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By Glen C. Ware

The Bureau of Mines determined the factors involved in the corrosion of starting sheets used in the production of electrolytic zinc with the ultimate purpose of adapting zinc starting sheets to commercial practice . Under present practice , zinc is electrodeposited on aluminum cathodes and subsequently stripped for melting . The use of zinc instead of aluminum would eliminate the need to strip the deposit , thereby reducing the cost of handling and melting it , but zinc has not been suitable because it was too vulnerable to the corrosive attack of the electrolyte . Serious attack was found to be limited to the areas of the cathodes situated immediately above the surface of the electrolyte and to re - entrant corners . It was possible to avoid solution - level corrosion by immersing the starting sheets completely , exposing only a relatively heavy suspension member to solution - level attack . Zinc starting sheets could be made as reliable as aluminum and could be continued in residence for periods up to 39 days . Periods as long as a week were feasible under conditions similar to those found in commercial practice . A test of zirconium as a starting - sheet material showed that it promoted corrosion of the deposit to a lesser extent than aluminum and that the deposit adhered less tenaciously . These two properties lend themselves to the development of ways to strip deposits mechanically from zirconium starting sheets . Titanium was unsuitable for use as a starting - sheet material .

Jan 1, 1963

By John J. Mulligan

Coalbeds were discovered in outcroppings of the Beacon group of sediments on the north end of the Willett Range ( altitude 77 ° 11 ' S , longitude 160 ° 20 ' E ) , Victoria Land , Antarctica , in December 1960 during an investigation undertaken as part of the U.S. Antarctic Research Program under the auspices of the National Science Foundation . Three separate exposures of coal or coaly material were found . Two of the exposures contain , respectively , eight and four beds of hard , compact , finely banded attrital coal ranging in thickness from 8 feet downward to a few inches , and reported to range in rank from mediumvolatile bituminous to semianthracite . The coals are associated with carbonaceous shales containing an abundant assemblage of fossil plants resembling those associated with the Permian coals of Australia and other Gondwana areas . The third exposure , apparently somewhat higher in the stratigraphic sequence , contains only coaly plant fragments scattered through a thin conglomerate and overlying sandstones . A sandstone bed that overlies these coal - bearing sandstones contains abundant logs and fragments of silicified wood . Preservation of features is poor , but one segment of a silicified stem suggests comparison with Rhexoxylon , a gymnospermous tree that usually is considered indicative of Triassic age . The Beacon sediments in this area have been invaded , broken , and uplifted by a massive series of diabase sills and dikes greater in volume than the intruded sediments . The heat emitted by these intrusives must have advanced the metamorphic development of the coals . However , there is no evidence of alteration to graphite , and coal found in direct contact with a diabase sill contains no vesicles or other usual evidences of natural coking . Either the pressure of overlying rocks inhibited the development of coke , or the coals had been metamorphosed beyond the coke forming stage before the igneous intrusion .

Jan 1, 1963

By W. E. Bruce, James Paone

Drillability or a measure of drilling performance has been based on ( 1 ) hardness and toughness of rocks , ( 2 ) power input to the drill compared with total volume of hole , and ( 3 ) penetration related to resistive forces of rock on the applied penetrative forces . An analysis of some representative previous work is made . Experimental drillability curves from AX- size diamond core bit performance in eight different rocks ranging from dense hard taconite to soft limestones are presented . Results show that in small bore diamond drilling , compressive strength and possibly other rock properties may be a useful parameter in predicting drilling rates .

Jan 1, 1963

By H. P. Hamlin, W. A. Grosh

Samples of clays , shales , and argillites from 21 locations were subjected to preliminary bench- scale tests for bloating properties , and several samples were tested for ceramic properties . Samples showing favorable bloating properties were further tested in a pilot - plant - scale rotary kiln . Physical characteristics and concrete -making properties of the bloated products were determined . The Decorah shale from one area made a suitable material for a lightweight aggregate ; however , the limestone layers in the formation must be eliminated or the resulting activated lime must be controlled by quenching .

