The Iron Age 1914-11-19: Vol 94 Iss 21

MMC syevvunvvocgnenvunyonsanvnasnpennnt UvUuanunennsnesuueveannunvnnanenaceneesvoesansanene VUNUAUUDENU EUAN ELEN NESS = QEUUEUUCOCUETAEUUT TDA T ETE Hie ent Established 1855 New York, November 19, 1914 Vol. 94: No. 21 By-Product Coke Ovens at Sparrows Point Koppers Plant at the Works of the Maryland Steel Company—Gas Sup- plied to For the past twelve years the Maryland Steel any has been operating by-product coke ovens at Sparrows Point, Md., on a large scale. It has produced coke suitable for use in its blast furnaces and supplied the surplus coke-oven gas as an illumi- nating gas for consumption in Baltimore, connected to the plant by a pipe line 12 miles long. This year a new coke oven plant was put in operation, dis- Lomi Baltimore for Illumination operation, but through wear and tear the useful ness of the plant gradually diminished until it was decided that it was no longer an economic propo sition to attempt to maintain it. Before definitely deciding on the type of oven for the new equip ment, the Maryland Steel Company contracted with the H. Koppers Company for an experimental plant consisting of six ovens of 15 tons capacity eacl e Southwark Exhausters, Showing at the Right One of the Suction Regulators: On the Platforr n the Rear Are Benzo! Stills placing the initial installation made in 1903. The A factor in the decision was the use of silica bricks omprised 200 United Otto ovens, arranged ir batteries of 50 each, each oven having a apacity of 9 net tons of coal. The new plant com- prises 120 Koppers ovens arranged in two batteries, en of 1314 net tons coal capacity. Both of batteries carbonize on 18-hr. coking time, there is a daily capacity of 2100 tons of elding about 1500 tons of blast furnace pioneer installation had a long successful in the Koppers oven, with the promise of longer life than from clay brick oven construction. Con- struction of the experimental plant was begun about November, 1912, but before this battery was started the Maryland Steel Company closed in May, 1913, with the Koppers Company for the present plant of 120 ovens. As in the original plant, th« gas from the ovens is divided into a rich and a lean portion, the former before being sent to Baltimore being enriched with benzol obtained from the 1165 1166 THE IRON AGE November 19 1914 ng House Screening House leaner as, as stated. the manufacture of The plant also provides fon and the Koppers process ol ammonium sulphate, and in the the lean gas is used as a source of heat in the ovens themselves. recovery of tar usual way The general arrangement of the new plant is shown in the accompanying plan. Ground was broken in May, 1913, and construction was com- pleted in July, 1914, when one battery of 60 ovens was put into operation. The ovens are located near the shore line in close proximity to the three blast furnaces. The new work installed by the Koppers Company starts with a belt veyor for the crushed coal and includes a new coal bin, the ovens and apparatus and appliances be longing to the oven plant, and a belt coke conveyor discharging the coke into the blast pin. designed and con furnace coke The complete plant, including the original coal storage yard and coal handling and coal crush- ing equipment, the by-product recovery plant, coke screening station and tracks tributary to the oven plant, occupies an area of about 11.5 The new batteries are built in a single line, with an axis at right angles to that occupied by the former ovens. The plant is designed so that two addi tional batteries of 60 ovens each can be installed to the eastward in line with the present batteries. The by-product plant parallels the batteries to the south, and is laid out so that additional by-product apparatus for future batteries may be installed in an extension of the first building without interfer- ing with the operation of the existing plant. The coke quenching station is located at the east end and will thus eventually lie opposite the free space of about 120 ft. which will be provided between batteries Nos. 2 and 3. One of the features of the plant is that the coke is delivered from the screen- acres Cente! Right, with ind Coke Storage Bins at the Conve ing station to the coke bin at the blast furnac trestle directly by means of a belt conveyor. Coal arriving at the plant by rail may be used immediately or stored and subsequently reclaimed by a revolving coal bridge of 280 ft. span, pivoted at one end and located at the extreme west end of the plant. A mixture of coal containing 28 to 29 per volatile matter is used. The coal is crushed in the coal crushing plant installed for the original ovens. When it leaves the building it is of such fineness that about 75 per cent. will pass through a ‘.-in. mesh sieve. Coals mixed in the desired proportion are elevated by the origina bucket conveyors, located in a 100-ft. coal tower and delivering to a belt conveyor which carries the coal! into the coal bin at the west end of and serving the two new batteries. The conveyor from the coal tower to the bin is a 36-in. belt and is about 65 ft. long. The coal bin is of 2200 tons capacity and square design built of steel plate heavily reinforce: and supported by a structural steel construction wit! roof and sides of corrugated galvanized steel. lt has four rows of four hoppers, each closed by gates which discharge the coal into the four conical hop pers of the coal larry car. Below the coal bin and flush with the top of the ovens there is a scale plat- form with a 50-ton scale of the indicating type for weighing the coal charged into the ovens. The larry car which travels on top of the ovens on rails spaced about 17 ft. 8 in. apart has a capacity corre sponding to one oven charge. It is operated by : direct-current motor completely enclosed for pro- tection against coal dust. Each hopper of the larry is closed by a gate which can be operated bj system of levers from the cab. After receiving th coal charge at the bin the coal larry is run over the cent. | | i | i ens $$$ Pusher Side of the Ovens Showing the Gas s Mains Running Over to the Coolers of the By-Product.Recovery Plant at the lL ft November 19, 1914 THE IRON AGE 1167 = rorage > 5 WNW \\ . \ 8 7 | j rot f pa! g | parartin | | : S va i} . 