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By Charles C. Rodd

Prior to 1938, proration procedure in Kansas required the physical testing of wells in order to set up a basis for allocating production. Subsequently the use of liquid-level data and bottom-hole pressure data was authorized on certain types of wells as a basis for calculating well capacities, thereby permitting wells to be tested at low rates and with small volumes of production. This paper gives some attention to the equipment used for obtaining liquid-level data but in general it is devoted to the theoretical and physical factors involved in well testing by drawdown methods. These tests are divided into two classifications: (I) liquid-level data used directly to calculate capacities, and (2) liquid-level data and liquid-level measuring equipment used in connection with other data to determine bottom-hole pressure. Equations and calculations for both types are shown. Well capacities calculated from fill-up data have not been used generally but offer a simple means of testing some wells. Theoretical factors and calculations for such tests are shown. In the state of Kansas, proration laws required that the "ability of a well to produce" be given consideration in state allocation orders and for many years this was the only factor used in prorating the allowed oil. The "ability of a well to produce", was the quantity of oil that could be obtained from a well in a prescribed period, usually 24 hr. Early in the history of State-regulated proration, Kansas operators realized that, unless some restriction were placed upon equip- ment, the competition between producers to obtain large well "potentials" might result in a race to install the largest pumping equipment. Consequently, restrictions were placed upon the size of tubing and length of pump stroke that could be used in pumping wells during potential tests. Later, restrictions were placed also upon the size of tubing and chokes that could be used in flowing walls. Despite the restriction setup, better pumping equipment was designed and installed, pumps were improved, and various devices were invoked to obtain high rates of production for short periods of time. By 1937 pumping cycles of forty to forty-five 54-in. strokes per minute were not uncommon, and numerous wells had produced at the rate of 3500 bbl. per day for short periods. Such production was far beyond any rate that could be long sustained. Equipment necessary to take "potentials" was several times larger than that needed for normal producing purposes, and repairs and replacements required by the high pumping speeds were excessive. Also, many operators suspected that the high rates of production main tained during '"potential" tests were conducivc to early water encroachment. By 1938 large-scale physical testing of wells in Kansas ended, the use of the bottom-hole pressure gauge had become common, engineers and operators were becoming familiar with the term ''productivity index," and bottom-hole pressure was being used as a factor in allocation in many areas. There were many drawbacks, however, to large-scale use of

Jan 1, 1943

By Charles C. Rodd

Prior to 1938, proration procedure in Kansas required the physical testing of wells in order to set up a basis for allocating production. Subsequently the use of liquid-level data and bottom-hole pressure data was authorized on certain types of wells as a basis for calculating well capacities, thereby permitting wells to be tested at low rates and with small volumes of production. This paper gives some attention to the equipment used for obtaining liquid-level data but in general it is devoted to the theoretical and physical factors involved in well testing by drawdown methods. These tests are divided into two classifications: (I) liquid-level data used directly to calculate capacities, and (2) liquid-level data and liquid-level measuring equipment used in connection with other data to determine bottom-hole pressure. Equations and calculations for both types are shown. Well capacities calculated from fill-up data have not been used generally but offer a simple means of testing some wells. Theoretical factors and calculations for such tests are shown. In the state of Kansas, proration laws required that the "ability of a well to produce" be given consideration in state allocation orders and for many years this was the only factor used in prorating the allowed oil. The "ability of a well to produce", was the quantity of oil that could be obtained from a well in a prescribed period, usually 24 hr. Early in the history of State-regulated proration, Kansas operators realized that, unless some restriction were placed upon equip- ment, the competition between producers to obtain large well "potentials" might result in a race to install the largest pumping equipment. Consequently, restrictions were placed upon the size of tubing and length of pump stroke that could be used in pumping wells during potential tests. Later, restrictions were placed also upon the size of tubing and chokes that could be used in flowing walls. Despite the restriction setup, better pumping equipment was designed and installed, pumps were improved, and various devices were invoked to obtain high rates of production for short periods of time. By 1937 pumping cycles of forty to forty-five 54-in. strokes per minute were not uncommon, and numerous wells had produced at the rate of 3500 bbl. per day for short periods. Such production was far beyond any rate that could be long sustained. Equipment necessary to take "potentials" was several times larger than that needed for normal producing purposes, and repairs and replacements required by the high pumping speeds were excessive. Also, many operators suspected that the high rates of production main tained during '"potential" tests were conducivc to early water encroachment. By 1938 large-scale physical testing of wells in Kansas ended, the use of the bottom-hole pressure gauge had become common, engineers and operators were becoming familiar with the term ''productivity index," and bottom-hole pressure was being used as a factor in allocation in many areas. There were many drawbacks, however, to large-scale use of

