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By R. Simon

The sources of energy dissipation for concentrated loadings on rock are considered in an attempt to account for the experimentally measured magnitude of the work required to break out a unit volume of rock from the free surface of an essentially semi-infinite medium. It is concluded that most of this work probably represents the elastic strain energy developed by the loading in a much larger volume of rock beneath the loaded region than the volume of the rock fragment broken out to the side of the loaded region. This strain energy is largely dissipated in the form of stress waves generated by the high rate of unloading produced by the propagating cracks. The energies associated with the formation of the new surfaces of the cracks and with the stress waves generated directly by the loading process are computed to be negligibly small. Possibilities for improving the utilization of energy to drill rod. subject to the geometrical limitations imposed by down-hole operation, are discussed. It is pointed out that any such possible improvements would probably have to be differential ones, since each rock configuration of more favorabIe loading geometry that can be created down the hole is accompanied by a complementary configuration of less favorable loading geometry. INTRODUCTION Dislodging each cubic inch of rock from the bottom of the hole by the action of a bit requires the expenditure of an amount of energy that varies from approximately 5,000 in.-lb to approximately 100,000 in.-lb, depending on the hardness of the rock, or, more technically, upon its fragmentation strength.1 In this paper we will discuss (I) why the energy expended in drilling is so large, (2) what happens to this energy upon completion of the drilling process, and (3) what are the possibilities for reducing the magnitude of the energy required to drill rock. DETERMINATION OF ROCK DRILLING ENERGY The volume of rock removed per unit time from the bottom of a hole of diameter D is evidently (7/4)D2R, where R is the rate of penetration of the bit. If P is the rate at which work is done by the bit on the rock at the bottom of the hole, the energy required to break out a unit volume of rock is given by: Ev =(4/p) P/D2R............(i) For rotary drilling, of either the rolling-cone or drag-bit varicty, P = 2pLN, where L is the torque resistance to rotation at the bottom of the hole and N is the rate of rotation of the bit. L is essentially the same as the torque measured at the rotary table only when drilling in shallow holes. The energies expended in rotating the drill string against the frictional resistance of the walls of the hole and and against the viscous drag of the drilling fluid are extraneous to the subject under consideration, although these may be much greater in magnitude than E, when drilling in a deep hole. For percussion drilling, P = fE where f is the percussion frequency and E is the work done on the rock per impact. The latter quantity can be both computed and measured for a percussion drilling machine. 2 (Under satisfactory drilling conditions, defined in terms of ranges of numerical values of certain dimensionless parameters, E is only 30 to 50 per cent less than the impact energy of the striker.2) Alternatively, E, may be measured directly by dropping chisels shaped like bit edges, backed by rigid weights, onto the surfaces of laboratory rock samples of effectively semi-infinite extent. Under these circumstances, essentially all of the impact energy is converted to work done on the rock, and the relationships among volume of rock broken out, chisel shape, impact energy and indexing distances can be obtained.3 The values of the energy required to break out a unit volume of rock under favorable circumstances are substantially in agreement for rotary drilling, percussion drilling and drop testing at atmospheric pressure. The energy per unit volume is a quantity of the order of magnitude of roughly twice the com-pressive strength of the rock as measured by a uniaxial loading test. The phrase "order of magnitude" in this paper means from about 1/3 as much to 3 times as much; i.e., the energy per unit volume may range from roughly the same up to several times

By Björn Saxen

Outotec atmospheric Direct Leaching has so far been implemented for zinc production capacities of around 100,000 t/a. Lately, there has been growing interest for small scale direct leaching plants, producing circa 30,000 t/a of Zn. Such small leaching plants can provide extra front-end capacity in existing roaster-based plants and enable treatment of feed materials not suitable for roasting. In small scale plants the proven OKTOP® 9000 Direct Leaching reactors are not readily applicable, due the large size. For smaller installations a modular approach is proposed providing multiple advantages, such as reducing the construction time and amount of the site work required causing less disturbance to regular plant operation with reduced cost. In this paper, we present advantages that can be achieved by using modular OKTOP®C reactors and discuss also process design when connecting a small scale direct leaching process to an existing zinc plant. Also benefits of direct leaching expansion are presented.

By C. Coetzee

Additives are commonly used in copper electrowinning to improve cathode morphology. Polysaccharides such as guar are generally favoured as additives due to their compatibility with solvent extraction. Polyacrylamides are, however, being considered as possible alternatives. Understanding the influence of the structural chemistry of additives on electrowinning performance is critical to utilise them efficiently. This paper investigated polyacrylamide additives which are structurally different; their effects on copper electrodeposition were characterized and compared to that of guar. Electrochemical impedance spectroscopy (EIS) were used to characterize the effects of molecular weight and ionic charge of the polyacrylamides on electrodeposition. The findings were compared against results obtained with an industrially used guar product. Equivalent circuit modelling of EIS data indicated that an increase in polyacrylamide concentration and a decrease in additive molecular weight increased the overall system resistance.