1c i} | Rs fe | | ~ wf | > | = : ‘§ 7 hil +2 on? 7 | BG | | , ‘> © | | J he +5 {| Dip ie x © . hawt } ¥ vA al > uT 7 /-eedy lrnk 3} Benzo! Tant =F Oi! Tank s, * 50000 ag: >) Water Fark eral Map of the By-Product Coke Ovens at Works of the M d Steel Comp t St ows Pe 1168 THE IRON AGE November 19, (914 oven which is to be charged, and the spouts register with the four charging holes in the top of each oven. The larry car has also attached a swab crane which can be swung out of the way when the car travels. This swab is hand operated by means of a winch and its position on the larry car is such that the swab is directly above the stand pipe when the larry car is in position for charging. A com- plete spare larry car is provided. THE OVENS Each battery of ovens comprises a space of ibout 235 ft. in length and 40 ft. in width, exclu- sive of pusher foundations. The oven chambers are 181% in. wide at the pusher end and 21 in. at the coke end. They are about 10 ft. high and 37 ft. long between doors. The gas offtakes are arranged on the pusher side. The regenerators oven are located below the oven chambers, each Showit nt Distance the Larry Oven-Charging ¢ having its individual regenerator, so that any num- ber of individual ovens can be shut down without affecting the regulation of the ovens remaining in operation. At the end of each battery the revers ing machine is installed which at intervals of 4 hr. by means of wire cables automatically operates the gas cocks and air valves as well as the reversing dampers. The open doors are of the clay luted Kop- pers type and are handled by electrically operated door-extracting machines on the pusher as well as on the coke side. Spare doors are conveniently sus- pended in racks at the ends of each battery and are easily handled by the door machines. The combined coke pusher and leveler machine, of which there are two, one in operation and one serving as a spare, runs on a 30-ft. gauge track and is equipped with individual motors for operating the pusher ram and the leveler bar and with a bridge motor for propelling the pusher on the track. The Pump Room of the Recover 19, 1914 The Primary Benzol Washers and ‘ ' Coolers tors are provided with solenoid brakes, indi- showing the positions of both rams and the ssary controlling apparatus, all located in the here is also a recording ammeter for the tor. The machine is provided with a hand crank for withdrawing the pusher ram the leveler bar in case of emergency. The isher bar is operated by rack and pinion and is ipported by rollers and equipped at one end with pusher head. The leveler ram for leveling the harge after charging is operated by wire e. At the extreme east end of the two bat- s, the ram changing station is installed, where pare ram for the pusher machine is kept. On the coke side of the battery there is a sub- tantial coke guide running on the same track as or extracting machine and propelled by the The coke is pushed into a coke quenching Saturators at the Left and THE IRON Final ¢ ‘oolers, teheaters AGE Looking Toward the car with four side gates operated by air cylinders. The bottom of the quenching car is inclined to one side and the capacity of the car is about one oven charge. The car is mounted on two 4-wheel stand ard trucks running on standard gauge tracks. The coke quenching car is propelled by an electric loco motive shown in one of the illustrations. The run to the coke-quenching station which is located at the east and north of the batteries. Water received from condensers and of course hot is used for quenching and a tank holding about 20,000 gal. of water is provided supported on a tower. A centrifugal pump supplies the hot water. Two pipes with flat nozzles are arranged above the centers of the two quenching tracks Hand-operated quick-opening valves allow a sheet of water to descend on the hot coke while the car is passed back and forth several times for a thorough car is two ° ed eee b i r = —7. my | 7 8 ik PR i ' | | A . a ’ | # - i Tar Extractors at the Right and i 1170 quenching of the coke. The coke is then taken to the coke cooling wharf where it is allowed to steam off for a short time. From the coke*wharf the coke slides upon a 36-in. belt conveyor by means of feeder rolls which uniformly distribute the coke on the belt conveyor. This arrangement serves to protect the coke against breakage, so that a very small amount of breeze results. The moisture in the coke delivered on the belt is about 4 per cent. The 36-in. belt conveyor carries the coke to the coke screening station. This is equipped for separating blast-furnace coke, do- mestic coke and breeze. The run of oven coke is delivered on a grizzly and the blast-furnace coke which stays on the grizzly is delivered to another 36-in. conveyor about 200 ft. long which delivers it into the coke bin located between blast furnaces B and C. The coke passing the grizzly falls on bal- anced shaking screens and is separated into domes- tic coke and coke breeze, which are deposited in storage bins whence they are loaded into railroad cars. Each battery has a stack of brick lining about 8 ft. in inside diameter and 200 ft. high built of steel plate. As already mentioned, each oven has a gas as- cension pipe on the pusher side. The gas is sepa- rated into a rich and a lean portion. For this purpose two collecting mains are installed. At the ends of these mains pitch traps are arranged and they are also provided with cleaning holes along the top for spooning the pitch. Four suction pipes are connected to the collecting mains of which two carry the rich gas and two the lean gas. The division of the gas into its rich and lean portion is made by means of butterfly valves, in such a way that the gas of the first part of the coking period is allowed to enter the rich gas main, while the gas evolved the latter part of the coking period enters the lean gas main by maneuvering the butterfly valves at a certain time. The suction pipes leading from the collecting main connect into two suction mains, one for rich gas and one for lean gas. These in turn are connected to the primary coolers. The gas pressure is automatically regulated by