The Iron Age 1915-12-30: Vol 96 Iss 27

ESTABLISHED 1855 Minnesota Steel Company Completes Plant A Detailed Description Layout and by Electric Drive The general facts regarding the location of a steel works subsidiary of the United States Stee Corporation at Duluth, the reasons that led to it, its advantages and lack of them, and the nature of the wits provided, have already been described, par ticularly in THE IRON AGE of Sept. 18, 1913. The present article is accordingly confined to a description of the construction features of the plant itself. The accompanying illustrations and drawings present a number of details to which it has therefore been thought unnecessary to refer, by way of repetition, in the text. A consid erable portion of the descriptive in- formation that could be expressed ( and + New York, December 30, 1915 f Construction Operation — Mill Massive Lurnace ; tures and the mil un Ld + T an) practice at oven operation in producin for the rol he OKC ) Featured Design it ne extre exibility o ng economk ling f wh HE COKE O vel St radical way struction, ex the unusually + +h Plant Summary ept large nu is + al tnat plant the J numerically will be Duluth Works, Minnesota Steel Company found in the ac- a at ia 96 in on iaiaiae epee tables. Aggregate capacity pel eee L000 tons Briefly, the plant No. of blast furnaces. oi Two 20 ft. ¢ 5 comprises coke Combined capacity per day.. 1000 tons ovens with a daily No. of stoves per furnace Five capacity of 1000 Gas washers. Grid spray prima tons; a by-product ; _ Seconda recovery plant; No. of open hearths. : n, sev ple two blast furnaces 9 ng “ anon » sadile capacity..... | tons. rated at 500 vons Waste iia boilers....... .400 hp., one ea each; a gas-engine- nace driven blower and Ingot mold size..... 22 x 26. x 77 electric generating Soaking pit capacity 96 ingots. station; an open- Blooming mill.... high, 10 revel hearth plant pro- No. of passes of ingot in blooming viding for ten 75- Ur ee ll to r e ton furnaces, of oe shi Regular section of bloom. s Q iy Which seven are BI - calliaaiiadl Yes completed; a com- eae eee “. 14:4 = ? Reheating furnaces 16-f 10 é bination rail, struc- erative type tural, billet and bar No. of passes on rail mill 10 mil, and a mer- NE IES oid.ne yi ecck<4o.0. .4 twin-tandem 3000 chant mill. The Air blast plant............ . 24,000-<« I entire works have Total estimated capacity of plant.. 350,000 tor II) OO 0 este alieiesenetenieneennenesiianimesangell nual capacity of 390,000 tons of semi-finished and finished steel coal to the 150-ton st Products. The first iron was produced on Dec. 1 iams pulverizers or han and the first steel on Dec. 13. t is agal! eyed t The distinctive characteristics of the plant are mixer. The two kinds the massiveness of its construction throughout and hontas, measured fr¢ the details which have been incorporated as precau- tions, are conveyed tionary measures against the severe weather condi- tower that surmounts tions of the winter at Duluth. The two principal Provision is made for a Problems in connection with which new experiences and a second breaker, are likely to be encountered are the operation of the ment features ar e} 1507 lew ‘the = The reprod iced { ved from bo supplen 1 ind nd mp: , . oal + rs in rack s, whence dump ca duplex t per fed bh feeders a indergrou belt convs - ‘ aker auton nd carri na Vinvel and stru ne irietl ! desig) . 