The Iron Age 1905-03-02: Vol 75 Iss 9

THE [ROMs 2AGE rns A. Review of the Hardware, Iron, Machinery... “1 | Trades. published every Thursday Morning by David Williams Co., 232-238 William St.. New York, Vol. 75: No. 9. New York, Thursday, March 2, 1905. ee rete: NS Saree Pewee Reading Matter Contents....... page 782 Alphabetical Index to Advertisers ‘‘ 241 Classified List of Advertisers.... ‘‘ 233 P ‘ Advertising and Subscription Rates‘ 240 “One URL of U. M. C. Short Range Shells is the same as re Forster Pulleus shells. For short range or bush shooting they are supéelp? for at 25 yards they give practically a 40-yard patt LIGHT and STRONG penetration. oer WM. ©. Shew Romgp CORDAGE shat Shrlls THE AMERICAN MFG. CO., 65 Wall Street, N. Y. are universally popular. One Sportsman writes: SEE PAGE 154, ** Having tried many shot spreading devices | was skepti- cal of the new U. M.C. Short Range Shells. Experience in THE BRISTOL COMPANY, the field shows them to be all you claim. They kill but Waterbury, Conn. never mutilate."’ Bristol’s Recording + Instruments. The Union Metallic Cartridge Company, ati Agency, 313 Broadway, New York City, N. Y. BRIDGEPORT, CONN. Silver Medal, rue Exposition. All Ranges, Low and Gear CAHALL BOILERS # sIMSON COmoAGE Rats, wm |? CAPEWELL HORSE NAILS TURNBUCKLES, “THE BEST IN THE WORLD” non BERG4 OC 1 Branden. Now York HIGHEST AWARD IN ALL COMPETITIONS TUR NEUO=—EL-S. GOLD MEDAL MERRILL BROS a QTd 115 10.61 Kent are ‘ eee LOUISIANA PURCHASE EXPOSITION BESSEMER - PIG St. Louis, 1904 MADE BY PILLING & CRANE, E:rarwecsteevat|) THE GAPEWELL HORSE NAIL CO., Hartford, Conn. JENKINS BROS. VALVES are the original Renewable Disc Valves, and are unquestionably the best for steady, every day service. No matter what may be the con- ditions, they always prove to be durable and reliable, giving the most perfect satisfaction with minimum amount of attention and repair. Write for Booklet—“Vaive Troubles.” of JENKINS BROS. NewYork Boston Philadelphia Chicago London OLD STYLE “Swetoh” Gold Role Steet sat Drang » Stamping TERICES. ... |mmppnede Ol Beene et. eee MAGNOLIA METAL. The a Best Anti-Friction Metal for all Machinery Bearings. MERICAN SHEET & TIN Fac-Simile of Bar. imitations. PLATE CO.’S a os Page : AGNOLIA METAL CO.., . on Fa 2 Owners and Sole Manufacturers, 3-116 Bank Francisco, Montreal, and Pittsburg. . Chicago, Fisher Bidg. ale We mapiufactare all gradee of Metals at POSIT TR FEES BU 3 CIS LS 0 2 Set ‘ww SG 080. 16 Soe Fed oe Ah alte dancer 3 em eka ate - oe Ss : menic o Se eo ey x —— he Tey ny ey ty = ge nen Det et Come tee AS Gas ES " nah re LER RE S * ae ra a = ZR vai Se Seer ET aoe bo THE IRON AGE j — [HE PLUME & Atwood Mrs, { ),, qT BRASS kel sheet __"* Sheet and Roll Bras COPPER; ™,,| wirz PRINTERS’ BRASS, JEWELERS’ METAL, GERMay SILVER AND GILDING METAL, COPPER Rivers GERMAN [ SHEET | suo sues ROD Pins, Brass Butt Hinges, Jack Chain, Rere. ent Sa SILVER | 1 "rimmtags, do oes PeTCMUL AMAA! |LoW BRASS. SHEET BRONZE.|# MURRAY t., NEW YORK We oats WANs) |SEAMLESS BRASS AND COPPER} “4 GH ST. BOSTON. Lock HAVEN, PA. JBRIA NCMEGLVASD EL. CO) Sites BRONZE TUBING. a ee THOMASTON. CONN. WATERBURY. CONN, A Complete Treatise aetinniainti SCOVILL MFG. CO., on Dies. WATERBURY BRASS CO., ‘BRASS, h . » wi struction and Use for the 99 John St., New York. Providence, R. I. anes meal, am eee. Brass Shelis, Cups, Hinges, Working of Sheet Bridgeport Deoxidized Bronze & Buttons, Lamp Goods. Metals. Metal ti Special Brass Goods to Order. Contains 384 pages, 505 illustra. ammnedueainn on Ww ATERBURY. CONN. tions. Insize 9 x6inches. Bound , r Derots, in cloth. Automobile Castings a Specialty, | § Ne york, CHICAGO. BOSTON. | PRICE, $3.00 Prepaid. High Tensile Strength. DAVID WILLIAMS CO., | Bronze and Aluminum Alloys. Henry Souther Engineering Co, 232.238 William St., New York. Write Us. eee Seavey Consulting Chemists, Metallurgists and | Analysts. mplete Ph hy steal Testing Laboratery: Expert | oun im Go urt and Patent Cace Matthiessen & Hegeler Zinc Co., oe Aritur T. Rutter & bo ee ae, 256 Broadway, SHEET ZINC AND SULPHURIC ACID. Special Sizes of Zinc cut to order. Rolled Battery Plates. NEW YORKA. Selected Plates f. : ; Sulsted @hacte Sop Bayer ena Cand ieaiead un Small tubing in Brass, Copper, Stove and Washboard Blanks. Steel, Aluminum, German Silver, &c. Sheet Brass, Copper and Ger- ZINCS FOR LECLANCHE BATTERY. ise Wide “Sinan Me ant German Silver Wire. Brazed and Seamless Brass and Copper Tube. HU aay Copper and Brass Rod. TEAS mee PPE ab THE BRIDGEPORT BRASS 60,, 88-74 West Monroe St. Chicago. BRIDGEPORT, CONN. ETUC OO: CISC RSE TORTI TTT MCR Lal eam Pe ae ee rage pronze sd CASTINGS) Brass ( SHEET 17 N. 7th St., Philadelphia. ww. G. ROWZELL ce Bridgeport, Conn. AND . TUBING HENDRICKS BROTHERS Copper | WIRE Belleville Copper Rolling Mills, | »=74ss ano copper cooo: In Great Varieties. Brasiers’ Bolt and Sheathing GEORGE KROUSE : COPPEHR, HEAVY CASTINCS Coo EY Et A7 rR Ee RIV ET i Mannfacturer of all kinds of — Importers and ond é = Brass and Composition Casti: 2% Ingot Copper, Block Tin, Spelter, Lead, Antimony, etc. Bresing Metals, mere | Competition ead 49 CLIFF ST., NEW YORK. 1650 to 164 Morgan Street. JERSEY City, ./ 2MAN VETS a THE IRON AGE New York, Thursday, March 2, 1905. The Illinois Steel Company’s Additions. NEW OPEN HEARTH STEEL WORKS AND BLOOMING AND STRUCTURAL MILLS. To keep pace with the rapidly increasing demands of Western markets for structural shapes the Illinois Steel Company is adding to its plant at South Chicago, Ill., a complete chain of steel works and mills, as follows: Open hearth steel works containing seven 50-ton fur- naces, a 40-inch blooming mill and a 28-inch structural steel mill. The additions include independent gas pro- ducer systems, a new boiler house, pump house, coal handling machinery and other modern accessories of a steel works. The new steel works will increase the pres- nected by standard gauge railway tracks passing around the western end of the slip. One of these lines will be used chiefly for conveying hot metal from the old blast furnaces to the new open hearth steel works, a distance of about 2000 feet, 20-ton ladle cars being used for the purpose. East and north of the open hearth steel works and between it and the lake shore is a stock yard 600 x 1000 feet, served by 8 standard gauge and 10 narrow gauge railroad tracks. Ore, scrap, limestone and pig iron are The Iliinois Steei Company's New Open Hearth Steel Works.