governors which maintain a slight pressure in the collecting mains within narrow limits. BY-PRODUCT PLANT The by-product plant is situated south of the ovens. The rich and the lean gas enters the primary coolers. The tar and weak ammonia liquor precipi- tated in the primary coolers is drained off at the bottom and piped to the hot drain and tar flushing tank. The gas then enters the by-product building which contains three rows of apparatus, one for rich gas, one for lean gas and one which is held as a spare. The present by-product building is 86 ft. wide by 160 ft. long and is subdivided by walls into a sulphate storage room of 40 ft. length, the apparatus room of 80 ft. length and one still room of 40 ft. length. When the two future bat- teries are installed the length of the by-product building will be increased 40 ft., moving the pres- ent sulphate storage room farther east and giving sufficient space to add two more rows of apparatus in the middle of the by-product house. The still room is arranged so that an additional ammonia still and the necessary benzol apparatus can be installed. The pump room is arranged in a lean-to of the by-product building proper. This is also planned to accommodate additional equipment for two more batteries. There are three turbo-exhausters to handle all the gas produced in the plant, operated THE IRON AGE November 19 1914 by high-pressure condensing steam turbines. Th,» sets were built by the Southwark Foundry « \. chine Company. Each turbo exhauster has a capa. ity to deliver 15,000 cu. ft. of gas per minute against 4 lb. pressure and is provided with a regy. lator to maintain a constant suction pressure on the suction mains. The exhausters draw the gas from a gas main located in front of the primary coolers A system of gate valves permits any of the pri- mary coolers to be shut off for cleaning and to be cop. nected for rich or lean gas. The exhausters discharge the gas into a main which in turn is connected ¢, four tar extractors, two of which are spares. (at; valves at the inlet and outlet of each tar extractoy allow each tar extractor to be cut off the line for cleaning. The tar extractors are of the Koppers P. & A. type and equipped with five bells each. From the tar extractors the gas enters the re- heaters, two of which are in operation, where the temperature is raised by exhaust steam. From the reheaters the gas enters the lead-lined saturators Here it passes through a saturated solution of am- monium sulphate containing about 5 per cent. of free sulphuric acid. The ammonia combines with the sulphuric acid producing ammonium sulphate. which is precipitated and collects in the conical bottom of the saturator to be discharged into the drainage table by means of an ejector. Two cen- trifugal dryers are installed for each draining table. The dry salt is discharged into buggies and wheeled to the sulphate storage room. The gas leaving the saturators passes lead-lined acid separators and then enters two gas mains, one for rich gas and one for lean gas, leading to the final coolers. The final coolers are located at the outside of the build- ing near the primary coolers and are of the direct water contact type. The lean gas then passes benzol washers and is conducted by an underground main to a gas holder of 17,500 cu. ft. capacity. From this pipe line branch off a bleeder pipe, a pipe line to the steel mill and a pipe returning the lean gas to the coke ovens. The rich gas, to which the benzol recovered from the lean gas has been added for enrichment, is piped to Baltimore, as stated. The still room contains the lime bin, lime mixer, lime pump and two ammonia stills to distill th small amount of condensed ammonia water from the primary cooler. Most of this ammonia is in a combined form and has to be treated with lime i! the stills. The vapors are returned into the gas main and subsequently enter the saturators. At the north end of the still room there are installed two crude benzol stills, the wash oil still, heat ex- changer, light oil cooler, separator, superheaters and the enrichment apparatus. The pump house contains three motor-driven air compressors for lifting the water from eight fresh- water wells, which provide the necessary fresh water for the plant. The water is piped to a fresh water sump and pumped by centrifugal motor- driven pumps into a 50,000-gal. tower. A steam- driven air compressor is located in the southeast corner of the pump house. Tar loading, ammonia liquor, hot drain and tar flushing pumps, as well as the wash oil pumps are located in the pump room and are driven by shafting and belts from electric motors. The hot drain and tar flushing tank which receives all drains from the plant is located outside of the pump room. The tar flushing pumps are connected to this tank for continuous circulation ©! tar through the gas collecting mains. Behind the hot drain and tar flushing tank, the wash oil circu- lating tank and the three wash oil coolers for the South of the by-product benzol plant are located. N iber 19, 1914 there are two benzol storage tanks, naph- pans and three acid storage tanks, and fur- } the east the ammonia storage tank, the tar iting tank and two tar storage tanks. ‘bout 5800 cu. ft. of rich gas per ton of coal ized, having an average heating value of 620 B.t.u., is delivered to Baltimore, and 1450 cu. ft. of lean gas of about 490 B.t.u. is sed for coking, so that of the total quantity of 250 cu. ft. of gas per ton of coal, only a little 13 per cent. is used for coal carbonization, nearly 57 per cent. is surplus gas. Reduced the B.t.u. basis, the requirements for coking are 38 per cent., while 62 per cent. of the total heat . of the gas is available for outside purposes. At the present time with only one battery in oper- ation the total surplus gas is furnished to Balti- nore. Provision is made, however, for future use if portion of the surplus gas in the steel plant. To this end a gas by-pass is installed between the rich gas and lean gas mains after the final coolers. This by-pass is equipped with a gas seal to permit travel of the gas only in one direction, so that rich ras may flow into the lean gas mains while it is mpossible for lean gas to find its way back into