Jan 1, 1943

By J. B. Pullen

THE United Verde mine is in the north central part of Arizona, on the. north-easterly slope of the Black Hills, near the town of Jerome. Ore was first discovered in the district about 1875, and the first mining claims were located by M. A. Ruffner and associates in 1877. In 1888 the late Senator William A. Clark secured control of the property and under his ownership it developed into one of the country's most important copper producers. The property was sold to the Phelps Dodge Corporation in 1935, and since then has been under this Corporation's management. Except for shutdowns caused by general world-market conditions, production has been continuous from 189o to date. GEOLOGY The mineralized zone ranges in area from approximately 12 acres to less than 5 acres. All mineralization occurs in the pre-Cambrian intrusives. The first intrusion, according to geologic records, was the quartz porphyry, which later was intruded by augite diorite. Following the diorite intrusion through a series of intrusions of lesser magnitude, a pipelike mass of massive sulphide, quartz and rock was formed. The diorite forms the hanging wall of this mass, and the porphyry the footwall. Between the footwall and the sulphide a band of chlorite schist was formed, probably owing to metamorphic conditions. Commercial ore occurs along the contact of the schist and sulphide extending into the sulphide, sometimes entirely through the schist, and fingering out into the porphyry. The ore deposit was formed by replacement similar to deposits formed in limestone areas. Faulting and deformation occurred in pre-Cambrian times and again in the Tertiary period, removing approximately 2000 ft. from the top of the main United Verde ore body, forming the United Verde Extension ore body, the only other major ore body in the district. Major development work has shown that the sulphide mass extends to the 3300-ft. level, and diamond drilling below this level has indicated that the mass might extend below the 3700-ft. level, but in a diminished quantity. While many copper minerals exist in the mine, the chief commercial mineral is chalcopyrite. A plan and vertical section of the mineralized zone showing the principal geological features is shown in Figs. I and 2. GENERAL DESCRIPTION AND PHYSICAL CONDITION OF MINE After over 50 years of active production, ore still exists on almost every level of the mine. This condition is due to many causes -mine fires, which broke out as early as 1894, caused the abandonment of certain areas; subsidence and ground movements retarded the cleaning up of others. Furthermore, in the early days there was such an abundance of ore that when mining became difficult it was a simple matter to replace the production by going to a deeper level. Several attempts were made to recover the ore in the fire zone, both by glory-holing

Jan 1, 1941

By M. L. Lissberger

entirely suitable for certain uses and even possess advantages over present solders at high temperatures, but they are certainly not suitable for all uses. However, it is conceivable that their use in many places will effect a material conservation of tin. It will probably be wiser to use cadmium in solders where good results have been obtained than in brass where this element will be a source of possible trouble. F. F. Colcord,* New York, N. Y.-—The cadmium-lead solder has a higher conductivity than the lead-tin alloy, which ought to make it advantageous in the manufacture of electrical machinery. In the case of solder for tin-can work, one of the high officials of the American Can Co. said that he fully intended to .give it a good trial, and I do not believe they are going to reach hasty conclusions and run the risk of poisoning the public. Solder, Its Use and Abuse Milton L. LissbeRgeR,† New York, N. Y.—Solder is a mechanical mixture of tin and lead, a fact which is susceptible of very simple demonstration. A bar of solder of a grade even as low as 30 per cent. tin and 70 per cent. lead, passed through a buffing machine, will show a surface practically identical with that of a bar of second-quality or reclaimed tin. The buffings, on chemical analysis, will prove to be almost pure lead. According to the best practice, solder is made in the following manner. Virgin pig lead is first melted, and when it is thoroughly liquefied, virgin pig tin is added, together with a small amount of flux; the latter is for the purpose of bringing to the surface the so-called "liver," consisting of impurities that may have remained in either the lead or the tin as a result of incomplete refining. The combined material, when completely liquid, is thoroughly stirred for some hours, and is then cast into small pigs. Just before casting, and continuously during this operation, the molten metal yields dross, consisting largely of the oxides of lead and tin; this should be carefully skimmed off. After the pigs have cooled, they are taken to a smaller kettle, re-melted, and cast into the desired shape for use; or if wires, ribbons, etc., are to be made, the solder is cast into slugs suitable for extrusion and rolling. During this second operation, the skimming of dross should be even more carefully done than at first. Hand mixing has proved to be the only reliable method for the production of the best quality of solder, irrespective of its percentages of lead and tin. The best quality of solder is not necessarily that which contains the highest percentage of tin, but rather is that composition which performs best on the required piece of work. In order to produce

Jan 1, 1919

By F. M. Lewis, J. E. Goodman

A larger, slow-speed, under-loaded ball mill and hydraulic classifier have almost doubled grinding efficiency at the lsabella mill. TENNESSEE Copper Co. operates two ore con-A centrators, the London and Isabella mills near Copperhill, Tenn. In 1948 and 1949 the small ball mills and rake classifiers in the London concentrator were replaced by one large ball mill and one hydraulic classifier. This new ball mill was designed oversize so that it could be operated at slower than normal speed. The proper operating conditions were established and the results published.' Later it was found that this mill operated more efficiently with a small ball charge." While this London grinding practice was being developed, the Isabella grinding circuit was not changed in any way. It remained a conventional two-stage rod mill—ball mill combination, the rod mill in open circuit and the ball mill in closed circuit with a rake classifier. Study of the data indicated that grinding cost could be lowered by converting to the London practice, but not enough would have been saved to warrant the expense of converting. No plan for improving this grinding operation could be developed. In 1953 this study was reopened when plans were made to increase the Isabella mill output from 1150 to 1500 tpd. At this time the grinding circuit consisted of a 6x12 rod mill followed by a 6x12 ball mill in closed circuit with a 6-ft rake classifier. Another 6x12 ball mill and 6-ft rake classifier would have been sufficient equipment and would have been the simplest and cheapest installation. However, this would have offered no improvement in grinding efficiency or operating cost. If, on the other hand, the grinding operation could be converted to the London practice, by installation of one large 101/2x9x9 tricone mill and a 10-ft hydroscillator,2 lower operating costs would justify the additional investment. Economics: Table I presents estimates for the two schemes for enlarging the Isabella mill. In the first scheme, column 1, one 6x12 ball mill and one 6-ft rake classifier were to be added. In the second scheme, column 2, the existing small ball mill and rake classifier were to be retired and one large mill and hydroscillator were to be installed. Estimated savings from the difference in operating costs made an attractive return on the additional investment for the large mill and hydroscillator. Actual costs of carrying out this plan are tabulated in column 3b. It will be seen that these costs follow the estimates in column 3a very Closely. The return on the additional investment is calculated from the difference in the operating cost in column 1 and the actual operating cost in column 3b. This too come very close to the estimate. Power and Steel: Power requirements and steel consumption for the rod mills and ball mills, both actual and estimated, are presented in Table 11.

