The Iron Age 1914-05-21: Vol 93 Iss 21

LADDEDANLODADDODEOAEREDUAUOREOOAUOUDOADATLTEPEEEDEL OEE | ; “ ew: UNUEDEDODUAYUREDURDUEDOEYODUOOOAUUODEODUDUOBEODODONOOOOUE OANA EON ODN NUON AO oen oa ' MT min New York, May 21, 1914 UPEEUURRDDCPOUE DERE REE DDEROEDAORODEAD EGE DUES OE DDEODER EEL Established 1855 A System of Keeping Records That En- ables the Purchasing Agent to Keep it Touch with Conditions Outside His Offic WHITAKER A purchasing agent must be prepared, at all hensive as p : times, to afford ready information on the prevailing The requisition, the purcha facts concerning the products of the world without his organization, to answer questions arising withi! record of receipt, and the of distribution are the five sonally, as to permit giving a portion of his workings hases has been broadly ad day to keeping in touch with outside conditions. many larg: Many buyers regret that the daily duties incident has to keeping a business supplied with its necessities, office records Therein a preclude giving the time they would wish to give every article purchase to interviewing callers, and following other lines of to large cards a port onecerns by special edi in tne quired for ments and co-operation with the other departments r : his concern are obviously the foremost duties of he purchasing agent. His chief concern should be the reach fo know what to buy and when, where and howto buy ondary d at. Sor quently handled as to impa hat an Purchas: sadvantages A iny factors enter into these considerations ystem employed to cover the details of ind consumption should be as compre- *} re form a large portion of t gent, J. H. Williams & Co., Brooklyn, N. Y iorm a l I 1255 necessitate transcription, a it and to co-operate in the fullest measure with al tribute the essentia departments of his concern. He must, therefore, ster so limit the clerical work devolving upon him per A comprehensive ste] ts convenient tne probable necessity o! tha | Li) . — . reased liability of error. SU Vol. 93: No. 21 Conservation of Effort in Purchasing eed not be complex e order, the invoice, the departmental debit sli original factors that co! ition for any purchasins lassifving p vertised and installed commercial house that natizing of all kinds of permanent inventor ibtained by transferring tne data trom eacn Ol! research, to determine the conditions which exist the last four original sources mentioned above in the commercial world. Thi ystem, admirabk Every time a salesman ee coe ee ee | because of its advantage is banished unheard, the OAM (169 _ pees 4+ of permanent invento1 buyer and his firm sus- sea pniaien i a and material classifica tain a loss in purchasing { 26 Wate haps 2-2 ‘Ne tior open to criticism power, which time aug- /2 de ‘ 6 a on fundamental ground ments, as rumor spreads j; Every minute given to its the tale; but there is a 3 £ ipkeep is spent in dup! subtle injury besides that ; ation. Transcription has affects the buyer preem1- | herges lessened the reliability nently, and is often over- j | Pores all data recorded. Efficie: looked. It is the result } tenance is unduly e produced upon him when fone. 77 betes . 4 Amount ting, and when effected he diverts his attention cist ieatlhiatie anes ifficient! re from the broadening to porm showing ork necessat the narrowing functions Made Up Eight t the | F to check properly invoice of his office. If this forations Hold ‘Carbon e receipts. The mis course of action becomes ["*°rm#tion Shown D ement or lo 4 habit it will produce t1 I ( either egoism or narrowness, depending upon for no piet iplicate record ¢ nd the Whether the habit is developed through choice or riginal records ar¢ ittered widely through the thoughtlessness. The buyer who is interrupted in various filing systen f the plant. Misplacement the performance of routine duties may deny such not unusual, for the filing classification, derived interruption, or neglect those duties; or he may do from the purchase ordet frequently at variance neither. He may instead eliminate the necessity with the description of the commodity on the in for such a choice and adopt the only remedy for oice or the receiving slip. The probability of loss, overwork. which has alwavs been more effective while less remote, is not le objectionable because work properly systematized. f the great difficult replacement The consid- The directing of purchases, the approval of pay- erable volume of the card file and the special desks torage, combined with ; torage being beyond the buyer when at his desk are sec ctive cards are so fre ir their record value, and dditional duplication, in Inactive cards wv h he file, for uniformit Ce ET — = t pr er te cee poe ie 1256 sake, are cumbrous, unwieldy and wasteful of space. Most other systems of which the writer has knowledge may be condemned for the unpardonable fault that they do not afford in compact form, under a material classification, the complete record of each and every purchase for instantaneous reference. Conscious that the purchase systems in general use left much to be desired, the writer several years ago gave careful study to the problem of developing for use in his own department a system better suited to that department’s needs. The reached were as follows: conclusions 1. All vital statistics of each purchase should be recorded upon one of the five original records that contribute the information applicable to that purchase. 2. The filing of the complete record should be under a material classification, in order. 3. The original record used as the groundwork of the system should conform to a standard size, cover but one class of material and elsewhere in duplicate form. 4. The size of the record best suited for acces- sibility is such as can be conveniently filed in the top drawer of the purchasing agent’s desk. 5. The original record selected should be one that is available to the department before the trans- action is finally closed and the invoice surrendered for vouchering. 