the rich gas main. This feature serves to provide or an automatic adjustment of the quantity of rich gas furnished to Baltimore according to the de- mand. Sinee the by-pass is located between the final coolers and benzol washers, the benzol is ex- tracted also from such portions of the rich gas which, owing to reduced demand on the part of the ity, enter the lean gas system through the gas seal Drilling Machine for Rapid Work After considerable study and experimenting an 1utomatie drilling machine for rapid work has een developed by Baker Brothers, Toledo, Ohio. \s the name indicates, it is automatic in operation nd performs the movements of bringing the work ler the drill, advancing the tool to the work, gaging the feed, withdrawing the tool and re- ng the work without any attention on the of the operator beyond one depression of a treadle for each piece. A constant production eight 1l-in. holes per min., including chucking, maintained by the machine which is driven by a yt hp. adjustable-speed Westinghouse electric tor. Two types of table are furnished, one of plain variety and one having automatic in- ng. On the plain table machine the operator places work under the drilling spindle and trips the chine with a foot lever, the same as in the peration of a punch press. The spindle is quickly inced to the work, the hole is drilled, the tool thdrawn and the feed disengaged. The finished e of work is removed from the table and an- er substituted, after which the foot lever is rain depressed and cycle of operations is repeated. this way, it is pointed out, the operator can use hands in placing the work and obtain rapid duction. The feed is secured by cams which relied upon to give a very powerful feed with a k return feature. A feed with a dowel end is obtained which enables the machine to be used lacing work to an exact depth as well as a feed which the correct lead for threading can be red, With the revolving table, an automatic indexing n is provided which, at the instant the spindle thdrawn, advances the table to the next posi- ind brings a new piece of stock under the THE IRON 1171 4 Motor-Driven Automatic Machine for the Rapid Drilling « Small Holes tool. - From six to eight chucks are usually pro vided on the table when this machine is employed for chucking work. With this equipment, all that it is necessary for the operator to do is to chuck and remove the work and it is pointed out that the operation of the machine does not require any at tention other than the keeping of the tools sharp The period occupied by the withdrawal of the work ing tool and the indexing of the table is from 1 to If a drill should break, the machine can be stopped instantly and if it should be found de sirable, it is possible to skip any number of chucks by so arranging the indexing mechanism instead of having it advance the table to the next position 3 sec. Industrial Education Meeting The advance programme of the convention of the Na tional Society for the Promotion of Industrial Educa- tion, to be held in Richmond, Va., December 9-12, has been issued. The leading feature of the meeting will be the presentation of the findings of those who have been studying the industries of Richmond, with the idea of developing proper methods for providing for the industrial education of the community. It appears that the survey has included analyses of 108 occupa tions in metal, printing, building and tobacco indus tries. This subject will be taken up on Thursday, De cember 10, in a morning session beginning at 9:30 a. n and an afternoon session at 2 p.m. The findings of the school survey are to be presented by Dr. Leonard P Ayres, of the Russell Sage Foundation, New York City, and those of the industrial survey by Charles H Winslow, expert of the PJ Washington. ‘ bureau o abo tatistic The Fenn Mfg. Company, Charlotte, Mich., manu facturer of post hole augers and scythe snaths, report that its outlook for business for the coming winter is exceptionally good. Enough orders are now on the books to provide for the continuous operation of it new plant through the winter. 1172 THE BORON IN STEEL AND IRON Interesting Results of German Experiments Show No Practical Benefits A report on the influence of boron on soft steel and cast iron, issued from the metallurgical labo- ratory of the *Bitterfeld Electrochemical Works, Germany, is printed in Stahl und Eisen, September 24, 1914. The literature of boron-iron compounds is very meager, and only in connection with boron- steels has there been anything definite accomplished. For purposes of the tests a quantity of ferroboron was made in the electric furnace out of boracite. As high grade material of this kind exhibits diffi- ‘ulties in application, boron being rather sparsely soluble in iron, a low percentage alloy was aimed at, and the analysis gave the following rough per- centages: Boron, 15 per cent.; iron, 81 per cent.; carbon, 0.7 per cent, and small quantities of silicon and aluminum. Tests with Mild Steel.—The best grade of soft steel was used and the alloy added in calculated quantities; melting was done in crucibles, and in- gots: cast. Percentage of Boror Mixtures as calculated Analysis of ingots 0.00 0.2: 0.00 0.20 1.00 oO. s0 0.50 0.40 The ingot made of remelted soft steel without boron addition was readily forged, whereas the ingots with boron became brittle in proportion as the percentage of this element rose. Moreover, piping became more pronounced, and for 0.80 per cent. boron it was 45 per cent. greater than in the ingot with no boron. Even with only 0.20 per cent. boron it was impossible to draw the ingot down for making test pieces. The first blows with the ham- mer developed cracks. Bending tests were also useless as cracks would form immediately. Heat treatment improved this evil somewhat, but the in- dications were that for practical purposes boron additions to soft steels were of no value. While the hardness obtained is in itself of great value, the brittleness accompanying it precludes the use of boron for high grade steels. Tésts with Cast Iron.