Jan 1, 1963

By J. L. Hoffman, F. W. Wood, R. A. Beall, W. E. Anable

For melting and purifying reactive and refractory metals , two electronbeam furnaces have been constructed and operated on the principle of highpowered vacuum diodes . It was necessary to design the vacuum and electrical systems , mechanical features , and operating procedures to cope with dynamic conditions . Vacuums of 10-5 torr , tens of kilowatts of power at 5 to 10 kilovolts , and the evolution of impurities at thousands of liters per minute constitute a challenging combination . The furnaces have been used to melt either button specimens weighing several hundred grams or , by feeding material as a consumable electrode , small ingots weighing several kilograms . Hafnium is among the metals that can be purified . For example , hafnium starting material with Rhn 94B was softened to Rhn 70B after 2 hours of melting under a 25 - kw electron beam , and impurity levels were reduced as follows : Oxygen , from 700 to 350 ppm ; nitrogen , from 71 to 20 ppm ; hydrogen , from 6 to 1 ppm ; aluminum from 75 to < 20 ppm ; chromium , from 80 to < 10 ppm ; iron , from 100 to 40 ppm ; and silicon , from 40 to < 20 ppm .

Jan 1, 1963

By C S. Beals

The Dominion Observatory was founded in 1905 and, from the beginning, it work included research in both astronomical and geophysical science. During its first years, up to 1916, the Observatory also included geodetic surveying as part of it scientific program. Although, at the beginning of the century, geophysics did not have the close connection with mineral exploration that it now holds , the founders of the Observatory were men of vision, and they laid a solid foundation for the application of the techniques of geomagnetism, gravity and seismology to an understanding of the Canadian terrain of plain , mountains, seacoasts and shield area . The particular sphere which the Observatory occupies in the field of geophysics has been evolving over a period of many years and it has now a rather definite relation to the work of other government bodies, university science departments and industrial organizations. We have, for example, an over-all responsibility for the regional magnetic mapping of Canada and, as the magnetic field is subject to slow but steady changes, we produce new magnetic maps of the country every five years. These maps indicate the strength and direction of the magnetic field, the variation of the compass and the rate of change of the magnetic elements.

Jan 1, 1963

By John A. Fagnant

At Elkol, Wyo., about 80 miles northeast of Ogden, Utah, the Kemmerer Coal Co. and the Utah Power and Light Co. are involved in a joint venture that will soon see 1 million tons of coal going "out by wire" to Ogden. Kemmerer, owner of a multi-seam strip mine, and the utility, now building a steam power plant adjacent to the mine site, expect to begin initial power generation by February 1963. Although capable of producing only 150,000 kw at that time, this plant is expected to be ultimately enlarged to 500,000-kw capacity which will require about 2 million tons of coal annually. The deposit consists of more than 30 seams of coal, usually varying in thickness from 2 to 40 ft, and separated by beds of sandstones and shales. In certain areas the aggregate thickness of all the coal seams measures 300 ft. The thickest and most spectacular of these seams is the lowest one, referred to as the No. 1 seam, which is 118 ft thick in some places.

Jan 8, 1962

By Nathaniel Arbiter, Edward L. Vickers

Complete automation of concentrator operations through computer control has been under increasing consideration by American engineers for several years. Although justification for full-scale automation of a mill must ultimately be economic- added profits exceeding instrumentation and development costs-the technical feasibility of automation will be determined by the availability of requisite, detailed knowledge of the various unit operations in the plant. This poses problems. BASIC PROBLEMS WHICH MUST BE CONSIDERED A hypothetical porphyry copper mill will be used here to illustrate these problems. Its flowsheet will involve: mining, crushing, storage, grinding and classification, flotation, product de-watering, and disposal.

Jan 8, 1962

By W. C. Spence, Burt C. Mariacher

Methods employed to beneficiate ores utilize relatively few fundamental principles to effect size reduction and concentration. In crushing and grinding only impact and compressive forces with a minor amount of shear are employed. In concentration, gravity, magnetic, electrostatic and flotation constitute the major methods of concentration with minor use of sizing, hand picking and adhesion. This industry, as all others, can expect in the near future to see the development of new techniques for improved efficiency, cost reduction, and exploitation of raw materials hitherto considered unmanageable. NATURAL AND INDUCED RADIOACTIVITY At the Canadian Department of Mines in Ottawa in 1946, C. M. Lapointe developed a picker belt system whereby radioactive ores could be concentrated by electromechanical means. This invention ultimately led to development of what is now refer- red to as the Lapointe Picker and which has been used commercially at Port Radium and Port Hope for the upgrading of jig concentrates. Basically, the system consisted of conveying sized uranium ore on a belt under a radioactivity detection device which in turn electronically operated a kicker or plunger that separated the ore from the gangue constituents. Thus, a new principle for mineral concentration, radioactivity, was introduced commercially.