6. The conclusions stated and other valid reasons stamp as impractical or in some way ex- tremely undesirable the selection of the requisition, the purchase order, the invoice or the departmental debit slip of distribution forms for the groundwork of this system. Difficulties were encountered in adapting the record of receipt to the purpose; principally because this record was kept in a bound book by the re- ceiving department, necessitating the submission to that department of all invoices for the checking of goods received. This delayed the approval of in- voices, and their occasional loss occurred. It offered to human frailty, moreover, the temptation to ap- prove without the careful counting or weighing that would be necessary if the invoiced amounts were unknown. A post binder was supplied the receiving depart- ment to retain the permanent feature of the old system and the purchasing department assumed the responsibility of checking receipts. Padded dupli- cate forms of suitable dimensions, with margins punched to fit the binder, were supplied. The orig- inal page was perforated to permit of its being easily torn into eight 3 x 5-in. cards printed as illustrated. The second sheet, of a different color, was not perforated or printed. The receiving de- partment was asked to enter but one class of goods on a card, using black ink for their record, which should reveal date of receipt, consignor’s name, quantity and description of merchandise, identity of carrier, all receiving charges and notes of condition on arrival when necessary. The pages so inscribed are delivered daily to the purchasing department, torn apart and filed alphabetically according to con- signors’ names. The duplicate pages bearing the carbon copy are retained in the post binder in the receiving room, serving as efficiently as the former record and furnishing a means for the renewal of any lost card. When invoices are received extensions are checked in the accounting department, andthe pur- chasing agent initials prices O. K. and records the terms of delivery thereon; the filing clerk then lays before the office assistant the purchase order, in- chronological be accessible THE IRON AGE May 2) 1914 voice and receiving slip. The assistant affixes j; red ink on the receiving slip the date of o: and invoice, the terms of delivery and the cost itials goods received on invoice, transcribes receipt and order thereon, classifies items distribution, compares terms of delivery on and receipt slip, deducts or charges back ranted transportation costs and stamps ; se order complete for permanent filing. Th: Q is then turned over to the accounting dep: and the receiving slip filed in the purchasin; drawer under a material classification. The same index affords on auxiliary cards fo, each commodity lists of the sources of supp catalogue references, quotations, etc., and its exist- ence obviates the necessity of a price card of a price book record. A card cabinet n reach of the purchasing agent contains the rd cf previous years. e Of If it is desired to maintain a permanent in- ventory the above system lends itself readily to that end. The only additional work that is necessary is to carry forward the totals of each successive slip, and file the departmental debit slips of distribution, similarly totaled progressively, in the same index. A balance may then be struck at any time by a ccm- parison of the last slips of receipt and expenditure. The system is flexible and is generally applicable to business of any magnitude. It is compact and gives a maximum of information to the cubic inch of filing space. It is automatically accumulative, may be started at any time, and becomes effective from its inception. It involves a minimum increase in routine clerical work over that required to per- form that work without it. It conserves the time of the purchasing agent, permitting him to give proper consideration to outside conditions, and to analyze internal requirements and ultimate econ- omies. Detroit Foundrymen’s Association The Detroit Foundrymen’s Association held its an- nual meeting and banquet at the Cadillac Hotel, De- troit, Mich., on the evening of May 14. The following officers were elected: President, A. F. S. Blackwood, Michigan Steel Casting Company; vice-president, It ert Carolin, Robert Carolin Brass Company; secretary, William A. Fletcher, American Blower Company; treasurer, E. I. Chase, Cadillac Motor Car Company Executive Board—H. W. Johnson, Fairview Foundry Company; J. A. Moore, American Blower Company; Edw. Bierwirth, Russel Wheel & Foundry Company; J. W. Collins, Aluminum Castings Company. E. J. Woodison acted as toastmaster and introduced several novelties in the way of entertainment features. The reports of the secretary and treasurer showed the asso- ciation to be in a prosperous condition. The year Just ended was a banner year in the way of attendance, new members and high standard of papers read at the meetings. Walter D. Sayle has been appointed receiver of the Avery Stamping Company, Cleveland, Ohio, as a result of a suit brought by some of the employees. It 's stated that the company’s liabilities are $50,000 and assets less than half that amount. The Avery 0m pany, which owns the site and factory operated by the Stamping Company, has also been placed in the hands of a receiver, Edward E. Newman having been 4? pointed for that purpose. The plans of the Broken Hill Proprietary Compa?) Ltd., Newcastle, New South Wales, call for the ere tion ultimately of four 350-ton blast furnaces. Une fur- nace is now under construction. Of ten 50-ton oper hearth furnaces projected three are now being erect®® a is ani Work is in progress also on a 35-in. blooming mill 3 a 28-in. rail mill. ’ 1914 THE IRON AGE 1257 A New Machine for Drawing Small Wire rawing steel wire from °s, in. in diameter Standard Machinery Company, Elmwood \uburn, R. L., has brought out a new ma- is designed for use in connection with nging from 22 to 30 in. in diameter, and e employed for drawing wire of copper precious metals. A feature of the ma- attachment for starting the wire after pointed and passed through the die. be noticed from the engraving, the con- heavy and rigid, and there are sheet nels for covering the underworks, like the as a safety measure. The machine is a friction clutch and the driving shaft is ired to a large spur gear. This is located inder the table and on the shaft with it is nion that in turn meshes with the vertical the