1930. The outlook for 1932 is for drilling activity in the whole area to continue at about the same rate or to decrease somewhat unless it is stimulated by a substantial rise in crude oil prices or by the discovery of extensive new productive territory. Discoveries of new productive areas and new sands during the year were few. A new gas area was discovered early in the year in Busseron township, Knox County, Indiana, in which the producing sand is in the Pennsylvanian at depths of 630 to 730 ft. The wells had a total initial open-flow capacity of 7 or 8 million cubic feet per day but are shut in for lack of marketing facilities. An exceptionally large gas well which was drilled in Gibson County between Oakland City and Francisco reached a total depth of 1490 ft. and produced from the Brown sand of Chester age. The initial open-flow capacity was reported as 13 million cubic feet per day. In western Kentucky a number of extensions to oil and gas-producing areas are reported. The most active drilling campaign was in Hart County, where 124 wells were drilled, most of them in the

Jan 1, 1932