6 ot dep rt ndard Koppe1 ‘ry is made up netv ovens ery similar to th ‘ (¢ npany (yal VOrkKSs Phe al i iLlol t vens with resp tne oal-h ng lant, VI ipparat ] wa j — the Robi yin Be! Con pany, Ww ee pene ie onl ad neg as etna ae — ae 1508 THE IRON AGE December : 2 for the handling of crushed coal from either breaker Company electrically-operated pushers and | to any hammer mill. The two 4-pocket coke larries serve the battery and on the pusher side m for charging the ovens, are of the usual electrically oven doors. On the coke side the door-m operated type, except for the fact that the larry machine is suspended from an overhead operation may be controlled from either end. This which also serves to carry the clay in 800-It permits the operator to run the larry from the end for luting the doors. where wind-blown smoke does not obscure his view From the pitch trough there are three ga along the ovens, the operator’s position permitting offs to the gas main, which extends above him to see ahead of the larry. with a continuous incline to its lowest point The coke ovens are built with a coking space 39 ft. long and 9 ft. 10%% in. high, with a width taper- <-{3'I5- >< -13 ing from 17 to 21 in. The usual charge of coal is 1234 tons for a product of 10 tons of coke, and the coking time 16 to 24 hr. Two Morgan Engineering kf it i=T gp Z gt 7, AY A ‘x S \f * FX ~~ 4 44 JSG WA ‘ ; . Sige Ae s/f ¥ f A y (G’) I > 7 Jian borer —h AY > J 7 ; y % i hy 7. 4 2 LD mS be 7 Ais. > ¥, —<* x rh wf A> ~ A Lo BAY Ly P= ¥ —_.6|( &, t 1 4 > hed Li f a + wea 4 < <4 = apna pay SoS peep op! = | 3 i ‘ % 4 eu = 7 Pa PELE, mo a7 ” j £ t+4 HF Pe i ny aod Ht J > x +4 a s f uy +4 yA ¥ +++ ‘ bh — Spry Ay A ) } r dias hia / \ K | ; 4 uh A ¥y = sad oa ’ f ¥/ A a / + : 4 = &y/ I] i : re [ : > Carl ¢ ; + Sig Sam : hid . 2 VA Ce | ne a ot i ‘ * + > > és 7 ae ; a & a f < rr tt ss | * ~ + _ . ; oa ; R i j : I Dee v | t _ — 1 = i = Z a Link et ; . j 4 j f . A k i , iat ET qj 14| 4 f _— 14] t yj ; 4. v4 1 ik i 4 y + | , 4 \ A y_ WY, ; ‘ Blast Furnace. Stock H se and Skip H Race ts UPPLEMENT TO THE IRON AGE, DEC. 30, 1915 ‘a4 +2488" 6 At the Left Are the Coke Ovens; Beyond Are the Open Heart! MINNESOTA STEEL COMPANY General Plan of the Duluth Plant of the United States Steel Corporation Northeast of the Steel Plant Are Located the Works of the Universal Port aq ts Plant and Beyond Is the Town of Morgan Park, Erected for the Superi: men and Skilled Workmen of the Two P Future Extension ey %, : ae ", +? Z 4 ’ — TAT TTT TE TPE TEE TT) 0) tt be eee tt ttt) ee eee) tt a) 1) ee eee tt | Heber ——. - rt ~ ae he — >> — . 3 eee ON Page 20 4 Le Beare ate ee Fs Se ee aaah ee | 1 Hearth Furnaces: Near the Center May Be Seen the Blast Furnaces, and Toward the § — = — es a gre | TTY f rl S z BLAST FURNACE DEPT. a ‘ ° ODORS Sh Hiei gn hee nM “ @ a Oo - a Br Br “ @ _———_ , Cee A x ea = ti- AH 2 ie 7 —T" 4\}\|—_———— e—+- : TITITINITT obra tte ae) het Bn a ae he Right Are the Rail, Bar and Structural Mills. December 30, 1915 THE IRON AGE 1509 dir outside of the cooler building of the by 8-ft. 3-i1 products recovery station. Such liquids as collect ty of 500 tons h, are 89 } t. 6 it . in the pipe thus drain to this low point and can beat the larges ihe diaimehs Wie, nana = ; removed. In the pitch trough a novel constructior diameter of 14 ft. 6 in., which gives to the hes i has n devised for keeping the trough clean, cor an inclination of 77 leg The furnace shel 4 sisting of a wooden boat drawn by means of a1 ed wit thicknes 16-i nd vate oled electrically-driven sheave and cable. The excessive w a serie eis rous 4 expansion and contraction of the pitch trough, due gated water space of 2087 — not to the wide range of temperature but als 15.632 gal.. or 130.430 f wate) Phe , to the unusual length of the ovens, made necessar space in the mant R05 « The top se a special device that would provide automatic ad f the stack in which the be re nted justment in the form of a ball-bearing expansior ist-iron ring 6 k wate woled vw sup} rt and an adjustable end casting at the drivir pipe, 12 ft. high and mad eight sect ‘ end the cable. Sketches of this are here show arge bell | ete! os : | } | | | | } | iy | h fs Coal Handling and Coke Plant Viewed from the Blast The coke screening station is erected on concrete