drum. The machine is then set in throwing in the clutch with the shipper hown at the extreme left of the machine. ndle at the extreme right controls the opera- the internal clutch and the setting of the t drum in motion. re the machine is started the wire to be nserted in the tongs of the wire starting nt which pulls the wire through the die machine is put in motion. As soon as the revolved as far as the back of the ma- the hand lever on the tongs of the starting nent is hit by the knockout and automatically i, the action throwing the main drawing drum operation. The wire that has been started in which is equal in length to half the cir- ference of the drum, is then clamped in the on the top of the main drum, and the machine this continuously through the dies, which are ported as shown on the machine table. It will noticed that there are yokes going up from the nside of the main drum, which are relied upon to er n Tit Y r + the wire from going any higher, and also ve as a guide for the fastening of the coils. (hese machines can be furnished for direct con- to the driving motor or in series. The ter of the drum is 22 in. and the hight is The linear speed of the draw-out drum is per min. The clutch pulley is 24 in. in diam- with an 8-in. face, the speed of operation being v of the Special Wire Starting Attachment 92 r.p.m. The hight of the machine is 5 ft., the width 4'% ft. and the length, including the clutch and the outboard bearing, 7 ft. The weight of the machine is approximately 4000 Ib Color in Safety Goggles \r effort to ecure tne prope! rorvle io workme n ubject to the intense glare of incandescent met: has been undertaken by the F. W. King Optical Com pany, Cleveland, Ohio. It has been found that the smoked and blue glasses commonly used defeat their very purpose of minimizing eye-strain. Two kinds of light rays are regarded a particu- larly injurious to the eyes, the chemical or ultra violet and violet rays, which have a deteriorating action on the tissues, and the heat or red rays which by their intense energy are probably the chief cause of eye fatigue. Smoked or blue glasses offer no resistance to the former, it is claimed, and are therefore of no benefit except to exclude much of the glare; while red, orange and similar glasses transmit the very harmful heat rays. In order to make the ideal goggle, it is held to be necessary first to cut off the invisible violet rays and then reduce the visible spectrum so as to absorb heat or energy rays to a point that produces no eye train whatever Of all the colors a yellow-green seems best to accomplish this It not o1 ly reduces the ight to the limits desired but it also distorts images less than any other. Moreover the variation of bright- ness of incandescent metals with temperature appears relatively the same through this kind of glass as through uncolored glass. An elaboration of this sub ject has already been printed in pamphlet form by the F. W. King Company, having reference for example to the correct glass for use in open-hearth work, cement burning and on the pulpit of the Bessemer co: verter and this pamphlet can undoubtedly be had for the asking. Thirteen new school buildings to be devoted exelu- sively to trade training, and to provide accommoda tions for 10,000 boys and girls, are to be erected in New York City if present plans are carried out by the Board of Education. Five of these buildings ars to be assigned to Brooklyn and two to each of the other four boroughs of the city. The plans for the extension of trade education are the result of a car vass of large employers begun by President Churchi of the Board of Education early this year. These 13 schools will represent the largest single advance in trade education made in this country The Trumbull Steel Company, Warren, Ohio, has placed an order with the Cleveland office of the West inghouse Electric & Mfg. Company for a 750-kw. ger erator and a 300-hp. motor—the latter for driving the cold rolls—and a four-panel switchboard. : : pe gp ti ree ee ge ER ieee o>) eer eaneie~ene ~-e6n or 8 eo er ee ree er eee wae Apia» wets - one ve errr oe or ur é 4 ; ; ' a : 7 te Pas Ce ' i ei 4°43 ae ad e4 i The Talbot and Other Open- Hearth Proces; Results at Witkowitz S the Former tent Varies Widely, BY DR. Since the founding of the Witkowitz works in 1829 a number of processes for manufacturing steel have used owing to the constantly shifting sources of supply of raw material, as well as to keep abreast with the times. peca been When low-phosphorus ores me scarce, the acid Bessemer process, originally introduced in 1867, was replaced the semer in 1879, or rather the two were run in com- bination, to be replaced entirely by the duplex proc- ess in 1882. The Duplex process was originated and basic Bes- developed at Witkowitz. In addition various modi- fications of the open-hearth process, both acid and basic, were operated at these works. While the duplex a gave a quality of steel which left nothing to be desired and the output of t rt a t Tere ? NOTA *~ FRIEDRICH § Worsnc Pearrown | i Steel Works Favor , Especially Where Pig-Iron Con- Also Amount of Serap. SCHUSTER+* miles away. It was necessary to select a ing process giving great latitude in qua gether with a minimum cost of productio: was to be replaced by electricity generat: waste blast furnace and by-product coke ov and transmitted to the new location. The } to be arranged for future expansion of ea ment independent of the others. Othe: ments were these—the shortest transport rial from the raw to the finished state; th: use of traveling cranes; floor space to same level throughout the plant and kept obstructions; accessibility of all moving par the floor level and replacement of manual machinery wherever there was danger 500 694. J : 90 ~ | by 4855 +; -T ttt TT A a —— ,.L? 4 ame a hones pe Ft -- 4 j ‘ yi og tee nah I iT] a = . , 4 | ee = if ee - > <= ° + af > te ie 1h eigen tee bh we Pee 2 —e = tT ra Ai i ee — 1 — ay tT ay | oh | t i} ° if | cry ‘ Amr SLAG -TRACK Cate ; totertc: orn . iene ee eounp Lewes PE = Ji | oP ate! siete ' Uber? for Prpedine § i x irs ies rs i Wis { A 411 Rss ¥ 4 } 4 ‘ I sb bda S 100. +500 os + 890 ; an eer at i a hee eT 44 i ‘ ~s2EeRe suceeErer - a + SERS