By Linda L. Chasko, Ronald S. Conti, John D. Cool

Mine operators often rely on mine rescue teams to save lives during an underground emergency such as an underground fire, explosion, roof fall or water innundation. It is extremely important that team members are provided with adequate exploration equipment and that training simulations are conducted in a realistic manner. A series of mine rescue training exercises was developed, conducted, and evaluated by the National Institute for Occupational Safety and Health (NIOSH) in cooperation with the Pennsylvania Department of Environmental Protection, Bureau of Deep Mine Safety and several mining companies. The exercises were conducted at NIOSH’s Lake Lynn Laboratory and operating mines during 1995 to 1999 and resulted in improved technology and training for mine rescue teams. For example, existing technologies were identified to help rescue teams during exploration. These included various chemical light shapes and laser pointers to identify team members and mark crosscuts and mine materials, strobe lights for mapping out escapeways and marking crosscuts, and thermal imaging systems to see through smoke. A hands-free communication system showed potential for enhanced communications between team members and the fresh air base. Anew team lifeline that allows for flexibility of movement between team members was developed. A positive-pressure inflatable escape device (IED) was used to isolate the “hazardous” environment from fresh air and allow rescue team members to traverse through. An inflatable feed-tube partition that can rapidly block large openings such as underground passageways and simultaneously provide a feed-tube for high-expansion foam generators was also deployed for several simulations. During the simulations, mine rescue team members donned self-contained breathing apparatuses (SCBA) and traversed more than 400-m of mine passageways filled with nontoxic smoke. Visibility ranged from 0.3 to 0.9-m. In one area of the mine, a kerosene heater was used to simulate a fire and reduce the oxygen concentration. In another area, a 1.5 pct methane zone was established. The team members searched for "victims,” administered first aid, mapped the passageways, built temporary stoppings, and ventilated the smoke-filled entries. Advanced training included the extinguishment of a conveyor belt fire in a surface fire gallery. Two teams, each carrying charged waterlines, were escorted into the fire gallery through both doors. These teams controlled the rollback smoke and extinguished 7 to 9-m of burning conveyor belt. Team members indicated that the exercises were extremely beneficial due to the realism of thetraining simulations.

By G. C. Wallick, W. R. Foster, J. G. Savins

A comprehensive review of the salient features of the differentiation method of rheological analysis in Poiseuille flow from its inception circa 1928 is presented. Here no initial assumptions regarding the nature of the function relating rheological parameters to observed kinematical and dynamical parameters are required in the data-analysis process. In contrast, the integration method involves interpreting flow properties in terms of a particular ideal model. It is shown that, although both methods represent modes of solution of the same integral equation, being relatively bias-free, the differentiation method offers a more discriminating procedure for rheological analysis. The application to problems involving plane Poiseuille flow is also described. INTRODUCTION In most instances, the approach to the problem of interpreting the rheological properties of various compositions as they are affected by changes in chemical or physical environment, assaying the characteristics of a particular constituent of a suspension, analyzing flow behavior in terms of interactions between components in a system, to cite but a few examples, has been in terms of what Hersey1 terms the integration method. Briefly, it consists of interpreting flow properties in terms of a particular ideal model. The usual practice of the integration method is to choose a model with a minimum number of parameters because, other things being equal, it is desirable to use the simplest model which will describe the behavior of a real material and yet be mathematically tractable for the requirements of data analysis. This expression is then substituted into an equation which relates observed kinematical and dynamical quantities, such as volume flux Q and pressure gradient ], and angular velocity and torque T, in a capillary and concentric cylinder apparatus, respectively. The rheological parameters appear on integrating, in an expression relating the pairs of observable quantities such as those just given. In many instances a particular model provides a good representation of rheological behavior over a reasonable range of compositional and environmental changes. Just as often, however, it is obvious that the interpretation of rheological changes by the integration method is not providing realistic information about changes in flow behavior. A more general method of interpreting rheological data for a given material is to make no initial assumptions regarding the nature of the function relating rheological parameters to observed kinematical and dynamical quantities, e.g., flow rate and pressure drop in capillary flow or angular velocity and torque in a rotational viscometer. This general method Hersey1 terms the differentia-ation method. Instead of integrating, one differentiates the integral equation with respect to one of the limits, i.e., one of the boundary conditions; the resulting expression contains the same observable quantities just given, their derivatives, and the rheological function evaluated at that boundary. By obtaining these derivatives from experimental data, graphically or by a computer routine, they can be substituted into the differential equation and a graphical form of the function derived. THEORY OF THE DIFFERENTIATION METHOD FOR POISEUILLE-TYPE FLOWS In this introductory paper, two flow cases which are important in viscometry are considered (one for the first time) from the differentiation method of analysis, flow in a cylindrical tube and flow between fixed parallel surfaces of infinite extent, the basic integral equations being formulated in a manner analogous to the way they originally appeared in the literature. In addition, the following ideal conditions will be assumed: (1) an absence of anomalous wall effects, (2) isotropic behavior everywhere, and (3) steady laminar flow conditions. Before proceeding it would seem appropriate to preface the analysis of these flow geometries with the comment that the basic philosophy of the differentiation method could be said to stem directly from the efforts of Herzog and weissenberg2 to indicate systematically the various ways of using