—This is a new field, and naturally would only be valuable for special cases where a higher cost per pound is of no special object. A first class grade of cast iron, for ma- chinability and strength, was selected for the melt ing tests, and the same boron additions enumer- ated previously were made in the crucible melts. The analyses for boron indicated the same recovery, except that in the last case the figure was 0.85 instead of 0.80 per cent. as in the steel test. Hard- ness and brittleness were observed in rising pro- portion here also, as the percentage of boron in- creased. With an 0.85 percentage of boron even the hardest files would no longer touch the metal and from a good, close grained iron in the remelt free from boron, all evidence of a grain structure had disappeared in the piece with the high percentage. It had become practically a white iron. The anal- yses which show this plainly are: Boron Boron Combined added, found, Silicon, Graphite, carbon, No per cent per cent per cent per cent per cent 1 . 6.00 0.00 2 48 9 38 0.94 é 0.25 0.20 2.42 1.67 1.465 3 0.50 0.40 2.44 1.9 1.96 Bika ee 1.00 0.85 2 30 4 17 Boron evidently has the effect of throwing carbon into the combined form very readily, as with a silicon content of 2.30, so high a combined carbon content as 2.17 is exceptional. As boron is understood to be valuable in pre- venting acid attack, a series of tests was made IRON AGE November 19, | ()14 along this line, but the results show very p that this is not the case with cast iron, and | boron will not prove valuable for either impr. the quality of cast iron or increasing its resist to acid attack. It may be of interest to state the tests in question were made with hydroch nitric and sulphuric acids of various strengths, hot and cold, and in varying degrees of concentra tion. While some good effects were obtained, th, bad effects on the mechanical properties out anced them greatly. For instance, with cor trated hydrochloric acid at room temperatures without heating, a period of 43 hours reduced : castings free from boron 50.9 per cent. by wei; the 0.20 per cent. boron castings, 32 per cent.; th. 0.40 per cent. boron castings, 15 per cent., and the 0.85 per cent. boron castings as little as 4.2 pe cent. As this iron, however, is almost white, it is of little practical value. Nitric and sulphuric acids concentrated, either hot or cold, show heavy losses all along the line, whereas dilute sulphuric acid shows little action under the same conditions, whether boron was used or not. Further tests with molten alkalies indicate heavy corrosive action: hence even here the use of boron is not of value. This information is given particularly so that useless further work may not be undertaken with this element in connection with iron. R. M A Gas-Heated Hot-Water Radiator A gas-heated hot-water circulating extended surface radiator has been put on the market by the Copper Coil Radiator Company, 19 Cliff street, New York City. The heat is generated by means of a gas burner of the Bunsen type, especially con structed for the work, and the flame is immediatel) beneath one length of the copper pipe of which the circulating coil is made. The different sections of G Heate Radiator vith Copper Coil Having Galva! Steel Fins the copper pipe have driven tightly upon them gal vanized sheet metal fins to increase the surface ex- posed, close contact of the added surface aiding i! the transmission of heat from the coil to the fins The pipe sections are connected into a continuous coil by means of brass return bends. At the top of the coil there is an expansion tank and at the bottom a drain cock. The radiator is for use where a gas supply is available, say, in an isolated office building of a factory. It has one-eighth the weight of a cast-iron radiator and also occupies consider ably less space for the same amount of surface exposed. The radiator may be supplied with an ornamental screen covering. OXYGEN IN STEEL* Ent Acid and Basic Product Compared—Hot- Worked Metal High in Oxygen yY J. A. PICKARD AND F. M. POTTER following work was undertaken as part of atic examination of the oxygen content of ial steels with a view to collecting trust- evidence as to the amount of oxygen nor- be expected in good class material, and the ithin which it is desirable to restrict this method of estimation, which consists in the steel in a confined volume of hydrogen weighed boat containing phosphorus pent- nd measuring the increase in weight of the been used throughout and has fully con- the opinion arrived at as to its conveni- nd reliability. The determinations were in ases carried out in duplicate by the two independently. \ll the steels examined were made by either id or the basic open-hearth process, and, as can be judged from the analyses, they were excellent quality. In the following the samples are arranged in order of carbon tent. The actual figures obtained for oxygen in ate analyses are given in the last two col- and show the amount of agreement ordi- ari ibtained when using this method. Six of e results are reprinted from the former paper yt erally of Carnegie Scholarship Memoirs, 1913, page 70) ire included here for ease in reference. bis leid Onen-Hearth Stee a a+ - 3 m+ 5k Bt @ b 7 2c = 2¢ (oOxygel =* =e ae per cent 7 T BO, 9 0.035 0.02 0.004 0.004 \ilean ‘ 21f 0.030 0.050 0.020 0.02 Re OS 03 0.031 0.027 0.007 0.006 O., 0.91 0.033 0.0299 0.012 O16 Mear 6 0.027 0.02 0.005 0.006 Bae “7o3a0 0.02 0.004 0.007 O., 0.01 ( 027 ‘ 0.010 0.012 Mean of all O., 0.0098 Table 2 Basic Onen-Hearth Stee i ‘e 5¢ Oxygen, = = = per cent Lh L. a 0.03% o.O3 ) { 0.01 0.010 0.011 0.031 0.028 Oot 0.026 0.013 0.014 Mean 00 0.031 0.003 0.006 C.. 6.2 0.030 0.027 ) 0.020 0.040 0.041 7 oO 0.024 0.02 4 +020 0005 Oo.00% 0.023 0.019 0.014 0.029 0.02 292 0.024 0.003 0.003 Mean 0 0.011 0.016 0.017 C., 0.52 0.020 Le ©O., 0.021 053 ool “HoO3s 0.044 LOO 0022 0.052 0.005 0.006 Mean 0.025 0.025 0.022 0.025 0.026 . Ges 096 0.030 0.028 0.004 0.007 O., 0.01 n26 0.016 9.02 0 006 0.007 Mean of all O., 0.0189 CONSIDERATION OF RESULTS nad been expected from the results pub- n a former paper that it might be possible paper prepared for the abandoned fall meeting in and Steel Institute Iror THE IRON AGE 1173 to discover some relationship between the oxygen and the carbon content, but the results quoted lend but little support to this theory. Samples 9 