CRC STs eee esrerss 2. i , yrearet ea FURSRCRGET Ios aa i Vat i wl w I : 2 es Se ", } Longit Secti d Elevation of Talbot wan fo: = i inen-H th I wi Rnowits i Ly bhi big ‘ ‘ tne s everal furnaces was large, yet the t of oper- ating the separate Bessemer and open-hearth instal- lations was such that a cheaper method was sought for. The : Bessemer, od for producing steel, was precluded by ore condi- tions. Scrap was not abundant at suffi- ciently low figures to make use of an all-scrap proc- for the relativel: h requirements. Hence the only and-ore prov ess. COS basi by far the cheapest meth enough ess hig alternative tonnage was a pig- REQUIREMENTS FOR THE NEW PLANT The study the situation was complicated by the necessity of a complete reorganization of the rolling mills as these were fairly antiquated. The dominating factors involved a removal of this de- partment to an entirely new location one and a half of *T) anslation, nearly in full, of paper read at a general meeting of the Verein Deutscher Eisenhuettenleute, Mav 3, i at the London meeting of the Iron and Steel Institute, Mav 7, 1914 +General 1 Witkowitz Steel Works, Witkowitz, Austr L I Nee RE A onstruction included a lime kiln and dolomit a gas-producer plant of 20 Kerpely units; storage yard commanded by cranes, with magnets for pig iron and _ scrap; plant, with blooming mill, soaking pit building adjoining the blooming mill a transformer for the reversing mill which is driven by di! rent: then the rolling mills consisting of 15 ™ f rolls—an armor plate mill, three sheet mills, ' universal mills, a reversing billet mill, a ral girder train, a three high breaking down medium and small mill trains. The area coveree roofs amounted to 1,130,000 sq. ft. and storage with crane facilities 485,000 tional. steel oO ting sq SELECTION OF THE TALBOT PROCESS Not only was the rolling mill problem one, but owing to the limited tonnage of each 54! made at one time and the great variety of 5! e i tions gotten out, it became a truly “Austria! 1258 THE IRON AGE 1259 » “ PLaT©coan Spry OS PATON ___ ao ; 7 ti : v1 + 4 e S ' - + L. | a = « Waive Semmes PLarrons $64 j ; ry > “ eens = ] r~ Lp ——- _ a) sn pager | bane a 7 ~ same P } rf ; ‘ mn mre it a ree mat | pppeenapbetie i eee ‘ ee ‘Z ye fp | a ee 4 tt Rpt AE | | Ne 0 ee | L me i y | pS a , : 2 tT ut % 2 i. atcstsaitedtisiiiicscscseseseees ¥ i| on an & i 2 PERSE ESETR A Se eSseeestess =2an8 L vRive 4 - 600 Bovit 700 ~y * + me : 7 he or ‘ | helene 6d Lot 9 f ooh AAA so : * vt ¢ Ht bi “i a ae Sd | game! i : YZ ee i oe nomen yj t i Soe! THe 14 i ) r 1] id é R if ; ; r i] ae fea a Ee, f , “RRS 8 ere ey nar ot was necessary that the steel making proc- production of open-hearth steel Germany, tilting ted should allow one kind of steel to follow furnace plants seemed to be almost absent rapidly and with absolute assurance, and doubtedly this was due to the greater first cost, ise of the scrap coming from the rolling greater running cost, and greater fuel cost as con tinually. Another condition was the use pared with the stationary open-hearth furnace iron with medium phosphorus content, as Apart from England and the United States (where in the company’s furnaces, and which a 75-ton Talbot furnace was in operation as early as be used for steel making at lowest productio1 $98) there was only one 175-ton Talbot furnace in yperation in 1906—that at Senelle, France, whic! ntinued studies and visitation of plants was shut down two years afterward sulted in the adoption of a pig-and-ore In spite of this situation and the rather aston the tilting open-hearth furnace. Natur- ishing information that an American works, in nanagement was much worried by the con building an addition to its existing Talbot installa reports received. Thus, in connection with tion, had adopted the duplex process which at Wit g open-hearth furnace, while England and kowitz it was decided to abandon, the studies were ted States gave excellent reports, it appeared continued and Prof. Eichhoff and Mr. von Maltitz that in view of the constantly expanding vere sent to England to investigate all the Talbot TABL} ] —.-! pa | $$$ peep r } 52 E - = - 2 as = = - o 2Me Ss28s = S35 25 . mes St ws - — ap | = = > y 36 ae 4, - ; ba s ~ Fm ° f . _ f) = ~ — ¥ ~— —~—— _ SS —— ] = a ‘ us 5 o 5 . = o™ oo 5 : 5° = é 5 z < a= me ~e ew & - - i- ~~ ' an as = <q, ~ - an oar Le a?" “ ~<a =F. a a j | 1 Hearth dimensions at height of bath with an average charge. Width=maximum width. 2 Chamber capacity, i.¢. the part of chamber filled with bricks=capacity of chequer work +spaces * Assumed: Talbot with 5 per cent. scrap ) Wellman ,, 13 a A band using mixer iron. Open-hearth ., 25 lhe mixer production is entirely dependent on charge and output f pig iron. - va pe a 1260 plants being operated there. The result was a determination to make comparisons of the several open-hearth processes on a sufficiently large scale at Witkowitz and then to select the one best suited to the requirements. The above-mentioned separation of the works units required the use of a heated mixer installa- tion for the blast furnace metal. To care for the contemplated production of 800 tons of steel daily, and at the same time to allow for future expansion, it was decided to put up two tilting furnaces of about 300 tons capacity, using one as a heated mixer and the other as the Talbot furnace, or, in case of an unsuccessful result of the test, as the second heated mixer. As a precautionary measure, in the event of dif- ficulty in getting satisfactory service when various steel qualities were required for successive charges, it was decided to build three 50-ton to 60-ton fixed open-hearth furnaces in addition, and further, in order to test the merits of the tilting as against the fixed open-hearth furnace, a 60-ton Wellman tilting furnace was added. To complete the plant a small electro-steel installation of one 2-ton and one 6-ton electric furnace was provided, the small one to serve for melting ferromanganese and the larger one for the production of special steels. The storage system and producer gas plant were so designed that it was possible to get exact figures in the case of each comparative test. It made the installations more complicated, but