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By G. R. Love, M. L. Picklesimer

Aboue 950°C the Nb-Zr system consists of a completely miscible bcc solid solution, commonly called the phase. Between 950 and 600°C, and between 20 and 85 pct Nb, the phase deconlposes, after sunciently long times, into two bcc solid solutions. The pct Zr alloys are conveniently descibecl with T-T-T (time-temperature-transformation) curves having a nose at about 2 hr at 700°C. The reaction rate varies only slowly with zirconium content and negligibly with oxygen contanzination; it is speeded up by a factor of 10 to 15 by 90 pct cold ulork and slowed dou by n factor oj 10 to 30 by a two-hundrecljold increase in grain size. Nb-r alloys with compositions between 40 and 85 pct Nb have been the basis for the majority of commercially important superconducting materials. In part because of their commercial promise, more is known about these alloys than about most other high-field superconducting materials. At the same time, there is considerable disputed or incomplete metallurgical information. For example, although Rogers and tkins&apos; indicate a monotectoid reaction at approximately 600°C and a two-phase 01 + 0, field extending between 20 and 85 pct Nb and to a maximum of 95OGC, erhout&apos; has reported that this entire region would be a single homogeneous B were it not for oxygen contamination. Again, although it has been shown that relatively short-time heat treatments in the vicinity of 700CZ significantly improve the ability of short wire samples to carry high currents in high magnetic fields at 4.2K, these observations have never been fully correlated with the structural change or changes occurring during the anneal. We intend to investigate in detail the effect of metallurgical variables, including heat treatment, on the superconducting properties of hard superconductors. To verify that our experimental techniques are valid and to establish a relative standard against which other materials may be measured, we feel it advisable to know the behavior of the Nb-Zr alloys under a variety of processing conditions. As an initial step toward this goal, we have determined in detail the kinetics of the transformations in Nb-Zr alloys. EXPERIMENT A number of problems had to be solved before beginning any fruitful work on the reaction kinetics in this system. While solving some of these problems, either by chance or by design, small amounts of information were obtained about alloys containing 40, 50, 60, 65, 67, 70, and 75 pct Nb, bal. Zr. In addition, a large range of grain sizes and a range of temperatures considerably greater than the range indicated by Rogers and Atkins phase diagram were examined. We will, however, report in detail only the results obtained for the Nb + 33 pct Zr and Nb + 25 pct Zr alloys at three grain sizes, two levels of oxygen contamination, and the temperature range 550 to 950°C. These data are most complete, but the other data are sufficiently complete to indicate the kind and magnitude of the variation of the transformation kinetics outside this range. The first and most difficult problem encountered in this inquiry was one of sample homogeneity. When Nb-Zr alloys are arc- or electron-beam-melted on a cooled copper hearth, solidification is sufficiently slow that there is appreciable coring in the cast structure and a large variation of grain size across the button thickness. Both these factors significantly affect the apparent reaction rate in the system. A two-step solution to the problem was attempted; an arc-melting and drop-casting technique has been developed by conald that greatly reduces the as-cast grain size and virtually eliminates coring segregation. Ingots made in this way exhibited no detectable (3 pct maximum) zirconium segregation. Before it was evident just how good this technique was, we attempted to supplement it with rather long-time, high-temperature annealing of the cast ingots. This annealing was carried out in evacuated and sealed (seal-off pressures < 1.0 x 106 torr) quartz capsules lined with tantalum foil at 1400 to 1450 C for 8 to 72 hr. There were two principal effects of this treatment: the grain size increased to a fairly uniform 150 p, and the surface and all grain boundaries near the surface acquired a film of a second phase, tentatively identified as an oxide (possibly additionally contaminated with silicon). There was no evidence that this 1400 C treatment had affected the zirconium segregation. High-temperature annealing was subsequently used only for grain-size control, but anneals of longer than 4 hr at temperatures greater than 1000°C were performed in dynamic vacuums (pressure no greater than 1.0 x lo torr). Any contamination resulting from these treatments was well below the limits of detection of our techniques. All samples, as cast, were cold-swaged to at least 85 pct reduction in area. The samples called cold-worked were tested as swaged. The minimum re-crystallization anneal for these alloys was about 12 hr at 1050 C; this produced an equiaxed grain diameter of about 4 to 8 P. Annealing for 4 hr at 1450°C produced a grain size of about 80 to 150 p; and annealing for 4 hr at 1650aC, close to the melting point of many of these alloys, produced a grain size of 0.5 to 1.0 mm. At all temperatures, the larger grain size was

Jan 1, 1967

By J. Mote, P. Ward Flynn, J. E. Dorn

The effect of strain and strain rate on the critical resolved shear stress for prismatic slip in specially oriented single magnesium crystals was determined over a range of temperatures in an effort to identify the thermally activated strain-rate controlling dislocation process. Below about 450°K prismatic slip was preceded by twinning and fracturing. Above 450°K extensive prismatic slip was obtained followed by fracturing. Neither the Peierls&apos; mechanism nor the dislocation intersection mechanism can account for the observations. The data, however, are in good agreement with the dictates of Friedel&apos;s theory for cross slip to the prismatic plane. PREVIOUS investigations on single and polycrys-talline magnesium have resulted in the identification of the mechanisms of plastic deformation summarized in Table I. The-only well-confirmed mechanisms are {0001}, (1010}, (1011) slip plus (1012) twinning. The other twinning modes were only tentatively established and additional investigations are required to further confirm their operation. As noted in Table I, slip in this hexagonal close-packed metal invariably occurs in the direction of greatest atomic density, revealing that the Burger&apos;s vector for-active slip dislocations is always given by b = a/3<1210>. Slip is easily induced on the basal plane, and recent investigations have shown that the strain-rate controlling mechanism at low temperatures is the thermally activated intersection of the glide dislocations with dislocations threading the basal plane. In contrast, very little is known about prismatic slip. It has been reported to be active at points of stress concentration in polycrystals below