Jan 7, 1962

By Robert L. Haffner

When mining operations of The Eagle-Picher Co. began in the Illinois-Wisconsin zinc mining field in 1949, all underground loading of broken ore and waste was by caterpillar-tracked machines. Beginning in 1956 rubber-tired end-loaders were brought in; ultimately they completely supplanted the tracked units. End-loaders proved to have the mobility needed for the mining conditions and additional merit in auxiliary capacities. Eagle-Picher operates five mines in this area; two are entered by shafts and three by inclined adits. Several ore zones, some of which are attenuated over a considerable distance, are worked from the same entry. Consequently underground haulage roads connecting or following these orebodies have attained great length. In addition, working places are often widely separated because of the character of the mining operations which include pillar recovery and extending haulage connections into old workings. At one mine, the haulage distance is 5000 ft on either side of the shaft, at another the maximum one-way distance is 8400 ft, and at another the present road system of 6800 ft is expected to reach 10,000 to 12,000 ft.

Jan 6, 1962

By Howard L. Hartman

There is reason to believe that ventilation systems so far devised for use with continuous mining machines fall far short of success. This is vividly demonstrated to anyone who has observed in a continuous miner section the localized ignitions of pockets of gas and the generation of dense clouds of dust by the cutting head of the machine. The alarming frequency with which major ignitions and disasters continue to occur in modern mechanical mining and the rise in incidence of pneumoconiosis serve as reminders that our ventilation systems are far from achieving the ultimate in providing protection from either short-term explosions or long- term dust diseases, both of which take lives. Human safety is the main concern in ventilation. But in this day of high-priced labor, let us not forget human comfort, either, for this is a major factor in motivation toward high productivity. The failure or inadequacy of most mine ventilation systems in providing the kind of working conditions at the face that are conducive to productive as well as safe operation is an indictment of our environ- mental control program in mining generally.

Jan 3, 1962

By Raymond W. Hiteshue

To aid in designing a continuous system for evaluating processes for converting coal to high-Btu gas] the Bureau of Mines determined the amenability of various coals and a char to hydrogasification at 800° C and 6,000 psig using a molybdenum catalyst. A lignite from Rockdale, Tex., an hvCb coal from Rock Springs, Wyo., a char from the low-temperature carbonization of the latter, an hvAb coal from Pittsburgh, Pa., and an anthracite from Luzerne County, Pa., were selected. Highest yields of gaseous hydrocarbons, 94 pet, based on maf feed, were produced from char, and lowest yields, 67 pct, were obtained from lignite. Hydrocarbon gases contained 82 to 92 pct methane, 8 to 15 pct ethane; and 1 to 3 pct propane.

