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By Fitchett K

Refractory application in the major iron and steelmaking units are discussed. Mechanis- ms of refractory consumption as revealed by pre- vious studies are reviewed and current practice is evaluated. Deficiencies in refractories now in use are noted and some lines of development are indicated. The iron and steelmaking units discussed are generally restricted to those subject to slagging, structural change or erosion at steel or iron making temperatures, and include the Blast Furnace, Hot Blast Stoves, Hot Metal Ladles, Basic Oxygen Furnaces, Continuous Cast- ing Units and Steel Teeming Ladles.

Jan 1, 1972

By J. L. Huiatt

Kerosine, fuel oil No. 2, vapor oil, and fuel oil No. 6 were separated into general hydrocarbon fractions by ion exchange chromatography and adsorption chromatography. The collecting properties of these fractions were evaluated by flotation of molybdenum and copper minerals from a natural chalcopyrite ore. Paraffin fractions and aromatic fractions of low polarity produced the best molybdenum recoveries. Selective flotation of molybdenite from copper sulfide minerals was not possible with any of the chromatographic fractions.

Jan 1, 1972

By B. Ladanyi, B. Hoyaux

A first requirement for assessing the safety of a rock slope, either artificial or natural, particularly if the rock behaves in an elastic-brittle manner, is a propw knowledge of the distribution of stresses within the slope and their development with time and advancement of workings. There are a uumber of different methods that can be used, in principle, for obtaining this information, such as (1) stress measurement in situ, (2) photoelasticity,1 (3) analytical methods, and (4) numerical methods. In cases where the stress distribution cannot be obtained by classical analytical methods, as in the one considered herein, either photoelasticity or numerical methods are norrnally used. However, actually, due to the rapid development of high-speed computers, increasing preference is given to the numerical methods. Among the latter, the most successful ones, to date, for determining the stress distribution in slopes have been (1) the finite difference method,2-4 (2) the lumped parameter method,5 and (3) the finite element rnethod.6 However, for determining gravity stresses in a natural rock slope, only the finite difference method has been used until now.7,8 A solution of the same problem by the finite element method will be shown here in which a particular reference is given to the development of tensile fracture zones within the slope. FINITE ELEMENT METHOD The stress analysis using the finite element method originates from an extension of the matrix analysis of structures.9 It consists in decomposing a continuous medium, assumed herein to be homogeneous and isotropic,

Jan 1, 1972

By Alan H. Goode

Glass wool meeting requirements for commercial use was made from glassy fractions of urban solid wastes by the Bureau of Mines. This research was a part of the Bureau's program to develop building products and other usable materials from reclaimed urban waste materials. Mixes of molten glass were fiberized into glass wool during laboratory studies by impingement of a jet of compressed air on a stream of the molten glass. The principal test variable studied was composition of the melt; this was varied by adding dolomite and alumina to obtain molten glass with the handling characteristics required for producing final wool products of the desired composition and physical characteristics. When no charge is made for the waste glass and approximately $75 per ton can be obtained for the wool product, an interest rate of return on investment after taxes of about 12 percent can be obtained. If a charge of $5 per ton is required for the waste glass, a selling price of about $78 per ton would be necessary to obtain a l2-percent-interest rate of return on investment after taxes.

Jan 1, 1972

By B. Dimitriades

Experimental work has been done to refine and to confirm an analytical procedure by which gas-liquid chromatographic (GLC) spectra are interpreted from retention time data alone. The rationale of this spectra interpretation technique involves whether or not a given peak invariably represents the same component or component mixture; if not, what factors influence changes in peak identifications. To answer these questions, peak-identification procedures, based mainly on the use of subtractive columns, were developed and applied to interpret GLC spectra of several exhaust (and fuel) samples.

Jan 1, 1972

By Warren K. Kourt

Many important discoveries of mineral deposits have been made as a result of routine exploration for oil and gas. Through the presentation of three hypothetical case histories, including cost data, the author shows how mineral evaluation can be performed during routine petroleum drilling operations and how mining companies and oil companies or oil operators can cooperate in such endeavors.

Jan 1, 1972

By Jarrett. K. M.