furnaces have two cinder notches 120 deg. apart piers on a side hill so that the entire operation is and 30 deg. off the center line of the furnace by gravity. The coke from the ovens in the quench each stack there are two concrete cinder g1 ing car drawn by an electric locomotive, after pass- lating pits, each of 15,000 cu. It. capacit n¢ ing the quenching station continues at the same each cinder notch and spanned by overhead crane, grade and dumps the coke directly upon the shaker as shown in one of the illustrations. Each stack screen. The screening station is 40 ft. 11 in. long carried on six cast-iron columns on a circle of 30 ft : and provides four screens, each 7 ft. 4 in. wide liameter at the top and 33 ft. at the bottor There Two separations are made, furnace and foundry are twelve tuyeres, two between ea pall Coxe. From the level of the track on which the ylumns quenched coke is brought to the station, the drop The furnaces are equipped with the Neela i to the track on which the screened coke is received charging system and top, the latter being similat ii is 33 ft. 1144 in. There are two screened coke re- to the Duquesne furnace tops. The top of the 1s eiving tracks, one 27 ft. 2 in. and the other 40 ft. way is supported on the framework which it 3 2 in. on center lines from the high level track. The the furnace, this framework serving also a + ‘creens are made adjustable as to slope so that de port for the corrugated sheeting within which thi > very of the coke may be made to cars on either stack is entirely inclosed The skip Va : ned 5 Tack. At the quenching station the water-cor at an angle of 61 deg. from the horizontal, and the tro valve is a self-draining type to prevent charging buckets have a charging capacity of ap : Tree g. proximately 16,000 lb. of ore and about 11,000 Ib e of limestone. They have a total cubical capacity of THE BLAST FURNACES 197 cu. ft. The bell-operating mechanisn a (3 two blast furnaces are located on 360-ft top of the stack with the control in the hoist house ic cent: ro kk } . . . oo nia = 1i¢ tir f +) orit } with five stoves for each furnace, spaced on over the stock bins. A modification riginal SUTRA AI CN sew al 1510 THE IRON AGE General View of the Blast Furnaces and Stoves arrangement of the bins in the stock house, which provided for a separate charging of coke from the bin into the bucket by means of a conveyor, has been modified so that the operation of charging will be under the control of a single man. The proximity of this plant to the ore mines has obviated the occasion for storage facilities for ore and as a result has considerably simplified the arrangement of the stock house. In the summer season the plant will receive daily shipments, with enough ore on track for 24 hr., and for winter ship- ments, which are likely to be frozen in transit, a sweat-house is built with capacity for steaming 36-hr. supply of ore. What is true of the plant in general is true of the stock house with respect to The Top of the Stoves Showing the Sta Construction and in the Background the F e Toy Decembe: 13 , Looking from the Approach to the Open-Hearth Department trestle approaches to building. Wherever possible excavations have been made, lowering the building elevations and yielding in many instances materia! for the manufacture of the cement blocks with which the mill buildings are erected. In conse- quence, the elevation of the top of the rails over the ore, coke and stone bins in the stock house is but 8 ft. above the tracks at yard grade, while the rails at bottom of the stock house below the bins are approximately 26 ft. 6 in. below yard grade A cross-section of the stock house is here shown indicating the double track arrangement for filling the bins above and below, for shifting the charging buckets for coke and stone and the several kinds of