Jan 1, 1962

By James F. Watson, Jack L. Christian

The austenite to martensite solid state phase transformation in the 300 series austenitic stainless steels was studied over the temperature range of 788° to -423°F. The primary variables controlling this transformation are temperature, plastic strain, and chernical composition. Consequently, temperature effects were studied by measurements at 78", -100°, -320°, ad -423°F; plastic strain was controlled by cold-rolling the alloys varying amounts between 40 and 80 pet; and chemical compositions were varied by using 301, 302, 304 ELC, and 310 stainless steel alloys which exhibit varying degrees of austenite stability. The martensite contents of various alloys were correlated with several mechanical properties including yield and ultimate tensile strength, elongation, and notched tensile strength (Kt = 6.3). The yield and tensite strengths generally increased with increasing martensite content, but ) no correlation was observed between elongation and martensite content. The notched/un-notched ratio (Kt = 6.3) at -423°F exhibited a maximun at about 65 pct martensite. Attempts to correlate austenite stability (as measured by the Ms temperature) with both martensite content, and incremental increases in martensite content resulting from tensile testing were generally unsuccessful because the variable of cold Work could not be separated. As a result, only a general correlation of these variables was obtained. A (111) pole figure of austenite in a cold-rolled 301 stainless steel mas prepared an attempt to further investigate directionality as exhibited by mechan- ical properties. Yield strength was correlated with this pole figure, but ultimate and notched tensile strengths were not. 1 HE literature contains a wide variety of references pertaining to the austenite to martensite solid state phase transformation in austenitic stainless steel, see references 1 through 18. Discussions of the crystallography and kinetics of this transformation are given in references 2, 7, 8, &apos;and 11, while further discussions of austenite stability and hardening mechanisms are given in references 1, 3, and 10. Two important processing variables involved in this reaction are the degree of cold work and the temperature at which cold work is performed, and the nature of these effects are outlined in references 4 and 12, and 15 and 16 respectively. The latter two references deal primarily with cold rolling conducted at subzero temperatures. The effect of chemical composition on the austenite to martensite reaction was treated in detail by Eichelman and Hull, and they determined an equation for the M, temperature of this type of steel which included the effects of nickel, chromium, carbon, nitrogen, silicon, and manganese.5 Previous studies have shown that austenitic stainless steels of AISI types 301, 302, 304ELC, 310, and 301-N exhibit mechanical properties between 78" and -423"~ that are microstructure dependent, and the dependence of this microstructure on chemistry, temperature, tensile stress, and prior deformation is in general accord with previous investigations which have measured the effects of each of these variables on structure, or more specifically, the austenite-to-martensite transformation.lg The behavior of fully stable alloys, such as ATST type 310, at cryogenic temperatures is

Jan 1, 1962

By Donald H. Dowlin

The design of a preparation plant for minimum maintenance and clean up requires both the skills of the Engineer and the practical experience of the Operator. From the initial flow sheet and preliminary design until the plant is completed and operating, each phase of the work must be thoroughly explored for simplicity, workability and high efficiency. It is the responsibility of the Designing Engineer to develop the plant around the basic flow sheet, selecting equipment and materials not only with regards to Initial cost but also required upkeep and repair.

Jan 1, 1962

By Adrian C. Dorenfeld

Laboratory data form the basis for the design of flotation circuits. These data, obtained from testing samples of the ore, should show the optimum con- ditions for concentrating the ore and the effects of change in process vari- ables. Among the more important variables commonly met in flotation practice are: Liberation Size-This is the particle size at which substantially all of the valuable minerals are detached from the gangue minerals. Reagent Additions- Experimental data will show the reagents used and their quantity, quality, and point of addition. Pulp Density-This is an important variable in the design of the flotation circuit because it is one of the factors determining the size and number of flotation cells. Flotation Time-The time necessary to make the separation into concentrate and tailing depends on such factors as particle size and reagents used and must be known for determination of the size and number of flotation cells in the plant. Temperature of Pulp-Temperature affects flotation reactions. Water at approximately room temperature is satisfactory for most flotation separations, but some minerals such as fluorspar are best floated in hot water. Type of Circuit-Many types of circuits can be designed, as discussed in detail later. The laboratory tests should provide data for design of the plant circuit best suited to the ore. Water-Knowledge of the quality of the future plant&apos;s raw water is important because water quality may drastically affect flotation results. If possible, flotation tests should be made using samples of the water to be used in the plant. Flotation results may vary with seasonal temperatures and with circulation of reclaimed water. Experimentation can show whether it will be necessary to provide for heating, cooling, treating, or reclaiming the water. Uniformity of Ore-The extent of variation of the ore in hardness, grind- ability, mineral content, and floatability should be investigated so that the designer can ascertain methods to overcome problems caused by ore variations. Settling and Filtration Data-To design the plant flotation circuits, settling and filtration rates and ultimate percentage solids of the various products must be determined. Corrosion and Erosion-Corrosion and erosion tests should be made on the flotation pulps, particularly if the pulps are acid or at an elevated temperature, so that suitable materials of construction can then be chosen.