served its pur- pose best that way. A COMPARISON OF THE FURNACES . Table I gives a comparison of the furnace dimen- sions as well as production data. The two large tilt- ing furnaces are practically alike in construction, differing only in the shape of the bath. While the furnace built to serve as a heated mixer holds 300 tons of molten metal, the one for the Talbot process is arranged for only 200 tons. It will be noticed from the table, in which the dimensions are in meters, that the two furnaces have a bath 48 ft. long, a width of 13 ft. for the Talbot furnace and 15 ft. for the mixer. The depth is 3 ft. for the Talbot furnace and 31% ft. for the mixer. The en- tire length of the tilting frame is 56% ft. The other dimensions may be taken from the illustra- tions, Figs. 1 and 2. In contradistinction to the English furnace con- struction in which the ports can be rolled away from the hearth, the two large tilting furnaces were made with stationary interchangeable ports, after the Friedrich system, which can be hoisted out. The hearth turns by hydraulic power, the central axis running through the gas port centers, giving excel- lent satisfaction in practice. All cooling rings, doors and door-frames are water-cooled, the doors, stack damper and reversing levers being operated by mo- tors. The Wellman tilting furnace has a length of bath of 35 ft., a width of 1214 ft. and a depth of 2 ft., holding roughly 60 tons. The three stationary open-hearth furnaces have a length of bath of 33.3 ft., a width of 12 ft. anda depth of 2 1/3 ft. The checker chambers have been placed a little backward and the slag pockets are readily accessible. This arrangement places the chambers somewhat deep and gives longer uptakes. The Talbot furnace has a single port each for gas and air, while the Wellman and the fixed open-hearth furnaces have two ports each for gas and air, an arrangement which will be changed to conform with the Talbot type at a future rebuilding. All furnaces have the interchangeable ports of the Friedrich system. The stacks for the large tilting THE IRON AGE May 21, 1914 furnaces are 173 ft. high and 6.7 ft. clear The four smaller furnaces have stacks of { hight, but are only 6.3 ft. diameter inside t} GENERAL OUTLINE OF OPERATIONS The working procedure is as follows: | metal is brought to the steel works from furnaces about 1 1/3 miles away, in standa ladle cars holding 30 tons each. These preheated with blast furnace gas and aft: are carefully covered with a fire-brick lin: thus saving splashing as well as undue « case of delays of several hours. A 50-ton cran off the cover, lifts the ladle from the car a) it on another one running between the house and the casting house, from which 50-ton crane picks it up and empties the met the mixer. Before the entrance of the molt the mixer has been charged with about 3! pe: ore and 1 per cent. limestone. Experience showed that the best results ar obtained when the mixer is used as a receiving b: only, and no attempt is made—as is done at other works—to do very much refining in it. While it is the aim to prolong the life of the hearths as much a possible by using silicons below 1 per cent., the effort is to remove this impurity in the mixer to th largest extent, and with good success. Moreover the mixer is advantageous in the desulphurization of the iron; in fact, even during the transportation of this metal from the blast furnaces as much as 50 per cent. of the sulphur has been occasionally re- moved. The average of a long series of observations indicates that 36.5 per cent. sulphur and 12.06 per cent. manganese is removed while the iron is in the ladles in transport. As the covering up of the metal in the ladles keeps it from skulling even when left stand for four hours, it is possible to draw upon the mixer just as wanted by the open hearths and refill from the ladle directly after. METAL AND SLAG ANALYSES The following figures give the averages of direct metal, iron from the mixer, and the mixer slag, as obtained during these tests: Direct metal: Silicon averages ran from 0.541 0.83; manganese, from 1.56 to 2.11; phosphorus, 1.74 to 0.55; sulphur, 0.06 and 0.07. Mixer metal: Silicon from 0.17 to 0.21; mangan- ese, 0.86 to 0.94; phosphorus, 1.67 to 1.07; sulphur, 0.03 and 0.04. Mixer slag: Direct metal being 1.1 phosphorus the silica ran 29.92, the phosphorus 1.78, and th iron 5.99. With direct metal of 1.7 phosphorus, the silica ran 29.60, phosphorus 1.96, and iron 4.51. _ About 500 tons of iron passed through the mixer every 24 hours; with a surface of 657 sq. ft., this means an average production of 7.6 tons per sq. ' For every ton of mixer metal there was charged 2127 lb. direct metal from the blast furnaces, 64 ! pig iron, 77 lb. ore, and 22 Ib. limestone. The entire series of tests, beginning with Ma 10, 1913, produced about 150,000 tons of mixer metal, using an average fuel percentage of 152 | per ton. The yield was practically 100 per cent. The mixer allows a complete independence 0 run of the blast furnaces, it being possible to ‘ur nish the secondary furnaces with metal of a uni! = composition at all times. The actual in eas production on the part of the steel made, after = mixer was put into commission, was 4 round 2 per cent. In addition there is a possibility of us" small quantities of pig iron or even scrap 1! oe mixer without perceptibly increasing the fuel per centage. the i takes place. 