By H. L. Hartman

The drop tester has proved an invaluable tool for the investigation of percussion drilling in the laboratory in "slow motion". It has allowed the process of rock penetration by impact to be studied a single blow at a time. In the present work, the relation of cratering to indexing has been determined under conditions simulating those in the bottom of the hole at atmospheric pressure. Indexed blows form craters which are influenced by others adjacent to them. Two unique effects are involved: (1) the provision of additional free faces in proximity to the point of impact and (2) the creation of subsurface damage by the previous blow(s). Both have a pronounced influence on the volume of rock removed per blow, which governs the rate of penetration in actual drilling. The emphasis in this study was placed on determining effects of index distance and impact energy on crater volume when blows were struck on a previorusly "drilled" or damaged surface, a situation most representative of down-hole conditions. The results indicated that (I) the optimum index distance on a damaged surface is greater than on a fresh, undamaged rock surface; (2) the volume of rock broken at optimum index distance is about the same for both surface conditions with die-shaped chisels but tends to be greater on a cratered surface with wedges; (3) the optimum index distance and maximum crater volume are proportional to the energy level; (4) at a given energy level, the volume of rock broken by dies generally exceeds that by wedges; and (5) maximum crater volume varies, approximately, inversely with width of die but is nearly independent of included angle of wedge. INTRODUCTION This is the third of a series l,2 of papers reporting on one phase of a continuing program of drilling research being conducted in the Rock Mechanics Laboratory at The Pennsylvania State U. The phase under consideration is crater geometry — blow energy relations in percussion drilling. While the previous papers have discussed mainly craters produced by single blows, indexed-blow studies are the subject of this paper. The basic mechanism of drilling under study here — that of penetration of a chisel-shaped bit subjected to impact — is the one employed in probably 90 per cent of all rock drilling in mining, percussion drilling. It also forms the fundamental action in nearly all oil well drilling with the so-called rotary (roller-bit) method. Here, the action is more complex, however, and may in actuality comprise rotary-percussion drilling. Certainly, the down-hole air and mud hammer drills, which superimpose percussion on rotation, belong in this latter category. In any event, impact blows constitute one of the principal mechanisms in the vast majority of drilling, mining or petroleum, and it is essential in drilling research to study percussion in all its basic aspects. Percussion drilling can be simulated in the laboratory by means of an impact drop tester. Striking one blow at a time with chisel-shaped bits, the drop tester permits study of most of the parameters in the drilling process except blow frequency and the interrelationship of certain variables. Single-blow craters, the simplest to produce, allow the determination of basic relationships, such as volume vs blow energy; while indexed craters most closely resemble the action in real drilling and provide data for the establishment of optimum operating criteria. Indexed-blow craters are those which are influenced by others in proximity. The simplest case to visualize, and the one studied in detail here, is that in which a given crater is formed adjacent and parallel to a previous crater, such that the second crater breaks into the first. A more complex situation usually exists downhole, where indexing is achieved by rotation of a radial-winged or rolling-cutter bit. But, admittedly, the phenomenon of indexing is more likely to be understood eventually if it is first studied in its simplest form, that related to parallel craters. Limited research has been conducted on indexed blows. The most complete study was that by Simon, 3,4 who proposed universal indexing curves to relate the important variables. His work, however, was conducted entirely with rows of craters formed on a

By Broggi Andrea

Condensates produced by SiO(g) and CO(g) have a crucial importance in silicon production. Condensation will follow the reactions 3 SiOðgÞ+COðgÞ→ 2 SiO2 + SiC and 2 SiO ðgÞ→Si+SiO2. Solid compounds generated during silicon production contain Si, SiO2 and SiC in different microstructures and amounts. In industrial systems, condensates limit the SiO(g) escape to the off-gas system. On the other hand, they can block the gas flowing from the high temperature zone, hence the necessity of studying an optimized condensation process. This review discusses SiO(g) condensation and its interaction with CO(g). The report gives an overview of the condensates found both at laboratory and at industrial scale. The two main compounds are the Si–SiO2 and the SiOx–SiC mixtures. The hypothesis on the mechanism of formation of SiC–SiOx condensates is presented through a wide selection of performed works. The advantages and disadvantages of the former experimental procedures are discussed.

By A. Navarra

Peirce-Smith converting (PSC) is applied for roughly 50% of primary nickel and 70% of primary copper production. PSC cycles produce batches of ironfree sulfide matte (or blister copper, in the case of copper smelters), that are subject to further processing. However, the number of cycles that can be performed simultaneously is limited by the offgas handling system. Moreover, PSC suffers from variation in the yield and duration of the cycles. This variation is managed by conventional smelter designs, in which the upstream smelting capacity exceeds the nominal converting capacity; PSC is thus a major bottleneck in conventional nickel and copper smelters. Stabilization and standardization of PSC operations can therefore increase smelter throughput. The current paper presents a discrete event simulation (DES) framework to assist in smelter debottlenecking. It features random number generation to represent cycle variability, and time-adaptive finite differences to represent thermochemical complexity. Preliminary computations are presented.

By Evgueni Jak

Pyrometallurgy is an important sector of modern industrial society actively participating in solving current environmental, economic, materials scarcity and other challenges. Recent advances in analytical methods, experimental techniques, thermodynamic, phase equilibria and process modelling tools provide new opportunities to increase the productivity of pyrometallurgical reactors, the treatment of complex feeds and metal recoveries. Fundamental theoretical models can now be used to make a significant next step towards the development and implementation of computerised models describing real industrial processes—Virtual Reactors, and computer-aided smart-decision-making systems that may be called Pyro-GPS by analogy to GPS; these developments can facilitate knowledge-based improvement and optimisation strategies. The implementation of these improvements require ongoing collaboration between researchers, industry and government.