— Pouring Side. ent annual capacity of the company’s plant at South Chicago by 250,000 gross tons of open hearth steel, and it will add to its finished product an annual capacity of 150,000 tons of structural shapes. On this page is shown a view in the new open hearth steel works on the pouring side. General Plan. As will be seen by the ground plan illustration, Fig. -, the open hearth steel works occupies one building, while the blooming and structural mills occupy jointly an adjacent structure. Each of these has its own gas producers. The new works occupies the northern end of the gen- eral inclosure of the company’s plant and is separated from the blast furnaces of the old works by a slip enter- ing Lake Michigan. The old and new works are con- brought in on the standard gauge tracks and either stored in their proper bins or unloaded directly to charg- ing boxes on narrow gauge cars. The loaded charging boxes are weighed on track scales and transferred by lo- comotives to the charging floor of the open hearth works. The Open Hearth Steel Works, This department, of which a plan is shown in Fig. 3, consists of seven 50-ton stationary type open hearth fur- naces built by the company. The hearths of these fur- naces are each 14 feet wide by 32 feet long inside. The construction is exceptionally massive, concrete and steel being used for foundations and for cinder pits. The bottoms of the uptakes are furnished with slag pockets, which can easily be cleaned by knocking out false arches. The regenerative chambers are located beneath the steel and concrete charging floor and away from the furnaces. ee Sa. re ae et ie iM z i 720 The air chambers are 10 feet 10 inches wide by 22 feet long, 15 feet 7 inches high, and the gas chambers are 7 feet 11 inches wide by 22 feet long, 15 feet 7 inches high. The hydraulically operated reversing valves are also located below the charging floor, the flues entering the base of the stack. The charging sides of the furnaces are furnished with three charging doors and three in- spection or repair doors, and the back of the THE IRON AGE March 2, 1905 x 25 and 15 x 29 inches, the weight ranging from 6000 to 8000 pounds each. The building is exceptionally massive and was de- signed and erected by the North Works of the company. The adjoining land east of the open hearth building is being filled up to the level of the charging floor, which is 18 feet above the pouring floor. This will facilitate the handling of materials to the charging floor, which furnace with two small doors. Access is had to the tap- ping holes by an unusually liberal extension of the charg- ing floor back of the furnace. In fact, the furnaces are accessible on every side, the whole works being marked by liberality in the matter of space. All the large doors and jambs are water cooled. The doors are lifted by hydraulic cylinders operated from nests of valves, two furnaces being operated from each nest. Ingot molds are provided for the following sizes: 18 x 20, 22 x 25, 25 GAS PRODUCERS TME IRON AGE #ig. 2.—General Plan of the Additions to the llliaois Steel Company’s South Chicago Plant. is also the floor of the furnace building. The main por- tion of the building is 562 feet 6 inches long, 125 feet 7 inches wide and 100 feet high to the apex of the ventila- tor roof, with a 33-foot lean-to running the entire length of the building. Adjoining this building and connected to it by bridges is the system of gas producers, 29 feet wide, with two hoisting towers 80 feet high. Seven steel stacks 160 feet high from the base and 5 feet inside brick work diameter pierce the roof of the lean-to. Raw materials to be charged into the furnaces are brought to the floor in charging boxes by means of a nar- row gauge railroad system, the tracks of which are pro- vided with three cross over switches. The boxes are lifted from the cars by means of either of two charging machines, which deposit their contents on the furnace bottoms. The charging machines dre the Wellman low type, electrically operated, shown in Fig. 4. They move on tracks running the full length of the building. CHARGING HOT METAL. As stated before, hot metal from the old blast fur- naces in another part of the inclosure will be used lib- erally, hot metal greatly accelerating the work and there- by increasing the output of the open hearth furnaces. When the 20-ton ladle cars arrive at their track inlet at the south end of the building they are weighed on track scales and the hot metal is poured into a 371¢ton ladle, by means of which it is transferred to the furnaces. This pouring ladle is handled by a 60-ton 7-motor double trol- ley electrical traveling crane furnished by the Whiting Foundry Equipment Company, Harvey, Ill. This crane has a span of 61 feet 6 inches and a lift of 35 feet. The main trolley has a 60-ton hoist operated by two 75 horse- power railroad type motors in series parallel and an aux- iliary trolley of 10 tons capacity. The two drums are so March 2, 1905 THE IRON AGE 721 arranged that the hoisting ropes fall out- side of the bridge girders. The hoisting ropes are double reeved independently,’ so that if one rope should be damaged the other would still stand the load. The auxiliary trolley runs between girders and is used for tipping the ladle at the fur- Se er Th SSS aware HOT) METAL TRACK by | ++ 3 nace mouth and also for repairs. To if => 100 .