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By John W. Buch

NeaRly 25 years ago operating officials in the northern anthracite field were confronted with the problem of profitably mining virgin beds of thin coal (those 48 in. and under) or destroying them by mining underlying thick beds. To solve this problem costly hand-mining methods were replaced by cheaper mechanical methods, which eliminated the need for the lifting of bottom or the brushing of top in excessive quantities, which was essential if proper height for hand loading1 was to be provided. During this period long-face mining was an outstanding development. In its favor in comparison with any other method were the ease with which undercutting machines could be used, a differential in powder cost of about fifteen cents per ton in favor of this method over mining from a solid chamber or pillar face, and a greater production per day from a single working place, resulting in lower capital expenditures for a given total production, closer supervision and lower transportation cost. The long faces were drilled by jackhammer and undercut by machines. The coal from the cut was loaded into mine cars placed on the gangway road by means of a double-drum mechanical scraper engine and a mechanical V-type scoop. A tugger hoist was used to spot empty cars at the loading point from a supply placed at the operation by an electric mine locomotive. During loading the roof was supported by vertical wooden props paralleling the face. After the loading was completed the scraper engine and the ropes that had been used to propel the scoop in the loading of coal transferred the props to and along the face. A row of unfilled cogs was then built parallel to the new face and about 6 ft. from it. These cogs were usually made 6 by 3 ft., the longer dimension paralleling the face; they were placed on an average at 12-ft. centers. These wooden cogs were left in place and were buried later by falling roof. Attempts to remove them were never successful. When a new long face was started, the cog spacing would be increased to about 20-ft. centers. As successive cuts were made, weight would begin on the cogs, and they

Jan 1, 1940

By Ralph H. Sweetser

At the joint session of Blast Furnace and Open Hearth Committees, April 7, 1937, at Birmingham, the subject of the quality of basic open-hearth pig iron was so well presented and discussed from so many different viewpoints that it was the general opinion that progress had been made and that such meetings were conducive to the advancement of the art of making pig iron of the right quality for the open-hearth man to produce the most satisfactory quality of steel. It was agreed that there is a decided differentiation between the chemical analysis of pig iron and the "quality" of pig iron. Paul J. McKim said that open-hearth furnace operators frequently make reference to certain types of iron as "bad iron," "dirty iron," "cold metal," etc., claiming that when using these irons, although they are within specified chemical analysis, it is impossible to produce quality steel. Mr. McKim gave a list of the suggested causes of those "certain types" of bad irons that have a thoroughly respectable analysis but a thoroughly disreputable character. Another open-hearth man, P. A. MacIsaac, of Nova Scotia, said that: The effects of iron that is below standard in analysis or in that mysterious property called quality, are well known to all open-hearth operators. It has been shown that iron of this type results in the production of steels on which the rcjections of finished product run high. What is to be done about it? I would say that the burden of producing high-quality iron should be placed squarely on the shoulders of the blastfurnace man, even as that of making good steel is shouldered by the open-hearth man. It is the purpose of this paper to bring out into the open this "mysterious property called quality"; that is, in those "certain types" of basic pig iron that make it impossible to produce quality steels; and at the same time to point the way for the blast-furnace man to be able to shoulder the burden that Mr. MacIsaac and all other open-hearth men and foundry-men have placed upon him. Silicon, sulphur, phosphorus and manganese are not the guilty elements because these are known, specified and usually kept within the

Jan 1, 1938

By Ralph H. Sweetser

At the joint session of Blast Furnace and Open Hearth Committees, April 7, 1937, at Birmingham, the subject of the quality of basic open-hearth pig iron was so well presented and discussed from so many different viewpoints that it was the general opinion that progress had been made and that such meetings were conducive to the advancement of the art of making pig iron of the right quality for the open-hearth man to produce the most satisfactory quality of steel. It was agreed that there is a decided differentiation between the chemical analysis of pig iron and the "quality" of pig iron. Paul J. McKim said that open-hearth furnace operators frequently make reference to certain types of iron as "bad iron," "dirty iron," "cold metal," etc., claiming that when using these irons, although they are within specified chemical analysis, it is impossible to produce quality steel. Mr. McKim gave a list of the suggested causes of those "certain types" of bad irons that have a thoroughly respectable analysis but a thoroughly disreputable character. Another open-hearth man, P. A. MacIsaac, of Nova Scotia, said that: The effects of iron that is below standard in analysis or in that mysterious property called quality, are well known to all open-hearth operators. It has been shown that iron of this type results in the production of steels on which the rcjections of finished product run high. What is to be done about it? I would say that the burden of producing high-quality iron should be placed squarely on the shoulders of the blastfurnace man, even as that of making good steel is shouldered by the open-hearth man. It is the purpose of this paper to bring out into the open this "mysterious property called quality"; that is, in those "certain types" of basic pig iron that make it impossible to produce quality steels; and at the same time to point the way for the blast-furnace man to be able to shoulder the burden that Mr. MacIsaac and all other open-hearth men and foundry-men have placed upon him. Silicon, sulphur, phosphorus and manganese are not the guilty elements because these are known, specified and usually kept within the