By Linda L. Chasko, Larry D. Stowinsky, Ronald S. Conti

Mine operators often rely on mine rescue teams to save lives during an underground emergency such as an underground fire, explosion or roof fall. It is extremely important that team members are provided with adequate exploration equipment and that training simulations are conducted in a realistic manner. A series of mine rescue training exercises was developed, conducted and evaluated by the National Institute for Occupational Safety and Health (NIOSH) in cooperation with the Pennsylvania Department of Environmental Protection, Bureau of Deep Mine Safety. The exercises were conducted at NIOSH’s Lake Lynn Laboratory during 1995 to 1998 and resulted in improved technology and training for mine rescue teams. For example, existing technologies were identified to help rescue teams during exploration. These included chemical light sticks to identify team members and mark crosscuts and mine materials, strobe lights for mapping out escape ways, and a helmet mounted thermal imaging system to see through smoke. A hands-free communication system showed potential for enhanced communications between team members and the fresh air base. A new high-visibility team lifeline that allows for flexibility of movement between team members was developed. A positive-pressure inflatable escape device (IED) was used to isolate the “hazardous” environment from fresh air and allow rescue team members to traverse through. An inflatable feed-tube partition that can rapidly block large openings such as underground passageways and simultaneously provide a feed-tube for high-expansion foam generators was also deployed for several simulations. During the simulations, mine rescue team members donned self-contained breathing apparatuses (SCBA) and traversed more than 305-m of mine passageways filled with nontoxic smoke. Visibility ranged from 0.3 to 0.9-m. In one area of the mine, a kerosene heater was used to simulate a fire and reduce the oxygen concentration. In another area, a 1.5 pct methane zone was established. The team members searched for "victims,” mapped the passageways, built temporary stoppings and ventilated the smoke-filled entries. The teams indicated that the simulations were challenging and very informative.

By H. D. Outmans

The paper presents a theoretical approach to the drilling problem based on rock mechanics and drilling fluid hydraulics at the bottom of the hole. The volume of the fractured rock around the vevtically penetrating bit tooth is expressed as a function of the tooth pressure, included tooth angle, drilling fluid pressure and formation characteristics on the assumption that fracturing is preceded by plastic flow. This assumption is verified by comparing the stress-strain state in the rock around the tooth to that in equivalent tri-axial compression tests described in the literature. An expression similar to the above is derived for the tooth penetration in the cuttings which have been retrained at the bottom. Combination of these two expressions leads to a relation between depth of tooth penetration in the virgin rock, the amount of cuttings retained and the other variables. By relating the cutting volume to the drilling rate, the hydraulic bit horsepower and the drilling fluid pressure, it is possible to arrive at formulas which express the drilling rate for viscous or turbulent flow at the cutting surface, for instant clearance, for retained cuttings, or for false tooth foundering as functions of such variables as the drilling fluid pressure, hydraulic horsepower at the bit, rotary speed and bit weight. Plotting the results as drilling curves and comparing them to published field and laboratory data justify the conclusion that the drilling model presented in this paper approximates the actual mechanism. The drilling curves serve to explain some characteristic features of the rotary drilling operation, and the equations may be used for numerical evaluation of the effect of changes in the magnitude of some of the variables on the drilling rate. INTRODUCTION Published laboratory data have established that consistent and relatively simple relations exist between the drilling rate and any one of the important variables. For instance, the drilling rate usually increases at an increasing rate with the bit weight. It increases at a decreasing rate with the rotary speed, decreases at a decreasing rate with increased drilling fluid pressure and plots as an S-shaped curve against the hydraulic horsepower at the bit. This relative simplicity seems difficult to understand considering that the drilling mechanism is a continuous process of generation and removal of innumerable individual cuttings, under different conditions for each. On the other hand, the drilling rate (although determined by this complicated process) only expresses the average rate at which cuttings are produced and cleared away. Ignorance of the drilling mechanism as far as individual cuttings are concerned, therefore, does not exclude the possibility of arriving at a concept of the drilling rate provided the mechanism is properly evaluated for the average cutting. It then may be concluded from the first sentence that this concept also should be rather simple in its final form, although not necessarily in its derivation. Two aspects of the drilling mechanism are difficult to evaluate — (1) the effect a penetrating drilling fluid has on the stresses around a bit tooth entering the formation and (2) the volume of rock fractured by a penetrating tooth which moves both vertically and horizontally. Thus, the scope of this paper has been limited to an evaluation of the drilling mechanism in formations which have a low permeability and are drilled with hard-formation bits. In the following sections, the drilling mechanism is analyzed in three steps. First, the effect of tooth pressure on the volume of fractured rock around the tooth is evaluated, assuming initially that the bottom of the hole is free of cuttings and, then, determining the effect of a layer of these cuttings. In the second section, the thickness of this layer is related to the drilling rate and the chip clearance time, and the latter to the hydraulic horsepower at the bit under conditions of laminar and viscous flow at the cutting surface. In the third section. the previous results are combined with the rotary speed into drilling equations which are then plotted and compared to experimental drilling curves. This section also contains some numerical examples of drilling rate computations. Some mathematical details are given in the appendixes. Finally, it should be mentioned that, although some drilling equations are already available, these equations (with the exception of one' which attempts to relate drilling rate to drilling fluid pressure) are all mathematical expressions for observed laboratory data; none considers the effect of delayed drill-cutting removal, an essential feature of the drilling mechanism.