— facilitate charging the hot metal a de- t = Sit _ [1O : tachable spout is inserted into the door of i | ina s. ——.) = is the open hearth furnace, the spout resting f | Ol | | i! a ri i =] on a small stand, which is moved from {| ®: — D4 Af LH i x furnace to furnace. The charging floor | OY rl | U6) 1} Oe fl : eG has the unusually great width of 75 feet, f Oye Wr tdi, $— feta | | enabling the free handling of materials “| SZ rot as 3) i 4 | w and preventing congestion. hi ©rull Po ; rt = THE POURING SIDE. : ennai J rie The pouring floor, shown in the front jatel L ae HS illustration, is 60 feet wide and 562 feet i i 8! tt) | 6 inches long and is 13 feet lower than the WI | \/)\ | =e .) . charging floor. It is spanned by two P a rh + 4] i 4H ON Wellman double trolley ladle cranes, each tt Wy [|| Be i iN of 55 feet span, and each provided with a f me 2 = main trolley of 100 tons capacity and an i 3] < x < br auxiliary trolley of 25 tons capacity. The i “al ©) < ' . e : bridge travel is 100 feet per minute, and ' & x | _ o 4 ie & & the tracks on which it is run are 39 feet 5 4) 5 r 2 = inches above the level of the floor. The 1 : f a main hoist has a 27-foot lift. These cranes r ©) (TT Z : s serve the seven open hearth furnaces. On Th — l : \ = the floor, running from end to end of the f i (©) r * = a = building, are narrow gauge and standard * la = ; ‘ < & gauge tracks, the narrow gauge being used i \ Za — for ingot mold cars and the broad gauge ij ©) | 2 & for carrying skulls, ladles, &c., outside of ? — Y =i. oe = the building and for other purposes. ff : 5 seewes pee e Two pouring platforms are provided, ai ; 1 a= : test} ~~ = eh Se . each equipped with hydraulic car pushers. ) & a | é + % At each furnace is installed a 10-ton hy- z|| 3“ & j ‘ S draulic jib crane for handling spouts, ' z «() “U = ; \ % = platforms, &c. These cranes were built by 58 --- re. - ©) z 5 > the Garrison Foundry Company, Pitts- “Ou b> 34 G & burgh, Pa. The ladle pits below each fur- 2 a IK ; i 2 my z @ nace are only 3 feet in depth, the shallow ti 3(C )) UU | Z rt 5 = depth facilitating the rapid and eco- = e ee = 10 pS nomical handling of hot cinder and slag. z / =— 3} ‘a The cinder is loaded on cars on the stand- te : E / 4 4 ard gauge track previously referred to by =-{} SII f ¥ the hydraulic jib cranes. When either - aa 7 t 1 sh] is Ne tf the ladles, which are of 55 tons capacity, | lao © Ti 5) S3 eS By is filled with molten metal it is lifted i -E oO ll Fa 7. yj 35 from its rest by the 100-ton crane, i a ee SK “|i /f a conveys it to the pouring platform, where i “tL_Onl | < 5 a it is poured, the same crane either return- A z =z — | FE if a id 5 saa | | ing it to its stand or carrying it to the re- ih Ly TEL © I) || i || | | y pair pit as necessity requires. The two i avi \ i —“s1| || | Lh. -4p—=-=--1 piches! oS drums of the 100-ton trolley hoist are : P + Cc) ‘ll | | odd lbs y/\ Cert ee spread so as to permit the cables and ‘ = S| 4 A | |g ma fi | EL “* t | hangers to pass down on the outside of the a <4 6© ut Ts 4 a tS | bridge girders, thus allowing the erga + edt eS Sat I / + bee & | hoist to be placed between the sna oe f VAI Sat YP 4 ie] to travel the full span of the crane 7 , i -4| xl) / omme a} enabling the craneman to tip the ladle in Ox) NL AAL w SEM: fsa \\| 2 either direction. | | lz 1c 3 To the west of the open hearth build- iy ‘ te | eas” ing is the mold yard, the south end of a—~ | 1} Vi Z j — which is spanned by a 15-ton gantry crane if WF | !! : f ; OY Bl furnished by the Niles-Bement-Pond Com- | @ Wh i844 ge tH le a pany. The span of this crane is 70 oo eh | = rt a ©) Me (lates BP Oy] and it has a travel of 850 feet. Broac i | On| Ut = fF as gauge tracks also come within reach of i ; >| rT) beet —r— 5 this crane, which besides aera i tA) peer a a molds, is used in handling scrap 1) rrr - 4 other materials. tH E ra STRIPPING THE INGOT MOLDS. ti ” eed From the pouring platforms the in- bssandei ea ranciigis A gots are transferred by means of steam locomotives on a narrow gauge railroad to an ingot stripper situated 200 feet north u of the building, shown in Fig. 5. Strip- ; ping is done by means of an electric over- f 4 4 4 LABORATORY OFFICE 722 THE IRON AGE March 2, 1905 head traveling ingot stripper, 40-foot span, fur- grades of coal are handled successfully and the formatio: nished by the Wellman-Seaver-Morgan Company, of troublesome clinker is avoided. The gas produced con Cleveland, Ohio. From this machine the molds are re- tains a very low percentage of nitrogen and carbonic acid turned to the mold yard west of the open hearth build- and its quality may be depended on to be uniform. Th = . ’ Per Fig. 4.—The Wellman Low Type Charging Machine in the Illinois Steel Company's New Open Hearth Steel Works. ing for cooling, and the ingots are immediately conveyed handling of coal to supply these producers was long under to the soaking pits of the blooming mill adjoining to the discussion, a number of plans being considered. A plan northwest, being weighed on track scales en route. suggested by the Morgan Construction Company, Worces- THE GAS PRODUCERS. ter, Mass., was finally adopted, as shown in Fig. 6, which Gas for the open hearth furnaces is furnished by 28 presents a transverse section through the steel works and : Pes “ft ¥e p 7 =” ; _ , J . J " om) ae =) r pers I ihe Fs, » iene en 7 eaten Be Fig. 5.—The Wellman-Seaver-Morgan Ingot Stripper at the Illinois Steel Company’s New Open Hearth Steel Works. 10-foot Morgan continuous gas producers, provided with gas producers. It consists of a building provided with the George automatic feed. The battery is divided into two 100-ton overhead storage bins, into which the coal is seven units of four producers each. The advantages of deposited by a simple bucket elevator. The coal, in the automatic feeding are becoming well known. ‘The poorer first place, is brought in on a standard gauge track i! March 2, 1905 THE IRON AGE 723 2 hopper cars and dumped into concrete bins under the capacity and is mounted on scales. A boy occupies the ; : track, from which it is conveyed by the above mentioned crane cage, fills the crane tank from the central storage } 1, bucket elevator to either of the two storage bins. The bin and discharges the coal as needed into the receiving t IS KF SS AI KES ™ SF SS Mt AES rw Ml ee BNI ON /w i bafioo TON €.0.7. cranel iii i y aa FA NI) oe: } 100 TON COAL j PBN ANZ cy —— | tonic Sad Id | ea = 0.5 CRANE : fi . : es K HI Te ; = ¥ ea _ ' Halt - =~ Ld i. : 18 1 | RB | if Mb oro H so'ene: — 06-034" ~ TH hy COAL MANOLINGICR ANE) | ; X AUK. noIST'Y “* EB oI AUK. MOIST eave Sif60 TON MAIN HOIST { # TON CAP. \7 1 eto lf | ||]! 