Jan 1, 1962

By J. D. Miller, R. J. Smith

The hot water process for Utah tar sands differs significantly from that used for Canadian tar sands due to inherent differences in respective bitumen viscosities and the nature of bitumen-sand association. These differences have led to the identification of certain design criteria necessary to achieve satisfactory phase disengagement during digestion (Sepulveda and Miller, 1978; Misra and Miller, 1980). Subsequent flotation of digested tar sand is a subject of current attention and is considered in this publication for the Asphalt Ridge deposit. Although contact angle measurements of solvent extracted Asphalt Ridge bitumen indicated moderate hydrophobicity, air bubble attachment to the bitumen concentrate is not possible. This surprising result suggests that flotation separation is dependent on air bubble entrapment rather than on air bubble attachment due to surface hydrophobicity. The entrapment of air bubbles in the bitumen was apparent from examination of the bitumen concentrate, especially at lower flotation temperatures. A factorial design of the major operating variables in flotation separation indicated that the quality of separation was significantly dependent on the flotation temperature and to a lesser extent on the degree of agitation. For a flotation temperature of 77°C a recovery of 96.7% was realized at a grade of 61.0% bitumen. The improved separation at higher flotation temperatures was found to be due to the decrease in bitumen viscosity resulting in more effective rejection of coarse sand from the concentrate. This research effort, which has been sustained for the past six years at the University of Utah, is being continued to provide necessary design data for the construction of a pilot plant to treat Utah tar sands.

Jan 1, 1982

By E. R. Borcherdt

METHODS and equipment are subject to study in the Butte district at all times in order that advantage may be taken of any new developments that might serve to increase efficiency and lower costs. Detailed time studies of each operation involved in the entire mining process have been of invaluable assistance in analyzing the individual operation for possible improvement. In other words, the fact that a practice has been in vogue for many years does not exempt it from change provided an easier and cheaper method can be found. EXPLORATION Ore occurs in the Butte district in such manner that structures must be drifted on, no matter how small or unimportant they appear when intersected by a crosscut. Parallel structures also add to the crosscut requirements. This prospecting work, which formerly was done entirely by drifting and crosscutting, is now being supplemented by diamond drilling, to aid in greatly decreasing the amount of waste. In long-shot prospecting, or in second or third class prospecting, where the chances of developing commercial ore are not very great, diamond drilling is of particular value. In prospecting where chances of encountering commercial ore are certain or where crosscuts can be used later for haulage or ventilation, drilling obviously is not applicable. Improvement in drilling machines and bits has contributed greatly to the present success of diamond drilling. STOPING For many years square-set filled sloping was the principal mining method used in the Butte district. Later timbered and untimbered rill stopes were used, also some horizontal cut-and-fill sloping where both ore and walls were particularly strong. Because of the amount of timber required for square-set stoping, and the relatively low production per scope unit, experiments with horizontal cut-and-fill scopes were begun in ore bodies of which many had fairly weak walls. It was felt that increase in the speed of the stoping operation, followed closely by filling, to avoid weight being produced by permitting ore and walls to remain insufficiently supported over comparatively long periods, would maintain the walls and backs in safe condition without the use of timber and without ore dilution from wall slough. Cycles of drilling, scraping ore, and filling were devised, which have materially increased stope production and decreased timber consumption, so that both stope labor and supply costs were lowered appreciably without materially affecting grade control. In the larger mines of the district, where wide veins favor this stoping method, half of the total production is now being mined by horizontal cut-and-fill stopes (Fig. I). The increase of the filling rate demanded by the increased stoping rate was the greatest obstacle encountered in the accelerated stoping operations. Finally this problem was solved by replacing the time-honored method of transferring filling waste by small cars, which were hoisted or lowered in the auxiliary shaft, by a transfer

Jan 1, 1941

By C. H. Stewart, R. A. Fagin

A two-dimensional, three-phasereservoir simulator was programmed for a large memory digital computer. It was designed to provide a practical solution to describing the complex physical relation between the natural forces and the physical properties of a heterogeneous reservoir when subjected to a specific set of conditions. A reservoir study is briefly described to illustrate application of the model. A full volumetric account of three phases (oil, gas and water) is performed simultaneously throughout an integration net representing the reservoir. Absence of one or two of the phases is treated as a special case of the more general situation. Expansion (or contraction) of all phases, including rock expansion, is performed so that the pressure calculation is the general unsteady-state case. To account for the large variations of subsurface elevation encountered in some reseruoirs, and to allow for segregation of the various phases, a gravity head term is included in the basic drive potential. Appropriate fluid and rock properties are used in polynominal surface form (functions of pressure and/or depth) or they can be entered as space variables at each position of the integration net. An unsteady-state water influx calculation, based on the method of van Everdingen and Hurst, l was connected to the boundary of the matrix to simulate aquifers of various sizes. In addition to reservoir calculations, three-phase fluid flow from the producing depth to the wellhead, including provisions for gas lift, was incorporated in the simulator. A workover routine was also built which can automatically switch to a different set of production relations when a gas-oil ratio or water fraction reaches a limit; or it can shut-in the well if prescribed. INTRODUCTION This paper describes a reservoir engineering mathematical simulator used to represent the complex interaction of natural forces and physical properties of a reservoir during natural depletion or with various injection schemes. The simulator, which was programmed for a large memory digital computer, is a two-dimensional calculation which handles three mobile fluid phases simultaneously (oil, gas and water). Basic requisites for the method are individual well production and pressure data, hydrocarbon fluid properties, geological data (producing depth and net sand), capillary pressure data, relative permeability data and permeability and porosity information. Matching the past performance of a combination drive reservoir often has yielded information concerning continuity and the validity of basic data. Detailed predictions of future performance can be made for continuation of current depletion methods (natural depletion) as well as for various types of recovery by gas or water injection. Combination injection cases and pattern studies can also be performed. Workover programs, gas lift and different types of artificial lift programs have been investigated using a technique similar to that described by Kern and Nicholson2 except that conditions of pressure and saturation at the block within which the well is located are used rather than average reservoir conditions. Drilling additional wells to optimize profit was explored, both as to number and location, by placing wells at different spots within the reservoir matrix. Special depletion processes can be examined, such as upstructure drainage and lateral (or strike) waterfloods in thin oil columns. In one case the mathematics of the simulator were modified to calculate the displacement in the vertical plane rather than in the horizontal plane. In this manner specific reservoir problems can be studied, such as coning of gas and/or water around production points, fingering along permeable stringers or, more generally, frontal advances in a heterogeneous section.