Jan 1, 1958

By E. R. Williams

Continuous casting of nonferrous metals has become a commercial reality. After years of slow and arduous experimentation by a number of independently working inventors, starting with Lord Henry Bessemer in 1865, success has finally been achieved. Nonferrous metals—aluminum, copper and brass—extremely vital to our production of war equipment, are being continuously cast every day in large quantities. In fact, some nonferrous metals —for instance, high-strength aluminum alloys—could not have been produced in the huge quantities required for planes and other war equipment if it were not for continuous casting. These casting processes for nonferrous metals have not been entirely perfected but continuous casting is here to stay. Continuous casting of carbon and alloy steel has not yet gone into commercial production but it is well on its way. A great deal of hard work has been expended and -small fortunes in money have been and are being spent in marching down the long road to success. Considerable tonnage of plain carbon, stainless and other alloy steels of high quality have been produced by pilot-plant continuous-casting units and at speeds that give indisputable evidence of commercial success. What has made the difference between failure and success? What is there left to do to revolutionize completely the method of casting metals, which has existed for centuries? These questions are being rapidly answered. Fundamental Methods Present continuous casting processes have many common problems but differ considerably in their methods of solution. The two fundamental methods are: I. Forming the solidifying metal against mold walls that move with the metal, so that there is no relative movement between the walls and the metal. This is a development of Lord Bessemer's idea of pouring metal between two rotating rolls. 2. Moving the solidifying metal along a stationary mold wall so that there is relative movement between the wall and the metal. This was proposed by Trotz in Germany as far back as 1889. Neither Bessemer nor Trotz achieved commercial success. The chief reason seems quite apparent today, inasmuch as they did not solve the fundamental problem of rapid heat removal from the molten metal. The Williams Continuous Casting Process is based upon this fundamental idea of fast heat removal and dissipation. The bessemer method of forming the ingot against a moving mold wall—either rotating rolls or endless moving plates—was carefully considered by the author and promptly abandoned as being commercially impractical. Primarily, only a very small tonnage output was possible except at terrific lineal speeds, because the very nature of this method required casting thin sheets rather than ingots. Secondly, the casting of a sheet between lolls that are pressed together meant the rolling of two layers of solidified skin separated by a molten core. Internal bursts and segregation of the metal usually resulted. Moving Solidifying Ingot Along Mold Wall It was decided therefore to devote our research activities chiefly to- the idea of moving the solidifying ingot along. a stationary mold wall. It was soon dis-

Jan 1, 1945

By M. D. Hassialis, Arthur F. Taggart

WARK1 observed some years ago that collector-coating reactions with xanthates and with fatty acids clearly follow paths parallel to those prescribed by the familiar mass-action law for reactions in dilute solutions. He proposed, therefore, the logical hypothesis that they are governed by the solubility=product principle. However, he went astray in the application of his proposal to collector coating by overlooking the fact that coating involves a heterogeneous reaction. A mistaken concept of the meaning of the word adsorption also entered. Wark thought that the concentration of metallic ion that must be used in setting up the solubility-product equation for the coating reaction was that which could be obtained by solution of the mineral. Since this is very low for sulphide ores, and since the amount of the collector ion necessary for coating produces an extremely low concentration, the resulting ion-concentration product, under conditions when coating occurs, is much lower than that which would indicate a saturated solution of the collector-coating compound. Hence he was forced to the position that the solubility product governing the coating is much smaller than the standard solubility product. To justify this position it was necessary to postulate a coating mechanism that did not obey the ordinary laws of chemical reaction. This Wark did by adopting the concept that adsorption is a property of matter, rather than merely a more or less ephemeral local concentration thereof. Thus he says (p. 142 of ref. I): "Adsorption is not a purely physical property of the solid surface, for the specific nature of the adsorbed molecule or ion is important." The result was that he destroyed the great potential utility of his postulate by tying it to this erroneous concept in the words (pp. 142, 143): "It will be obvious that the adsorption solubility product is less than the normal solubility product." The writers have found quantitatively in the case of galena and potassium ethyl xanthate, and semiquantitatively in the case of covellite and the same collector, that the coating reaction does follow the mass-action law to the extent that coating occurs when the ordinary solubility product of the coating compound is exceeded, and that coating does not take place under the reverse conditions. In the course of the investigation leading to the establishment of this fact it was necessary to work with xanthate concentrations so low (down to 0.0004 mg. per liter), that very long conditioning times, and bubble-contact times of as much as 16 hr. were necessary sometimes to follow the reactions. The results have led to some illuminating conclusions as to necessary collector concentrations in normal flotation operations, and the action of the frothing agent in connection therewith. The experimental work comprised. accurate determination of the standard solubility product of lead ethyl xanthate, development of a much less laborious