Jan 1, 1938

By T. T. Quirke, L. C. McCabe

The object of the present investigation was to discover a physical basis for rank differentiation of coals, particularly the coals of the Illinois basin. Vitrainl was selected as the most appropriate coal material to use in the investigation, because of its homogeneity and ease of acquisition and handling. Previous Investigations.—Hoffman and Jenker2 have shown that their index of reflection is a characteristic of coal rank and that the Leitz slit microphotometer may be used in determining the different intensities of reflection. Zhemchuzhnikov3 measured the luster of several Russian coals with a color analyzer and found that the degree of luster was indicative of rank. Luster-volatile matter curves based on data from Sucan and Donetz coals were satisfactorily used for determining the rank or volatile content of other coals after the luster strength was determined. In 1934 Fisher4 reported refractive indices of 1.76 for bituminous vitrain and 1.87 for semibituminous vitrain. Investigation of Angle of Polarization.—Early in the present investigation several determinations of the refractive indices of the vitrains were made by immersing the minus 150 plus 200-mesh powder in oils. It was found that all the samples fell within the range 1.6 to 1.8. However, difficulty was encountered in securing oils in this high index range that were closely enough spaced to separate some of the coals. The writers made a number of determinations of the angle of maximum polarization from the polished surfaces of the vitrains and derived their refractive indices by the procedure described in the following paragraphs. Johannsen5 states the fundamental concepts underlying this procedure as follows: In general, in an isotropic medium light vibrates in all directions at right angles to the direction of propagation, and when it meets with another isotropic medium at an angle, part of the light is reflected and part refracted. It has been found that after reflection or refraction, the vibrations do not move with the same freedom in every

Jan 1, 1938

By T. T. Quirke, L. C. McCabe

The object of the present investigation was to discover a physical basis for rank differentiation of coals, particularly the coals of the Illinois basin. Vitrainl was selected as the most appropriate coal material to use in the investigation, because of its homogeneity and ease of acquisition and handling. Previous Investigations.—Hoffman and Jenker2 have shown that their index of reflection is a characteristic of coal rank and that the Leitz slit microphotometer may be used in determining the different intensities of reflection. Zhemchuzhnikov3 measured the luster of several Russian coals with a color analyzer and found that the degree of luster was indicative of rank. Luster-volatile matter curves based on data from Sucan and Donetz coals were satisfactorily used for determining the rank or volatile content of other coals after the luster strength was determined. In 1934 Fisher4 reported refractive indices of 1.76 for bituminous vitrain and 1.87 for semibituminous vitrain. Investigation of Angle of Polarization.—Early in the present investigation several determinations of the refractive indices of the vitrains were made by immersing the minus 150 plus 200-mesh powder in oils. It was found that all the samples fell within the range 1.6 to 1.8. However, difficulty was encountered in securing oils in this high index range that were closely enough spaced to separate some of the coals. The writers made a number of determinations of the angle of maximum polarization from the polished surfaces of the vitrains and derived their refractive indices by the procedure described in the following paragraphs. Johannsen5 states the fundamental concepts underlying this procedure as follows: In general, in an isotropic medium light vibrates in all directions at right angles to the direction of propagation, and when it meets with another isotropic medium at an angle, part of the light is reflected and part refracted. It has been found that after reflection or refraction, the vibrations do not move with the same freedom in every

Jan 1, 1938

By P. Nicholls

Patent records show that the attempt to improve the burning of fuel by mixture or pretreatment with chemicals dates back to the early years of the last century. By 1845 English and French patents had included the specific beneficiations of elimination or reduction of smoke, soot and clinker; reduction of the ashes; elimination of sulphur fumes; increase of the rate of burning; increase of the time a given charge of fuel would last; and, in most patents, a saving of fuel. The earlier patents specified additions up to 80 lb. or more per ton of fuel, but after 1860 the quantity was seldom more than 4 lb. There is no record of the extent to which these patents were commercialized, but after 1874 many American patents were assigned to companies specializing in treatment of coal, so it is probable that the products were marketed on a considerable scale at least as early as that date. From 1900 on, many proprietary products were marketed under the general name of "fuel savers," the principal sales being in small packages for the use of householders; savings of from 10 to 40 per cent of the coal were promised. Starting with 1927, the use of proprietary or other mixtures of chemicals was extended to power plants and to treatment of coals at the mines, the claims of saving of fuel being subordinated to those of general improvement and, in particular, to reduction of clinker-ing. Such expectations are attractive and a number of companies experimented with or adopted the practice. There were reports of improved operation, but, apparently, few were confident enough that these improvements were due to the salts to publish the results of tests or their records of operation. There are no data on the yearly tonnage of coal treated but indirect reports suggest that it has been relatively large. Since its establishment in 1910, the U. S. Bureau of Mines has continually received inquiries about these products. At the request of other governmental departments it made tests in 1910, 1916 and 1930, using certain proprietary products applied according to the instructions of the vendors; these tests were made with eastern coals in domestic and

