Search Documents

By W. D. Haselton

This paper dealing with the mining methods used in producing iron ore from an underground operation located in the central-western part of the Mesabi Range in Minnesota is one of a series being prepared by the Bureau of Mines on mining practices, methods, and costs in the various mining districts in the United States. The mine here discussed was laid out in accordance with a plan adapted to a rather unusual type of ore body, the nature of which is such that the mining method necessarily differs in certain respects from the method used at most of the mines in this district. A description of it may therefore be of interest.

Jan 1, 1930

By Ionel I. Gardescu

Natural gas influences the movement of oil through reservoir rock by affecting the physical properties of the oil and the pressure within the reservoir. The presence of gas bubbles changes the laws of flow and the distribution of forces. The problem of flow of oil and gas through a porous rock is complex, and most authors, in order to analyze their problems, have found it necessary to make or accept certain generalized assumptions. Some of these assumptions, particularly the ones dealing with capillary phenomena and moleculnr forces, have not received sufficient attention and by lack of understanding have often been misinterpreted. Herold1 has called attention to the resistance offered by gas bubbles in capillary spaces and has drawn some interesting conclusions with regard to the action of natural gas in a reservoir rock. He has duplicated an experiment of the French physicist Jamin, has interpreted his findings in terms of molar mechanics, and, from experimental observations, has made a number of assumptions which he later applies in discussing problems of natural flow and recovery of oil. The Jamin action is an assumption because it lacks a physical proof and has never been determined quantitatively. Tickel12 attempts to develop a formula expressing the work performed by a distorted bubble. H. A. Wilson, in the recent publication of the American Petroleum Institute on the function of natural gas, discusses the phenomenon in terms of classical physics. Both contributions are incomplete and offer no experimental data. This paper includes a study of the static condition of equilibrium of gas and liquid bubbles confined to capillary spaces. In order to avoid any possible confusion, it is proposed to restrict the term "Jamin action"

Jan 1, 1930

IN this paper the author's intention is to convey a brief resume of the lead flotation treatment and lead flotation machines, which have replaced the May jigs and Wilfley tables at the plant of the North Broken Hill Ltd., and converted this mill into an all-flotation plant.Attention is directed to the fact that this drastic change from semi-gravity to all-flotation treatment, has been successfully accomplished without resorting to finer grinding than that previously in vogue for Wilfley table concentration, viz.: 10% to 16% plus 40-mesh I.M.M. screen.From the figures now available it is manifest that the scheme of all-flotation concentration-new as regards its successful application to Broken Hill ores is resulting in considerably higher-grade lead concentrates, and is substantially decreasing charges for labour, stores, and maintenance.The new treatment is far-reaching in its simplification of plant, as evidenced by the idle jigs and tables, and the results being obtained by North Broken Hill Ltd. may possibly influence metallurgical practice generally in Broken Hill.The outstanding features of the treatment are:(1) The coarseness, and high grade of lead concentrates obtainable.(2) The low time factor required for flotation.(3) The plant capacity, and the simplicity of its operation.(4) The low horse-power consumption.(5) The small cost for reagents used (not exceeding 3d. per ton of ore).

Jan 1, 1930

By H. T. Matson

IN the Northern Rhodesia copper fields the size of the orebodies and the exceptionally consistent values over great distances made it possible to outline the ore with drill holes spaced at 1000-ft. intervals; in some cases, 2000-ft. intervals.. Owing to the fact that the size of the deposits made it very evident that much outside capital would have to be called in to develop them and, owing to the wide spacing of the holes, it was essential that the sampling of drill holes be as accurate as possible, so that outside examining engineers could adopt the results as trustworthy within the limits of accuracy of the drilling method. With this object in view, the field staffs of the Selection Trust group of companies have studied for the past three years, and are still studying, drill sampling in a very thorough manner, and for this reason it is felt that these notes may be of interest to engineers or students who are, or in the future may be, in charge of drilling operations. The orebodies in this field lie in shales and sandstones, more or less indurated, in the lower strata of the Roan series, and the copper mineralization is in the form of sulfides predominantly, with some oxidized copper minerals. Those interested in the geology and history of the area can find full details in a recent paper by Anton Gray and Russell J. Parker.1