Jan 1, 1967

By B. E. Terkelsen, B. J. Piearcey

A study has been made of the effect of unidirectional solidification on the creep behavior, stress-rupture properties, and thermal shock resistance of four nickel-base superalloys. The alloys Mar-MZOO, B-1900, IN 100, and TRW 1900 show improved rupture ductility and thermal shock resistance when tested with the columnar grains parallel to the major stress axis during test. The relative improvement in creep-rupture properties depends on the intrinsic strength of the alloy, a property which depends on composition, heat-treatnient, and crystallographic orientation. The data clarifies some of the factors affecting the properlies of the cast nickel-base superalloy. COMPONENTS designed for high-temperature use have, in recent years, been fabricated by precision casting techniques using nickel-base alloys developed specifically for use in the conventionally cast condition. This development was a result of both the increasing complexity of the component and the recognition that high-temperature strength was incompatible with workability. The use of castings can be economically favorable, but, more important, the recent complex designs of air-cooled gas turbine blades and vanes in alloys which possess the necessary high-temperature strength cannot be forged. Common modes of failure of high-temperature components are excessive creep, creep rupture, and thermal fatigue. If rupture occurs then the mechanism is usually by inter crystalline cracking along those grain boundaries oriented transverse to the major stress axis. In the stronger alloys, rapid propagation of intercrystalline cracks result in apparent premature failure demonstrated by the absence of third stage creep in a creep-rupture test and low rupture ductility. Tensile ductility shows a similar trend, that is, decreasing ductility with increase in strength. It is not surprising, therefore, that increases in creep strength have only been obtained with a loss in resistance to thermal shock, a property which shows a dependence on tensile ductility. VerSnyder and ~uard&apos; showed that the application of unidirectional solidification to a brittle Ni-Cr-A1 alloy both improved the rupture life of the alloy and increased rupture ductility. Since this casting method results in columnar grains, it appeared that the solution to the lack of ductility in nickel-base alloy components was the elimination of the source of failure, namely the transverse grain boundaries. This concept was recently developed2 to produce cast-to-size gas-turbine blades and vanes consisting entirely of columnar grains oriented parallel to the major stress axis of the component. Not only did the process impart increased rupture life and ductility to the components, but it also increased their resistance to thermal shock. During this development, the effect of unidirectional solidification on the properties of several alloys was investigated. The resulting data allows certain conclusions to be drawn regarding the factors affecting the creep and stress-rupture properties of the cast nickel-base superalloy and also its resistance to thermal shock. Detailed information was obtained on the alloys Mar-MZOO, B-1900, In 100, and TRW 1900. The composition of the alloys studied are shown in Table I. MATERIAL PREPARATION AND TESTING The conventionally cast alloys are cast as +-in.-diam bars in innoculated shell molds under conditions designed to maintain control of grain size. Unidirec-tionally solidified casting were produced in the form of 3-in.-diam ingots. Specimens from the latter were machined such that the axes of the columnar grains were parallel with the axis of the test bar, except in certain cases where the transverse properties of the material were being evaluated. The specimens were tested in an axial loading creep machine.&apos; Temperatures were measured with thermocouples, attached just outside each end of the gage length, to assure uniform temperature along the entire specimen. Chromel/alumel thermocouples were used up to 1800"F and Pt/Pt-10 pct Rh thermocouples above 1800"F. The specimen temperature was recorded and maintained within i2"F throughout the test. Creep extensions were measured automatically with extenso-meters attached to ridges on the specimen and recorded continuously using linear variable differential transformers and multipoint recording equipment. MICROSTRUCTURE The microstructures of transverse sections of the four alloys studied are shown in Figs. 1 and 2. Fig. 1 shows optical micrographs of the alloys, both in the conventionally cast and unidirectionally solidified conditions. Each alloy displays a cored dendritic structure, a distribution of MC carbide, and the presence of the y — y&apos; eutectic constituent.~ In the case of IN 100 and B-1900, Fig. 1 indicates that in these specimens the eutectic is degenerate. That is, it consists only of y&apos; pools indicating that the y constituent has been solutioned during the cooling period after solidification. The major effect of unidirectional solidification on the microstructures of the alloys is a tendency to promote a more dendritic form of MC carbide and an increase in dendrite arm spacing, both effects being a result of the slower solidification rate in the unidirectional solidification technique. V, lec tron micrographs of transverse sections of the four alloys in the two cast conditions are shown in