Jan 1, 1938

By P. Nicholls

Patent records show that the attempt to improve the burning of fuel by mixture or pretreatment with chemicals dates back to the early years of the last century. By 1845 English and French patents had included the specific beneficiations of elimination or reduction of smoke, soot and clinker; reduction of the ashes; elimination of sulphur fumes; increase of the rate of burning; increase of the time a given charge of fuel would last; and, in most patents, a saving of fuel. The earlier patents specified additions up to 80 lb. or more per ton of fuel, but after 1860 the quantity was seldom more than 4 lb. There is no record of the extent to which these patents were commercialized, but after 1874 many American patents were assigned to companies specializing in treatment of coal, so it is probable that the products were marketed on a considerable scale at least as early as that date. From 1900 on, many proprietary products were marketed under the general name of "fuel savers," the principal sales being in small packages for the use of householders; savings of from 10 to 40 per cent of the coal were promised. Starting with 1927, the use of proprietary or other mixtures of chemicals was extended to power plants and to treatment of coals at the mines, the claims of saving of fuel being subordinated to those of general improvement and, in particular, to reduction of clinker-ing. Such expectations are attractive and a number of companies experimented with or adopted the practice. There were reports of improved operation, but, apparently, few were confident enough that these improvements were due to the salts to publish the results of tests or their records of operation. There are no data on the yearly tonnage of coal treated but indirect reports suggest that it has been relatively large. Since its establishment in 1910, the U. S. Bureau of Mines has continually received inquiries about these products. At the request of other governmental departments it made tests in 1910, 1916 and 1930, using certain proprietary products applied according to the instructions of the vendors; these tests were made with eastern coals in domestic and

Jan 1, 1938

By Ralph A. Sherman, E. R. Kaiser

The remarkable increase in the distribution of the small underfeed stoker for use in furnaces and boilers in small industrial plants, apartment houses and homes has brought producers and distributors of bituminous coal to consider the problem of which coals and which sizes are best suited to this market. Many papers have also appeared, mostly in the trade journals, discussing the problem of the combustion of various coals and various sizes of coal in small stokers. Much difference of opinion has been apparent in these articles; due often, it would appear, to a misunderstanding of the fundamentals of the process of combustion in the stoker fuel bed. During the past year and a half, a program of research has been conducted at Battelle Memorial Institute: (1) On the process of combustion in the fuel bed of the small stoker, sponsored by Battelle Memorial Institute, and (2) on the relation of the characteristics of bituminous coals to their performance on small underfeed stokers, sponsored by Bituminous Coal Research, Inc. As a result of this program of research, two publications have been made, one1 dealing with the problem of clinker formation, and the other2 with the relation of the size of the coal fed to the stoker hopper to that of the coal that reaches the retort to be burned. The experimental research on the relation of size to the performance of the coal is being actively continued. A publication of Bituminous Coal Research, Inc. presenting the data obtained on the performance of several sizes of four typical bituminous coals will appear shortly. Because of the early appearance of that publication, the present paper includes few numerical data. The purpose of this paper is to follow the coal from the hopper through the furnace with a discussion of the various actions that occur, in the hope that it will lead to a clearer understanding of the relation of the type of coal, the size of coal, and other characteristics, to the performance. The authors do not pretend to have obtained the answers to all the complex questions involved; many unanswered questions will be proposed on which future research work is planned.