Jan 1, 1930

By Robert E. Palmer

The Hawkesworth detachable drill steel shank and bit were invented by A. L. Hawkesworth, while he was a mechanical foreman for the Anaconda Copper Mining Co., at Butte, Mont. Mr. Hawkesworth died on June 16, 1925, at the time that his invention was practically a proved success. The first application for patents was made by him in November, 1918, and the bit is now being manufactured under patents issued in 1922 and 1923. The credit for its development in the early stages belongs to A. L. Hawkesworth, Roy S. Alley, Harry A. Gallwey, E. J. Bowman and various officials of the Anaconda Copper Mining Co. Later improvements, manufacturing problems and the direct usage in the mines were originated and perfected by the mechanical department under C. D. Woodward, E. R. Borcherdt, head of the Rock Drill Equipment Department, Robert E. Kelly of the Mechanical Department, and various operating department heads of the Anaconda Copper Mining Co. The author wishes to acknowledge the assistance of these officials in the preparation of this paper. Comparison of Costs Using Regular Drill Steel and Detachable Drill Steel In 1922 production was satisfactory and sufficient enough to warrant a complete installation in an operating mine. The study and tests were made at the Badger State mine, the production of which averaged 1200 tons of ore per day. E. R. Borcherdt, head of the rock drill equipment department, was in direct charge of the trials, installation, operating problems and records during the entire .period, arid still continues in that position. This mine is a typical Butte mine, operated through a standard four-compartment shaft, served by a double drum hoist and an auxiliary hoist. The texture of the ground and ore has all the variations from soft to very hard granite and sulfide ore with production from levels between the

Jan 1, 1930

By F. W. Bremmer

The experiments described in this paper constitute the preliminary work of an investigation outlined to determine the combined effects of steam and temperature on the endurance properties of certain steels. Essentially of a fundamental nature, it was found necessary, in order to make the investigation comprehensive, to test materials treated to give a wide range of properties. The work reported deals chiefly with nickel steel with one series of tests including nitriding steel. Such a study involves numerous variables, and requires an endurance-testing machine of rather special design. Testing Machines The testing machines used were designed by C. E. Weaver;l they are a modification of the White-Souther and McAdam types. Each was driven directly by an individual 1/2-hp. 115-volt direct-current motor, running at a speed of 2200 r.p.m. Fig. 1 shows the assembly drawing and Fig. 2, a photograph of one of the machines. Specimen B is held by the rotating specimen holder A inside the steam box F, which is closed at the top by a tight-fitting, elliptical cover G. The load is applied to the specimen through the rod D and bearing C. E is an oil pipe leading fromthe lubrication system to the bearing C. The steam, which comes from the power house, is admitted through an inlet (not shown in Fig. 1) at the side of the box, the drain being at the bottom. Steam packings were placed around the rod D and the rotating shaft at H, from which the water was drained by means of a vacuum, which usually showed a gage reading of about 10 in. The temperature was measured by a mercury thermometer, and the pressure by a steam gage. Method of Applying Load After the motor has been started and the specimen as a consequence put in rotation, the load is applied by placing the foot pedal A (Fig. 2) in contact with electromagnet B, the winding of which is connected electrically in series with the motor. This operation releases the support under the weights that constitute the load. By this means the load

Jan 1, 1930

By D. B. McGilvra

This paper, describing the mining practices and methods at the Black Rock mine, is one of a series of similar papers on mining methods in the various mines of the United States being prepared by the Bureau of Mines. The Black Rock mine is located in the northeast corner of the Butte district, about 3 miles from the center of the town of Butte, and is owned and operated by the Butte & Superior Mining Co.