1, 1914 TALBOT FURNACE PRACTICE en as the 200-ton bath of the Talbot fur- reached the required composition, about 65 steel is tapped into the ladle and the neces- rromanganese added. The remaining 135 tee] is allowed to stay in the furnace under slag cover for about 10 to 15 minutes. After the tap-hole and making any necessary epairs about the slag line, the ore and lime for the next charge are introduced by charging apparatus. These additions are vy heated up in 15 to 20 minutes to allow 30 tons of mixer metal to be introduced, ng in a ladle. A violent reaction between mixer metal takes place, the carbon content atter being oxidized to CO. The reaction is es so severe that it is necessary to cut off of regenerated air and open the doors to the furnace pressure. In spite of this rea the bath is perceptibly cooled. In hour it has become quiet enough to add the ladle of mixer iron and a much milder reac- The heat is now run up sharply the charge is properly liquefied. carbon content of the finished bath of steel ry according to the products required, being 0.08, with manganese about 0.30, and phos- 0.02 to 0.03 per cent. The greater part wever, he slag cover is tilted out to one side of the form and if required the necessary ore and lime rge added to complete the operation. he length of the heats, with same scrap per tage, will vary with the phosphorus content in xer metal, and shows no serious retardation | per cent. With 1.8 per cent. phosphorus me is increased by about 8 per cent., with a esponding decrease in the day’s production of The oxidation of the silicon, manganese and rus after the ore addition takes place at a ratively low temperature, and if sufficient added, will be complete by the time the s are fully melted. The oxidation of the car- epends upon the degree of concentration of this the temperature existing and the rate of The higher the temperature the quicker tion, which in the case of the Talbot furnace, ts comparatively high temperature at the be- ng of the heat, is quite marked. The rate of g is very important, for in decarburizing, as the decomposition of the iron carbide which ase of the white irons includes all the carbon, lerable heat is required. According to Camp t takes 705 calories to take care of 1 kg car- Moreover, the heat developed by the almost ntaneous combustion of the CO formed is above ath and therefore practically lost to it, and in spite of the combustion taking place, there tual cooling. \CTICE WITH TILTING AND FIXED FURNACES the Wellman tilting furnace the required f scrap, ore and lime is first introduced, and me the two ladles of mixer metal. The then goes on in the usual manner as the regular stationary open hearth fur- lust before tapping the slag is run off into ries, at one side of the platform, and the any remaining slag tilted into the ladle. irization is effected in the ladle in the usual The Witkowitz experience indicates that results are obtained when 10 to 15 per cent. s used. three 50-ton to 60-ton stationary furnaces, previously, were intended to care for the ing from the rolling mills on the one hand, THE IRON AGE and on the other for making special grades of steel as required. The operation of these furnaces is therefore no different the case of the usual scrap-pig iron process. [rom SATISFACTORY STEEL BY ALL PROCESSES The following points were considered in making the elaborate tests in question, which lasted prac- ssary to prove that each steel of the qualities re on ol tically a year. It was nece system tried could deliver quired; tnat was even with varying composli- possibie to obtain tion it steel of the desired qualities together with a and at urnace tested required the establishment of the most favorable conditions of working, particularly the relation between direct metal from the blast furnace and solid scrap added Finally the was which upon the foregoing, would suit the conditions from an economical standpoint? sufficient tonnage low enough cost. Each question based best system, as The investigations show that it was possible t secure from each of the three systems tried out a uniformly good steel of the desired physical and chemical constitution. The original fear that, for instance in the Talbot furnace, it might be impos sible to get billets, soft and hard sheets, rails, etc., in relatively intervals after the other, proved to be unfounded. Not only was it possible readily to obtain this result, but also to make steel tubes, both hard and soft, a product known to be most difficult to make satisfactorily The range of products made is well illustrated in the Gas and other pipe, seamless tubes drop forge steel, beams, plates, light ning rods, spring steel, rails (Austrian). The car bons ran from 0.09 (gas pipe) to 0.48 (rails); manganese, 0.43 to 0.87; silicon in spring steel and rails, 0.24 and 0.12; short one for seamless follow ing: { soft } phosphorus from 0.02 up to 0.04, and sulphur, 0.017 to 0.030. VARIATIONS IN CHEMISTRY AND IN SCRAP In order to test the range of composition of the blast furnace metal wide variations in compositions were made for long continued periods, and every kind of steel required was produced satisfactorily In phosphorus the steps represented the following average percentages: 0.50, 0.75, 1.00, 1.50 and 1.75. The manganese percentages tried to nearly 3. While there was no difference to be noted in the quality of product got from each of the three sy tems tested, it was observed that for tonnage pro duction there was a variation when the phosphorus content ran considerably over 1 per cent. For in- stance, with the phosphorus at 1.75 the production of the Talbot furnace dropped about 8 per cent., and that of the Wellman and the stationary open hearth about 12 per cent., as compared with a production on the 1 per cent. phosphorus basis. It is to be observed, however, ran from 1 up that with the higher phosphorus percentage the value of the slag made increases, and consequently this offsets the loss proportion- ately. After a long series of tests it was concluded that the Talbot process is most effective when the quantity of scrap added was a minimum. Up to 5 per cent. of scrap did not matter, but above this the cooling of the bath was marked, the time of the heat extended and the production decreased. The fixed open hearths gave their best results with a 25 per cent. scrap charge. A rise in the phosphorus content affected the results seriously as shown above. Trials in these furnaces with mixer metal only, or with very small scrap per- centages had to be abandoned soon, as the slag quan- a — ~ 1262 tities became a nuisance, and it was seen that this would not solve the problem. BASIS OF COST COMPARISONS In judging the running cost of the three sys- tems the following points were considered. 1. Rela- tion of the first cost independent of the building put up and local conditions. 2. Fuel expenditure. 3. Expenditure for ore and lime additions. 4. Durability of the furnaces and consequent repair material and supervision, By-products. One the nace will always labor. 