Jan 1, 1938

By E. R. Kaiser, Ralph A. Sherman

The remarkable increase in the distribution of the small underfeed stoker for use in furnaces and boilers in small industrial plants, apartment houses and homes has brought producers and distributors of bituminous coal to consider the problem of which coals and which sizes are best suited to this market. Many papers have also appeared, mostly in the trade journals, discussing the problem of the combustion of various coals and various sizes of coal in small stokers. Much difference of opinion has been apparent in these articles; due often, it would appear, to a misunderstanding of the fundamentals of the process of combustion in the stoker fuel bed. During the past year and a half, a program of research has been conducted at Battelle Memorial Institute: (1) On the process of combustion in the fuel bed of the small stoker, sponsored by Battelle Memorial Institute, and (2) on the relation of the characteristics of bituminous coals to their performance on small underfeed stokers, sponsored by Bituminous Coal Research, Inc. As a result of this program of research, two publications have been made, one1 dealing with the problem of clinker formation, and the other2 with the relation of the size of the coal fed to the stoker hopper to that of the coal that reaches the retort to be burned. The experimental research on the relation of size to the performance of the coal is being actively continued. A publication of Bituminous Coal Research, Inc. presenting the data obtained on the performance of several sizes of four typical bituminous coals will appear shortly. Because of the early appearance of that publication, the present paper includes few numerical data. The purpose of this paper is to follow the coal from the hopper through the furnace with a discussion of the various actions that occur, in the hope that it will lead to a clearer understanding of the relation of the type of coal, the size of coal, and other characteristics, to the performance. The authors do not pretend to have obtained the answers to all the complex questions involved; many unanswered questions will be proposed on which future research work is planned.

Jan 1, 1938

By Richard Downs, Stephen P. Burke

The oxidation of pyritic sulphur associated with coal is important for the following reasons: 1. It is the predominant cause for the formation of acid mine drainage issuing from bituminous coal seams. This drainage pollutes the streams in coal regions, making the water unfit for industrial purposes and causing the disappearance of fish and wild life. As a consequence the movement of industry and especially recreational industry, so important to the population of these areas as an alternative means of livelihood, is impeded. 2. It is instrumental in effecting a series of reactions, which bring about the degradation and ultimately result in the spontaneous combustion of bituminous coal in storage. 3. It contributes to the breaking and shattering of the coal structure and is one of the causes of roof falls and floor lifts in mines. 4. It is the primary cause of the many nuisances associated with gob piles and the refuse of cleaning plants. 5. Its proper control and application might possibly be employed in the preparation of coal to reduce the inorganic sulphur content. The research that has been conducted on the oxidation of the various forms of iron sulphides is extensive and the literature voluminous. Nevertheless, few efforts have been made to determine experimentally and with some precision the mechanism of the reaction under the conditions of its occurrence in bituminous coal mines. It has generally been accepted that the oxidation of pyritic sulphur proceeds according to the reaction 2FeS2 + 2H2O + 7O2 ? 2FeSO4 + 2H2SO4 [1] The ferrous sulphate in the drainage streams is further oxidized by air to produce ferric hydroxide and more acid. Yet the literature fails to disclose any pertinent investigation on the mechanism of this reaction. The present contribution is concerned primarily with this aspect of the problem and while the work to be reported is not yet complete, it has yielded results from which interesting and significant conclusions may be drawn.

Jan 1, 1938

By Richard Downs, Stephen P. Burke

The oxidation of pyritic sulphur associated with coal is important for the following reasons: 1. It is the predominant cause for the formation of acid mine drainage issuing from bituminous coal seams. This drainage pollutes the streams in coal regions, making the water unfit for industrial purposes and causing the disappearance of fish and wild life. As a consequence the movement of industry and especially recreational industry, so important to the population of these areas as an alternative means of livelihood, is impeded. 2. It is instrumental in effecting a series of reactions, which bring about the degradation and ultimately result in the spontaneous combustion of bituminous coal in storage. 3. It contributes to the breaking and shattering of the coal structure and is one of the causes of roof falls and floor lifts in mines. 4. It is the primary cause of the many nuisances associated with gob piles and the refuse of cleaning plants. 5. Its proper control and application might possibly be employed in the preparation of coal to reduce the inorganic sulphur content. The research that has been conducted on the oxidation of the various forms of iron sulphides is extensive and the literature voluminous. Nevertheless, few efforts have been made to determine experimentally and with some precision the mechanism of the reaction under the conditions of its occurrence in bituminous coal mines. It has generally been accepted that the oxidation of pyritic sulphur proceeds according to the reaction 2FeS2 + 2H2O + 7O2 ? 2FeSO4 + 2H2SO4 [1] The ferrous sulphate in the drainage streams is further oxidized by air to produce ferric hydroxide and more acid. Yet the literature fails to disclose any pertinent investigation on the mechanism of this reaction. The present contribution is concerned primarily with this aspect of the problem and while the work to be reported is not yet complete, it has yielded results from which interesting and significant conclusions may be drawn.