and 12, containing 0.14 and 0.26 per cent. of carbon re- spectively, contain only 0.011 and 0.005 per cent. of oxygen, while No. 14 with 0.32 per cent. of carbon contains 0.041 per cent., and even No. 22 with 0.61 per cent. of carbon also contains 0.041 per cent. of oxygen. One most important conclu- sion to be drawn is that it is possible to make all kinds of open-hearth steel, even silicon basic (No. 9), practically low free from oxygen le Ww -( arbon containing only 0.010 per cent. or under That some steels are made containing more than that amount is, however, abundantly shown by the other results, and it is to be observed that the cheaper steels contain higher oxygen. Acid open-hearth steel is generally admitted to be of better quality than basic open-hearth, and it has been suggested that this is due to the higher oxygen content in steel. In the foregoing tables all the high-oxygen steels (that is, over 0:020 per cent.) except one (No. 2) are found in the basic group, so that the evidence does support the conclusion that basic steel is higher in oxygen. It is to be noted, however, that only two of the basic steels are higher in carbon than the lowest of the acid group, and no marked difference is to be noted in those samples comparable in carbon content; indeed No. 2, an acid steel, is higher in oxygen than Nos. 23, 25 and 26, which are basi An interesting question is raised by the fact that the samples that must have received most hot working are all high in oxygen. Nos. 14 and 15 were taken from two fishplates, No. 22 from a rail, while the other samples were from fair-sized billets. The possibility that the oxygen content may vary after the steel has solidified has, so far as the authors are aware, not hitherto con- sidered. It must be borne in mind, however, that these steels, as judged from their other constitu ents, were not of the very highest quality, and that Nos. 8, 10, 13, 18 and 21, which are all high in oxygen, were of cheap make. It is hoped to in- vestigate the influence of hot-working on the oxy gen content in a subsequent paper basic been Japan’s Imports of Iron and Steel A writer in the Tokio Economist calls the rapid increase in Japan’s imports of iron and steel In 1908 total exports were 330 million yen (1 yen 19c.) and imports 490 million yen, one-ninth of the latte: being iron and steel. In 1913 the total exports were 640 million and the imports 720 million yen, iron and steel representing one-tenth of the imports. The in attention to crease in the last decade is shown by the following table: i] 1,970,000 ver ; 17 »7,000 Ver * “ ’ | 121. H00 '¢ ‘ } € Vear 0.237.000 ver Vea ‘ $30,000 Ver Thus in a decade the imports of iron and steel have more than trebled. The increase in six years was 157 per cent., and in 10 years 258 per cent. Imports of ore totaled 51.800 tons in 1903 and 280,200 tons in 1913 The value of the imports of locomotives, steamships and machinery was 10 million yen in 1903 and 40 mil lion yen in 1913. Based on a population of 60,000,000 the requirements of iron per capita are 2.60 yen per year, of which Japan herself produces only 17 per cent. No other nation im ports 83 per cent. of its requirements of iron and steel The writer adds that the iron-ore deposits of Japan, known to the geological survey, amount to about 36,- 000,000 tons and that in this estimate only the vest deposits having about 50 per cent. of iron are sidered. con- 1174 A NEW GERMAN PLATE MILL Three Stands, Two Three-High and One Two- High, Driven by a Reversing Engine A new plate mill, with several novel features, recently built at the plant of the Bremerhiitte A.G., at Giesweid, near Siegen, Germany, is described in Stahl und Eisen, June 18, 1914. As may be seen from the plan the mill has three stands of rolls, all driven by one engine. On one side of the engine is a three-high mill, 950 mm. (37.4 in.) diameter, and 3290 mm. (129.5 in.) long. On the other side is a second three-high mill next to the engine with rolls THE IRON AGE November 19, (914 mills in relation to the engine has worke well. It allows the mill couplings to be nected on either side for roll changes, or ne repairs and one mill can therefore be kept ru The screw-downs of the three mills are 0; electrically, as is all the auxiliary machine) cluding the manipulator in front of the rolls smaller middle roll of the two three-high is balanced by counterweights which are op: automatically with the roller tables. The arr: ment is that the counterweights cause the roll normally to press against the upper rol! the tables are raised they carry the weights them and cause the roll to press against the low: + eri 750 mm. (29.5 in.) diameter and 2020 mm. (79.5 roll. Due to this dependence of movement o/ in.) effective length. Adjoining this is a slow middle roll and the tables it is no longer pos: ce | T | =| . nm ¥ f : | } c @ « | & C en i} * o y i er. A Ha sss : ~ 000 - i | > r mm a 4 es 3 _ sh ry Machin praia MIEN 7'QIQ FE : A foe} - mit late 5, Vi U hea 4S face D he : a i fe a UL 7 : ‘a 2 : : late Mil) ; rh - tr. He! Pe ! = be x -—* S yy —_ > ~ *\4 S 2 “Cy | — a = — \ noler \ Niet x ' 7 is t. A f . ry t ay : Ja > and See Ht t ret * es 7 ioe wh Hig i = a HI : se ey + ij }i> {! Atte i HO OT. tere eae i! UY + hi iil pA [BE ao et 1 OF Wabi i eae tt R > Ht if Hi ia tH 86s OH 4 a. b $3 1 eae 40N Zi ii Wi HAL eae se ’ S — | 240¢ 3 EMT iu i aie ig | it dh th see st BB a3 a Y ll i ' . a} =... . y a—sh " L* " ] va Plate Ny l/ < o #4 t+ 7 P ace i = oe cg 3 so ‘ hy* Li? ' r # Ax i «6 ta 3 |}! ; (WBF a a bt? fete Vee trent | z aE | | Plan of the New |! \ t Bremerhiitte, Giesweid, Germany moving two-high mill with rolls 700 mm. (27.5 in.) to roll steel underneath the tables, as was form- diameter and 1800 mm. (70.8 in.) effective length, erly the case. In front of the front roller table o! for the production of special surface plate. The the smaller three-high mill is a traveling roller rolls are commanded by a 40-ton crane. All the table, which serves to carry the finished plate over mills are, therefore, driven by the one engine, to the two-high mill. The mill is provided with an- which is a reversing steam engine. One reason for the choice of a reversing engine is that, with slow