Jan 1, 1946

By C. E. McCarthy, A. George Stern, Stanley J. Green

The national interest prompts consideration of any new source of mineral wealth even though the immediate need may be of minor importance. A critical shortage of potash in the United States during the World War of 1914-18 stimulated broad development, which established an American potash industry on a basis so sound that this commodity is not even listed as urgent in the present war program. However, this should not minimize its importance, and the need remains, not only for adequate supplies of the usual potash salts (the chloride and the sulphate) but of all potash chemicals. Potassium carbonate (known commercially as pearl ash) has been a high-cost commodity; in consequence, the quantity used by industry has been relatively small. By a combination of fortuitous geographical circumstances, there is opportunity to produce a low-cost potassium carbonate with the possibility that this might become an important source of chemical potash. The following paper considers a recently developed process1 taking advantage of these conditions. Wyomingite Deposit For many years it has been known that a deposit of potash-bearing igneous rock known as wyomingite occurs in the south- western part of Wyoming at Zirkel Mesa, which is 44 miles northeast of the town of Green River (Fig. I). The western escarpment of this deposit is about 3 miles east of the Superior Branch of the Union Pacific Railroad. This mesa alone covers approximately 3300 acres, and the average thickness of the wyomingite flow is 75 ft. It has been estimated2 that about one billion tons of wyomingite occur in this one deposit, all of which can be mined by open quarrying without overburden. In addition, there are several smaller deposits within 10 miles, so that the aggregate wyomingite in the area approaches two billion tons. This is one of the world's largest sources of leucite, and the only known deposit of its kind in the United States. The wyomingite (which is in the form of a lava flow and numerous small craters), with the mineral leucite as its most important component, has a mineral composition3 of: leucite, 50 per cent; phlogopite, 15; diopside, 12; kataphorite, 15; glass and apatite, 8. The phlogopite is present in visible phenocrysts 1/8 to 1/2 in. in diameter, but the leucite usually is almost microcrystalline and not capable of liberation by grinding. Chemically, the Wyomingite has a potash Content averaging slightly higher than eleven per cent K2O. The potash is mainly in the leucite, but part of it is in the phlogopite and a small amount is in the feldspars that are occasionally seen as undigested occlusions of the granite country rock, through which the leucite-bearing lava intruded, and as sanidine feldspar both in the crystalline and glassy phases of the rock. A typical analysis of the wyomingite from Zirkel Mesa is as follows:

Jan 1, 1948

By A. George Stern, Stanley J. Green, C. E. McCarthy

The national interest prompts consideration of any new source of mineral wealth even though the immediate need may be of minor importance. A critical shortage of potash in the United States during the World War of 1914-18 stimulated broad development, which established an American potash industry on a basis so sound that this commodity is not even listed as urgent in the present war program. However, this should not minimize its importance, and the need remains, not only for adequate supplies of the usual potash salts (the chloride and the sulphate) but of all potash chemicals. Potassium carbonate (known commercially as pearl ash) has been a high-cost commodity; in consequence, the quantity used by industry has been relatively small. By a combination of fortuitous geographical circumstances, there is opportunity to produce a low-cost potassium carbonate with the possibility that this might become an important source of chemical potash. The following paper considers a recently developed process1 taking advantage of these conditions. Wyomingite Deposit For many years it has been known that a deposit of potash-bearing igneous rock known as wyomingite occurs in the south- western part of Wyoming at Zirkel Mesa, which is 44 miles northeast of the town of Green River (Fig. I). The western escarpment of this deposit is about 3 miles east of the Superior Branch of the Union Pacific Railroad. This mesa alone covers approximately 3300 acres, and the average thickness of the wyomingite flow is 75 ft. It has been estimated2 that about one billion tons of wyomingite occur in this one deposit, all of which can be mined by open quarrying without overburden. In addition, there are several smaller deposits within 10 miles, so that the aggregate wyomingite in the area approaches two billion tons. This is one of the world's largest sources of leucite, and the only known deposit of its kind in the United States. The wyomingite (which is in the form of a lava flow and numerous small craters), with the mineral leucite as its most important component, has a mineral composition3 of: leucite, 50 per cent; phlogopite, 15; diopside, 12; kataphorite, 15; glass and apatite, 8. The phlogopite is present in visible phenocrysts 1/8 to 1/2 in. in diameter, but the leucite usually is almost microcrystalline and not capable of liberation by grinding. Chemically, the Wyomingite has a potash Content averaging slightly higher than eleven per cent K2O. The potash is mainly in the leucite, but part of it is in the phlogopite and a small amount is in the feldspars that are occasionally seen as undigested occlusions of the granite country rock, through which the leucite-bearing lava intruded, and as sanidine feldspar both in the crystalline and glassy phases of the rock. A typical analysis of the wyomingite from Zirkel Mesa is as follows:

Jan 1, 1948

By R. G. Patterson

The usual procedure in determining the magnetic susceptibilities of rocks and formations has been to take samples in the field and measure their volume susceptibilities in the laboratory, using one of numerous methods available. In none of these methods is the measuring instrument suited for field use. Usually the sample is pulverized; sometimes it is machined to a desired sue and shape, and in one method1 a cast of the sample is made and the susceptibility of the rock compared with that of a material of known susceptibility of the same size and shape, made from the cast of the original sample. Some writers assert that the difference in susceptibility of a rock sample in powdered and solid forms is negligible, and while doubtless this is true in many cases there are others in which the difference becomes appreciable. Further, the susceptibility of a small specimen may differ from that of the rock from which it is taken, owing to the stresses produced by the hammering or other forces used to obtain the sample and shape it for testing. Wilson2 found that an individual specimen of granite had about the same susceptibility in the solid as in the powdered form, but that pieces from different parts of the rock varied as much as 750 per cent because of unequal distribution of magnetite. The most accurate value of susceptibility would, obviously, be obtained from averag- ing a number of tests on the undisturbed rock instead of from one or two samples. No such procedures have been published, to the writer's knowledge. It is the purpose of this paper to describe a method by which susceptibilities of rocks may be determined in place by means of a portable instrument. Method The principle involved in this new method is that there is a change in inductance of a coil due to the presence in its magnetic field of a paramagnetic or dia-magnetic medium. In this case, however, the windings of the coil do not enclose any part of the rock under test. Instead, the coil is circular, being small in cross section as compared to its radius, and consists of several hundred turns of fine wire. It is placed flat on the rock of which the susceptibility is to be measured. Thus only part of the magnetic field from the coil penetrates the rock under test. The relation between the change in field strength or inductance of the coil and the susceptibility of the medium will be developed later. To measure the change in the inductance of the coil due to the presence of a magnetic material an alternating-current inductance bridge was chosen. Description of Apparatus Of many alternating-current bridge methods applicable,3 the one shown in Fig. 1 (Owen's bridge') was adopted for its simplicity and sensitivity. In Fig. I, the test coil is indicated by PlL1. It is connected to the bridge by about