5. such etc. Remaining costs, current, ingot molds, as water, 6. of main objections of the tilting fur its comparatively high first cost, this depending not so much on the dimension- ing of its parts as the economic condition of the country where it is put up. Comparisons are onl) possible where furnaces of several types are put up Witkowitz. Naturally, actual be given, but the comparison following is based on absolutely ac- The construction costs of the Talbot, Wellman and fixed open hearths were in the 1659 : 1259 : 1000. Comparing this daily production of ent set of figures Wellman, fixed open-hearth compare 882 : 1070 : 1000. These figures take into account not only the first cost of the furnaces themselves, but the ground the be side bv side at well as figures cannot made in the curate costs. ratio of with the differ- Talbot, however, furnaces, obtained, first these cost, quite a and the furnaces IS as floor occupied in buildings, though not the accessory apparatus, as charging rnachines, cranes, etc. The following table summarizes the operating results of the three systems in question, using iron with 1.1 as well as 1.7 It per cent. phosphorus. will be noticed that in practically every point, as THE IRON AGE TABLE 2 Working Results of the Three O tems Talbot Wellman Lturnace Lurnace per per per p Material per cent. cent cent cent Ton of Steel ¥ P. Ps P 1.1 ey 1.1 1.7 Kilos Kilos Kilos Kilo irg Pig iron (and nixer iron). .$90 878 845 8; Scrap ‘ 66 11 17 rro franese and Fes 6 6 7 (oxides Gelliy r Ls: 160 137 16 Mill cinder, ete 7 i4 4 { me 1) 10 ; li¢ f tories M InAs i re ractory bricks { Magnesite and dolomit ] L¢ Chron 0 0 () { i 0 ur n t Ub 21 t ( ul fe nixer , 52 17 (‘o Oo steam LS 19 20 irre ts ‘ 5.4 i.3 Kilos 155 187 00 Per Per Per Pe cel cent cent é P.O il y 15.1 19.1 10.9 Viel 103.8 105.2 03.4 4 (ixides to pig iror 19.1 23.2 20 Scrap to charge : 7.0 7.0 2 The slag quantities are naturally low Talbot process, highest in the Wellman, to the use of greater quantities of scray straight furnaces, this is of medium quant W itkowitz experience further indicates that phosphorus content in the Talbot slag is highest contradistinction to published reports on the su ject. higher the phosphoric acid is in the slag, being The higher the phosphorus in the charge th almost proportional to the percentage of slag per t of steel made. Here are typical analyses of the Ta bot slag: Pig iron with wit : : . . . > 1 er cent é fuel, refractories, lime, direct metal, and oxides Lp Pp » added, the Talbot S) stem came out best. the W ell- —— per man next and the fixed open hearth last. The FeO 863 » 2 . ° . > k's ) ».D6 recovery of iron from the added oxides is as fol- AID 40: lows: Talbot furnace, 86 per cent.; Wellman fur- AO wae : 72 Cad 41.97 nace, 80 per cent., and the fixed open hearth, 78 MgO 5.87 Ss 0.38 per cent. Total P.O 14.7 ‘I 3 Charge ¢ Yield . ph 1 Pig Ir 11} 1‘1 per Cent. 1‘7 per Cent. 17 per Cent. | 1°] Scrap in Charge : : 5°0 | 15°0 } 10°0 3°0 ad 25°0 t 5 | } Pe ve Ve oe | hee | | ION ia Talbot, | Wellman,| Talbot, | Wellman, | Wellman, | . 7. Talbot, ( Kil Kilos. | Kilos. | Kilos. Kilos. Kilos Kilos. | } er t teel— ee a Se ~ g ir 42 36 70 69 47 r iron 868 836 744 735 806 { oo ' 915 90 817 |} 817 855 | ! S 1 a | 58 | 140 142 87 2 | 27 ) 248 , | 6 . 4 e- 3 6 6 | 6 ' es. ; | 124 44 | «(123 147. | «167 190 139 lee Oxides (cinder,&c.) . . «© . | bd ss (| 44 | 44 40 | 22 CO 79 25 Slag, per ton of steel . | 160 206 151 | 198 | 240 | 249 208 156 | Per Cent. | Per Cent. | Per Cent, | Per Cent. | Per Cent. | Per Cent. Per Cent Per’ Oxides in pig iron (calculated) 19°5 20°1 20°4 23°3 242 24°7 23°9 | avs Scrap in metallic charge | 4:3 | 6°90 14°5 14°7 92 9°5 28 | 25°2 Yield 103'9 | 103°4 103°8 103°6 | 105°4 1048 105°8 | ol Tons. | Tons. Tons, Tons. Tons. Tons: Tons, a | Production per furnace per day 317 197 2%) 202 180 140 292 155 — = EE ————-- = aan SS MS. ee m a ee ———— ol tiie eatin tee ee a . F ; : = = : ’ : ~ . : - - et . - a. 3 ie wot ~~ I we Te a rt gy NaS a eae me ec — a . « eee be Y be : : wn X - ‘e — . ~ ol summegemen 2 . -* - 80.96 80 (x ' t ; . 2 Da yc . + ? 89. 69 0-l rey 49 “2 » t or jO WOO WN ag.0 06 ‘ rt 0.4 at 2 }USg OIFEA PUT UIFETS £9 Le ’ z . ' Ow rl s : . ‘ A vA i 2 G8 89.1 y “ s ‘ ; 1 z , ’ t vs BUM 398 “ 2 atem ‘suonerme Ay } v3 ’ ‘ 7 oO vy < 4 7 a 9 Satum 2 ’ a) - - "JO" yh) > , ’ Of wu AsO 9% Px | . r } 2 sy Ww.9 f . 82.5 t ’ ‘ - \ ” i 7 a “ Ki 1 ag ee ' a ' ° et ‘ 0 ' Hurdjisesd | } wt. O eT 70 1 . . | t yi , > o.< ¥ LOT 4.0 4 ) I 1 ‘ h . I UMo) saputl | Sat Zuvu juss sed 99 BI 0.2 : 2 THE IRON AGE 91-0 a cL co gh. oot wt a1 0-86 — | i KI} { Jaxty , Zid puw des (09-¥¥) (16-99) |} , oma oh. ., PS. FF ote 09.9 6-2! id puv des bi lax] i j saxty a JaXI I 5.07 2. a3:eud jo 00} Jed 1805 (11-96) 9-09) 1) yuan 08) 1 uaa 68-68) | qn “ 4 | Z.oettT 686 HOB OCB 9. F£6 9f0T ¢.91TI —_—— } . 0 ct. 2 *t 1.90 ~ et. 09 - - OL-09 00- Sh OA FF-f O19 % . uastajaZaidg 8-O158 J a °° io OF.T : OF.T ( 0-6 99.1 xE.9 L ‘ 9 oR. 1 6 0e.T 9.9 0.002 jeu and a E ? | GR: Of ‘ . 96-25 rol cl 0.02 0.99 PS | o ; re | 19s , , 99 “ ne | ; uost Sid o1seg 0- Lb 1. 8901 496 | oP. 08 8l8 ry. (19% 96-L6 | 0.060T 0.+ | ’ i ) } Joly Zour | x | j } Ww ; Y i | ! | aiat] nT I el] wo] ny] 10T 1] Teo] wia}] 0] ui] | PIPtA JO PIVIAS PISA J PI? 1K JO uc uo 1 sad 1 sed lO} 3 ! 1 sad I , . ua 4 1 5 "PISIA jo WAIN Peta jo PISIA J iydte t KY ’ nN NAY 1 PI9tA 3 pla GFN ’ no] sed sduty 10 | sad s3 is uo] Jad SA 10] 49d s3 ad s3 voy sad si 1 JO] 32 1c =— 103 FIG sucl (WK LI ¢ U0} FREI } I oT 101) pod Ayrecy I eg - ; 0 ,IUTTeQ jo sO] ay ). 88 1. ToT t. 60 I , ) 6.68 Ja PIPAIA 1G 1264 THE IRON AGE May 2), 1914 The iron content in the slag in the first case is 11.3 per cent. and manganese 5.67, or total metal- lic content of 16.99 per cent., whereas in the second case these figures are 7.8, 3.38 and 11.18 per cent. The composition of the slag naturally depends a good deal upon the nature of the oxidizing medium used. The fewer silicates from the ore, the greater the concentration of the phosphorus. THE LIFE OF THE FURNACES Comparing the durability of the several fur- naces, we have the following figures: Talbot furnace.