Jan 1, 1968

By J. P. Matoney, E. J. Sandy, D. A. Dahlstorm

INTRODUCTION Before an understandable discussion concerning coal-dewatering processes can be initiated, it is necessary to define some terms of usage. The many different meanings and interpretations of terms preclude development of standard definitions so that the terms which are defined in this chapter should be regarded mainly as working terms intended to facilitate communication. A coal slurry &apos; might be defined as a watery suspension carrying particles of fine coal and other assorted material ranging upward in size from the finest clay particles. Some particles may be in the colloidal sue range and exhibit characteristics of suspended colloids. The dilution of the system generally is such that it is in a condition of independent particle subsidence. In some coal mining areas a slurry is regarded as a suspension of fine coal and other materials having a dilution that cannot be economically dewatered by filtration. A coal slime may be regarded as a slurry containing particles of such size range that 50 per cent or more (by weight) will pass a 200-mesh sieve. Slime suspensions generally are difficult to handle without special treatment in conventional sedimentation equipment. A coal sludge is defined as a slurry that has been partly dewatered by sedimentation usually to a thick or viscous consistency where further dewatering can be most readily facilitated by filtration. Culm and silt are terms characteristic of coal-preparation practice which should be defined. In anthracite terminology, culm is the generally coarse residue or waste accumulation of coal, bone and rock from preparation plants most of which are no longer functional. Culm has a wide range of sizes, some rather coarse, and except to differentiate it from silt, the term is of limited interest in this discussion. In anthracite terminology, silt is the accumulation of waste fine coal, bone and slate settled out from preparation plant water in excavated basins. Silt is generally made up of particles ranging in size from 3/32-in. round-opening screen to the very finest sues. Silt is also referred to at times as sludge, fines, slush, and mud and is the partly dewatered derivative of what has been previously defined as slurry. In the terminology of the bituminous coal producing areas, the word culm commonly corresponds to slurry or slime, depending upon the size distribution of the suspended solids. Editor&apos;s Note: Because of the numerous and varied contributions of the associate authors of this chapter, the text does not differentiate between sections authored by each individual as is the case in most chapters of this book.

Jan 1, 1968

By Eugene Guccione

Evidence that the United States is gradually converting to the metric system of measurement can be perceived today even by housewives in a supermarket. The question is no longer whether but when the country will have completed the conversion. To the extent that any bickering about metrication still exists, the debate now centers on such issues as finding agreement on details of implementation, and whether federal legislation should speed up the metric-conversion process or allow it to proceed along its present evolutionary and voluntary course. Apparently, the voluntary or "make-haste-slowly" approach is gaining widespread support. According to The Research Institute of America, Inc., if and when federal legislation is enacted it will likely include the following national ground rules: (1) A National Metric Conversion Board will develop and submit to the President and Congress a comprehensive plan to achieve a coordinated, minimum-cost changeover. (2) The change- over will be completed 8 to 10 years after the board&apos;s plan goes into effect, and by that time the US will be predominantly, though not exclusively, metric. (3) Costs will "lie where they fall"; subsidies, special tax concessions, and antitrust exemptions will not be authorized by the legislation. (4) The changeover will be voluntary because of the recognition that while some firms can "go metric" in a matter of weeks, others may require 15 years or more, and a few might never convert. (5) In determining whether or not to convert, on an individual company basis, adherence will be to the "rule of reason-that is, ". . . do not convert unless the engineering, economic, or other benefits outweigh any metric-related disadvantages. No one is talking about rip- ping up our railroad tracks or rewiring our homes just to conform to the practice of metric nations in Europe." (6) Government is to be part of the solution, not part of the problem; in effect, says The Research Institute of America, the leverage of federal procurement will not be exerted to force-feed the metric changeover but will be coordinated with the sector-by-sector conversion of the economy.*

Jan 12, 1975

By J. B. Warriner

Stripping is the name given to the process of removing clay, rock, or other cover from deposits of coal or ore. In this paper it is intended to cover the methods used in carrying on this operation in the anthracite coal regions of Pennsylvania. In doing this, attention will be chiefly devoted to those methods wherein practice in different sections of the region differs, or is susceptible to change or improvement, though it is intended to give as complete data as possible concerning all stages of the operation. The data from which this paper has been prepared have been collected and submitted by a committee† representing the larger users of stripping methods, of which committee the writer has acted as chairman. Data and assistance have also been obtained from various mining men, engineers, contractors and manufacturers of stripping equipment, to all of whom our appreciation is due. Early History and Statistics The earliest mining operation on a commercial scale in the anthracite region was a stripping operation. This was the famous Quarry mine at Summit Hill, where this method was used only because no other method of mining a deposit of the nature found there seemed feasible to the early operators. A description of this stripping from a report published in 1821 is as follows: "The coal mine at present worked by the company lies on the top of a mountain, and appears to extend over some hundred acres of land covered by about 12 ft,. of loose black dirt resembling moist gunpowder, which can be removed by cattle with scrapers, and thrown into the valley below so as never to impede the work. The thickness of the coal is not known, but a shaft has been sunk in it 35 ft. without penetrating through. More than an acre of mine has been uncovered and presents a huge rock of coal, which is easily quarried without blasting."