Jan 1, 1938

By Martin A. Mayers

It has long been recognized that it would be highly desirable to be able to predict the temperatures at various points in a burning fuel bed and their variations with changes of the properties of the fuel and the rate of air supply. Experimenta1 investigations of fuel-bed temperature1-4 have not been lacking, but the absence of any theoretical background has made it impossible to use the results of these tests as a basis for prediction, except in a very general may. A mathematical analysis", based on a somewhat simplified theory of the distribution of lieat in a fuel bed, lias recently been completed by the author. Even though numerical values of some of the coefficients are not known, the calculations result in some conclusions of general significance. Thus, for example, it appears that when the temperatures throughout the fuel bed can be calculated, the rate at which ignition of the fuel by underfeed action can be maintained can also be calcu1ated. The uncertainty concerning the values of the coefficients referred to above is serious limitation on the use of that method. The following paper presents a discussion of these coefficients and includes estimates of their values based on the data now available. A brief description of the theory on which the analysis is based, and some results of the calculations showing their degree of agreement with experimental results, are presented by way of introduction to the discussion of the coefficients. For a more. extended discussion of the theory, see the A.S.M.E. paper5. Theory and Comparison with Experiment The theoretical analysis is similar to that used in the calculation of the stationary temperatures in a conducting solid in the classical theory of heat concluction. The fuel bed is pictured as a uniform, continuous, porous solid through the interstices of which air can be blown and ill which combustion can take place. The solid lias a finite thermal conductivity, so that heat may be transported in any direction, against the flow of air as well as in the same direction. While it is true that nothing

Jan 1, 1938

By Martin A. Mayers

It has long been recognized that it would be highly desirable to be able to predict the temperatures at various points in a burning fuel bed and their variations with changes of the properties of the fuel and the rate of air supply. Experimenta1 investigations of fuel-bed temperature1-4 have not been lacking, but the absence of any theoretical background has made it impossible to use the results of these tests as a basis for prediction, except in a very general may. A mathematical analysis", based on a somewhat simplified theory of the distribution of lieat in a fuel bed, lias recently been completed by the author. Even though numerical values of some of the coefficients are not known, the calculations result in some conclusions of general significance. Thus, for example, it appears that when the temperatures throughout the fuel bed can be calculated, the rate at which ignition of the fuel by underfeed action can be maintained can also be calcu1ated. The uncertainty concerning the values of the coefficients referred to above is serious limitation on the use of that method. The following paper presents a discussion of these coefficients and includes estimates of their values based on the data now available. A brief description of the theory on which the analysis is based, and some results of the calculations showing their degree of agreement with experimental results, are presented by way of introduction to the discussion of the coefficients. For a more. extended discussion of the theory, see the A.S.M.E. paper5. Theory and Comparison with Experiment The theoretical analysis is similar to that used in the calculation of the stationary temperatures in a conducting solid in the classical theory of heat concluction. The fuel bed is pictured as a uniform, continuous, porous solid through the interstices of which air can be blown and ill which combustion can take place. The solid lias a finite thermal conductivity, so that heat may be transported in any direction, against the flow of air as well as in the same direction. While it is true that nothing

Jan 1, 1938

By W. I. Garms, J. L. Stevens

Because of the many conflicting opinions regarding the functioning of the ball load and the characteristics of ball wear in ball-mill grinding, the following résumé of reports covering recent tests conducted at the Hayden plant of the Kennecott Copper Corporation is submitted with the view of pointing out certain salient features that should throw additional light on the subject. Mills Used Cylindrical drum mills with trunnion feed and discharge were used. The discharge trunnion was 13½ in. in diameter. Dimensions inside the lining were 6 ft. 6 in. in diameter and 9 ft. 6 in. long. The mills were Britannia-lined and nine lifter bars projected 2 in. from the lining. The mill speed was 162/3 r.p.m. Feed to the mill was 9 per cent on 10-mesh, 85 per cent on 100-mesh, 77 per cent solids. New balls measured 2 in. in diameter and the approximate weight of the ball load was 40,000 pounds. Initial Test During a test that was being conducted to determine the relative economic value of standard cast balls vs. forged steel balls in the local 'grinding operation, certain observations were made in regard to the functioning of the various ball sizes and the characteristics of ball wear, which warranted a supplementary test for the purpose of confirming such observations. For the initial test, the necessity for developing a graduated load of the new forged balls before the test could be started was realized, but the time required to obtain a graduated load and the functioning of the various ball sizes was not clear. No advantage could be seen for starting out with a full load of forged balls, as this initial load, at the least, would have to be completely ground out and replaced by daily additions of balls before the graduation could be complete and a normal static condition of ball sizes reached. For a considerable period prior to exhaustion of this initial charge there would be an unusual quantity of worn balls of a certain size, which would not be typical of a normal charge and could influence the characteristics and functioning of the entire load. Therefore, it was decided to start by daily addition of the forged balls to a mill that contained a normal operating load of cast balls. After 88 days of operation the mill was shut down for inspection. By that time the load consisted of a mass of forged balls functioning around a large core of the residual material of the former cast-ball load. This core of cast slugs, locally referred to as "the kidney," was well defined from the forged-ball load.