By A. B. Kinzel

Since the exposition of the behavior of certain iron alloys by Sykesl involving the existence of an austenite loop and the discovery of such a loop in the chrome-iron system by Bain,2 there has been much conjecture both on his part and on the part of metallurgists in general as to the exact shape and location of this loop. In previous work commercial steel has been used and the microscope has been employed to locate the critical points so that the position of the loop has been quite approximate. Numerous attempts have been made to measure the critical points of the carbon-free alloys but all of these for one reason or another have failed. A satisfactory method for studying these phenomena is presented here. MateRial The first difficulty in this study was to obtain pure chromium-iron alloys. This has been overcome by melting in a vacuum electrolytic iron and chromium analyzing 99.84 Cr, Fe and C. A pure magnesite crucible was used and the melt allowed to solidify in the crucible. A typical analysis is chromium, 10.10 per cent., carbon, 0.006 per cent., silicon and manganese nil. To overcome the problem presented by segregation, ingots were made into wire 0.04 in. in diameter. This was accomplished by hand-forging the ingots into rods, using an oxyhydrogen flame for heating, in order to avoid carbon. Subsequently the rods were swaged to wire, the heating being carried out in hydrogen. Thus local segregation was eliminated although differences in analysis between portions 50 ft. apart were noted. An electric-resistance method was first tried to determine the critical points, but due to the physical defects in the wire this failed. Bain had previously shown the presence or absence of critical points in a qualitative way by observing the sag in a catenary. The author has devised the following method which gives an accurate determination of the critical points from expansion-temperature curves of suspended wire, a special telescopic dilatometer being used for the purpose.

By R. E. Holmes, T. W. Leland

The solution to the unsteady-state mass- and heat-transfer equations describing the adsorption of a dilute component from a gas stream flowing through a packed bed is readily applicable to the design of hydrocarbon recovery units. The solution to these equations depends on the assumption of a linear equilibrium equation to relate concentrations on the surface to concentrations in the gas. This assumption is shown to be justifiable for components which are very dilute in the gas stream. This approach permits the prediction of the effects of bed shape and size, cycle time, and gas mass velocity on the recovery of each component. It also allows the time and gas flow rate needed for regeneration to be determined. The equations involve a constant for each component and another constant characterized by the type of adsorbent. These constants must be evaluated from operating data. Values of these constants determined for silica gel are presented. This paper points out the type of experitrrental data needed for a thorough design of hydrocarbon adsorption units. INTRODUCTION The growing importance of adsorption processes to recover hydrocarbons from natural-gas streams has created an urgent need for better methods to design and predict the performance of these processes. Since the original use of solid adsorbents in natural-gas processing was for dehydration, most of the current design methods for hydrocarbon recovery re extensions of those developed earlier for dehydration. These methods are based on an adsorptivity or bed loading factor defined as the amount of a particular component adsorbed per unit weight or per unit volume of the packed bed. The recovery of a given component is then expressed as an empirical function of its adsorptivity on a given adsorbent. In spite of the simplicity and initial utility of these methods, they are not completely satisfactory in that they do not predict the effect of the dimensions of the bed in relation to flow rate and cycle time, and do not predict the distribution of various components along the length of the bed. It is possible, however, to make a considerable improvement in the design of these processes by applying the basic equations of mass and heat transfer applicable to gases containing small concentrations of adsorbing components flowing through granular beds. These equations have been developed and solved by Anzelius,' Furnas,% nd Hougen and Marshall." where G = mass velocity of the inert constituents (assumed to be methane), lb/hr-sq ft, y = weight of an adsorbing component in the gas per unit weight of inert, lb of a given constituent per lb of methane, x = bed length, ft, p, = packed bed density, lb/cu ft, P, = gas density, Ib/cu ft, f = void fraction in the bed, t = time, hours, and w = weight of a given component adsorbed per unit weight of adsorbate free solid, Ib/lb pure adsorbent. The term on the left side of Eq. 1 represents the flow rate per unit bed volume of a component entering less the flow rate per unit bed volume of that component leaving the differential bed length. The terms on the right side represent, respectively, the accumulation rates per unit bed volume on the solid and in the gas phase within the differential bed section. The last term is negligible for this application since pgfv is quite small in comparison with p, and G. The partial differential is determined by the mass-transfer rate between gas and solid in the differential section.