Nobody has, as yet, made a perfect machine. Therefore, when a machine is operating and functioning as it is designed to do, there is always some vibration present. This is easily and simply measurable with present-day equipment and any increase in the amount of vibration will indicate a potential failure. When an increase is noted, vibration analysis can pinpoint the cause of the potential failure and remedial action can be taken before an unscheduled shutdown is necessary or a breakdown occurs.

Jan 1, 1972

By Wilson GR

Pellets were produced from carefully sized iron ore and silica sand fractions, under controlled moisture conditions, using a sealed balling drum. The strength of these pellets was measured as a function of moisture content and particle size. The results showed that the strength of the pellets could be adequately described by a model which equates the strength of the pellets with the negative pressure developed within the porous mass, provided that the particle size distribution was narrow and the mean particle size relatively large. However this model failed to account for the observed strengths of pellets produced from systems containing even small quantities of ultrafine particles (

Jan 1, 1972

By Hillary W. St. Clair

This report gives the results of an experimental study of the progressive changes that occur in particle size and size distribution when a homogeneous and isotropic mineral is subjected to crushing by impact. The mineral used in the study was uniformly sized quartz, which was crushed in a simple drop¬-weight machine that applied impact energy up to about 100 kg-cm per g. Screen analyses of the crushed products were analyzed by the method of moments to determine the mean size, variance, skewness, and kurtosis. Analysis of the data from these experiments shows that the mean size of the crushed product is a function of the energy input and the initial size. The size distribution is functionally related to the degree of size reduction. As the mean particle size is decreased, at first there is a corresponding increase in the variance and decrease in the skewness, But, as size reduction is carried further, each tends eventually to approach a steady value, and the form of the size distribution becomes stable.

Jan 1, 1972

By James M. Link

The transportation of solids by slurry pipeline is a rapidly growing field. Although early patents date from the latter part of the nineteenth century, it has only been within the last twenty years that successful long distance slurry transport lines have come into their own. The pioneering efforts in this country include the gilsonite slurry pipeline from Bonanza, Utah, to Grand Junction, Colorado, and the coal slurry pipeline from Cadiz to Cleveland, Ohio. Both of these lines were constructed in 1957 and had a combined annual capacity of about 360 million ton miles. Although the Cadiz pipeline was mothballed in the early 1960's, the interest in slurry transport systems continues to increase and one engineering and construction company is predicting that by 1980 an annual slurry system rate of more than eight billion ton miles will be achieved. The design and construction of cross-country pipelines for fluids such as crude oil appears relatively simple when contrasted against the complex problems encountered in slurry systems. Considerable effort has been expended in hydraulic research laboratories in an attempt to improve our understanding of slurry behavior. This effort has been rewarded with considerable success and is best illustrated by the large number of slurry systems now planned or under construction. However, slurry transport in pipelines is still, in many instance more of an art than a science. In order to minimize the risk factors in the construction and operation of large scale slurry systems, studies are frequently conducted in pilot scale test

Jan 1, 1972

By R. C. Croft

Many chemical methods of upgrading ilmenite to enhance its titanium dioxide content involve reduction of the FeO in this mineral followed by solution of the metallic iron produced. While the use of most mineral acids for this purpose entails acid regeneration or salt disposal problems, these difficulties can be overcome with carbonic acid. Satisfactory rates of iron removal have been achieved at temperatures below 100° C and at CO, pressures up to 600 psi. Lowering of gas pressure over soluble bicarbonate solutions permits recovery of CO. and precipitation of iron oxide. The removal of the manganese, often present in ilmenites, is also feasible with these treatments.