60 TON O.H. FURNACE °°] = | 9 rs Xx 10 TON HYD. ">a rH | © | | 3714 TON HOT “1 | ms f 1 Jia crane f= oe SST TA ywerac cave] | |r 7" ‘ x] st — <i ici i A ‘ Ld 1 TON LADLE “ i | — ih =p = 2 \. | | i ar’ ‘aioe SLAG BOX - ieee QAI IT T neeeWanarive Huawe : el eh eg - 7 i "EES | incor mouros ete Fee po copia os ATLEP Ye =e LEB ee th erhel mem est | ' f @AR PUSHER ¥ ' Pat. — 1 WA r= f r - L t= = aft me = i | | <== — 33 § Fig. 6.—Transverse Section through the Illinois Steel Company’s New Open Hearth Steel Works and Gas Producers i if = y r " D (i * ff h ' d ‘ —j ~ — 2, 74 TON CRANE ar 7 ‘ 2 rt or] ia . a ; > = 39 13g - 1v7- th ' ia * } a | | qv o> 2 i 2 z= baleen nF zh, t c a - ee hy 7 a = pw j ajnt ee *! FR ae oe rai. Sik ust ét ee mB i WU ge] lite 3 1! ; 44 Ss ey 2 ; pal = Up “Ueki T i j a c VAs 4, > ' ‘ 7 “if Siig sss | ! ' f oe i : oe -— eens THE 'RON AGE Fig. 7.—Sectional Elevation of the Soaking Pits in the Illinois Steel Company's New Blooming Mill. coal handling machinery was erected by the Interstate hopper of the producers in lots of 1000 pounds or less. Engineering Company, Cleveland, Ohio. The scale beam is located in front of the crane cage, and The coal is distributed to the producers as required separate coal records may be readily kept for each pro- by two light electric overhead traveling distributing ducer. ‘The valves at the hopper of the producers are cranes traversing the length of the building, each crane operated by the crane boy. carrying a fixed hopper. The hopper is of about 5 tons The charging crane in connection with the automatic Sree & eae ee Ps i ti b apt agieleaaee 7, i z ae Sonia een a ‘ Py rn 1% y 724 THE IRON AGE feeding device has proved to be a great saver of gas house labor. On the charging floor one man can easily attend three 10-foot diameter producers, while one man can remove the ashes from 15 producers. This gas house construction, with central storage bin and electric dis- tributing crane, has been adopted as a standard by the | THE IRON AGE Fig. 8—Morgan Crane Tongs Serving the Soaking Pits in the Illinois Steel Company’s New Blooming Mill. Morgan Construction Company. Comparatively low first cost and economy in operation are claimed as its prime features. The gas from the producers is conveyed by pipes of large diameter to overhead receivers, from which it is piped to the regenerative chambers of the furnaces, the flow being regulated by Forter valves controlled by operating stands, one stand to each furnace. The Blooming Mill, This building, like its neighbor, is solidly constructed from steel, with a very liberal use of steel and concrete March 2, 1905 lean-to 20 feet wide covering the reversing valves run ning the full length of the building. A sectional eleva- tion of the structure is shown in Fig. 7. In this building are four four-hole soaking pits in two groups, each group being 39 feet 114 inches by 40 feet 2 inches outside of the brick work and 18 feet deep. Each pit provides space for heating four 22 x 25 inch or six 18 x 20 inch ingots. In other words, 64 ingots of the larger size or 96 of the smaller size could be heated at once in this plant. Each pit has its own reversing valves, the gas valve being of the Forter type, and the air valve of the common butter- fly type, and, in addition to this, air and gas are con- trolled independently by mushroom valves. The ingots, received on small cars from the stripper, are hoisted and lowered into the soaking pits by means of two 7%4-ton four-motor electrical overhead charging cranes built by the Morgan Engineering Company, A\li ance, Ohio, shown in section in Fig. 8. These machines have all the facilities of operation of the ordinary travel- ing crane, possessing, besides the usual mechanical and electrical brakes, an independent slipping or safety clutch on the main hoist. This safety clutch is arranged to pre vent the trolley from climbing the charging bar should Fig. 10.—Section through Hydraulic Carriage and Soaking Pit Cover. the bar be driven with great force on the ingot. The automatic tongs for gripping ingots are suspended from a steel stem attached to the end of the charging bar and revolve on bronze bearings. The charging bar being bal- anced by counterweights in the tower, the motor has only the actual weight of the ingot to lift. Friction is reduced to a minimum, as the charging bar passes through the guides, with a stuffing box at each end having ample provision for oiling. These machines are provided with independent motors for hoisting, trolley travel, bridge travel and for operating the tongs. These cranes have a span of 60 feet 6 inches between runways and a lift of 15 feet. The tops of the pits are strengthened by a layer of heavy steel rails side by side, covered with steel plates, to prevent damage should an ingot slip from its hoist. The soaking pit covers are suspended from hydraulically operated carriages which travel on rails, Figs. 9 and 10. The method of gradual release of the covers to permit them to fall to their seats by gravity but without vio THE IRON AGE Fig. 9.—Hydraulic Carriage Operating Soaking Pit Cover in the Illinois Steel Company’s New Blooming Mill. in its foundations. It is irregular in shape, its greatest width being 266 feet 8 inches at the soaking pit end, and its length up to the reheating furnaces of the structural mill, which forms part of the same structure, being 442 feet. Including the structural mill, the building when completed will be over 900 feet long. THE SOAKING PITS. The portion of the mill devoted to the soaking pits is 64 feet 8 inches wide by 266 feet 8 inches lohg, with a lence is so well illustrated in the engravings that com ment is unnecessary. All covers are controlled from one pulpit by one operator. At each end of the building, on a level with th crane, is a raised steel platform to facilitate ordinar) repairs to the cranes. Two raised platforms under tl lean-tos are also provided on a line with the tops of th: pits, and on these platforms are located all stands for operating the valves that control] the inflow of gas and — 05 un Va- ing yup the for In the ich of March 2, 1905 air. This construction will be of obvious convenience in repairing and caring for the valves and piping. The ingots, after soaking, are lifted out by the charg- ng cranes and delivered to small electric transfer cars unning on a track on the general ground level. These rs convey the ingots to the approach table of the bloom- ig mill. Gas for the soaking pits is furnished by 14 10- foot Morgan producers, duplicates of the ones described i connection with the open hearth works. The coal handling mechanism is also the same. Each of the four soaking pits has a 4-foot by 100-foot steel stack. THE BLOOMING MILL. In Fig. 11 is shown the 40-inch reversing blooming mill installed by the United Engineering & Foundry Company, Pittsburgh, Pa. This mill is designed to roll beam blanks as large as 12 x 15 inches and interme- diate square sections down to 4-inch billets. The rolls are of cast steel and weigh 28,000 pounds each. The roll housings are made of a special mixture of air fur- Fig. 11.