Jan 1, 1946

By R. G. Patterson

The usual procedure in determining the magnetic susceptibilities of rocks and formations has been to take samples in the field and measure their volume susceptibilities in the laboratory, using one of numerous methods available. In none of these methods is the measuring instrument suited for field use. Usually the sample is pulverized; sometimes it is machined to a desired sue and shape, and in one method1 a cast of the sample is made and the susceptibility of the rock compared with that of a material of known susceptibility of the same size and shape, made from the cast of the original sample. Some writers assert that the difference in susceptibility of a rock sample in powdered and solid forms is negligible, and while doubtless this is true in many cases there are others in which the difference becomes appreciable. Further, the susceptibility of a small specimen may differ from that of the rock from which it is taken, owing to the stresses produced by the hammering or other forces used to obtain the sample and shape it for testing. Wilson2 found that an individual specimen of granite had about the same susceptibility in the solid as in the powdered form, but that pieces from different parts of the rock varied as much as 750 per cent because of unequal distribution of magnetite. The most accurate value of susceptibility would, obviously, be obtained from averag- ing a number of tests on the undisturbed rock instead of from one or two samples. No such procedures have been published, to the writer's knowledge. It is the purpose of this paper to describe a method by which susceptibilities of rocks may be determined in place by means of a portable instrument. Method The principle involved in this new method is that there is a change in inductance of a coil due to the presence in its magnetic field of a paramagnetic or dia-magnetic medium. In this case, however, the windings of the coil do not enclose any part of the rock under test. Instead, the coil is circular, being small in cross section as compared to its radius, and consists of several hundred turns of fine wire. It is placed flat on the rock of which the susceptibility is to be measured. Thus only part of the magnetic field from the coil penetrates the rock under test. The relation between the change in field strength or inductance of the coil and the susceptibility of the medium will be developed later. To measure the change in the inductance of the coil due to the presence of a magnetic material an alternating-current inductance bridge was chosen. Description of Apparatus Of many alternating-current bridge methods applicable,3 the one shown in Fig. 1 (Owen's bridge') was adopted for its simplicity and sensitivity. In Fig. I, the test coil is indicated by PlL1. It is connected to the bridge by about

Jan 1, 1946

By Stanley D. Michaelson

The selection of the proper size of grinding mill for a given installation has long been a subject of discussion by mill manufacturers, consulting engineers, and their clients. It would be presumptuous for the author to propose a simple cure-all. Instead this paper describes a method that has been used over a period of years to determine mill size with a reasonable degree of accuracy. Furthermore, this method claims no theoretical background, for ball milling, as practiced today, is still an art. The selection of the proper size and type of mill must, therefore, be made on an empirical basis. A ball mill, in order to grind, must deliver power through its grinding media to the material to be ground. Assuming that a mill is properly supplied with grinding media, ore pulp, and power, the amount of grinding done is closely proportional to the power expended. With this as a basic premise we can, for the moment, forget about type of mill (i.e., overflow, low-level mill, or other design) and base our calculation of mill size on the total power required to grind a ton of a particular ore from a given size of feed to a given size of product. When this is determined the type and size of mill, its speed, and the weight of the load of grinding media can be selected to absorb this amount of power. Development of Technique Some years ago, W. L. Maxson, F. Cadena, and F. C. Bond, working in the Minerals Research Laboratory of Allis-Chalmers Co., Milwaukee, developed and described a laboratory technique for comparing grindability (or relative ease of grinding) of various ores at different mesh sizes of grind.' Additional papers2 have described the work done since that time, and the most recent paper3 summarizes results for hundreds of tests on many ores and materials. The essentials of the testing method are: a 12 by 12-in. laboratory mill operating at a constant speed of rotation, using a constant volume of ore, and a constant ball load having a relatively constant grinding surface. Tests are run at 250 per cent circulating load with the feed, circulating load and products screened on calibrated Tyler standard screens. Certain ores from operating mills, representing various mineralogical types, were selected for reference and designated "standard ores." In most cases, detailed studies of the grinding circuits were made when samples of mill feed were taken for grindability tests. Each analysis formed a basis for comparison of the grindability in the laboratory with actual power requirements for a particular grinding circuit. In addition, a critical study was made to evaluate the differences in the various grinding circuits so that two or more field installations having different layouts (single-stage grinding, two-stage grinding, or others), and using mills of various diameters operating at various speeds with differing circulating loads, etc., could be compared. Large-scale tests by mill operators complemented by laboratory investiga-

Jan 1, 1947

By Stanley D. Michaelson

The selection of the proper size of grinding mill for a given installation has long been a subject of discussion by mill manufacturers, consulting engineers, and their clients. It would be presumptuous for the author to propose a simple cure-all. Instead this paper describes a method that has been used over a period of years to determine mill size with a reasonable degree of accuracy. Furthermore, this method claims no theoretical background, for ball milling, as practiced today, is still an art. The selection of the proper size and type of mill must, therefore, be made on an empirical basis. A ball mill, in order to grind, must deliver power through its grinding media to the material to be ground. Assuming that a mill is properly supplied with grinding media, ore pulp, and power, the amount of grinding done is closely proportional to the power expended. With this as a basic premise we can, for the moment, forget about type of mill (i.e., overflow, low-level mill, or other design) and base our calculation of mill size on the total power required to grind a ton of a particular ore from a given size of feed to a given size of product. When this is determined the type and size of mill, its speed, and the weight of the load of grinding media can be selected to absorb this amount of power. Development of Technique Some years ago, W. L. Maxson, F. Cadena, and F. C. Bond, working in the Minerals Research Laboratory of Allis-Chalmers Co., Milwaukee, developed and described a laboratory technique for comparing grindability (or relative ease of grinding) of various ores at different mesh sizes of grind.' Additional papers2 have described the work done since that time, and the most recent paper3 summarizes results for hundreds of tests on many ores and materials. The essentials of the testing method are: a 12 by 12-in. laboratory mill operating at a constant speed of rotation, using a constant volume of ore, and a constant ball load having a relatively constant grinding surface. Tests are run at 250 per cent circulating load with the feed, circulating load and products screened on calibrated Tyler standard screens. Certain ores from operating mills, representing various mineralogical types, were selected for reference and designated "standard ores." In most cases, detailed studies of the grinding circuits were made when samples of mill feed were taken for grindability tests. Each analysis formed a basis for comparison of the grindability in the laboratory with actual power requirements for a particular grinding circuit. In addition, a critical study was made to evaluate the differences in the various grinding circuits so that two or more field installations having different layouts (single-stage grinding, two-stage grinding, or others), and using mills of various diameters operating at various speeds with differing circulating loads, etc., could be compared. Large-scale tests by mill operators complemented by laboratory investiga-