Jan 1, 1972

By George L. Atwood

The Monsanto Company's Henry Mine is located 17 miles northeast of Soda Springs, in the southeast corner of Idaho. Ore being mined is phosphate rock which lies in the Permian Phosphoria formation. The ore is the raw material for Monsanto's three furnace elemental "P" plant near Soda Springs. The finished product from the furnaces is elemental phosphorus which is subsequently used in the manufacture of detergents, food preservatives, fire retardants and other consumer items. Mining is by open pit methods using 0-9 crawler tractors to rip and push-load rubber tired scrapers in stripping and mining operations. The equipment spread consists of six D-9G crawler tractors, four Caterpillar 6578 scrapers, eight Euclid S-24 scrapers, one Reich T750 drill and one Caterpillar No. 16 patrol plus various support equipment. Stripping is performed on a 12-month basis, two shifts per day. Mining is performed mainly in the summer months on a one shift basis. The hauling season begins May 15 and ends November 1 due to freezing weather and snow conditions. Annual production is 1,000,000 tons of phosphate rock and 2,500,000 to 3,000,000 yards of stripping. Stripping, mining and hauling is performed for Monsanto by Dravo-Soda Springs, a mining contractor. Dravo-Soda Springs owns, operates and maintains all equipment used in stripping, mining and hauling. The contractor is paid for stripping by the bank yard and for ore mined and hauled on a tonnage basis. The Monsanto elemental phosphorus plant began production in 1952 with ore being trucked to the plant from the Ballard Mine. Haulage was over public roads in 15, 24-ton semitrucks. A private haul road was constructed from the Ballard Mine to the Monsanto Plant in 1958 and 1959 to accommodate trucks with two twenty-yard trailers. This 11/ mile road was first used in the 1959 hauling season. In 1965, five new Kenworth tractors with two, 'forty yard trailers were introduced into the haulage system. These units carried 120 ton payloads and were used until

Jan 1, 1972

By C. M. Mason

The methods currently used by the Bureau of Mines to evaluate the sensitivity, strength, incendivity, gaseous products, and physical properties of explosives and hazardous chemicals are described. Included are the tests used to evaluate explosives which arc certified as permissible for use in underground coal mines.

Jan 1, 1972

By Martin G. Castro, Renato G. Bautista, Morton Smutz

During the last 25 years, multistage mixer-settlers have been used extensively for liquid ion exchange work. The mixer-settler has the advantage of being a compact device in which a large number of stages can be assembled in a relatively small area. They are particularly advantageous for the separation of rare earths. Most of the adjacent rare earths have separation factors which are near one, which means that a large number of stages are needed to produce a good separation. When two elements (m, n) are extracted simultaneously, the separation factor (ßm, n) is defined as: [ ] where Ym, Yn are the molarities of the respective elements in the organic phase and Xm, Xn, are their molarities in the aqueous phase at equilibrium. The industrial consumption of rare earth oxides rose to over 6800 tons in 1968, an increase of 33% over 1967.1 The increased production and demand for rare earth and lanthanum chlorides for petroleum cracking catalysts was one of the principal factors in this increased consumption of rare earths. In 1968 approximately 59% of the rare earth oxides produced were used for gasoline cracking catalysts in the form of rare earth and lanthanum chlorides. There was also an increase in the sales of lanthanum oxides for use in optical lenses and in fiber optics. The future looks good for the rare earth industry. The rare earths can be expected to be used in many new products which are being developed. Until the late 1950's tributyl phosphate (TBP) was the principal solvent used in rare earth liquid ion exchange. In 1957 Peppard3 reported the use of di (2-ethyl-hexyl) phosphoric acid (D2EHPA) as a solvent for separating the rare earths. Rare earth separation factors of up to 2.5 were obtained in nitrate and chloride systems while the maximum separation factor using the

Jan 1, 1972

Electrical trailing cables are frequently damaged in usage, especially on continuous minors, and because of their weight and damaged condition present a safety hazard to personnel required to handle them. The U.S. Bureau of Mines and FMC Corporation signed Contract No. HO 122011 in August 1971. One of the contract tasks was to study the feasibility of techniques to improve trailing cable support and handling of power cables on underground coal mine machinery and to design a cable-handling device for a continuous mining machine. This report presents the results of the feasibility study, describes the design for a proposed cable handling device and concludes with a recommendation for future action to construct a test rig to evaluate the cable reel system.

Jan 1, 1972

By J. M. Van Langen

In 1965 Hoogovens was looking for additional capacity for burden preparation in the order of 2,5 to 3 million metric tons per annum of some kind of optimal blast furnace ore feed. In principle four solutions offered them-selves for further investigation: 1. purchase of screened ore and/or run of mine ores with the provision of a corresponding ore screening capacity on the blast furnace site; 2. manufacture of sinter; 3. purchase of pellets; 4. manufacture of pellets. After studying the technological, technical, economical and commercial factors Hoogovens decided for the last mentioned possibility. Before taking this decision not only a great number of different mixtures of iron ore were tested, but during a long period in one of the big blast furnaces a number of tests were also executed with purchased pellets from South and North America. It was found, that using 50% acid pellets with 40% basic sinter a coke rate saving of 25 kg per ton hot metal (50 lbs/net THM) and a production gain of 15% could be obtained as compared with a full sinter practice. With some pellets it became clear, that due to properties, commonly referred to as swelling, we got very poor furnace performances; so in studying the production of pellets, pellet quality should be regarded as the most important aspect of the problem.