Jan 1, 1947

By W. I. Garms, J. L. Stevens

Because of the many conflicting opinions regarding the functioning of the ball load and the characteristics of ball wear in ball-mill grinding, the following résumé of reports covering recent tests conducted at the Hayden plant of the Kennecott Copper Corporation is submitted with the view of pointing out certain salient features that should throw additional light on the subject. Mills Used Cylindrical drum mills with trunnion feed and discharge were used. The discharge trunnion was 13½ in. in diameter. Dimensions inside the lining were 6 ft. 6 in. in diameter and 9 ft. 6 in. long. The mills were Britannia-lined and nine lifter bars projected 2 in. from the lining. The mill speed was 162/3 r.p.m. Feed to the mill was 9 per cent on 10-mesh, 85 per cent on 100-mesh, 77 per cent solids. New balls measured 2 in. in diameter and the approximate weight of the ball load was 40,000 pounds. Initial Test During a test that was being conducted to determine the relative economic value of standard cast balls vs. forged steel balls in the local 'grinding operation, certain observations were made in regard to the functioning of the various ball sizes and the characteristics of ball wear, which warranted a supplementary test for the purpose of confirming such observations. For the initial test, the necessity for developing a graduated load of the new forged balls before the test could be started was realized, but the time required to obtain a graduated load and the functioning of the various ball sizes was not clear. No advantage could be seen for starting out with a full load of forged balls, as this initial load, at the least, would have to be completely ground out and replaced by daily additions of balls before the graduation could be complete and a normal static condition of ball sizes reached. For a considerable period prior to exhaustion of this initial charge there would be an unusual quantity of worn balls of a certain size, which would not be typical of a normal charge and could influence the characteristics and functioning of the entire load. Therefore, it was decided to start by daily addition of the forged balls to a mill that contained a normal operating load of cast balls. After 88 days of operation the mill was shut down for inspection. By that time the load consisted of a mass of forged balls functioning around a large core of the residual material of the former cast-ball load. This core of cast slugs, locally referred to as "the kidney," was well defined from the forged-ball load.

Jan 1, 1947

By T. K. Prentice

The January-February number of the Journal of the Chemical Metallurgical and Mining Society of South Africa, 1943, is made up entirely of a discussion of Ball Wear in Cylindrical Mills. Following the principal paper by T. K. Prentice are several remarkably pertinent and carefully prepared discussions. Few persons in this country would be likely to see this publication, and since the information presented is new and of current interest, it seems desirable to abstract and review this publication for the benefit of the members of the A.I.M.E. The purpose of the investigation is stated in the first two paragraphs of Prentice's paper, as follows: Early in 1941, The Chamber of Mines Steel Products, Limited, initiated a series of tests under semi-working scale conditions to determine, if possible, those physical and chemical properties of a ball which make it resistant to wear when used in a cylindrical mill as a grinding medium, with the primary object of incorporating those beneficial qualities in the balls being produced at their works. This paper describes the tests carried out and discusses the results obtained. From these results it was possible to formulate a new theory relating to ball wear in cylindrical mills. This theory is presented in the second portion of this paper. Practical Ball-mill Tests in a Cylindrical Mill Part I of the paper begins with a discussion of the methods used for the manu- facture of grinding balls in South Africa. The following paragraph is of particular interest. The cast steel ingots, 4¼ in. square by 3 ft. 6 in. long, are re-heated in a gas-fired sloping stationary-hearth furnace and then rolled in a six-pass continuous mill into 25/8 in. round billets. Some of these billets are then removed and cut into suitable lengths for forging into 4 in., 3¼ in. , 3 in. or 2½ in. balls by means of three Drop and two Beche hammers, but the greater number, whilst still at about 1,000, pass directly into a set of scroll rolls which produce, in an ingenious manner, finished 3 in. balls direct from the 25/8 in. billets. Except in special cases, all balls are allowed to cool in the atmosphere and are not water quenched. Details of the Tests In order to enable the reader to evaluate properly the results and conclusions in the rest of the paper and in the discussions following the paper, most of the information presented by the author under this heading is quoted: The testing unit was a nominal 30 in. diameter and 18 in. long centre discharge Denver Ball Mill. The ore pulp to the ball mill comprised a small portion of the normal feed to one of the fourteen City Deep 5 ft. 6 in. X 22 ft. tube mills, and the grinding media consisted of the balls under test plus other balls to give the desired load. The running time of the test-mill was divided into approximately equal periods of five days 13½ hours each. The usual procedure was to examine and make up the load