—The Illinois Steel Company’s New 40-Inch Reversing Blooming Mill, with Electric Screw-down. nace iron and weigh 86,000 pounds each. The shoe plates are made especially heavy to insure great rigidity and weigh 2100 pounds per lineal foot, with a total length of 45 feet 7 inches and a table weight of 192,000 pounds. The pinions for driving the mill are steel castings with staggered teeth, 40 inches pitch diameter. The pinion housings, carriages and pinions weigh 197,000 pounds. The driving crab is of very substantial construction, weighing complete 15 tons. The screws for operating the top roll are of high car- bon steel, 11 inches diameter and 1% inches pitch, and are driven by an electric screw down of a new design, operated by a 75 horse-power motor, with magnetic brake, the speed of the lift being about 10 feet per min- ute, The rolls are 30 inches diameter and the neck 21 inches, with an extreme opening to the rolls of 30 inches. The top roll is balanced by hydraulic cylinders, one for each housing, under constant pressure maintained by un independent accumulator. The windows of the hous- ing are large enough to permit the changing of rolls ithout in any way dismantling the mill. The total ngth of this mill, including the engine, is 53 feet, the eXtreme hight above foundations 20 feet and the total weight 860,000 pounds. Its plan is shown in Fig. 12. THE IRON AGE 725 The front and rear mill tables are of very heavy con- struction, with 16-inch rollers, 96 inches long between journals. The journals of these rollers are 6 inches in diameter, and the side guards of the front table are heavy steel castings made in sections to provide against serious damage from the impact of the ingot. Both front and rear tables are 59 feet 2 inches long. The mill tables are driven by beveled gearing from line shafts direct connected to a 12 x 12 inch Crane reversing engine, one for each table. The approach table leading from the buggy track to the middle table is 70 feet long. It is divided into two parallel sections, one of which (the in- got run) is furnished with solid forged rollers 16 inches diameter, 45 inches long, at 24-inch centers, driven by miter gears by means of a geared 50 horse-power West- inghouse motor. The other section of the run, which has its rollers at 48-inch centers, is a run-out table for sup- porting the ends of billets or shapes in process of rolling. After the ingot is deposited on the table from the electric buggy it is run up to the end of the switch of the table by the operator of the ingot buggy, who starts it to the mill table on receiving a signal from the roller. The roller has charge of the ingot from this time on, as he and the manipulator man operate the manipulator, the attachments of the top roll and the reversing and con- trolling of the table engines, all of which are governed from the roller’s pulpit, located above the mill table, 45 feet from the rolls. The engineer controls the reversing engine from the same pulpit. The manipulator is of the Kennedy type. In addition, the mill is furnished with a single pronged auxiliary manipulator, which has both ver- tical and horizontal motions for taking care of long billets. This manipulator as well as the whole ingot run was also furnished by the United Engineering & Foundry Company. The single pronged manipulator avoids the necessity of employing a man with a wrench to help turn long bars. THE MESTA ENGINE, The blooming mill proper is driven by means of a twin cylinder reversing engine built by the Mesta Ma- chine Company, Pittsburgh, Pa. The engine is of the direct connected type, the shaft being carried in three bearings. The crank shaft is a single forging with a 6-inch axial hole drilled through its entire length. The cylinders are 55 inches diameter, 60 inches stroke, equipped with valves of the piston type. The bushings or seats for the piston valves are cast separate and are fitted in the steam chest. The piston valves are a sepa- rate piece for each end of the cylinder and are connected by the valve stem; the packing is one broad ring the width of the piston. The piston valves are operated by a reversing link motion, triple eccentrics being used to drive each link. The two outside eccentrics have the same angular advance and are in effect one eccentric. They connect through the straps and rods to the bottom end of the link, the middle eccentric to the top end of the link. This arrangement avoids all side strains, as all connections from the eccentrics to the links are made in a straight line. The links are reversed by a steam operat- ing cylinder, the power from which is transmitted by a pair of links to the tumbling shaft. An oil check cylinder directly in line with the steam cylinder has its piston on the same rod. The valve which distributes the steam to the operating cylinder and the valve which by-passes the oil in the check cylinder are on the same stem or valve rod. This rod is controlled through a floating lever by the operator’s lever and by the motion from the operating cylinder piston. With this arrangement the links can be shifted to any position by the engineer and held there without further effort. The piston rods are of hollow forged steel. The pis- tons, which are of cast steel and of umbrella pattern, are held on the rods between a forged collar and a large nut. The piston rods extend through the rear cylinder head and are supported by a head with an adjustable shoe. In this way the body of the piston is carried