By J. L. Fitch, B. G. Hurd

The presence of gypsum in samples subjected to standard core analysis introduces serious errors in the measurement of water saturation and porosity. The magnitude of these errors, depending upon the type of analysis procedure used, has been evaluated experimentally and theoretically. Water-saturated pore volumes determined by vacuum distillation or retort procedures may be too high by as much as 48 per cent of the volume of gypsum present. The maximum error in this value determined by Dean-Stark extraction with toluene is 36 per cent of the gypsum volume. If pore space is measured by a Boyle's law type porosimeter the maximum erorr due to gypsum is 38 per cent of the original gypsum volume present. The conscientious core analyst may eliminate the errors caused by gypsum by either of two methods. He may apply suitable corrections for the water of crystallization removed from gypsum, or take special precautions to prevent dehydration of gypsum during core cleaning and alzalysis procedures. These alternatives are discussed and methods for obtaining reliable core analysis data are proposed. Gypsum (CaSO4 . 2H2O) occurs as a common mineral in many of the world's sedimentary basins. In addition to its presence as primary bedded evaporitic deposits, it is often found as secondary replacement zones and pore-fillings in host rocks. That it may cause false indications in porosity, both on neutron logs and in standard core analysis, has been generally recognized. False porosity interpretations from neutron logs result because the chemically bound water in gypsum attenuates neutrons as effectively as free water. Errors in core analysis result when gypsum is dehydrated prior to or during the analysis. Vacuum retort procedures used by many laboratories to determine fluid saturation and porosity effect a complete removal of water of crystallization from gypsum. The crystal water, distilled and collected with free water from the sample, is counted as water-sat11rated pore space. Dehydration of gypsum results in a decrease in volume occupied by calcium sulfate and a corresponding increase in pore volume. Thus, if gypsum is dehydrated by sample cleaning and drying procedures, subsequent porosity measurements with gas expansion or compression instruments will be high. The qualitative effect of gypsum on porosity determinations by retort procedures was discussed in a recent article by Bynum and Koepl3. They concluded that since false porosity was interpreted as being water saturated, determinations of oil content were not affected. Others in the industry, however, have pointed out that porosity values are often used with values of water saturation determined independently, e.g., from electric resistivity logs in making reserve estimates. Values of water saturation calculated from the formation resistivity using the Archie equation, S4= are actually low if values of are high due to gypsum. In this case, false porosity values due to gypsum could cause serious errors in calculations of oil-in-place. This investigation was made to determine quantitatively the effect of gypsum on porosity values determined by different core analysis procedures. EXPERIMENTAL PROCEDURES Dehydration of Gypsum The extent and rate of removal of water of crystallization from gypsum under conditions encountered in core analysis procedures were studied. Taken for the experiments were three types of relatively pure, naturally occurring gypsum, viz. selenite, satin spar and massive gypsum. Although all samples probably contained trace chemical impurities, each type lost the theoretical amount of water upon complete dehydration. An automatic recording thermobalance, similar to one described by Mauer2, was used to obtain dehydration rate data for samples heated in dry air. Water

By Timothy P. Smirnoff

Sustaining the region?s mobility needs, achieving projected economic growth, and maintain Midtown Manhattan as a center of regional, national and global importance has led to continued investment in commuter rail and transit infrastructure in New York City and resulted in design and construction of large underground caverns. The current plans for stations in Manhattan include New York Penn Station Expansion (NYPSE) caverns for Trans Hudson Express (THE) Tunnel Project for New Jersey Transit (NJ Transit) and the Port Authority of New York and New Jersey (PANYNJ), Metropolitan Transportation Authority Capital Construction Long Island Railroad (MTACC/LIRR) twin caverns for East Side Access (ESA) Project, and station caverns of the No. 7 Line Subway Extension Project and Second Avenue Subway Project for Metropolitan Transportation Authority Capital Construction/New York City Transit (MTACC/NYCT). This paper provides a general overview of these large caverns now in design or construction in Manhattan, the area?s geologic setting, the geotechnical factors considered and approaches commonly applied for cavern design.

By R. E. Cook

This paper presents results of a study to determine to what extent errors in estimated free gas saturation affect the results of static pressure calculations from build-up curves in two-phase systems. Use is made of the method of pressure build-up curve analysis developed by Miller, Dyes and Hutchinson1 , with modifications for two-phase flow advanced by Perrine2. Cornhined fluid compressibility of gas-oil mixtures is included, with special attention given to the discontinuity that occurs in fluid compressibility at the saturation pressure and its effect on static pressure calculations from build-up curves. The sensitivity of static pressure calculations to errors in gas saturation is considered over wide ranges of formation and fluid properties and reservoir pressure conditions. It is concluded from this study that for analyses of two-phase pressure build-up curves (I) the use of under-saturated crude compressibility data, even when producing GOR's are at or near solution values, will result in very significant negative errors in calculated static pressrrre, and (2) except for large values of buildup curve .slope and/or very low crude gravities, rather large errors in calculated gas saturation can he tolerated without .significant effect on calculated static pressures. The conc1usions arc qualified as referring only to the effects of gas saturation and excludc possible errors in the nuumerous other factors that enter into the ancllysis of pressure build-up curves. INTRODUCTION As part of the analysis of basic data for several major Eocene reservoirs in the Bolivar Coastal field (Western Venezuela), it was necessary to analyze a large number of pressure build-up curves for oil permeability and static reservoir pressure. From performance data it became apparent that gravity segregation is very active in these reservoirs. As a result of this performance it was recognized that the free gas saturation within the oil leg of the reservoirs would be small but would be subject to certain errors in calculation due to the inaccuracy of relative permeability data in the low gas saturation region. Since all of the various methods of build-up curve analysis were originally derived for sin- gle-phase, constant compressibility systems, and since the presence of a small but rather indeterminate gas saturation would greatly affect the reservoir fluid compressibility, a study was undertaken to investigate the effect of gas saturation on the results of two-phase pressure build-up analyses. TWO-PHASE BUILD-UP CURVE ANALYSIS The method of analysis used in this investigation is basically that originally developed by Miller, Dyes and Hutchinson1, with modifications for two-phase flow advanced by Perrine2. Miller, et al, showed that the original equation for single-phase permeability away from the well bore, held for two-phase flow except that the calculated permeability is the effective permeability to oil away from the wellbore. This finding was acknowledged by Per-rine, who also presented the equation for effective gas permeability* as Since Eqs. 1 and 2 contain no terms influenced by fluid compressibility, no distinct problem should develop in calculating permeability from two-phase build-up curves. In regard to the calculation of static reservoir pressure from build-up curves in single-phase systems, the modified Miller, et al, method as presented by Perrine is briefly as follows. 1. From build-up curve data, PVT data for the reservoir fluid and the well spacing and sand thickness, calculate the climensionless shut-in time corresponding to the highest value of actual shut-in time (t, hrs) on the straight-line portion of a semi-log build-up curve. Dimenrsionless shut-in time is related to actual shut-in time by the relation, t- 0.000264 kt 2. From a graph of dimension less shut-in time vs dimensionless pressure difference (Fig. 1 1 ) find the value of dimensionless pressure difference corresponding to the value of 7 calculated under (1) above. Dimen-