—First change of ends (Fried- rich system) required after taking out 300 heats. Next change after a further 250 heats. Third change after another 250 heats. This with the same furnace roof. Or, 800 heats made, with 65.6 tons in each, giving a total of 52,480 tons of steel pro- duced for this run. Wellman furnace.—This made 220 heats hefore new ports and repairs to walls and uptakes, etc., were necessary; then again 220 heats. Total, 440 heats with the same roof. At 62.8 tons per heat, this meant 27,600 tons of steel. Fixed open-hearth furnace.—Similarly 250 heats until ports and other parts had to be replaced; then again 250 heats. Total, 500 heats with the same roof. At 55.7 tons per heat, this made 27,800 tons of steel production. This indicates the superiority of the Talbot fur- nace, and is mainly due to the faster operation and more intense reaction in it as compared with the other furnaces. In the Talbot furnace the oxides and lime added react from the great surface space of the bath downward to the bottom, whereas the Wellman and fixed open hearth furnaces react from the bottom upward, causing a long continued boiling of the bath, with consequent spattering of the walls, bridges and ports, and their eventual destruction. A further reason for this condition is the fact that in a furnace like the Talbot, where some molten metal is always left remaining, the lining is not subject to the serious fluctuations in temperature as is the case in furnaces which are periodicalls emptied out completely. The longer life of the re- fractories in the ladles for the Talbot furnace was distinctly noticeable, as compared with that of the ladles for the other furnaces. There was absolutely no slag in the first case, whereas in the Wellman furnace, and particularly in the fixed open hearths, the presence of more or less slag on the steel cut the ladle linings rapidly. Finally it may be said that the miscellaneous charges against the cost of production ran lowest for the Talbot furnace steel. FINAL COMPARISON OF COSTS A summary of the total operating costs of the three systems tested out would be as follows: Tal- bot system, 100; Wellman system, 105; and the fixed open hearth, 107. These figures include the cost of operating the mixer. In order to compare the Witkowitz costs with those of western Germany a paper by N. Schock fread at a general meeting of the Siidwest Iron Works on February 15, 1914] was made use of. Placing the cost of basic Bessemer steel at 100, the figures of Schock show that the scrap-pig process would stand at 129, the pig-ore process at 111 (which seems a little low), the Talbot process at 114, the Wellman at 123, the fixed open hearth at 128, and the duplex process at 133. Putting the Talbot process figure in the above series at 100, we have the Wellman at 108, and the fixed open hearth at 112. The experiences at Witkowitz, as stated above, place these figures at 100 for the T for the Wellman and 107 for the fixed ope The only reason for this variation from ern Germany equivalents is the difference r of raw materials. In order to obtain information regardi: important subject, namely, the maximun itny that can be obtained with each of the systen | a run of six weeks was undertaken, everythi: accurately weighed night and day by a la) of engineers and assistants. The materia! as well as obtained were carefully anal metal spilled returned to the proper furn: everything carefully watched. The result test was that when the same raw materials we, put in, and the same proportion of mixer meta] and scrap was used—as nearly as might be—the sam production was obtained. This is perfectly log as the ore addition is really dependent w amount present of the elements that are oxidized out. A variation of output is only pos when this percentage is shifted. 05 CONCLUSIONS A summary of the final conclusions is given here- with: 1. By the use of the heated mixer and refining only slightly therein, the output of the furna serves can be increased by about 30 per cent. 2. The quality of the steel produced, both ph: cally and chemically, is independent of the system selected. 3. The extent of the output is dependent upon the metal used, as well as the proportion of mixer metal and scrap making up the charges. Identical conditions in these points result in an identical out- put. 4. Where iron of varying composition is to be used and the range of scrap percentage is fairl wide, the Talbot furnace offers the best opportunit for economical work. 5. The Talbot furnace allows the use of the est up to the highest phosphorus cat wit out damaging the quality of the steel made, the r duction of output in the case of high seal ru being lowest in this system. 6. Although the actual first cost of the Tall furnace is appreciably higher than that of a tilti furnace of small capacity, or of a fixed open-heart furnace, these costs, calculated per ton producé daily, work out most favorably for the Talbot tur nace. 7. The yield of iron from the oxide add is highest in the Talbot system. 8. Where high phosphorus irons are used the phosphoric acid content of the slag is propor- tionately higher, meaning a greater profit from the slag in the case of the Talbot furnace. 9. The fuel economy of the Talbot furnace |s greater than that of the other furnaces. 10. The life of the Talbot furnace is longer than that of the other furnaces, and hence the r pair expenses are lower. 11. The operation of the Talbot furnace 's easier and simpler than in the other furnaces, a ticularly as the slag can be tilted out more re adil 12. The labor involved in the Talbot furnace 's not so severe, and comparatively fewer men are r& quired for its operation per ton of output. From the foregoing it would seem that for ope! hearth steel works producing medium ané larg‘ quantities the Talbot system offers better returns than any other, and hence it may justly be called th open hearth furnace of the future. 1914 A Simple Rapid Working Surface Gauge nid working surface gauge which has a nge of uses in any shop where accurate ns are required on interchangeable parts developed by W. P. Kirk, 336 West Fourth ncinnati, Ohio. The gauge is made up of ee pieces, the ground bar b, the round and the pin d. There is a reamed hole ar through which t