clear of the walls of the cylinder and only the cast iron pack- ing ring comes in contact. The slide stand for the above mentioned shoe is made so that it can be quickly moved back when the cylinder head is taken off. 6 Ate ~ al, ee Ne eto wer the ae: sre so" March 2, 1905 AGE Zz oO mY — Q en) aod WOVUL ADDNE-L.OONI— — BDV NOM! BWL S30IND N33ML38 ~30¥ NOM! SH NOILVLS-8NS'O'yv — «= *1"O Bb SHBTION é “1D #2 SH31ION HOLOW'd H Og JNION3 ‘ASH “ula 08 x 9¢ SINIONS Zi xX Z4~ “«@ ‘THA [BanjonI3g «MON S,LUBdUIOD [293g sJouTIIT 94} JO UBIg [eIEUEH— ET “314 1! | | \\| aNvud ALND ( ww «dS SNIHONOS “Aau 278 039 /L10H Q38/ 10H Pe ee ra 3SNOH Y¥31I08 “IA ~Zuymoolg Zujs19aAoy qoul-0F MON B,AUBdMIOD [997g Ssfoul[[] eq} Jo uvlg [B1909D—"ZL *3Ig F - - =I , $301INO N3I3M1398 $30IND N33M1L38 lh 830IND N3I3M1398 x — — —— — — — 1 4 _ - — = vole suatiod |. Te "10 iz sdaTIO" TT r 7 8201IN9 NI3M1398 “1'O OF SuZTION HOLOW'd H OS 4 SINIONS Zi x 24 * ¥YOLVINdINVN “TO NOINIG F TW - ¥V3HS WOO1E Zr 830IND N3I3Mi36 ———*7°9-#Z-Su9T10N— La YOLOW'd'H 09 ~ 7A UV3HS UZONITAD & YOLOW'd'H 08 | +. ‘ ayeve ONICVO? "1'0' Z4/su3z77 0" | / BOLOW ‘d'H OF S30IND N33M136 March 2, 1905 THE SHEAR BUN. The run between the mill and the bloom shear is livided into two sections, the first of which is 51 feet 9 inches from the center of the first to the center of the last roller. ‘Che run is 87 inches wide between guides and the rollers are set at 27-inch centers. This section is run by a 12 x 12 inch Crane type reversing engine direct connected to the table. The second section, 36 feet 8 inches between centers of first and last rollers, is 66 inches wide and has rollers at 40-inch centers. It is driven by a 50 horse-power Westinghouse motor. The second section leads the bloom up to the 42-inch hydraulic bloom shear, furnished complete with tables by the United Engineering & Foundry Company. THE HYDRAULIC BLOOM SHEAR. This shear has a capacity of cutting 12 x 15 inch hot blooms and is equipped with a constant pressure push THE IRON AGE C.L.—COAL TRACK 727 The tilting and loading tables of this shear are driven by a 25 horse-power electric motor. The rear shear table is 16 feet long and is provided with rollers at 12-inch cen- terssoas to carry short lengths. The table is 46 inches wide between guides and is driven by a 30 horse-power motor. It is a tilting table with the fulcrum in the back. The front is raised or lowered by a hydraulic cylinder under the control of the shear operator. In its highest point the table is level, the elevation being the same as that of the front shear table, enabling the operator to shear the last piece of each billet to its greatest useful length, as it holds the bar in a level position while the knife de- scends on it. It is capable of making a longitudinal sliding motion, making possible an opening between the table and the ends of the shear knife, through which may be dropped scrap ends to the conveyor underneath. A dis- appearing idle roller is provided to fill the space between the loading table and the shear table when the latter STAND \90-GAUSE = C.L.4,A8H Sh » ‘ ad a ae whee oa 103% RS FSS — . —v7 r - 4 eed ¥ ' a r { prs ss ] ( ! Fig. 14.—Plan of the Boiler House of the Illinois Steel Company's New Mills. back cylinder. It is located 101 feet 8 inches from the center of the blooming mill and is used for cropping off split ends of ingots and for cutting long billets in two, as well as for emergency purposes. The stroke of the shear is 19 inches and its total weight is 210,000 pounds. The shear tables are driven by direct connected electric motors. Located 72 feet 6 inches beyond this shear is a 26-inch 3-cylinder hydraulic shear, also built by the United Engineering & Foundry Company, for cutting blooms, billets, &c., to different lengths, the material passing to this shear over a roll table 46 inches wide, with rolls at 24-inch centers. This shear has a capacity of cutting material ranging from 4inch billets up to 10 x 30 inch slabs hot. The stroke is 16 inches and has a specially designed stop, driven by an electric motor, which regulates the quantity of water used, making the shear one of the most economical of its type. The hy- draulic valves are arranged so that the middle cylinder can be used on light work and all three cylinders can be used when the shear is being operated at its maximum capacity. This shear is capable of a pressure of 500 ‘tons and has a total weight of about 150,000 pounds. is in its most forward position. This prevents short pieces from dropping down between tables. The loading table, which is a continuation of the rear shear table, is 19 feet long between roller centers, and like the shear table its rolls are 46 inches long between guides and are spread 12 inches apart. This table is driven by a 30 horse-power motor and has a steam pusher for skidding the product across the table and down an incline into cars. An adjustable and removable stop is provided behind the pusher so as to stop any pieces beyond the pusher that may have to be loaded on the cars. The motors driving the rear shear table and loading table and the hydraulic mechanism for con- trolling valves for the hydraulic car pushers are con- trolled by an operator on the elevated platform, where he has a clear view of the whole run. The same operator manipulates the removable stop at the far end of the loading table and the pusher for skidding the product off the table into cars as well as controlling the car pusher itself. Beyond the loading table is a 12-foot weighing table for weighing billets. This is electrically driven. Sear SS - <pey Aee wand mimeo vet aaa ey eran nen nt a ae WS rade ee ee re , RON sees SE Se Maa ™ nowt oe 728 THE CRANES AND HOISTS. The shearing end of the mill is spanned by a 30-ton 8-motor overhead electric traveling crane furnished by the Whiting Foundry Equipment Company. The span of this crane is 39 feet 6 inches, its lift 40 feet and it is fitted with Westinghouse motors and Electric Supply Company controllers. A Whiting 40-ton 4-motor elec- tric traveling crane spans the blooming mill end of the building. This crane has a span of 75 feet 5 inches and a lift of 40 feet, and has besides its main 40-ton hoist an auxiliary 5-ton hoist. Outside