Jan 1, 1947

By Richard M. Foose

MOST of the roofing granules produced in Pennsylvania are made by two companies at three plants. The Advance Industrial Supply Co. has three quarries and a mill at Gladhill Station, in southern Adams County. The Funkhouser Company is actively engaged in mining, quarrying and milling at Charmian, about one mile west of Gladhill Station, and at Delta, in southern York County. These three plants produced approximately 100,000 short tons of granules in 1943. The production of roofing granules in 1937 for the whole country was only about 500,000 tons, generally indicating the large growth of the industry since that time. The fundamentals of producing roofing granules were discussed comprehensively by G. W. Josephson in a paper before the Industrial Minerals Division in October 1943 (Mining Technology, March 1944). The purpose of this paper is to describe the actual methods of mining the rock and milling it to make roofing granules, as practiced by the three Pennsylvania plants. MINING AND MILLING Funkhouser Company (Delta) The Funkhouser Company, near Delta, in southern York County, Pennsylvania, operates three joined quarries and a mine in the Peach Bottom slate. The joined quarries extend 1200 ft. in a northeast southwest direction along the strike of the slate cleavage and are about 200 ft. wide. The working face is about 45 ft. high. The quarrying operation is rather simple: Ingersoll-Rand Jackhamers, 1-in. and 1 1/4-in., with hollow drill steel, are used to undercut the quarry face with10-ft. holes. The face is "blown" and allowed to slump on the quarry floor. Loaded by a Marion electric shovel into trucks, the shattered rock is taken to the primary crusher 2500 ft. away. In addition to the normal quarrying operations, a drift into the northeast wall of the middle quarry was begun about 1935 and has advanced about 2000 ft. since then. Rooms have been driven at angles to the drift along choice beds of slate. The drifts and rooms have a roof more than 35 ft. high and the main drift and rooms are all more than 40 ft. wide. There is no cribbing at any place in the mine. Several of the rooms were driven upward on a 5º slope and in some of them there was stoping. Ingersoll-Rand Jackhamers are used, and only wet drilling is practiced. When visited in January 1940, an electric shovel was operating at the head of the drift, scooping up the slate blasted out of the working face. This, too, is trucked to the primary crusher. Some of the better quality slate is saved for making slate shingles. The primary crusher, which is a No. 30 McCulley gyratory, receives the slate from the trucks and crushes it to about 2-in. size (Fig. I). This product travels by a 30-in. belt conveyor to Niagara vibrating screens with 2-in. holes. The minus 2-in. product moves to a storage silo by bucket

Jan 1, 1945

By Henry H. Angst

Tim history and efficiency of 40-ton capacity dump trucks for surface waste removal at the New Cornelia opencut copper mine, at Ajo, Ariz., are summed up in this paper. Tabulations of truck performance, together with detailed cost figures, prove the value of truck transportation for certain special operations at a large mine. Emphasis is given to the fact that truck transportation not only reduces the haulage costs but also reduces the breaking ground and shovel-loading costs per ton. The New Cornelia opencut copper mine is in the desert. The climate is ideal for seven months of the year, but the five summer months are uncomfortably hot. The elevation is 1820 ft. above sea level and the annual rainfall is approximately 6 inches. The ore body is a monzonite-porphyry deposit. The waste-rock capping consists of hard rhyolite, conglomerate and porphyry. All the material is hard and cannot be excavated without blasting. The rhyolite and conglomerate waste is very blocky. The weight of the rock in place is 2.16 tons per cubic yard. The average mine production per day is 22,000 tons of ore and 18,000 tons of waste rock, the latter consisting of surface rock and material within the ore body too low in grade to send to the concentrator. The rock is loaded by electric shovels with 4 1/2-cu. yd. dippers. The primary transportation of ore to the concentrator and waste to the dumps is by 30-yd. dump cars and oil-burning steam locomotives; therefore truck haulage of waste is a minor factor of the New Cornelia operation. However, as New Cornelia was one of the first mines to use large-capacity dump trucks for haulage, the results obtained are of interest. EQUIPMENT On the south side of the New Cornelia is a hill rising about 500 ft. above the normal surface elevation, roughly 1000 ft. in diameter at its base, called locally Arkansas Mountain peak. Exploratory drilling in this area developed additional ore that could be made accessible for open pit operation only by moving the mountain face a maximum distance of 400 ft. to the south. The slope of the mountain adjacent to the pit averaged 35°, and the small area involved precluded the use of train haulage for the removal of the 4,000,000 tons of waste estimated above the normal pit elevation. A study of dump-truck haulage at Boulder Dam and San Gabriel Dam led to the decision to use large-capacity end-dump trucks rather than smaller trucks, for the following reasons: I. The truck would have to withstand the impact of hard, heavy chunks, some of them weighing as much as 10 tons, which would be dumped from the 4 ½ -cu, yd. dipper. 2. The coarse, rocky, abrasive material would soon damage a light truck body. 3. The body of a small truck could not be efficiently loaded with coarse rock.