ore. Baldwin-Westinghouse electric locomotive are used for handling the cars in the stock house The gas from the top of the stack is taker at four risers and brought down in two dow! comers to two 20-ft. dust catchers. From the d catchers the gas passes through 10-ft. Brassert whirlers, and then into 18-ft. grid spray prima! washers. The gas for the power plant goes throug! a further washing process in a battery of Ernst secondary washers. All of the gas used, theretor will be washed gas. The probable expectancy of high hot-blast-stov' efficiency appears to have been offset by the extra provisions for extreme winter temperatures in U building of five stoves for each stack. These stoves are the improved three-pass Massicks-Crookt McClure type, 101 ft. high x 22 ft. 6 in. inside dian eter and lined with a special corrugated brick y'e ing a total heating surface per stove of 68,000 sq The furnaces, however, were started on four stoves and it is expected that the operation may sw quently be brought to the point of using but stoves. The stoves were built by the Penns! Engineering Works, Newcastle, Pa., and pres somewhat unique appearance on top by reason of t! combination of a three-pass stove with stack construction for each group of fiv This central stack has a diameter of 9 ft. ' the individual stack. connections from e are 5 ft. inside diameter. y+ er 30, 1915 t Furnaces Have a Corrugated Steel Housing ELECTRIC POWER AND BLOWING PLANT [he power plant contains no steam units. It sists of four Allis-Chalmers 3000-kw. gas engine-driven generators, delivering current at 600 volts to six sub-stations, where it is stepped to 440-220 and 110 volts, the gas engines ng a rated capacity of 4200 hp., and five Beth gas-driven blowing engines, rated at 2200 hp h, and delivering 24,000 cu. ft. of air per minute the aggregate the plant represents an installation 29 000 hp. On the basis of the following calculation, it is parent that this plant in full operation will closely roach in its consumption of gas the entire pro- of the blast furnaces, less the approximate per cent for heating the stoves. Each blast fur will yield about 50,000 cu. ft. of gas per min- r a total of 6,000,000 cu. ft. per hour for the of which about 3,600,000 cu. ft. is available the power plant. This is equivalent to 354, 00 B.t.u. per hour. On the basis of 12,000 i. per hp.hr. for each blowing engine and 15,000 per kw.-hr. for the generators, a total of -,000,000 B.t.u. will be absorbed with the entire t in operation. This leaves an approximate gas production of only 7200 cu. ft. per min- (he operation of one gas-blowing unit as a vill add something to the margin of safety. plant was started on producer gas prior to eration of the blast furnaces, and subse changed over to blast furnace gas. The am plant at the works other than the waste ilers in connection with the open-hearth is ery of four 400-hp. coal and gas fired boilers n a separate boiler house at the southeast the open-hearth building. Profiting from experience with respect to the excessive in the building structure of gas-engine ations, the foundations for the engine units th are completely isolated from the building In the floor construction a continuous *4-in irates the concrete piers from the concrete f the building. + THE IRON AGE 1511 THE OPEN-HEARTH PLANT The general arrangement of the open-hearth plant is shown in the supplement, and an accom panying drawing gives the cross-sectior The open hearth group consists of the main building, 984 ft long x 141 ft. wide, the charging de bay of the building being 77 ft. 7 in. and the pouring side 63 ft. 5 in. The building provides for ten 75-ton oper hearths spaced on 84-ft. centers. Of the ten fur naces seven so far have been completed. Auxiliar to the open-hearth building is the stock house o1 the left as one approaches from the blast