rolling during the last pass, the work of straighten- ing is greatly reduced, and in many cases may be dispensed with. Such rolling is easily possible with the type of engine chosen, but not with the usual constant running fly-wheel engine. Up to the present time this arrangement of the nealing furnaces, shears, scales, etc., arranged 4s shown in the plan. The main reason for choosing a reversing &)- gine was that by doing so the time that the m1! is running without steel in the rolls can be lessene¢ Using a reversing engine one is in a position t take hold of the ingots or slabs quietly and with- out sudden stoppage of the mill, + and when the! Nol er 19, 1914 en somewhat elongated to put them through quickly. greatest speed of the rolls is found during passes. The engine is at rest not only be- the rolling of the different slabs or ingots, , usually between the various passes, and so Jly at work for only a relatively small part time. Notwithstanding the fact that such must be of large capacity they are more if steam than fly-wheel engines. For these such engines have been recently introduced ving three-high mills and are in operation ngen, Rothe Erde, Weidenau, and are being ed at other mills. They can run in one direc- ntinuously if desired, or they can be re- The latter is generally done during the passes, and as soon as the plate has reached ertain length the mill is used as a three-high. there is trouble with the raising or lowering of tables the mill can be run as a simple two-high. (he following results may be given as an ex- e of the practice at the Bremerhiitte, with this of engine: Time of test, 8 hr. 23 min.; 133 nlates rolled with a total weight of 127 tons. Sev- tv-four of these were from 0.156 in. to 0.234 in., | 26 from 0.273 in. to 0.429 in. thick. The aver- ve hourly output was 15.25 tons, the steam con- mption 15,200 Ib. per-hour. The largest hourly nsumption was 17,970 lb. and the greatest con- sumption 7540 Ib. in 20 minutes. In the latter case | three stands were rolling plate. The steam consumption per ton was 992 lb. which, in view of the large amount of thin plate rolled, was consid- ered very satisfactory. G. B. W. Pneumatic Hammer of Wide Application With a view to eliminating blacksmithing or hand forging expense in the handling of heavy work in the making of lathe and planing machine ols, producing forged parts, making plant re- pairs and turning out miscellaneous pieces in piants every description which now consume the time of an and a helper, H. Edsil Barr, 922 State street, Erie, Pa., has brought out a pneumatic hammer. he hammer is built in two sizes, the larger of h is illustrated, and it is distinctive in that elts or pulleys, springs, rubber cushions, leather wooden beams, band brakes, etc., are re- red. It can also be placed wherever an air pipe hose can be run, and this portable feature en- it to be used for tool dressing on contract tions. In general appearance the hammer mbles a small sized steam hammer and pressure a cylinder is employed to lift and throw the ram, mpressed air at a pressure of from 80 to 100 lb. g used. (he hammer consists of a solid cast anvil with ntegral box housing supporting the cylinder. frame, which is at the back of the machine, ries planed guides for the ram shoe, thus keep- he front and sides free from obstruction and ng stock which makes a large angle with the clear the frame. The piston and its rod are n one piece from special oil treated steel, and ram and the guide shoe are forged from a e piece of high carbon steel. The dies, which hardened faces, are readily removable for the { special forms of dies. he valve is of the D slide type with a special ngement of ports that is relied upon to give a and readily controlled action. The ram is s at the upper end of its travel and the blow ruck by depressing the foot treadle at the front. THE IRON AGE 1175 Front ing the ind Rear Views of a New Pneumati Arrangement of the Working Parts Frame Hammer With a full drop of 10 in. and the full air pres sure behind the piston, about 2500 ft.-lb. of energy is secured, and the force of the blow can be varied as desired or a powerful squeezing action secured The amount of pressure required is said to be the same as that for a sewing machine treadle. The foot treadle moves rapidly and it is pointed out that with a few days’ practice an operator can strike continuous blows which vary in intensity as may be desired. An air-cushioned stoppage is relied upon to prevent the piston from striking the head of the cylinder. The amount of floor space required measures 14x 24 in. and the over-all hight of the hammer is 66 in. The tool weighs 1200 lb., and the maximum air consumption is 10 cu. ft. per min. The maxi- mum size of stock, which the hammer is designed to handle, is 2 in. square, although 3-in. stock can be handled where the reduction required is not too great. If desired, the hammer can be equipped for light die stamping, forming and embossing, and centering screws for locating the lower die are furnished. A smaller size of hammer, having approximately half the capacity, is built for tool room work, copper drawing, jewelry manufactur- ing, etc. Cincinnati Business Men’s Club The annual election of the Business Men’s Club of Cincinnati, Ohio, was held November 10. The follow- ing directors were elected for the ensuing year: F. C. Colwell, F. W. Galbraith, Jr., Clifford Miller and B. H. Kroger. In the evening a banquet was served which was attended by over 800 members of the club. In accordance with custom, the directors met on the following evening and selected officers as follows: Presi- dent, William P. Rogers; first vice-president, George W. Weedon; second vice-president, John L. Shearer; secre- tary, Morris W. Wickersham; treasurer, George G. Mc- Morris. James W. Brannin was re-elected manager of the club. E. W. Edwards, president Edwards Mfg. Company, is the retiring president of the club. 1176 ROLLED STEEL ROLL SHELLS* How the Wearing Surfaces of Grinding Mills are Manufactured BY JAMES C. H. FERGUSON+ The application of steel shells as wearing parts in the various types of grinding mills is compara- tively new, but the purely mechanical features of their manufacture is easiy