Jan 1, 1918

By R. D. Satterley

The Sherwood mine is an iron-ore mine owned and operated by the Inland Steel CO. in the Iron River district of the Menominee Range in Michigan. The property consists of an 80-acre tract in the village of Mineral Hills, about a mile north of the city of Iron River. The Ore mined is a reddish brown, nonbessemer hematite and limonite. The ore bodies lie in a large syncline having an east-west strike and are associated with a rock structure that is folded in a complex manner. The two 40-acre tracts run north and south and the shaft is at about the center of the north forty. The shaft is 1286 ft. deep, with the principal operating level at a depth of 1000 ft. from surface. A new level at a depth of 1200 ft. is in process of development. The ore body at the 1000 ft. level is east and west at approximately the line between the north and south forties and at this elevation is from 50 to 250 ft. wide and extends above the level at varying heights of from 50 to 250 feet. The 1000-ft. haulage drift extends south from the shaft, through the east-west ore body to the slates on the south side of the body. The ore body was intercepted in the drifting at about goo ft. from the shaft and was about 200 ft. wide at that point. A crosscut was extended to the east and west property lines along the south boundary of the ore body. This east-west ore body is laid out in areas go ft. wide for stoping with pillars 40 ft. wide. With this plan a stope is approximately 80 by 200 ft. and has a pillar on both sides that is approximately 40 by 200 ft. The ore has a height of from 50 to 250 ft. above the elevation of the level, therefore the height of the stopes varies in accordance with the height of the ore body at each location. From the crosscut, two main raises, each 6 by 7 ft., are put up into each 80 ft. stope area (Fig. 1). One of the main raises serves as a manway and the other as an ore raise, through which the ore is transferred from the stope to the tramming equipment. The original layout as for scraping of the ore from under the stopes into the ore raises. The ore raise is put halfway (east and west) along the 80-ft. stope area and usually is in iron formation. The manway and ore raise are on approximately 15-ft. centers. These main raises are Put up to a height of from 22 to 30 ft. above the level floor, then from the toll of the ore raise a scraper drift (8 X 8 ft.) is driven across the width of the ore body, which is in the neighborhood of 200 ft. From the scraper drift, mill raises are put up at 12½-ft. centers, staggered on opposite sides of the drift, and these are extended 23 ft. above the elevation of the scraper-drift floor. The sublevel connecting the top of these mill raises is called a mill "sub." Other sublevels are developed parallel to the scraper and mill subs at 25-ft. vertical intervals above the mill sub. The mill sub and the other subs above the mill sub are known as sublevels or dog drifts, and are 4 ft. wide and 6 ft. high. These dog drifts

Jan 1, 1946

By H. Biloni, B. Chalmers

Metallographic studies of the segregation of solute in and near the surfaces of chill-cast alloys have shown that, under sufficiently severe conditions, nucleation on the cold mold surface is followed by the formation of a disc of solid of the same composition as the liquid. This disc is surrounded by two concentric rings in which the concentration first decreases and then increases. The discs and rings are surrounded by a region in which arms of low solute concentration separate regions of high concentration. These arms start at the periphery of the outer ring and are initially radial; they make a gradual curved transition from the radial direction to a crystallographic direction. A normal dendritic substrcture is established beyond the position at which the arms have become crystallographically aligned. When the cooling is less severe, the disc becomes less irregular in shape and has a concentration minimum at the center. The term "Predendritic" is proposed for these transitions. A qualitative explanation is outlined for the phenomena observed at the surface and in the equiaxed region of the ingots. It is well-established1-&apos; that the normal mode of solidification for alloys under most conditions is dendritic. A characteristic of dendritic solidification is the growth of rods or plates in specific crys-tallographic directions. The remaining liquid solidifies later, usually with a higher concentration of solute than the original liquid. Very little is known, however, about the transition from a crystal nucleus until the dendritic pattern is established. It is clear that there must be a transition because the nucleus is much smaller than the characteristic spacings found in the "steady-state" structure. And it also seems clear that the initial conditions must be important since the undercooling existing during the nucleation of the grains has a remarkable influence upon the grain size4 and the segregation pattern. The present paper reports a study of the micro-segregation in regions where crystals have nucleated, and the conclusions that can be drawn regarding the early stages of growth, in connection with the details of the solidification process. Aluminum of 99.993 purity, A1-Cu alloys containing 0.5 to 20 wt pct Cu, and Pb-Sn alloys with 5 wt pct Sn were cast and examined metallographically at the as-cast surface, close to the surface, and in the interior after casting. The alloys were cast from controlled temperatures against surfaces at different temperatures ranging from room temperature to approximately the liquidus temperature of the alloy. The surfaces were, in various experiments, graphite, stainless steel, copper, and aluminum. The methods used for metallographic examination were as follows. 1) The Nomarski phase contrast interferometer6 was used to obtain information on the topography of the as-cast surface. 2) The distribution of any solute present in A1 99.993 pct and copper in the A1-Cu alloys was studied by the anodic film technique originated by Lacombe and Mouflard7 and previously applied in the study of the solidification of aluminum by Biloni.8 The electropolished surface of the specimen is anodized under controlled conditions so that the thickness of the oxide film and therefore the interference colors under white light are sensitive to the local composition. This technique was applied to the as-cast surfaces and to metallographically prepared surfaces from the interior. 3) If in Al-Cu alloys, the surface is anodically oxidized for several minutes, instead of seconds as in the color-film technique, the copper segregation is outlined by a different level with respect to the matrix. This method is less sensitive but complementary to that for the color films. 4) The distribution of copper revealed and mapped by the metallographic techniques was confirmed by electron probe. 5) In samples with high concentration of copper, evidence for the copper distribution could be seen optically after electropolishing.

Jan 1, 1965

By J. M. W. Mackenzie

A microelectrophoresis technique has been used to measure the zeta potential of quartz over a range of pH and ferric iron concentration. The results have been discussed in terms of the adsorption of ferric cations and ferric hydroxide to the quartz surface. Possible relationships between the experimental results and the flotation of quartz have been examined. The adsorption of multivalent cations at the surface of quartz has been studied by many investigators who have used a variety of experimental techniques ranging from streaming potential 1 to radiometric2 measurements. Two possible mechanisms of cation activation of quartz have emerged from the results of these investigations viz: the adsorption of the cation to the negatively charged quartz surface, followed by adsorption of the collector anion to the adsorbed cation site, or: formation of a cation-collector complex which is then adsorbed to the quartz surface. In many natural and industrial systems one of the most prevalent activating species for quartz is ferric iron, this is especially so in the acid-circuit, anionic flotation of iron ore. The adsorption of ferric iron to the quartz surface is complicated by the ability of ferric iron to form complexes with anions, a phenomena which is of minor importance in one of the most widely studied quartz activation processes, ca ++ activation.* *The pK value for [ca(oH)+]/ [ca2+] [oh-] is 1.46 indicating that the influence of Ca (OH)+ ions will be minor in all but strongly alkaline solutions. In order to obtain a better understanding of quartz activation by ferric iron the zeta potential of quartz in the presence of ferric iron has been measured over a range of pH and ferric iron concentration. EXPERIMENTAL METHODS Materials: Selected samples of "rock clystal" quartz from New England, N.S.W., were ground in a pebble mill, washed for three hours in boiling concentrated hydrochloric acid, washed in hot chromic acid and then washed repeatedly with distilled water until the washing water gave no trace of chloride ion.