Jan 1, 1947

By T. K. Prentice

The January-February number of the Journal of the Chemical Metallurgical and Mining Society of South Africa, 1943, is made up entirely of a discussion of Ball Wear in Cylindrical Mills. Following the principal paper by T. K. Prentice are several remarkably pertinent and carefully prepared discussions. Few persons in this country would be likely to see this publication, and since the information presented is new and of current interest, it seems desirable to abstract and review this publication for the benefit of the members of the A.I.M.E. The purpose of the investigation is stated in the first two paragraphs of Prentice's paper, as follows: Early in 1941, The Chamber of Mines Steel Products, Limited, initiated a series of tests under semi-working scale conditions to determine, if possible, those physical and chemical properties of a ball which make it resistant to wear when used in a cylindrical mill as a grinding medium, with the primary object of incorporating those beneficial qualities in the balls being produced at their works. This paper describes the tests carried out and discusses the results obtained. From these results it was possible to formulate a new theory relating to ball wear in cylindrical mills. This theory is presented in the second portion of this paper. Practical Ball-mill Tests in a Cylindrical Mill Part I of the paper begins with a discussion of the methods used for the manu- facture of grinding balls in South Africa. The following paragraph is of particular interest. The cast steel ingots, 4¼ in. square by 3 ft. 6 in. long, are re-heated in a gas-fired sloping stationary-hearth furnace and then rolled in a six-pass continuous mill into 25/8 in. round billets. Some of these billets are then removed and cut into suitable lengths for forging into 4 in., 3¼ in. , 3 in. or 2½ in. balls by means of three Drop and two Beche hammers, but the greater number, whilst still at about 1,000, pass directly into a set of scroll rolls which produce, in an ingenious manner, finished 3 in. balls direct from the 25/8 in. billets. Except in special cases, all balls are allowed to cool in the atmosphere and are not water quenched. Details of the Tests In order to enable the reader to evaluate properly the results and conclusions in the rest of the paper and in the discussions following the paper, most of the information presented by the author under this heading is quoted: The testing unit was a nominal 30 in. diameter and 18 in. long centre discharge Denver Ball Mill. The ore pulp to the ball mill comprised a small portion of the normal feed to one of the fourteen City Deep 5 ft. 6 in. X 22 ft. tube mills, and the grinding media consisted of the balls under test plus other balls to give the desired load. The running time of the test-mill was divided into approximately equal periods of five days 13½ hours each. The usual procedure was to examine and make up the load

Jan 1, 1947

By N. A. MacLeod

Ball wear in wet grinding mills has been the subject of considerable discussion in the last few years. Its importance to millmen is obvious in view of the fact that ball wear may cost from 2 to 4 per ton of ore for the more fortunate operators and many times this cost when a refractory ore must be reduced to a fine state of comminution. Consequently, any factual information that may be obtained on the nature of ball wear may be applied to introduce changes leading to lower ball consumption and therefore also to lower costs. In 1940, while employed with the Britannia Mining and Smelting Co., Britannia Beach, B.C., I had occasion to investigate factors that might affect ball consumption. We performed a number of tests, which will be briefly described. These tests originated as a result of changing from a 3½-in. ball to a 2-in. ball of different type of manufacture and were motivated by the desire to obtain the best possible type of 2-in. ball. Our testing was helped by the fact that the company operated a one-ton electric furnace, so that it was quite easy to make steel changes. It should be emphasized at the beginning that these tests produced results that in their general application to milling should be interpreted qualitatively rather than quantitatively. As will be evident in the description of the method used in testing, the balls were subjected to an intermittent batch grinding treatment, which may have produced results in rate of steel wear that may not have an accurate correlation with steel consumption in full scale mill operation. However, with this bed and rather arbitrary method of testing, results were obtained that may be of some interest and may stimulate further work on this subject. Unfortunately, owing to pressure of war work, our tests, which we had intended to repeat on a continuous grinding operation, had to be discontinued. Method of Testing Tests Were made in a Small cylindrical mill, rotating at 72 r.P.m. Internal dimensions of the mill were 10½-in. dia. by 9 in. The cylindrical inner surface was lined with rubber and the two ends were formed by steel plates. A charge of 2000 grams dry feed and 2000 C.C. of water was added evev 2 hr., the mill being drained of pulp before the addition of each charge, by tilting and sluicing with water. The mill was run On afternoon and night shift for daily periods of about 15 hr. total grinding time, and each test lasted from 60 to 150 hr. This batch method of testing involved a higher average pulp temperature in the mill, which undoubtedly affected comparative results in Some of the tests. Hardness oF Ball vs. Wear In these tests, special "eutectoid" steel balls were used, some of which were chill-Cut and quenched, some sand-cast and quenched, and some sand-cast and annealed to a dead soft condition. The results obtained, using as mill feed an ore containing considerable free quartz and