Jan 1, 1972

By John M. Smith

Kaolin is an important industrial mineral because of its unique properties and low cost. Strictly defined, kaolin is the name given to a group of hydrous aluminum silicates of which kaolinite is the most common mineral (1). Through common usage the mineral, kaolinite, is called "kaolin" or "china clay". In 1972 over 4, 000, 000 tons of kaolin will be beneficiated and shipped by domestic producers. By far the largest user of kaolin is the paper industry which utilizes approximately 65 to 70 per cent of the total production. Kaolin is used in paper as a filler in the interstices of the sheet and as a coating to impart smoothness, gloss, brightness, and printability to the paper. The rubber industry is also a large user of kaolin where it is used as a filler because it adds strength, abrasion resistance, and rigidity to both natural and synthetic rubber goods. Kaolin is used as an extender in paints because it is chemically inert, has a high covering power, gives desirable flow properties, and is low in cost. In ceramics, kaolin is used in whitewares, tile, insulators, refractories, and in some face brick where a white color is desired. Kaolin is also used extensively in plastics as a filler in thermosetting and thermoplastic mixes to give smoother surfaces, a more attractive finish, good dimensional stability, and resistance to chemical attack. Many other process industries use kaolin as a filler, suspending medium, or for color improvement.

Jan 1, 1972

The maximum current density at which conventional copper electrowinning plants will result in satisfactory, adherent, and dendrite·free cathodes is determined by the thickness of the diffusion boundary layer. A decrease in the value of that thickness will permit an increase in the current density. This fact is utilized to develop a high current density cell in which the reduction of the boundary layer thickness is accomplished by means of a specially designed electrolyte circulation system. The high current density cell is used to determine the effect of current density on such process parameters as current efficiency, cell voltage, power consumption, and cathode purity. A number of empirical equations are developed for the purpose of estimating the magnitude of these effects.

Jan 1, 1972

By Richard H. Oitto

With increased interest and urgency for coal mine safety and the passage of the Federal Coal Mine Health 'and Safety Act, the Bureau's research effort in roof control has been greatly expanded. One new project, the subject of this paper, concerns improving conventional roof bolting and has been involved with the effects of different variables on the performance of roof bolt expansion anchors. These include types of expansion anchor, rock type at the anchorage horizon, borehole roughness, rate of torquing a roof bolt to set the anchor, installed tension, bolt length, and relative humidity fluctuations. For this work, two types of experiments were carried out. One was concerned with tension loss in bolt-anchor assemblies and simulated anchor performance in a static roof. The other dealt with anchor slippage as tension was increased and simulated anchor performance in an active roof. Trials were made in the laboratory under controlled conditions so that factors suspected of affecting expansion anchor performance could be selectively studied. Because of the natural variability in rock and the fact that most expansion anchor components are essentially rough castings or forgings, the experiments were designed to permit using analysis of variance techniques for analyzing data. Thus, in this paper, "significant" means statistically significant.

Jan 1, 1972

By Larman J. Heath

Preliminary results of an explosive fracturing-solvent injection heavy oil recovery experiment conducted by the Bureau of Mines at a shallow oil reservoir near Bartlett, Kans., are given. Three wells 35 to 50 feet apart were drilled to a depth of 360 feet, and an open hole interval from 300 to 350 feet in the Bartlesville Sandstone Formation was explosively fractured with 3,000 pounds of pelletized TNT in each well. Laboratory tests were made on cores obtained from these wells to confirm the suitability of using an aromatic-type solvent. Injection of a 74-percent aromatic solvent was begun into one well and continued intermittently for approximately 2 months. Crude oil production amounted to 29.6 bbl, or 11.7 percent of the total oil con¬tained within the three-well interwell zone.

Jan 1, 1972