Jan 1, 1967

By A. J. Teplitz, T. Bardeen

In the course of an investigation of lost circulation, a new tool has been developed which gives a qualitative measure of the relative velocity between the fluid column in the borehole and the tool. The position of a diaphragm in the side wall of the instrument depends on the flow through the device. This position is established by using the conductive borehole fluid in a potentiometric circuit. The instrument has high sensitivity and can detect changes in velocity as low as. 5 ft/min. Lost circulation mud additives do not interfere with the satisfactory performance of the tool. In a number of circulation losses of the pressure induced type, the instrument has shown that the losses were confined to extremely narrow zones (less than I ft), indicating that such ruptures occur in a more or less horizontal rather than vertical plane as has often been assumed. This pinpointing of the zone of loss is important in remedial procedures since it allows the treatment to be applied directly to the point of loss rather than to the entire open hole. The device can also be employed for indicating points of entry of water in producing wells. INTRODUCTION The need for an improved means of locating the positions of lost returns zones became evident during an investigation of lost circulation difficulties in the Gulf Coast area.1 With instrumentation available at the time, it had been learned that, contrary to common belief, the position of the thief zone responsible for a given loss seldom coincided with the point of bit penetration at the time the loss was encountered. In the majority of cases, the losses were found to be occurring at some distance removed from the bottom of the hole —sometimes as much as a few thousand feet. This information, along with other observations made during the investigation, led to improved techniques&apos; for dealing with lost circulation problems. Highlighted, however, among the results of this work and of similar studies subsequently conducted in drilling operations in other parts of the country, was the indication that a considerable portion of the difficulty and expense involved in treating prolonged circulation losses is due to the unsystematic application of remedial measures to one or more apertures of unknown position. Basis of Tests It is worth considering that if the troublesome formation could somehow be transported to the surface where it could be directly observed, there would likely be little difficulty in readily effecting a seal. Although this is a decided oversimplification of the situation, it does appear that the chief obstacles to similar ease of handling of a lost circulation zone in a well are lack of visibility and of ready accessibility. The latter handicap is overcome to a considerable extent by placement techniques already in use, and other procedures now in the process of development are expected to offer further improvement. But in the matter of visual observation, the technique to be presently described appears to afford a quite satisfactory substitute.

Jan 1, 1957

By E. R. Borcherdt

Methods and equipment are subject to study in the Butte district at all times in order that advantage may be taken of any new developments that might serve to increase efficiency and lower costs. Detailed time studies of each operation involved in the entire mining process have been of invaluable assistance in analyzing the individual operation for possible improvement. In other words, the fact that a practice has been in vogue for many years does not exempt it from change provided an easier and cheaper method can be found. Exploration Ore occurs in the Butte district in such manner that structures must be drifted on, no matter how small or unimportant they appear when intersected by a crosscut. Parallel structures also add to the crosscut requirements. This prospecting work, which formerly was done entirely by drifting and crosscutting, is now being supplemented by diamond drilling, to aid in greatly decreasing the amount of waste. In long-shot prospecting, or in second or third class prospecting, where the chances of developing commercial ore are not very great, diamond drilling is of particular value. In prospecting where chances of encountering commercial ore are certain or where crosscuts can be used later for haulage or ventilation, drilling obviously is not applicable. Improvement in drilling machines and bits has contributed greatly to the present success of diamond drilling. For many Years square-set filled stoping was the principal mining method used in the Butte district. Later timbered and untimbered rill stopes were used, also some horizontal cut-and-fill stoping where both Ore and walls were particularly strong. Because of the amount of timber required for square-set stoping, and the relatively low production per stope unit, experiments with horizontal cut-and-fill stopes were begun in Ore bodies of which many had fairly weak walls. It was felt that increase in the speed of the stoping operation, followed closely by filling, to avoid weight being produced by permitting ore and walls to remain insufficiently supported over comparatively long periods, would maintain the walls and backs in safe condition without the use of timber and without ore dilution from wall slough. Cycles of drilling, scraping ore, and filling were devised, which have materially increased stope production and decreased timber consumption, so that both stope labor and supply costs were lowered appreciably without materially affecting grade control. In the larger mines of the district, where wide veins favor this stoping method, half of the total production is now being mined by horizontal cut-and-fill stopes (Fig. I). The increase of the filling rate demanded by the increased stoping rate was the greatest obstacle encountered in the accelerated stoping operations. Finally this problem was solved by replacing the time-honored method of transferring filling waste by small cars, which were hoisted or lowered in the auxiliary shaft, by a transfer