By M. D. Arnold, P. B. Crawford, P. C. Hall

An experimental study has been made to determine the optimum flooding pressures for four different oils. The oil formation volume factors ranged from 1.08 to 2.13, and solution gas-oil ratios ranged from about 200 cu ft/bbl to 2,250 cu ft/bbl. Viscosities ranged from 0.38 to 0.95 cp at the respective bubble points of the fluids and from 0.7 to 20 cp at atmospheric pressure. Water floods were conducted at various pressure levels from run to run. The recovery as a function of flooding pressure was found to be different for each fluid, with optimum gas saturations ranging from 7 up to 35 per cent. The data indicate that substantially higher recoveries may be obtained if water floods are conducted at an optimum pressure and that this optimum pressure is a function of fluid properties. The same core was used for all tests, and the reproduction of saturations for various runs indicates that wettability in the predominantly water-wet core did not change. INTRODUCTION A paper was presented by Bass and Crawford' which described an experimental study of the effects of flooding pressure and rate on oil recovery by water flooding. This work was conducted using high-pressure models operated in a manner similar to that of an actual reservoir, with gas saturations being obtained by a solution-gas-drive mechanism. They found that the greatest oil recovery was obtained for the system studied by flooding in the presence of a 5 to 7 per cent gas saturation. Another experimental study simulating field conditions was presented by Richardson and Perkins.' They used an unconsolidated sand pack containing kerosene-natural gas fluid and interstitial water. They flooded at various pressures and flooding rates. For their system it was found that the recovery was independent of the pressure level at which the water flood was performed. Kyte, et al," found that oil recovery by water flooding was increased as the free gas saturation at waterflood initiation was increased. However, after the initial gas saturation was increased above 15 per cent, the increase in oil recovery tended to level off. All of their runs were made at the same pressure using a light oil saturated with helium. The desired gas saturation was obtained by injecting helium into the core. Dyes' made calculations which showed that an optimum gas saturation of 12 to 14 per cent may result in an increase in oil recovery of 7 to 12 per cent over that obtained by flooding at the bubble-point pressure. Others have also found that the presence of a free gas saturation may increase the waterflood oil recovery. In each case shrinkage was small and changes in fluid properties with respect to pressure were small. A careful review of the literature reveals that at the present time there is a wide difference of opinion on the factors affecting waterflood recoveries. This diversity of opinion is probably due to the fact that very little research has been done which has taken into account the many variables existing in an actual field being water flooded. Since the literature contains little information on high-pressure waterflooding studies using various types of reservoir fluids, it was believed appropriate that such a study should be made. EQUIPMENT AND PROCEDURE All tests were made using the same consolidated sandstone core. Torpedo sandstone was used to turn a cylindrical core 13.5-in. long and with a 2.92-in. average diameter. The core had a porosity of 28 per cent and a permeability to brine of 146 md. This brine was made up by adding 20,000-ppm sodium chloride and 30,000-ppm sodium nitrite to distilled water. This was used as connate water and flooding water. No fresh water was ever brought in contact with the core, as tests showed the sandstone contained argillaceous material which swelled in the presence of fresh water and plugged the stone. The core was sealed in a section of 6-in. N-80 tubing with Woods metal filling the annulus. The core was mounted horizontally; an injection well was placed in the center of one end and a production well in the center of the other. Pressure control was maintained by placing a back-pressure regulator (upstream control) on the producing well. The "live" oil was stored in a separate bottle and water was injected into this bottle to displace the oil for saturating the core using a two-cylinder standard-proportioning pump. This same pump was used for water flooding the core at a constant rate. This system was enclosed in water jackets and the temperature was automatically main-