Jan 1, 1941

By W. T. Isbell

IN the Parkes process of lead refining, after desilverization has been completed by means of the addition of zinc, there remains in the lead from 0.5 to 0.6 pct zinc. At this stage in the refining operations virtually all impurities are reduced to refined lead specifications except zinc and antimony. All excess copper, nickel and cobalt have been removed by the zinc additions. The silver remaining should not exceed 0.1 oz per ton. It then remains only to remove the zinc and antimony in order to produce refined lead. At the Herculaneum plant of the St. Joseph Lead Co., practice formerly was to complete the refining by means of oxidation in a reverberatory furnace. This process consisted of heating the lead to 14000 to 1500°F and allowing it to come in contact with excess air passing over the surface of the lead and periodically agitating the bath of lead with air. This procedure not only resulted in the loss of zinc but of a considerable quantity of lead converted to the oxide in the form of dross and fume. The fume, collected in the baghouse, together with the dross was returned to the blast furnace, thus adding appreciably to the circulating load on the blast furnace and refinery. In addition, operation and maintenance of the reverberatory furnace was expensive and required the performance of disagreeably hot and somewhat hazardous work. The process of dezincing with high vacuum was developed at this plant as a substitute for the oxidation process and finally led to lower operating costs, the practical elimination of dross and fume and the direct production of metallic zinc, which is very suitable for re-use in the desilverization process. Essentially this process consists of subjecting the lead to high vacuum, in a kettle provided with means for heating, a bell-shaped member open at the lower end so constructed that it can be immersed in the molten lead, and means for evacuating the interior of the bell and for sealing an agitator. Metallic zinc is thus produced and collects on the upper cooled part of the bell member. This metallic zinc is periodically removed and re-used in the desilverization process. The process is quite simple. It is conducted at a low temperature, thus permitting the use of iron equipment, and shows a material saving in refining costs over the old method. EQUIPMENT AND ITS USES Dezincing Machine.-The equipment employed in this process consists of a dezincing machine, a steel kettle of 120 tons capacity, a vacuum system and equipment for handling the dezincing machine (Fig I). The dezincing machine consists of a compact assembly, suitable for handling with an overhead crane, consisting of a treating chamber and the agitating mechanism. Treating Chamber.-The treating cham¬ber is a bell-shaped shell (4), similar in shape to a hemispherical kettle with a lid

Jan 1, 1947

By Walter Miller

Crude oil stocks were some 10,000,000 bbl higher on June I, 1947, than at any time during 1946 but the extremely heavy refinery runs the last half of 1947 cut crude inventories to approximately the 1946 closing level of 225,000,000 bbl. Many refiners were seriously short of crude oil during the year. This shortage was reflected in numerous advances in the posted price of crude, justified in part as an incentive for more production but more generally due to competitive bidding. Some purchasers of crude, endeavoring to keep their plants running, resorted to the payment, either directly or indirectly, of premiums above the posted price. Another common practice employed by some suppliers of crude oil was to demand refined products in exchange or trade for their raw material. The refined products picture has darkened in spite of record throughputs. Stocks of gasoline and light and heavy fuel oils were uncomfortably low at the beginning of the year and were in general still lower at the close. The rationing of some products, principally gasoline, to dealers and stations? initiated during the year, gained momentum as stocks continued to diminish. The emphasis placed by the manufacturers of oil-burning equipment on the convenience and economy of heating with oil, together with the tight situation in coal, has developed a tremendous demand for burning oils. Consumption of liquefied petroleum gas for domestic and household fuel had more than doubled in 1946 over 1943, and the demand seems to be limited only by the ability of the equipment builders to furnish necessary storage. transportation, and burning equipment. The supply situation is likely to become more acute in 1948. Demand for petroleum products is being pushed to new heights not only by the unprecedented domestic market but by a sudden and drastic upswing in estimates of military and governmental requirements. Additionally, oil exports are running far below the volume requested, amounting to less than forty percent in a recent quarter, and export licenses are reportedly being approved on the basis of urgent need *only. AX recent White House release sees little likelihood that estimated requirements of the sixteen nations participating in the proposed Marshall Plan can be met in full over its projected life—1948 to 1951. Present demand dictates maintenance of refinery operations at the highest possible level and the Bureau of Mines has forecast daily average crude runs in 1948 of 5,265,000 bbl. The Economics Advisory Committee of the Interstate Oil Compact Commission recently estimated the 1948 demand for petroleum products at nearly 6 pct above 1947. They further estimate daily average crude runs of 5,375,000 bbl in 1948, some 2 pct higher than forecast by the Bureau of Mines. Projected demand exceeds supply to the extent that Capitol Hill is reportedly investigating ways of enabling oil companies to act in concert without danger of antitrust prosecution, such as elimination of crosshauls, pooling of products, and lowering of octane.