furnaces, a view of which is shown among the illustrations The gas-producer plant consists of one battery of ' ; ; 1512 THE IRON AGE Decembe; q)> ; ‘ x > \ ' 5 i <i t ; t The Open-hearth Building and Approact The stock house is at the left and the steel covered gas-producer ! vaste eat boilers and fans are shown between the stacks and at the end of the open-hearth |! boiler } e for fe i00-hp. gas-fired boilers In the view of the open-hearth furnaces from the charging § ne pipe fe the Knox water cooled ports at the end of the furnace bass ve ey Be, 1s er 30, 1915 THE icers and cne of eight, with provision for llation of an additional ten, together wit! in and charging facilities and a battery waste-heat The mixer building is a win ypen-hearth building, boilers, one for each ope! irnace, arranged for re ‘tal on a direct track from the blast fu d houses the 600-ton mixer, with provisio1 ibsequent duplication. ipproach to the charging iilding is a gradually ascending trestle f1 metal tracks of the blast-furnace plant yroach, as indicated in the general layout ead directly into the open-hearth building an elevated runway off which ens directly on one side and over which ar¢ e ore, limestone and dolomite bins for the arth supply. Below this runway are ks at ground level which span receiving for raw materials, from which these mate e delivered by elevators to the bins al fic or ot the one! the stock Mace ove. Blowing Engines in the Power k house, 436 ft. long and 80 ft. wide, is nged with a platform at the open-hearth charg ‘ floor level for the storage of charging trays on and also for the entrance at ground level of raw-material tracks. The building is spanned 10-ton erane. nediately below the runway which separates ck house from the gas-producer installation tracks on which also the coal for the gas ers is received. From cars on these tracks is dropped into 70-ton track hoppers, which to a double-skip hoist. This hoist elevates and discharges it onto a belt conveyor, elivers it to an overhead bin with capacity tons per lineal foot, or approximately 56.6 producer, the producers being spaced at 16- enters. The coal bin is constructed of steel th a 3-in. concrete lining. The producers Hughes mechanically-poked type and the s mounted above a standard-gage track, fords facilities for the removal of the ashes ion to the novel arrangement for the of coal to the producers there is an addi- ature in the carrying of the gas to the open- IRON ‘ y re irna sé < rrie¢ ul ; 4 ©] e¢ ca? ¢ té i } i) ~ ‘ ’ eact ey 14 ; all aiscna tne stack i fie ; re t neter The ws ( ‘ tT) ’ re waste ' ers , , . [ ire equipped W i Birk ler ‘ , ; ir] I I é 1? ng < ( Ke Vel i | 7 ’ } } : ‘ e! rth enerator cnambe! are ! ! I n re nerator prov 22.6% { r-f tins irface, of which 18,851 3 resenter eckKers, al i tota 15 Us , is-ne t Ll} I t { Whict . Zz ( | cnes I Che cal T tne neckel } ne L117 regenerato} 9265 1. ft. as compare vith 3442 1. ft. in the Gary regenerators; that the check SS 4 neal er n tne gas side 4.9 cu. It s compared with = 40 : 2015 cu. ft or tne Wal ns tio! Che gas vaive irom the pen heartn to tl ' te neat | ers i? , y + . | the {) , < ll diameter and tne I eo Mm, ~~ san i it Rei: ae The hearth of the open-hearth furnace 16-ft. long and wide, with a height of 9 ft. 11 ir bottom to back The thick, is arched on a 24-ft. radius and the wid from back, which is 12 in + the combustion port is 4 The supporting ture of the furnace is exceedingly clearly section and in the hearth The Knox water-cooled ports and doors, nea\ as indicated both in the ac« sketcl building. ‘ompanying cross f ge! eral view it furn: the open ces are equipped with the latter being harging the furnaces a installed The ar electrically operated. For Morgan low-type machine is rangement of the furnaces is conspicuous for the liberal allowance for passageway on all