Jan 1, 1930

By J. Walter Scott

IT is usual practice in the copper industry to use open horizontal molds for casting tough-pitch copper wire bars.1 A wire bar cast in this manner is partly characterized, by heavy wrinkles and a comparatively deep skin of oxide on the top of the bar, corresponding to the open side of the mold. On the theory that the rough, high-oxide surface might have an adverse effect on the rolling and drawing properties of a wire bar and might account for some of the irregularities of mill behavior, several bars which had been planed to remove the wrinkled surface were processed into wire. These bars responded to mill treatment more satisfactorily than did the regular wire bars. Realizing that machining the surface of one face of each bar would not be commercially feasible, it was decided that casting the metal into a vertical mold and cropping off the pouring end would accomplish. approximately the same result. Several wire bars of commercial size (250 lb.) were so cast and processed into wire for comparative test with bars cast in the usual horizontal molds. It is the purpose of this paper to present the results obtained from this investigation, in which commercial bar sizes and processing technique were used throughout. The results show that in general copper wire bars cast vertically are superior to those cast horizontally.

Jan 1, 1930

By C. P. Crawford

In the current issue of Link-Belt News is this quotation: "Advancing waves of other people's progress sweep over the unchanging man and wash him out." As we look over the industrial world today we are struck by the many waves which are sweeping over backward industries. Mergers are being consummated in all lines of endeavor. General Motors are making radios and the Bendix Brake Company are making airplanes. Railroads which twenty years ago were called to account by the Federal Government for their efforts to form combinations are today being ordered to combine. But what is of immediate concern to the coal industry is the fact that there is now in existence or in project a total of 3,641 miles of pipe lines to carry natural gas to most of the country's industrial centers. This is the wave of progress which is sweeping toward you and me. If we are to grasp the significance of these many changes, we must widen our vision so that we may learn some- thing from 'the other fellow's experience. The first lesson is that cost of production alone is not a measure of profit. It is an interesting fact that the production of an article represents a definite loss until that article has been sold for a price in excess of its total cost, and the money is in the hands of the producer. If this is true, then the selling price is more important than the production cost.

Jan 1, 1930

By O. C. Ralston

Flotation is now commonly practiced in alkaline ore pulps, yet little is known regarding the action of the alkaline solutions on the ore particles beyond the fact that films of oxidized material form. We wish to chronicle our discovery of the presence of soluble reducing agents in alkaline ore pulps of the United Verde, and present some data on lime consumption. During the grinding and flotation of a pyritic ore containing small amounts of ferrous sulfate and other soluble salts, an excess of lime was added to precipitate the salts, and filtered samples of the solution were titrated with standard permanganate solution. Even in pulps of high causticity an appreciable permanganate titration was always obtained, in spite of the fact that the solutions were shown to contain little iron. Investigation of the cause brought about the discovery of several previously unsuspected compounds in flotation pulps made from pyritic ore. Not only the reducing agents present had to be identified, but also the amount of dissolved oxygen, and a survey was finally made of the free oxygen content and reducing agents of the mill pulp in the concentrating mill at Clarkdale. A great many compounds might form, caused by oxidation of pyrite or other metal sulfides or by reaction between a lime solution and pyrite. The most probable compounds considered were calcium sulfides, polysul-fides, thiosulfates, and polythionates. Later it was discovered in the literature that in alkaline pulp polythionates do not exist and if introduced are decomposed into sulfites and thiosu1fates.l Any precipitated sulfur is changed by alkali into thiosulfate and polysulfide. Sulfites and sulfides react to form thiosulfate, so that in the end it is possible to have in an alkaline solution only thiosulfate and an excess either of sulfide or sulfite. Confirmatory tests were made and it was finally established that the alkaline mill pulps made from the United Verde ore contained

Jan 1, 1930

By G. S. Rice

[This paper describes preliminary tests at the Bureau's Experimental Mine to determine, under conditions that may prevail ira bituminous coal-mine heading, how small a quantity of fire damp may bring coal-dust into suspension and ignite to it. The results show that the explosion of as little as 150 cubic feet of an explosive mixture of gas and air containing 9 per cent natural gas may start a disastrous explosion Of coal-dust. This is a very small volume, of gas, to cause such a result. Let us suppose that this amount of exclusive mixture, was at the face of an entry which was 10 feet wide and the face was overcut to a depth of 6 foot and an upper layer of coal 2 1/2 feet thick had been removed, the recess so made would save a volume of 150 cubic feet. Furthermore, only 13 cubic feet of pure methane is needed in this volume to produce this 9 per cent explosive mixture.]