of the building is a large billet storage yard served by a 10-ton half-gantry crane, also furnished by the Whiting Foundry Equip- ment Compgny. One end of this crane travels on a track at the ground level and the other end is supported on a runway on the side of the building 28 feet 7 inches above ground. Its span from centers of runway rails is 70 feet and length of travel 225 feet. The frame is open, and there is a cantilever extension on the bridge, permit- ting the trolley to travel 15 feet beyond the track. This crane is used for unloading hot billets to cooling beds and for loading materials on cars fdr shipment. The billet yard is 6 feet lower than the floor of the blooming mill building, this depression facilitating the handling i seas ptte i ' i sete eet Barts i pelt) eed i Py | oR (C)) (ey) LEN ord } Ds DAL GD Thi PEE { yp ety Ny hu?) YW) batt +e 1 rer | Pet Pet Vp teegpetteanetater ve j ivV¥ewee ee ey \ Vie em eee ee SECTION A-A THE IRON AGE March 2, 1905 posited them there and are transferred to the roll tables of the structural mill. This mill is provided with two trains. The first is a 32-inch blooming or roughing mill furnished by the Mesta Machine Company complete with tables and manipulators, is of the 2-high reversing type and is driven by two Tod engines direct connected to the rolls, which are 78 inches long and 25 inches minimum diameter. The other is a 3-high 28-inch mill, with two 3-high stands and one 2-high finishing stand, having. rolls 68 inches long. Provision is made in this latter mill for substituting a 27-inch universal mill for rolling flats and universal plates 6 to 18 inches wide up to 100 feet long in place of the 2-high finishing stand referred to, and the Tod reversing engine is built with that end in view. This mill was also built by the Mesta Machine Company after designs furnished by the Illinois Steel Company’s engineers. An interesting feature of the 28-inch mill is a modifi- cation of the plan which was installed by A. J. Moxham at the Johnson Works at Johnstown and later put in the Lorain Steel Company’s plant by him. By consult- ing Fig. 9 it will be seen that there is a large unoccupied space beyond the engines of this mill. This space will be known as the roll echanging.room, and it will be pro- THE 'FON AGE Fig. 15.—Cross Section of the Boiler House of the Illinois Steel Company’s New Mills. of materials. Another Whiting crane spans the pump room. It is a 1-motor electric of 12 tons capacity, 53- foot span and 19-foot lift. The Structural Mill. The structural mill, as before stated, is a continuation of the blooming mill, the arrangements being shown in Fig. 13. It may be said to begin with the east wall of the reheating furnaces, which is 441 feet 7 inches north of the south wall of the soaking pit building. From this point to the northern end of the structural mill is approximately 470 feet. The width of the main build- ing is 52 feet 8 inches, and the reheating furnaces oc- cupy a lean-to 44 feet 6 inches wide and 206% feet long, beyond which are two mill buildings, in which are lo- eated respectively the 32 and 28 inch mills. These buildings are each 76 feet wide, the 32-inch mill building being 76 x 190 feet and the 28-inch mill building 76 x 226 feet. The distance from the north end of the 28-inch mill to the northern wall of the building is 120 feet, and the width of this portion of the building is 72 feet. The blooms intended for this mill after leaving the blooming shear are picked up by an overhead traveling charging machine, with revolving trolleys, and conveyed to the regenerative furnaces, of which there are three, whose hearths are 14 x 31 feet, each having six 8-foot charging doors. The heated billets are picked out of these furnaces by the same charging machine which de- vided with a number of stands or pedestals, on which duplicate housings will be deposited by the overhead crane and fitted with the necessary rolls for the next turn. When it is desired to change rolls the mill is dis- connected from the engine by means of releasing links and the crane picks up the mill, housings and all, and car- ries it back to the roll changing room, returning with the duplicate housings already fitted with rolls. In this way a great deal of time is saved in making changes of rolls. The roughed billets are conveyed from the roughing mill tables to two traveling lift tables transversing each side of the mill. These tables are 50 feet long, with rollers 12 inches in diameter, set at 30-inch centers. These tables are lifted by a bell crank arrangement and operated by a 75 horse-power Westinghouse motor. The transverse drive is operated by two 50 horse-power motors and one 50 horse-power motor for the roller drive. These tables have a roller speed of 320 feet per minute. The back table is driven by a 30 horse-power Westing- house railroad motor connected series parallel for the transverse drive and one 30 horse-power motor for the roller drive. Steel chutes or inclined runways are pro- vided as extensions of both runways, these chutes serv- ing as supports or carriers for the ends of long pieces. By their use it will be possible to roll lengths over 200 feet. After leaving the finishing mill the shapes are run on March 2, 1905 roller tables to the hot saw, which cuts them to desired lengths or saws off imperfect-ends. From the saw, which is 175 feet northwest of the rolls of the 20-inch mill, ma- terials are conveyed by roller tables to either of two hot beds. These hot beds are provided with a series of endless chain conveyors located about 8 feet apart. The convey- ors are fitted with spikes or pushers, which move the ma- terial a little beyond the center of the bed, when it is seized by another series of conveyors, which push it as much further along as is necessary. At the north end of the first bed, and between it and the next hot bed, is an- other hot saw, which is used for cutting to stock lengths before the material is conveyed to the straightener. The second hot bed will be spanned by a 100-foot crane, which will act in conjunction with cranes in the stock yard be- yond. The space for stock piles is not definitely fixed, but it will ultimately be at least 450 feet long by 180 feet wide, the longitudinal transfer of materials being ac- complished by means of roller tables, while transverse 4 p ne PX ( — Uf | u i | | . | “ } t f L dine Se a 4 Ly ic ro : mi | BN r etl 2 ad B { Gia a = t ate r * Ld bed ceo J Fig. 16.