sides of the furnace, particularly around the columns on the The charging side of the open-hearth 100-tor pouring side. building ing side by 150-ton cranes is spanned cranes and the pour The mixer building 75-ton served by a crane THE ROLLING MILLS On the pouring side of tl t three platforms are provided for pouring the ingot these a run-out i@ open-neartn plant and from each of there track December AGE THE IRON 1514 eT a + Te errr aeecy WereerttrrrrrrnnyT ‘ oad ayy Ul ‘syonpoad jo Ayotava B Yons [jot 0 st yduie}ye Ou aroym ‘ynoARy [ru Aavuipso ayy Woods ginjaedep snonoidsuo0o {SOUL S}I sjueseid [[1ul oy -Q7 ‘[[Iu surwoo[4 oud : ‘Bulpio JO WazsAs padj-ao10J aarpisod Be UyIM payjddns pue 4no auIyoVU 1B sivas Jajos jedioutad pue suorutd {jw ey oyul pazyesodizo0out Used sey ssouadtsseu Yord au} 0} joedsol (yypeseqiy ayy Aq paanyeay St [tu ey} ynoysnory, |, yum qr ey Zuryesrsdo Jo uvjd ay} SsezBorpul os[® a[qe} sursued ‘pao s[eiteyeul -woo0e eu, ‘ayeId jequewerddns ay} ur ued ay} uo UMOYS ST ‘qu yuUBydTEU OY} 0} UOTPEI: [Sa i \ i ue UEeet yy 1944080} ‘“uawdinbs 3auedo pue sjuswyiedep Surysiuy “speq 704 YIM “TW “Ul-sT pure [[iu [fea “ul JO yNoAR| jeraues 98 } apeul *so0Ru a1q%} -iInj ay} sjayjeaed [ru Burwo0o0[jq 34} yovoidde ‘[reyep AraAe ayy ‘Burpling j[1ui-Burwmoo[q ey} Jo auly yysTBays #B AM UBM ul UOIsUe}xXe UB Sureq Surpling yid-BuryeVos 9,1, ‘sysneyxe seovuiny eu} WOIt 794 aysem oy} YorumM ysnoiyy qezimouo0se UB JO suvoul Aq poyeoy-oid Zuieq ses ay} ‘Zurpling Surulofpe [eioues uBR UL pazyBoo, ST SeoBUANY asey} 10J s1aonpoid ses II IY} jo Arayyeq eL ‘souRId BSulsreyo urs10w 04-5) L Meee Stee SSS CESS om} jo suBall Aq syid oy} O7Ul pasavyo aie YoryM ‘sjosut 96 J° Suipeoy snosurynuis ayy 405 {yI vdeo ojes0133¥8 uv SploHe SIU ‘“SdaA0o poze. 0 -Ayeotarpoo[a Uys saovnuany pid-Suryeos aOUrF Inoj peprAoid 318 a10yy, “eueso jaddiays Uess0 uo0}-0G1 B® jo suBolul fq pue ysemyz1o0u ay} ye Burpring 944 Zutsayus 19}58 Ajayerpowult poddiajs 418 sj0oSul 89UL ‘aprIm “4F CG pues Zuol “Ul 9 “35 06S ®! Surpying yid-sul -yBos ou ‘oanjoniajys [pruu Sutulool[gq ayy jo uoIsud} -x9 uv SI yorum “SurpTing yid-SuryBos 94} OF yap “74 sjayjered yorum st youordde oy} Prva siy} WoOly ‘pavd yoSUT ay} OF Burpying ayy JO epts au} ysnoiyy mber 30, 1915 for reheating the blooms and billets. The or billet delivered from the blooming mill is ed to 16-ft. lengths in a Morgan electrically- ted gap shear, from which it passes to a rotary fer. This transfer is arranged to permit the uous passage of the steel in a straight line the blooming mill to the first stand of the rail ut its purpose is to transfer the 16-ft. length cross table at 90 deg., on which table it is Ny) © ¢ Y -urna ox o'6" a C Section Y % & te) as . ; # Cf ‘ laa — _! rpce AIFIEX a (ssssase 4 1 ds che } eea% \ > r THE IRON AGE 1515 transfer table, elevates it to the height of the furnace charging opening and pushes it into the furnace. The movement of the steel in course of reheating through the furnace parallels the run of the mill. At the delivery end of the furnace the billet discharges on a second transfer roller table, upon which it may be either returned to the 28-in. rail mill or pass in the opposite direction for de- livery to the continuous stands of the merchant _ ee Sectional Elevation and Plan of Half of One d to the 16-ft. continuous reheating fur- se furnaces are heated with producer gas ‘ operated on the regenerative principle. The elevation of the furnaces, the location of producer, with the gas connections between ers and furnaces, are shown in the drawings. eheating furnaces are installed. Each fur- served by an hydraulically-operated charg- which receives the steel billet from the ’ Pp rrr > >t ay o> mill, a rotary transfer at either end of the transfer table rotating the billet for its delivery to the mills. It is the expectation that practically all