Jan 1, 1930

By C. E. Wood, E. P. Barrett, T. L. Joseph

The United States Bureau of Mines has been studying the blastfurnace process for about ten years. An experimental furnace was developed by the Burcau in cooperation with the Minnesota School of Mines Experiment Station, University of Minnesota. Many data have been obtained and published.' Royster, Joseph and Kinney §(48) found that the particle size of ore had an important effect upon the blast-furnace process. Kinne(28) stated: Economy in blast-furnace practice depends largely upon efficient gas-solid contact in the shaft of the furnace. If efficient work is not done in the shaft, the hearth and bosh will not function properly. A condition may be readily imagined where the particles of ore in the shaft are so large that the time entailed in the descent of these materials into the bosh is not sufficient to permit proper reduction and preparation prior to the time the ore enters the bosh of the furnace. Another condition may be pictured where the density of theatock column and the flow of stock is such that the ore will take one course and the gas another. Both of these examples will result in insufficient contact between the gas and the ore. Unreduced ore will reach the hearth, and the gas which has not been efficiently oxidized will reach the stock line. The result is the use of an excess of carbon in the smelting process. It is obvious that fine ore particles occurring in the ore as charged, or formed in the furnace due to heat and mechanical action, place a definite limitation upon the efficiency of the operation. There is also an economic loss of fine material as dust. Effect of Size of Material Kinney reported (p. 83(29)) the reduction of iron oxides between planes at three furnaces as given in Table 1. The Chicago furnace was operated on Lake ores. Distribution of gas was not good and much of the charge passed into the hearth before the iron oxide was reduced. The Holt furnace was operated on coarse ore. Distribution of gas was fairly uni-

Jan 1, 1930

By H. J. Rose

In a paper1 presented before this Institute in 1926,I briefly discussed the evaluation of coking coals by means of ultimate analysis. The paper contained several graphic studies in which coal analyses calculated free of moisture, ash, sulfur and nitrogen were plotted on triaxial diagrams in which carbon + hydrogen + oxygen = 100 per cent. From a study of such data for 600 coking coals of the United States, and 150 coking coals of Wales, France and Germany, it was concluded that it was usually possible to predict coking properties and by-product yields with fair success from ultimate analysis. The coals which have proved exceptions to the general rules were found to have physical peculiarities. Run-of-mine Coal It must not be forgotten that run-of-mine coal is a composite material consisting of many constituents differing in physical properties and chemical analysis. A coal sample usually contains: 1. Glossy black coal known as anthraxylon or vitrain. This constituent usually has the strongest coking properties, and the lowest ash content. 2. Dull black coal consisting of attritus containing thin layers of anthraxylon. It is also known as clarain. This constituent, in a coking coal, usually has good to excellent coking properties. 3. Mineral charcoal or fusain. This is a porous black material which is soft and crumbly (unless impregnated with mineral matter) and which has absolutely no coking properties. It is different in every respect from the other constituents in coal. The volatile matter content of mineral charcoal is less than 20 per cent. even when it is associated with high-volatile coals. As would be expected the hydrogen content is low, and the carbon content is high. 4. A coal sample may contain tough gray canneloid material which has a high-volatile matter and a high hydrogen content, but is poor in coking qualities.

Jan 1, 1930

By L. B. Berger

In this investigation, the ampoule type of carbon-monoxide (CO) detector which is manufactured under license of U. S. Patent 1,644,014 (October 4, 1927) was tested for sensitivity and reliability. This detector was devised primarily for examining the air of manholes and sewers for possible dangerous contamination with CO before workman enter those places, but dine to the simplicity of the device it may have a more general usage for examination of atmospheres which are known or suspected to be contaminated with CO. Some of the suggested uses are the examination of the air in garages, tunnels, mines, around blast furnaces, gas plants, and in the home.