Jan 1, 1943

By E. R. Borcherdt

Methods and equipment are subject to study in the Butte district at all times in order that advantage may be taken of any new developments that might serve to increase efficiency and lower costs. Detailed time studies of each operation involved in the entire mining process have been of invaluable assistance in analyzing the individual operation for possible improvement. In other words, the fact that a practice has been in vogue for many years does not exempt it from change provided an easier and cheaper method can be found. Exploration Ore occurs in the Butte district in such manner that structures must be drifted on, no matter how small or unimportant they appear when intersected by a crosscut. Parallel structures also add to the crosscut requirements. This prospecting work, which formerly was done entirely by drifting and crosscutting, is now being supplemented by diamond drilling, to aid in greatly decreasing the amount of waste. In long-shot prospecting, or in second or third class prospecting, where the chances of developing commercial ore are not very great, diamond drilling is of particular value. In prospecting where chances of encountering commercial ore are certain or where crosscuts can be used later for haulage or ventilation, drilling obviously is not applicable. Improvement in drilling machines and bits has contributed greatly to the present success of diamond drilling. For many Years square-set filled stoping was the principal mining method used in the Butte district. Later timbered and untimbered rill stopes were used, also some horizontal cut-and-fill stoping where both Ore and walls were particularly strong. Because of the amount of timber required for square-set stoping, and the relatively low production per stope unit, experiments with horizontal cut-and-fill stopes were begun in Ore bodies of which many had fairly weak walls. It was felt that increase in the speed of the stoping operation, followed closely by filling, to avoid weight being produced by permitting ore and walls to remain insufficiently supported over comparatively long periods, would maintain the walls and backs in safe condition without the use of timber and without ore dilution from wall slough. Cycles of drilling, scraping ore, and filling were devised, which have materially increased stope production and decreased timber consumption, so that both stope labor and supply costs were lowered appreciably without materially affecting grade control. In the larger mines of the district, where wide veins favor this stoping method, half of the total production is now being mined by horizontal cut-and-fill stopes (Fig. I). The increase of the filling rate demanded by the increased stoping rate was the greatest obstacle encountered in the accelerated stoping operations. Finally this problem was solved by replacing the time-honored method of transferring filling waste by small cars, which were hoisted or lowered in the auxiliary shaft, by a transfer

Jan 1, 1943

By J. R. Campbell

A DOZEN years or so ago, the general superintendent of our company, now the president, Mr. W. H. Clingerman, detailed me to make a study of the coal-washing problem and collect data, which threw me into contact with the best washery men of the country. and took me to those districts where the washing of coal for metallurgical purposes is carried out. I investigated many kinds of coal-cleaning schemes, made numerous tests on them, and collected voluminous data, yet I confess frankly that I have had but little practical washery experience and that little has been at the Middlefork washery of the United States Fuel Co. at Benton, Franklin Co., Ill., which was put in operation last fall. While this wash-cry installation may not be the "last word," I am quite sure it embodies some long steps in advance over older designs and constructions. From the washery man&apos;s standpoint, the removal of pyrites, or marcasite, a disulfide of iron, is the one vital problem, and the one productive of the most beneficial results, so far as elimination of sulfur is concerned. Sulfates and so-called organic sulfur occupy quite a secondary -position and are generally lost sight of in coal washing: The elimination of sulfur in coal in the past has usually been accomplished by jigging in water, but lately the use of concentrating tables has been employed with good success, and some mention may be made of the flotation process on fine coal, though hardly considered practicable. Coal washing, is rapidly coming into its own, due to the depletion of low-sulfur coals for coking purposes, and before many years we predict as careful attention being given to the design and construction of coal washeries, ,as is now being given to byproduct plants and other allied industries. Heretofore, coal washing has been considered only as an incidental and a necessary evil-instead of the big problem it is one worthy of the most careful study by men well trained along technical lines and capable of delving into the fundamental principles.

Jan 9, 1919

By B. M. Larsen

Attempting to review the fundamental aspects of segregation in steel ingots of all types in a paper of reasonable length, we encounter two difficulties: (I) the fact that a large number of different physical and chemical effects are involved, and (2) rather incomplete and confusing evidence on certain aspects of detail and mechanism in the freezing process in which the segregation effect is involved. The best solution seemed to be to link together most of the underlying factors into a simplified theoretical picture that appears to the writer to explain most of the observed data, in the hope that this will serve as a reasonably good target for discussion and criticism. Segregation effects, especially in steel ingots or castings, are often divided into " microscopic" and "macroscopic," depending on whether the variations in concentration of solutes or dissolved elements in the iron occur as: (I) a periodic variation over the small distances between the nuclei and the surfaces of the primary grains, or (2) as a larger scale effect involving concentration gradients over distances of the order of several inches, more or less. The reason for this somewhat artificial division is, of course, that it is only the macroscopic scale effect that has much practical importance. About the only effect of practical importance that results from microscopic segregation is the banded structure often left in rolled sections, and even this is relatively harmless in most cases. However, the causes of microscopic segregation also untlerly the larger scale effect, so we must first consider matters such as the formation and growth of crystal nuclei, selective freezing and diffusion, and others that are fundamental to all sepregation effects. Undercooling and Nuclei Formation It is probable that although the degree of undercooling is small in iron, as in metals in general, a certain amount of it takes place, and also that the number of crystal nuclei increases very rapidly with increased undercooling below the liquidus temperature. In practical terms this means that the nuclei number illcreases very rapidly with increased cooling or freezing rate, thus being dependent on the rate of heat flow out from the zone of crystallization. Temperature Gradients and Heat Dissipation during Freezing Each pound of steel evolves about 100 B.t.u. when freezing. In addition to this, the temperature gradient in the solidified portion (required to dissipate the heat as freezing progresses into the axis) necessitates a loss of heat required to cool the solid metal below its freezing range, which is equivalent to an amount of not so much less in magnitude. In a 5-ton ingot, the total would include about one million B.t.u. for freezing alone and about 0.4 to 0.5 million B.t.u. for the gradient, up to the end of the freezing period. Thus the rate of freezing depends primarily on the rate of heat dissipation. In the ordinary ingot shapes, the axial rate of growth of the solid