—The Ash Handling Arrangement Under the Bollers in the Illinois Steel Company’s New Mills. transfers will be made by means of the overhead cranes. These stock piles will be arranged in series according to the lengths of materials being stored, the longer mate- rials being given the shortest haul. The overhead cranes which will span the piles will be arranged so that they can pick up materials intended for shipment and lay them directly on cars without rehandling. THE TOD ENGINES. The engines applied to the 32-inch roughing train and to the 28-inch 3-high finishing train were built by the Wm. Tod Company, Youngstown, Ohio, in accordance with designs which, by conference with the engineers of the Illinois Steel Company, were esteemed most appro- priate to the particular installation. These engines are in every detail duplicates and may be defined as twin tandem compound 4cylinder direct connected reversing engines. The dimensions are: Stroke, 54 inches; high pressure diameter, 86 inches; low pressure diameter, 62 inches; maximum revolutions per minute, 150; maximum horse-power, 4500. The low pressure cylinders are at- tached to the engine frame. Intermediate and tail rod cross heads, with the front cross head, support the pis- tons free from the cylinders. The control of the speed and power of the engine is secured by holding the links at such appropriate inter- mediate points as to favor an expansive use of steam. While the use of the cataract cylinder to move the links to the extremes of position is a common practice, it has been’ found practically impossible to hold the links at THE IRON AGE 729 intermediate points—in other words, to shorten the cut off—owing to the stresses imposed by the lack of balance on the usual type of piston valves, Examination of the exhaust chamber pressures under the indicator has shown that high steam velocities in these cavities have frequent- ly caused excessive unbalanced pressures along the valve stems. The Wm. Tod Company has provided for the ready equalization of pressures on the two sides of the piston valves by constructing the latter with large central communicating passages. Utilizing the advan- tage of this construction, it is proposed to use the links almost entirely as controlling agents, since a throttle valve is applied to the high pressure cylinders only. Even the throttle valve is operated by an individual cata- ract cylinder through the agency of a 4inch shaft reach- ing from the pulpit. The leverman’s duties are expected to be far less arduous with such mechanism for control than the usual construction compels. It is a generally accepted view that it is nearly im- possible to obtain any useful results in the application of a condenser to the ordinary two-cylinder reversing en- gine, Cushioning effect must be retained to meet the enormous inertia stresses of reciprocating parts. The abstraction of steam by a condenser compels such an addition of exhaust lap to the valves, with the incident of greater port resistance, to attain the necessary com- pression, that the useful effect of a condenser is practical- ly nullified. With the tandem compound arrangement it is conceivable that sufficient compression for cushioning can be localized in the high pressure cylinders, thus mak- ing the use of a condenser on the low pressure cylinders permissible. The Pump Room. Adjoining the Mesta engines to the northwest is th> pump house, 56 x 90 feet in floor dimensions. In it are installed two 3-cylinder compound fork-frame pumps, with Corliss steam valve gear, double acting outside packed water ends, furnished by the Laidlaw-Dunn-Gor- don Company, Cincinnati, Ohio. These pumps are 22 x 32 x 54 x 30 inches. They are fitted throughout with Corliss valve motion. Each pump has one 22-inch high pressure cylinder, with two 34-inch low pressure cylin- ders, one on either side, all three cylinders being bolted directly to the frame. The piston rod is 5% inches diam- eter and the stroke 30 inches. The double acting pump ends are connected to the steam cylinders by heavy cast iron housings, the rods between the steam and pump cylinders being joined by heavy screwed couplings. Two fly wheels are provided, these being mounted between theframes. Adeep cast iron bed plate is extended under the entire length of each subunit. This bed plate forms the lower member of a truss, of which the upper member is composed of the frame, cylinder, housing and pump end, resulting in exceptional stiffness throughout the length of the machine, the rigidity thus obtained being, in fact, much greater on account of the truss construction than if a deeper bed plate and stiffer rods were used for joining the parts together. The 3-cylinder arrangement is followed for two rea- sons: In the first place, this construction will allow a far higher ratio of cylinders and a consequently later cut off in the high pressure cylinder, without uneven dis- tribution of frame loads, than is the case with a cross compound machine. The advantage of a late cut off in the high pressure cylinders exists in this case because of the occasional necessity for the machine to be self start- ing, in which case the late high pressure cut off, with cranks at 120 degrees apart, is of material assistance in getting the machine quickly under way. In the second place, the 3-cylinder arrangement of the engine per- mits a triplex pump end, giving a much greater uniform- ity of flow than is obtainable in a duplex double acting pump end. For high pressures an approximately uniform rate of flow during the entire revolution is exceptionally important, since air cushions in the line are not practicable, and since fluctuations in the rate of flow are as a result felt through the entire system. It is for this reason that a triplex pump end will give much better high pressure results than a duplex machine. Among the other unusual features of construction are the crank shafts, which are built in accordance with marine wer + eee eo ——— — sewer > + 2 ah