Jan 1, 1962

By W. H. Ode

An investigation of standard methods for determining ash in low-rank* coals showed that generally 60 to 95 percent of the total sulfur in the coal is retained in the ash as SO3. This large sulfur retention causes a positive error in the determined mount of ash of as much as 6 percentage points for the coals examined, although it usually is 2 to 3 percentage points for lignites and about 1 for subbituminous coals. Unless the sulfur content is low or unless a correction is made for the SO3 retained, the fixed carbon and oxygen have an equivalent negative error when determined by difference; also other inaccurate analytical values occur when the data are calculated on an ash- free bas is. No simple modification of the ashing procedure was found that would reduce the sulfur retention to a point where its effect on the ash determination would not be significant, Therefore, for accurate analytical work on law-rank coals, the SO3 should be deducted from the determined ash to obtain a "corrected" ash value.

Jan 1, 1962

By G. W. Birge

Carbonizing properties of the principal coal beds of Perry County, Ky., are described in this Bureau of Mines report. Seven samples, representing the Hindman, Flag, Haddix, and Fire Clay beds, were carbonized by the Bureau of Mines-American Gas Association (BM-AGA) method, and yields of products and physical properties of cokes were determined. Carbonizing properties of blends of Flag and Fire Clay coals, with 20 and 30 percent Pocahontas No. 3 low-volatile coal from McDowell County, W. Va., also were determined. Expanding properties of the Flag and Fire Clay coals and their blends were determined in the Bureau of Mines sole-heated oven. The Perry County coals tested are high-volatile A bituminous in rank and, with the exception of the Hindman-bed sample, which contained excessive sulfur, were chemically suitable for metallurgical use. The three coals tested in the sole-heated oven contracted less than normal for Appalachian coals of similar rank, Blending the Fire Clay and Flag coals with 20 or 30 percent low-volatile coal increased coke strength appreciably but increased the expansion beyond normal limits for industrial blends.

Jan 1, 1962

By G. Asai

The purpose of this Bureau of Mines investigation was to determine the properties of arc-melted iron-chromium alloys ranging in chromium content from 12 to 50 wt.-pct. Alloys were prepared by consumable-electrode arc melting of electrodes composed of high-purity chromium and high-purity iron. Alloys were fabricated to rod and sheet, and the following data were obtained: Electrical resistivity, hardness, tensile strength, and impact strength at room temperature; and creep-rupture life at 650° C. (1,200° F.). As the chromium content of the annealed alloys varied from 12 to 50 pct., the properties varied as follows: The electrical resistivity increased proportionally from 41 to 53 microhm-cm,; the Rockwell hardness varied from A 38 to A 58; the tensile strength ranged from 52,000 to 96,000 p.s.i.; the impact strength of V-notched charpy specimens varied from 140 to 405 ft.-lb., and the 100-hour creep rupture life at 1,200° F. varied from 5,000 to 16,000 p.s.i.

Jan 1, 1962

By G. W. Birge

Carbonizing properties of the principal coal beds of Butler County, Pa., are described in this report by the Bureau of Mines. Eight samples, representing the Upper Freeport, Lower Freeport, Upper Kittanning, Middle Kittanning, Lower Kittanning, Clarion, and Brookville beds, were carbonized at 900° C. by the Bureau of Mines-American Gas Association (BM-AGA) method. Butler County coals rank as high-volatile A bituminous and are generally characterized by high sulfur content compared with Appalachian coals used for industrial coking. If cleaned, the Brookville and one sample of Upper Freeport coal would be acceptable as the major component of metallurgical coking blends. The other Butler County coals tested would be unsuitable for this purpose because of either excessive sulfur or poor coking properties.

Jan 1, 1962

By G. E. Willey

F OR many years, only one grade of structural steel has been used in volume in Canada. Its characteristics have not been altered appreciably and its long use speaks well for its performance. This standard grade of structural steel may be bought and specified as C.S.A. G40.4 steel or the American equivalent, A.S.T.M. A7. The principal limitations and requirements of this specification are shown in Table I. Within the last five years there has been a growing awareness among the steel producers and steel fabricators that economic forces are at work which make desirable the availability of new and better grades of structural steel. Competition from other materials has increased. The use of concrete bridges and pre-stressed concrete beams is a prime example. New sources of steel from outside the country have become a threat to the Canadian industry and its high cost-price structure. The need for improved properties in the steel, to make possible technologic

Jan 1, 1962