of the steel will be reheated. The power units for driving the mills follow standard practice. The blooming mill is driven from a 40 x 66 x 60-in. Allis-Chalmers twin-tandem reversing steam engine developing 6000 hp. at 88 r.p.m. The manipulator for the blooming mill is hydraulically operated, and with the hydraulic pals Sead In the Background May Be Seen the 6000-Hp. Motor in Opposite Directions from Which Extends the Shaft Driv THE IRON AGE December > Different Stands of the S-In. Rail Mill Through Bevel Gears At the Right in the Motor Room Are Motor-Generat — pusher installed for the charging of the reheating furnaces is the only hydraulic equipment installed at this mill. The main drive for the 28-in. mill is a 6000-hp. alternating-current Westinghouse motor. This mo- tor is housed in the main motor room between the rail and merchant mills, which room also contains the 16-in. continuous-mill motor and rope drive. The Drive to the Continuous Mill, with the 10-In., 12-In and 8-In. in the Background and the Hot Bed in the The 28-in. mill motor is located to drive five stands of the mill on one side and three on the other, the power being distributed through the extended arma- ture shaft with a bevel pinion and gear for each mill stand, all of which were furnished by the Allis Chalmers Mfg. Company. The mills and mill machinery were furnished | the Allis-Chalmers Mfg. Company and the Mor- a baal ra . = | Distance December 30, 1915 THE IRON AGE Gearing and Shafting for the Drive to the he Conditions on the Other Side of the 6000-Hy in At the delivery side of the hot-beds rineering Company and the motors by the 113 ft. 4 house Electric & Mfg. Company. The ar-_ the roller table extends in either direction. Toward nt of the mill following the delivery of the the right the rails are delivered to the rail-finishing pieces from the last stand to the row of five department and toward the left the tables deliver s indicated in the general drawing. After to the structural and bar finishing departments the marker and cambering machines, the Directly opposite the hot-beds provision is made other sections are delivered to the hot- for the shearing and punching e plates and th ich have a length of 175 ft. and a width of finishing of splice bars, as well as the storage of HAHAH. 4 ; + iL ip ind Pilers, with the Double Mill from the Finishing End, Showing Shears, Scales Background ee mies a Oe 1518 THE IRON AGE Sections Rolled at Duluth Mill On the 28-in. rail mill Rails 100-lb. to 60-Ib Channels 9, 8, 7 and 6-in Beams 8, 7 and 6-in Angles 6x6, 6x4, 6x3 5x4 5x34, 4x4, 4x3 4x3 in Flats 10 to 6-in. by 1'4-in k to ' Rounds 5 to 344-in Squares t to 234-11 tt} » Rails 15 to 20-lb Channels 5 and 4-in Beams 5, 4 and 3-in Angles 3 4ox3 4, 344x3 and 3x3-u Flats 6 to 4-in. by 1 Rounds 33% to'2 Squares 2\4 to 2-in. Angle splice bars 100 to,60-lb On the Merchant M Full rang ar sizes and spikes and bolts. Into each of these finishing de- partments access can be readily had for shipping purposes by direct track from the yard. The data covering the design and operation of the 16, 12, 10 and 8-in. mills will be found in the accompanying table. The cooling, shearing and straightening equipment of the merchant mill is of the standard type furnished by the Morgan Con- struction Company. The cooling bed is 300 ft. long and delivers material from either side, the bed slop- ing down from the hot run-out rolls in the middle to cold run-out tables at either side.’ These cold run-out tables deliver the bars to shears, and from the back shear tables the bars pass, on the one side, to a roller straightener, and on the other to an angle straightener. From the center line of these straighteners to the center line of the first pair of , £ er = =e, abel | 4 — 4 a Kee Neem } : 12 | 1? i } | Aphiak | if | ' . 