Jan 1, 1945

By F. C. Schora, H. P. Meissner

Both a graphical and an analytical technique are presented for calculating stream compositions and temperatures in adiabatic staged systems in which solids travel countercurrently to a gas stream. Such a system might be a tower containing several plates, on each of which the descending solid is fluidized by the rising gas stream. Examples are presented in which chemical reactions occur, including the oxidation of SO, by a solid catalyst and the gaseous reduction of iron oxides. COUNTERCURRENT staged processes involving reactions between solid and gas streams are becoming more common. These operations are generally carried out in a series of beds of fluidized solids, with each bed or "plate" acting as a stage. Fig. 1 is a schematic diagram of such a series of stages located in a column, down through which a solids stream moves from stage to stage counter to a rising gas stream. Typical reactions carried out in such systems are the dehydration of aluminum trihydrate, the calcining of limestone, and the gaseous reduction of iron oxides. Calculation of the performance of these counter-current systems rapidly becomes more complex with increases in the number of stages and in the number of chemical reactions occurring. Calcula-tional procedures for isothermal operations of such systems have been described.4 Actual tower operations, however, are generally adiabatic, and in consequence far from isothermal. The object here is to present both graphical and analytical techniques applicable to such adiabatic towers operating continuously and in steady state. In this introductory discussion, the graphical techniques presented are of the McCabe-Thiele type, rather than of the Pon-chon type. In all the examples presented, it will be assumed that both thermal and chemical equilibrium are attained in each bed. The assumption that the gas and solid streams leaving each bed are at the same temperature as the bed is in accordance with the familiar behavior of actual fluidized solid systems. Chemical equilibrium, on the other hand, is not necessarily attained in any given stage between these two streams, even with deep beds, since reaction rates may be slow. In the last section of this paper, discussion is presented of methods suitable for use when chemical equilibrium is not attained. The adiabatic tower in Fig. 1 has "n" stages numbered from 1 to n, starting with the bottom stage as number 1. In analyzing this tower&apos;s performance, it is important to express gas flow rates in terms of a key component or element which remains completely within the gas stream throughout the tower. Similarly, solid flow is best expressed in terms of a key compound or element which remains within the solid phase throughout the tower. Thus, in burning limestone with a hot flue gas, the gas flow might be expressed as G, the pound mols of nitrogen flowing through the tower per unit time, while solid flow might be expressed as S, the pound atoms of calcium in all forms in the solid stream per unit of time. Defined in this way, both G and S are constant throughout the tower. The enthalpy of the gas and solid streams are now best expressed in terms of these key components. That is, the gas stream enthalpy H is expressed as Btu in the total gas per mol of the key component in the gas. Similarly, the solids stream enthalpy h is expressed as Btu in the total solid stream per pound mol (or pound atom) of the key component in this stream.

Jan 1, 1962

By Robert Craig, Earl L. Rau

Introduction Grinding circuits are used to reduce the particle size of ores to the size desired for beneficiation or to grind a concentrate to a size required for final marketing. Grinding and classification can be carried out using either wet or dry circuits. Most sulfide ores are ground in wet circuits using one or more stages of grinding to obtain the necessary mineral liberation to produce a final concentrate which will meet the desired criteria. Iron ores are ground in circuits applicable to the particular ore using either wet or dry grinding. Nonmetallic minerals frequently present different requirements. Barite is likely to be subjected to wet grinding before beneficiating the ore; the concentrate is dried and then dry ground to meet market particle size requirements. The one thing that most mill operators will agree to is that there is no such thing as the "best" configuration of equipment for grinding. The circuit which works well on one ore may be totally unsatisfactory for another ore body. The general trend in the industry is flow sheet simplication with fewer parallel circuits instead of multiple-line circuits using small mills. This change in philosophy has been brought about by the saving of both capital and operating costs that may be possible with larger equipment. Remember that comminution is basically a very inefficient process, and that the costs can range upwards to 50% of the total milling costs. It, therefore, behooves the mill operator to carefully design his grinding and classification circuits. He must ascertain the optimal economic particle size for beneficiation and then make certain he has achieved the best balance between capital and operating costs to achieve the desired mesh of grind. Equipment Grinding circuits consist of one or more pieces of equipment to grind the solids. Generally, these circuits include one or more grinding mills, classification equipment, and the necessary materials handling equipment such as pumps, pipelines, and conveyors. There are many different types of equipment available which are used to grind and classify ores and minerals. Following is a tabulation of most of the equipment used for wet and/or dry grinding.

Jan 1, 1982

"In the mines producing over 500 tons per day, skips have replaced the old method of hoisting ore by cars run onto cages. In the car and cage method, two men (station tenders) trammed the loaded cars onto the one-deck cage, and as the production increased the one-deck cage was increased to two decks and later to four decks. Landing chairs at the underground stations were necessary in this method and were the cause of many serious accidents by being carelessly left in the shaft by the station-tenders when leaving one station for anotherabove. The labor and time occupied in loading the leaving cages were con¬siderable, and, at times of rapid hoisting, four men were necessary in taking off empty and caging loaded cars. This also required at the surface landing, as many as ten men on a shift to remove the loaded cars and replacing them with empties, and tram the loaded ones to the surface ore bins, where the railway cars were loaded.The skips used in Butte are generally of 100 cubic feet capacity and hold five tons of ore, and weigh 7,500 lbs. The cage above, to which the skip is attached, weighs 2,300 lbs. The skips dump automatically into a pocket of 50 tons capacity. Two men are with the skips underground and load them from 125 ton capacity ore-pockets, under each station, the bottoms of the pockets having an inclination of 50 degrees from the horizontal. At the bottom of these pockets a gate is operated by compressed air. The labor of loading the skips amounts only to the opening and closing of a valve in the air-line, the ore running by gravity into the skips.Besides the saving in labor, the use of the skips has removed the necessity of underground landing chairs in the shaft and the accidents which are inevitable where such chairs are used."

Jan 1, 1913