Jan 1, 1930

By W. W. Adams

Reports received by the Bureau of Mines, Department of Commerce, from State mine inspectors, for November, 1930, showed that 219 men were killed in the coal mines of the United States during the month, an increase of 25 over the previous month and 33 over November, 1929. On the other hand the production of coal decreased, the output of 43,329,000 tons in November being 8,397,000 tons less than in October and 9,005,000 tone less than in November a year ago. The larger number of fatalities accompanied by a smaller output of coal resulted in a higher death rate4 per million tons in November than in the same month last year or in October, 1930. The November rate was 5.05, as compared with 3.55 for November, 1929 and 3.75 for October, 1930. The increase in the rate for the industry as a whole was chargeable entirely to bituminous mines, as the anthracite mines had fewer fatalities in November than in either of the previous months to which reference has been made. Reports for bituminous mines alone showed that accidents at this class of mines resulted in a death rate of 5.12, based on 195 fatalities and a production of 38,122,000 tons. This rate indicated an increase of 55 per cent over the rate for October, of the same year, and 72 per cent over the rate for November, 1929. The October record was 146 fatalities and 44,150,000 tons, and that for November a year ago was 138 deaths and a production of 46,514,000 tons.

Jan 1, 1930

By D. K. Crampton

INTERNAL stress and season cracking in brass have been studied for many years and the technical literature contains many data on various phases of the subject. A résumé of the literature shows certain fairly well established points upon which various authors are mostly agreed: 1. Season cracking is primarily caused by the presence of relatively high internal stresses, or possibly in some cases by external stresses, or both. 2. A specific corrosion is also essential to season cracking: Certain agents, particularly mercurous salts, mercuric salts and ammonia salts; have such a specific corrosive effect. 3. The tendency to season crack under given conditions increases with increasing zinc content, brass containing less than 20 per cent zinc being relatively immune. 4. In alpha brass the season cracks are intercrystalline; in alphabeta brass they lie between the two constituents; and in beta brass they are transcrystalline. 5. The ordinary impurities or added elements in special brasses have little or no effect on the tendency to season crack. 6. Internal stresses can be eliminated, or at least reduced to a safe 'limit by annealing treatments at temperatures that do not produce visible microstructural changes or appreciable softening of the worked brasses. There are, however, some points in connection with the phenomenon of season cracking which have not been thoroughly investigated, or wherein different authors and investigators are not entirely in agreement. The investigations described in this paper were undertaken to determine: 1. The correlation between mercurous nitrate tests and actual season cracking on long-time atmospheric exposure. 2. The quantitative effect of type and degree of drawing operations on the intensity of internal stress and on the tendency to season crack in brass tubes. 3. The possibility of drawing high-brass tubes in such a manner as to prevent the occurrence of harmful stresses rather than to find a remedy for such stresses once having obtained them.

Jan 1, 1930

By Stanley C. Herold

Only two years ago there appeared in our technical magazines articles wherein it was shown that the application of back-pressure increased the ultimate production of a well, that edge water can be stopped in its encroachment by the injection of gas into the productive formation, with the consequent conservation of energy within the pool, that gas is the source of all energy involved in oil production, and that each pool has a definite minimum-valued gas-oil ratio to be attained for the most economical operation of wells. Today we are not so certain of these matters. Probably in some fields, under special circumstances, these ideas are correct, but certainly they must not be correct in all fields, under any and all circumstances. The nature of the productive structure, the location of particular properties on the structure, the existence of adjoining neighbors, whether these are higher or lower on the structure, and the methods of production followed by all operators on the structure, sand for sand on depth, make these subjects worthy of full consideration. Our difficulties in analyzing and comparing the performance of reservoirs in various parts of the world do not rest solely upon structural features and property lines. We do not complete the list of causes for these difficulties if we add lithologic features and correlation of strata encountered by the drill, with the magnitude of pressures exerted by fluids within any of these strata. A further cause, one which the author believes will complete the list, is one involving the theoretical mechanics of fluids within porous formations—porous in the nature of interstices in sandstones and some limestones, networks of fractures in shales, and cavities in otherwise compact limestones. The confusion of ideas concerning reservoir mechanics still with us today seems largely due to our failure to recognize among all wells three great divisions of theoretical mechanics, three great systems which are distinct in themselves, and according to which each well, or better, each group of wells, must be analyzed separately. These systems have been named by the writer Hydraulic Control, Volumetric Control and Capillary Control, respectively.' Wells in these controls behave dif-