accomplished by the use of ire-rolling mills which for many years previous had been used for making locomotive driving-wheel and car-wheel tires. Shells which have given good satisfaction in actual operation have shown the fol- lowing analysss in the heats from which they were produced: Carbon, per cent.. 7 0.70 0.73 0.78 Phosphorus, per cent 0.035 0.029 , 0.015 Sulphur, per cent.. 0.022 0.018 0.028 Manganese, per cent .0.741 0.786 0.745 Silicon, per cent..... 0.253 0.252 1.258 MANUFACTURE Briefly, the process of manufacture of roll shells is this: A cylindrical steel ingot is cast about 7 ft. high. When the metal is cold he ingots are sliced cold in a lathe into a number of sections or billets. Cold slicing is a vastly su- perior method as it gives an opportunity t omake a thor- ough examination of the cen- ter of the billet. Only those porions are used which are free from impurities. The billets represent the weight of the finished product desired, plus the proper allow- ance for loss in heating, forg- ing and rolling, and for ma- chining afterward if the shell calls for machine work. The billet is heated and forged out roughly and flattened under a steam hammer to the approxi- mate diameter and face desired. A hole is punched through the center in the ame operation and then, at the same heat, “beaked” on the horn of the anvil; this means hammering the rough ring thrown over the horn, producing an increase of the outside and inside diameters, and giving the ring the proper ratio, roughly, of diameter to face required. These rough rings, after being thus forged, are again placed in a heating furnace and the temperature raised to the proper degree for rolling. A modification of this hammering process of the billets, is used by one of the manufacturers who has the most recent and up-to-date plant, and who, after heating the billet to the required temperature, works it down under a 5000-ton hydraulic press, which gives the metal a good reduction. During this pressing, which is done in three operations, the billet is flatened, a hole is punched in the center, and the rough ring prepared for the rolls, similarly, but unquestionably more thoroughly, than by hammer- ing the billet. The rolling out of the shells to the desired size is done on a tire mill, where they are revolved through pressure rollers, either in a horizontal or verical plane. During this operation all faces of the shell are subjected to a very high hydraulic roll pressure, which insures a thorough reduction of the Chilean Mill *From a paper presented to the American Institute of Mining Engineers. *+Monadnock Building, San Francisco, Cal THE IRON Tires Worn So Thin that Crescent Shaped AGE November 19 Y14 metal, giving it the necessary work to dev: 9 ideal structure for the severe service to which ro) shells are usually subjected in actual use. rolling the inside and outside faces and he ty of the shell are engaged at the same time, increasing the diameter of the shell by squ: out and lengthening its circumference unti| sired size is obtained, both as regards diamet face. A hard skin is left due to the quicker chi the metal on the periphery, which is very us: grinding, and enhances the life of the shell erably. The inside of the shell is left rough to be secured t othe center of the rolls by w wedges for wet grinding. If he bore of the to be machined either straight or tapering, proper allowance is left for that purpose on the insicd« the outside or wearing face of ring, being finish¢ practically smooth by the rolling operations, s! preferably be left in that condition, by reason of th advantage mentioned. i Ur des Piece Was Pulled Out By Hand From Its Circular Shape A mass of metal thicker than 5 in. cannot be sufficiently worked by the pressure of rolls, unless the rolls can be made very much more powerful tha! those in use at present, particularly when the com- bination of rolling and pressing naturally has is relative limits. Then again, the width, regardless of thickness, would have its limit at about 15 or 16 in., because a very wide mass, even thinner than 5 in., would experience the same difficulty in being thoroughly worked. It may therefore be assumed that shells over 5 in. in thickness and wider than 16 in. cannot be rolled advantageously in a tire mill and produce homogeneous and dense metal, which will give good service and wear. The following gives the limits of sizes for rolling as used in the practice of one of the largest tire manufacturers in the United States: Roll shells 8 to 10 in. wide 108 in. outside diameter by 3 in. thick; over 10 t 16 in., or under, 68 in. outside diameter by 3 in thick. Shells over 16 in. wide and thicker than 5 in. anc weighing say 5000 Ib., or over, are produced to the best advantage under a hydraulic forging press 0! adequate power, as a strictly forged, instead of 4 rolled product. Sufficient stress cannot be laid upo! the necessity of thoroughly working the metal 1” these forgings all the way to the center by the use of machinery of this kind, which is sufficiently heav) and powerful to perform the necessary forging oper- ation and is better able to do so than rolls. The November 19, 1914 WI is convinced that most of the cases of un- ear in roll shells of extreme widths, where e to improper seting or improper mill feed- both, is largely owing to the face that the s not of uniform density, resulting from be- rked in a tire mill, which was too light for avy and thick section passing through the LIFE OF SHELLS e following examples taken from users of-roll n the widely separated states of Montana, ido, he accompanying illustration is an excellent le of how thin shells should wear in actual ting practice in order to be considered as most ent and satisfactory. It shows rolled tires used e of the best types of Chilean mills, also worn so thin that the half-round or crescent-shaped shown was pulled out by hand from its cir- ilar shape. The example proves more than any amount of elaborate tests or record keeping, that the material of which these particular shells and tires was made, was homogeneous and durable as well as tough, the latter being indicated by its strength and resistance to breaking, even when worn to the thin section shown. Auto