By D. R. Wieland, H. T. Kennedy

The object of the work reported here was to determine the content of elemental sulfur in gaseous methane, carbon dioxide, hydrogen sulfide, and in mixtures of these gases, at pressures and temperatwes encountered in natural gas reservoirs. Sulfur content at equilibrium is reported for pure methane, carbon dioxide, hydrogen sulfide, and on three binary mixtures of each of the three pairs of gases at pressures of 1,000, 2,000, 3,000, 4,000, 5,000 and 6,000 psia and at temperatures of 150°, 200° and 250°F. In addition, the sulfur content of three ternary mixtures at the same temperatures and pressures are reported. The results indicate that the sulfur content is higher in the gases at higher temperatures and pressures. The content is highest in hydrogen sulfide, intermediate in carbon dioxide and lowest in methane. INTRODUCTION At ordinary pressures and temperatures, the concentration of a nonvolatile material, such as sulfur in a gas at equilibrium, is a function of the vapor pressure of the material and is independent of the nature of the gas. As the pressure and temperature increase, the gas assumes some of the properties of liquids, including the power to dissolve other liquids and solids, to an extent dependent on the nature of both the gas and the material dissolved. At equilibrium, the content of sulfur in the several gases considered here may thus be considered as solubilities which are fixed for a given composition of gas, temperature and pressure. The study of the solubility of elemental sulfur in gases is of interest because sulfur is sometimes present in reservoirs producing natural gas and must be present in the vapor phase. Upon reduction of pressure and temperature, the sulfur precipitates from solution in the reservoir and in the tubing and fittings. Due to the fact that the greatest pressure drop in the reservoir is around the wellbore, the volume of sulfur precipitated will be greatest in this locality and can cause a substantial reduction in the permeability of the formation in this area. As the natural gas flows up the tubing string, the pressure and temperature are further decreased, causing further sulfur precipitation. If the volume of free sulfur is large and remedial measures are not taken, complete plugging of the tubing can occur. Knowledge of the content of sulfur as a function of composition, temperature and pressure will enable the operator to determine what changes in pressure and/or temperature are necessary to keep the sulfur in solution. If the sulfur solubility is large and can be controlled, the operator may desire to produce the well at a high wellhead pressure and temperature and reclaim the sulfur at the surface. The high solubility of sulfur in hydrogen sulfide (5.6 per cent by weight at 5,000 psi and 200°F) suggests the feasibility of recovering sulfur by injecting this gas into sulfur-bearing reservoirs and expanding the produced gas to precipitate out the sulfur. The present project was designed to measure the solubility of sulfur in carbon dioxide, methane, hydrogen sulfide and mixtures of these three gases at various temperatures and pressures. These gases were the major constituents of the gas well where plugging by sulfur was encountered. A study of the published literature shows no data on the solubility of sulfur in any gas, although Hannay and Hogarth,' in 1880 reported that it was soluble in carbon disdlide above the critical temperature of carbon disulfide. EQUIPMENT AND PROCEDURE Fig. 1 shows the layout of equipment employed to bring gases to equilibrium with sulfur and to isolate the quantity of sulfur contained in a known volume of gas. Pure gases were measured in the charging bomb at known temperatures and pressures and displaced into the reservoir bomb to make up the desired mixtures. When equilibrium was achieved

By William Reininger

Microtunneling provides a necessary solution for multiple utility crossings associated with the New York Metropolitan Transportation Authority Capital Construction Company?s (MTACC) Eastside Access Project for the Long Island Rail Road. Construction of four TBM tunnels and their approach structures at the eastern end of the project in Sunnyside, Queens required significant modification and expansion of the railroad infrastructure at this location. Maintenance of railroad traffic during project construction is a principal requirement. As a consequence fourteen (14) utility crossing segments are being installed under active traffic by microtunneling methods. Microtunnels were installed in a variety of conditions including depths, types of soils and construction restraints.

By L. T. Stanley

A method is described whereby the behavior of the front is approximated when gas is injected into a thick reservoir having reasonably homogeneous properties. The method is applied to the Abqaiq field of Saudi Arabia. The producing member is the Arab-D, a high-permeability calcarenite which has no continuous betlding planes. Field performance indicates the injected gas to be partially miscible with the reservoir oil because gas volume factors experienced are lower than those predicted by the gas law. Eqlrilibril~m calculations confirnz ihis and also show that the volume factor may vary appreciably, depending on the relative quantities of oil and gas in contact in the reservoir; consequently, volutnetric balances are made for the purpose of determining the behavior of the gas volume factor during injection history. The effect of gravity segregation on position and shape of the gas front is approximated by dividing the producing section into three zones vertically and tracing the movement of the average interface in each zone, with counterflow of oil and gas taking place betweell zones behind the front. This results in a gas front that advances more rapidly along the top of [he formation than along the base, producing an "umbrella" effect in cross section that becomes more pronounced as the front progresses. The calculations cover the gas-injection period of Abqaiq field history through 1958, and the position of the gas front is plotted at one-year intervals. Finally, some comparisotls between the calcrlated fronial position and the gas-oil contact as Measured by neutron logs are made. INTRODUCTION Fig. 1 is a structure contour map of the Abqaiq field. For analytical purpcses, the field has been divided into two areas designated A and B, as shown on the map. Gas injection into Area A was begun in early 1954 into two wells located near the crest of the structure on the north-south axis of the anticline. During the period covered by this paper, the average injection rate has been 122 MMscf/D with a maximum sustained rate of 160 MMscf/D. The reservoir pressure has been maintained at 2,450 psig since start of gas injection. The reservoir originally was undersaturated but, prior to pressure maintenance, the pressure was drawn below the bubble point in most of the Area A section, creating an in-place free-gas saturation of 8 per cent at the crest of the structure. The average critical gas saturation is 13 per cent established by laboratcry core tests. That the entire reservoir remained below critical gas saturation prior to gas injection is borne out by the fact that none of the crestal wells have exhibited high gas-oil ratios during production history. The Area A reservoir is a carbonate section about 200-ft thick having average porosity and permeability of the order of 22 per cent and 500 md, respectively. The productive horizon is the Arab-D member of Jurassic age and is encountered at an average depth of