Jan 1, 1948

By Walter Miller

Crude oil stocks were some 10,000,000 bbl higher on June I, 1947, than at any time during 1946 but the extremely heavy refinery runs the last half of 1947 cut crude inventories to approximately the 1946 closing level of 225,000,000 bbl. Many refiners were seriously short of crude oil during the year. This shortage was reflected in numerous advances in the posted price of crude, justified in part as an incentive for more production but more generally due to competitive bidding. Some purchasers of crude, endeavoring to keep their plants running, resorted to the payment, either directly or indirectly, of premiums above the posted price. Another common practice employed by some suppliers of crude oil was to demand refined products in exchange or trade for their raw material. The refined products picture has darkened in spite of record throughputs. Stocks of gasoline and light and heavy fuel oils were uncomfortably low at the beginning of the year and were in general still lower at the close. The rationing of some products, principally gasoline, to dealers and stations? initiated during the year, gained momentum as stocks continued to diminish. The emphasis placed by the manufacturers of oil-burning equipment on the convenience and economy of heating with oil, together with the tight situation in coal, has developed a tremendous demand for burning oils. Consumption of liquefied petroleum gas for domestic and household fuel had more than doubled in 1946 over 1943, and the demand seems to be limited only by the ability of the equipment builders to furnish necessary storage. transportation, and burning equipment. The supply situation is likely to become more acute in 1948. Demand for petroleum products is being pushed to new heights not only by the unprecedented domestic market but by a sudden and drastic upswing in estimates of military and governmental requirements. Additionally, oil exports are running far below the volume requested, amounting to less than forty percent in a recent quarter, and export licenses are reportedly being approved on the basis of urgent need *only. AX recent White House release sees little likelihood that estimated requirements of the sixteen nations participating in the proposed Marshall Plan can be met in full over its projected life—1948 to 1951. Present demand dictates maintenance of refinery operations at the highest possible level and the Bureau of Mines has forecast daily average crude runs in 1948 of 5,265,000 bbl. The Economics Advisory Committee of the Interstate Oil Compact Commission recently estimated the 1948 demand for petroleum products at nearly 6 pct above 1947. They further estimate daily average crude runs of 5,375,000 bbl in 1948, some 2 pct higher than forecast by the Bureau of Mines. Projected demand exceeds supply to the extent that Capitol Hill is reportedly investigating ways of enabling oil companies to act in concert without danger of antitrust prosecution, such as elimination of crosshauls, pooling of products, and lowering of octane.

Jan 1, 1948

By Basil B. Zavoico

The World War I1 spread to Russia on June 22, 1941, when the German Armies began their invasion. The Soviet industries, which were already engaged in a tremendous armament program, further accelerated the flow of munitions, and equipment and supplies for all purposes not directly military were either entirely eliminated or reduced to an absolute minimum. With the occupation by German armies of the Dniepr and Kharkov industrial regions, this trend was necessarily further accentuated. The oil industry of Russia, in consequence, was left to rely more and more upon itself, its own very limited manufacturing facilities, extensive repair shops and probably much used equipment out of order stacked in the warehouses. All evidence available to date points to the fact that the new situation not only did not affect the production either quantitatively or qualitatively, but, on the contrary, caused a larger flow of much needed fuels to the country's war machine, primarily by renaissance of both management and labor. The oil industry of the Soviet Union, left to depend entirely upon itself for equip ment and supplies, and even for new workers and technicians to replace those called into the services, did and is still doing a good and effective job. Since it could not hope for new equipment and parts and could not blame any other industry for the delays in delivery, it dragged out old machines from storage and repaired them in its own machine shops. Often such stored and used equipment was but slightly defective, waiting for some small part from factories in Central Russia, plants that now were either in German hands or entirely converted to the manufacture of munitions. More particularly, instead of the pipe that could not be taken to the Caucasus from Central Russia, casing reclaimed from abandoned or submarginal wells was used, or pipe from the abandoned or but slightly used pipe lines; and this practice is being continued even now on a large scale, to create an ample reserve for the duration of the conflict. Indirectly such a development was even an improvement on pre-war days, when many wells about to be completed had to wait for weeks, even months, for the arrival of new pipe, all blame then being placed outside of the industry on the factories in Central Russia. For the purpose of reclaiming equipment and pipe still usable, special crews were organized. The war also caused much quicker adaptation of certain American practices and introduction of many emergency measures, such as: removal of derricks upon completion of wells and the use of drilling equipment mounted on skids for rapid transfer from location to location—both of these practices, while standard in the U.S.A., being new in Russia; installation of simplified surface pumping units; substitution of wooden bearings in the surface pump equipment; completion of wells in the Ural-Volga district, where formations are hard and tight throughout the sedimentary column, without either casing or

Jan 1, 1942

By A. R. Denison

Several productive areas in the Mid-Con-tinent are broadly and briefly examined with respect to the present depth of drilling on productive structures, and the thickness of sediments remaining untested. Evidence is offered to show that a vertical mile to two miles of untested but prospective formation remain within reach of the drill. In no case would a well deeper than 15,000 ft. be required, and in most cases to no greater depth than 10,000 ft. Recent outstanding success of deeper prospecting in West Texas demonstrates the merits of deeper drilling on known structure. Introduction New fields discoverd during I942 equaled or exceeded the number in any preceding year. The total amount of oil found by these discoveries was less than in any previous year, for which accurate records are available. This means that the pools now being discovered are much smaller than in past years. This is to be expected, since the prospects available during 1942 were largely those overlooked in the earlier years and therefore represent a second or third order (in quality) of structural feature. This failure to find pools of good size and quality raises grave doubt as to the security of our future oil supply. With military needs rising almost daily, and the period of heaviest con- sumption in our war effort still in the future, there is even a growing doubt as to our ability to supply the amount needed for our ultimate victory. This does not mean that our reserves are inadequate, but rather that our "capacity to produce" may be inadequate. Lacking large fields with flush production, our capacity to produce is rapidly approaching our current needs. ,Since the industry is unable to find the large new fields necessary to keep a safe margin of "capacity to produce," other means are needed. It seems obvious that one of these should be deeper prospecting on the large, proven, productive structural features now known. The exploratory wildcat is drilled primarily in search of a trap and the reason for failure to find oil and gas in nine out of ten cases is due to the absence of a suitable trap under the drill site. Therefore, deeper drilling on a known structural feature that is productive largely eliminates the greatest hazard in wildcat drilling. While by no means all the oil known today is found in structural traps—in fact, some have estimated that less than half is so located— the fact remains that structural traps are far more commonly the oil fields that have multiple horizons of production superimposed one over the other. Outstanding examples are the Eldorado field in Kansas, the Tonkawa and Cushing fields in Oklahoma, the Louden and Salem pools of Illinois, and the richest and most prolific of all structural traps, the Long Beach, Ven-tura and other similar fields of California.

Jan 1, 1944