Jan 1, 1947

By N. A. MacLeod

Ball wear in wet grinding mills has been the subject of considerable discussion in the last few years. Its importance to millmen is obvious in view of the fact that ball wear may cost from 2 to 4 per ton of ore for the more fortunate operators and many times this cost when a refractory ore must be reduced to a fine state of comminution. Consequently, any factual information that may be obtained on the nature of ball wear may be applied to introduce changes leading to lower ball consumption and therefore also to lower costs. In 1940, while employed with the Britannia Mining and Smelting Co., Britannia Beach, B.C., I had occasion to investigate factors that might affect ball consumption. We performed a number of tests, which will be briefly described. These tests originated as a result of changing from a 3½-in. ball to a 2-in. ball of different type of manufacture and were motivated by the desire to obtain the best possible type of 2-in. ball. Our testing was helped by the fact that the company operated a one-ton electric furnace, so that it was quite easy to make steel changes. It should be emphasized at the beginning that these tests produced results that in their general application to milling should be interpreted qualitatively rather than quantitatively. As will be evident in the description of the method used in testing, the balls were subjected to an intermittent batch grinding treatment, which may have produced results in rate of steel wear that may not have an accurate correlation with steel consumption in full scale mill operation. However, with this bed and rather arbitrary method of testing, results were obtained that may be of some interest and may stimulate further work on this subject. Unfortunately, owing to pressure of war work, our tests, which we had intended to repeat on a continuous grinding operation, had to be discontinued. Method of Testing Tests Were made in a Small cylindrical mill, rotating at 72 r.P.m. Internal dimensions of the mill were 10½-in. dia. by 9 in. The cylindrical inner surface was lined with rubber and the two ends were formed by steel plates. A charge of 2000 grams dry feed and 2000 C.C. of water was added evev 2 hr., the mill being drained of pulp before the addition of each charge, by tilting and sluicing with water. The mill was run On afternoon and night shift for daily periods of about 15 hr. total grinding time, and each test lasted from 60 to 150 hr. This batch method of testing involved a higher average pulp temperature in the mill, which undoubtedly affected comparative results in Some of the tests. Hardness oF Ball vs. Wear In these tests, special "eutectoid" steel balls were used, some of which were chill-Cut and quenched, some sand-cast and quenched, and some sand-cast and annealed to a dead soft condition. The results obtained, using as mill feed an ore containing considerable free quartz and

Jan 1, 1947

By Albert E. Reed

The development of the modern highspeed vibrating screen, together with the increasing availability of long-lasting stainless-steel screen cloth for relatively fine-mesh separations, means that more screen circuits will be used in the future. It seems pertinent therefore to examine a few characteristics of screen-circuit products, and especially the points of difference as compared with products of classifier circuits. The most noticeable change that takes place when substituting screening for classification in a grinding circuit is a substantial drop in the circulating load, owing to the greater ease with which the "fines" leave the circuit. Where circulating loads of 500 to 600 per cent are considered fairly normal in classifier grinding circuits, the grinding circuit equipped with screens for equivalent work will have a circulating load of only 20 to 75 per cent. As a result, the products of screen circuits will show a minimum of overgrinding or sliming as compared with a classifier circuit. The desirability of this characteristic will naturally vary according to the metallurgical requirement in each case. Because screen separations make a sharper division according to particle size, the products of screen circuits can be expected to show greater crowding of particles near the point of separation. These changes in product characteristics are so important that other factors, both in the grinding and concentration processes must be adjusted if the operator is to take full advantage of the increased tonnages and higher efficiencies available to him through the use of the screen circuit. One factor that too often is overlooked when changing to screen circuits is the importance of adjusting the ball-mill or rod-mill charge, to compensate for: (I) increased tonnage of new feed, (2) decreased circulating load, or (3) more granular character of feed. These same factors should also be taken into consideration for their effect on the various types of concentration or flotation equipment that may follow the screen circuit. Over a period of years, this equipment has generally been designed and adjusted to the product of the classifier, therefore it seems obvious that some research on the adjustment and adaptation of concentrating and flotation equipment to screen-circuit products will be most profitable to the operators. To illustrate the points mentioned above, the results from three recent installations follow, with data on the comparative characteristics of screen and classifier circuits. A range of separation from 10 to 48 mesh has been chosen, using two general types of screening equipment and two types of classifiers. The first of the installations of which the results are to be examined is that of an iron-ore installation where eastern magnetite was being concentrated prior to sintering. Fig. I shows the original grinding circuit, using classification, while Fig. 2 shows the same circuit equipped with a

Jan 1, 1947