Jan 1, 1930

By Robert Mehl

THE importance of the Widmanstätten structure to structure theory in metallography has been recognized by many writers.1 It is a structure produced by the precipitation of a new phase from a solid solution upon cooling as a result of changing solid solubility, and displays a characteristic appearance indicating a crystallographic relationship between the new phase and the original solid solution (Fig. 1). First discovered in 1808 by Alois de Widmanstätten2, the structure has been traced by analogy through many alloy systems. Particularly is this true of the steels. Sorby's classic work3 on the microstructure of iron and steel was in essence an attempt to explain the origin of this characteristic structure in meteoric iron. He observed in a Bessemer steel and in a cast-steel ingot structures which we now recognize as typical Widmanstätten figures.4 Osmond5 observed structures in a steel ingot analogous to those found in meteorites. Arnold and McWilliams6 obtained (and recognized) a

Jan 1, 1930

By Albert J. Phillips

When brasses containing from 61 to 62.5 per cent. copper are very rapidly cooled from temperatures near their melting point to below 0" C., unusual results are obtained. These results are quite unexplainable from a consideration of the old copper-zinc constitutional diagram but they can be satisfactorily explained by means of the diagram revised by Genders and Bailey1 (Fig. 1). Experiments on a 60/40 Brass If an alloy containing 60 per cent. copper is heated to any temperature between approximately 760' C. and its melting point, it will consist entirely of beta. Upon slowly cooling, alpha will start to separate just below 760" C. Since this alpha will contain nearly 65 per cent, copper, the beta will be impoverished by its separation. As the temperature decreases the composition of the separating alpha will approach approximately 61 per cent. and the beta in contact with the alpha will maintain an equilibrium composition approaching 54.5 per cent. copper. If the rate of cooling is extremely slow, especially at the lower temperatures, stable equilibrium will be established by diffusion through the alpha and beta so that eventually 85 per cent. of the alloy will consist of alpha containing 61 per cent. copper, while 15 per cent. will be beta containing 54.5 per cent. copper. With a faster cooling rate diffusion cannot keep apace and the constituents will be cored, the alpha varying from 65 to 61 per cent. copper and the beta from 60 to 54.5 copper. In this case the amount of alpha will be less than 85 per cent. and the beta will be increased correspondingly. The general structure thus obtained is illustrated in Fig. 2. When a more rapid rate of cooling is effected by quenching in water, the alloy is retained largely in the beta form. However, the crystals of beta are usually outlined with dark fringes which at high magnifications are found to be very fine alpha-beta structures almost martensitic in appearance. The separation of this fringe can be greatly suppressed

Jan 1, 1930

By J. W. Bolton, S. A. Weigand

This paper discusses some fundamental metallurgical principles involved in production of sound cast bronze. In a previous paper the writers advanced the theory that "oxidation" in bronze castings is due to incipient shrinkage, and showed the effect of reducing melting atmospheres.' In the present paper the effects of certain impurities and of actual oxidizing conditions are shown. The appendix deals with the appearance of various inclusions. For many years the prevailing opinion has been that unsoundness, dark colored fractures and other phenomena accompanying porosity and weakness in bronzes are due to oxidation. The actual troubles are caused by fissures of intercrystalline type, which are often mistaken for intercrystalline films. These weaken the metal and make it porous. Grave doubt regarding the accuracy of the oxidation theory appears when several research papers presented within the last 10 years are reviewed critically. In 1919, Comstock2 conducted metallographic researches, attempting to identify "oxides" in synthetically prepared metals. He found that oxides of tin, aluminum, zinc, etc. are different from the intercrystalline films (or cavities) to which porosity is due. Apparently he believed that these "oxide films" may be caused by volatile oxides of zinc or of phosphorus or by dissolved gases thrown out of solution during solidification of the metal. In 1923, Woyski and Boeck3 definitely questioned the accuracy of the oxidation theory and indicated the danger from reducing atmospheres. They say that "oxidation, gassing and shrinkage may produce effects very similar." In 1926, investigations by Iwasé4 showed marked change in absorp-tion coefficients for various gases in copper above and below the liquidus.

Jan 1, 1930