4 a) , } -—is | = yl ‘y | — —-—_ — —~ 4 . a. > q [oor 7 t ™ , = —-—-.-- J : —_ tr ris. os 1 PN ‘, a4 PUL? December 1915 Sequence of Roll Stands and Passes, Du Mi Minnesota Steel Company 40-in. Blooming Mill. Breaks down from 22x26x77-in. ingot to 8x8-in. billet 28-in. Rail Mill,—rolls 56-in. long Stand 1-A Pass No. 1 Stand 2-A Pass No. 2 Stand 3-A Pass No. 3 Stand 4-A Pass No. 4 Stand 5-A Pass No. 5 Stand No. 6... Passes Nos. 6 and 7. Finishes billet Typical Diagram of Roll Section—Star ae 56 bes. _ A aint: B cakes Cc } YX on Flats Rai Ra ‘ =x Angles Beams 54-30 hannels and 4 Stand No. 6 as part of 25-in mill with 56-in 6 and 7 on 100-lb. to 60-lb. rail section San 18-in. mill, fitted with 38-in. rolls gives passes Nos rail section Stand No. 7 Passes Nos. 8 and 9 on 100-lb. to 60 Stand No. 8 Pass No. 10 Finishing 100-Ib. t 18-in. Rail Mill,—rolls 38-in. and 30-in. long. Stand No. 6... Passes Nos. 6 and 7 on 45-lb. to 20 Stand No. 7... Passes Nos. 8 and 9 on 45-lb Stand No. 8... Pass No. 10. Finishing light rails Merchant Mill.—See separate summary. shuffling bars the distance is 8 ft. 2 in., and fro the first pair to the last pair of shuffling bars the distance is 60 ft. Then follow additional shears for cutting the bars to short lengths and, at the er of the mill, scales and bins from which to fina deliver the material for shipment. Concerning the general feature of cement | construction for all of the mill buildings, comment | a, 4 > -~ tT } ne WA : 4; Jc | j i o}/ +} m4 } { IE 1 a [ze qr TO eS ] 1 4 Sal ia j ~~ fi 7 ¢ YY : t——— | t ae, A 4 } 8 women d Elevation of Reheating Furnace for Merc! pecer ber 30, 1915 Rail Mill Roller Tables Lengths and Speeds Between passes 1 and 2,—rollers, 16 in. diameter, 4 ft en guides; length (center line to center line if passes $0 tt 38 ft. per min. Length, 36 ft.; speed, 119.98 ft. per min Length, 50 ft.; speed, 157.8 ft. per min. Length, 70 ft. 6% in.; speed, 270.6 ft. per min. Length, 90 ft. 2 #y in.; Length, 109 ft. 444 Length, 181 ft. 0 Length, 157 ft. 444 in.; speed, 403.9 ft. per min Length, 180 ft. 0% in.; speed, 405.8 ft per min. in.; speed, 377.8 ft. per min. ¢ in.; speed, 405.8 ft. per min speed, 403.9 It. per min previously made. The accompanying hows the shape of the blocks and the man- which they are laid. The result is an ex- as Ue n Fa axe i Los EL | nent Block Wall Section for Mill Buildings, Mi: nesota Steel Company substantial and very warm building. The struction is also relatively cheap, largely because the manufacture of the blocks at the works from material excavated in the construction of the mill. of rough finished cement for walks in most ‘the buildings, and also the use of channel sec- ns laid with flanges projecting upward and filled level with cement for steps in all of the stairways also a feature. The organization which will conduct the opera- the Duluth mill includes George L. Reis, e-president; S. B. Sheldon, general superintend- K. C. Hoxie, chief engineer; W. R. Pendry, itendent of coke ovens; A. O. Baer, superin- ent of blast furnaces; P. B. Wheeler, superin- lent of the open-hearth department, C. A. iver, superintendent of the rail mill; C. C. , superintendent of the power station, and Smith, master mechanic. ~a ucer at One End and Charging Pusher at the Other THE IRON I les ntinuous mill, 12 and S-in. milis f VU Dr : 3 Mot I 214 LD ‘ iriv s ; ) ame r iTiy I “ t N f ropes, 56 ands 134 Mill takes 4x4 De ur ” . N passe ) VU 4 re ) 4 ; D 3p 671.96 I r eA 5 “ ‘ 2 gt I gh stands a 2 i VM Driven direc I or at I Delivery sp totr t. pe Length of r 18 [wo 2-hig i s Vf Lr p. 1 is Db 1016.178 tt. pe ‘ higt ta AGE 1519 Merchant Mill—Condensed Summary Substitute for Sulphuric Acid in Pickling A circular issued by the Research Mfg. Company, Oak Lane Station, Philadelphia, points out that the elimination of sulphuric acid fumes is accomplished and many other advantages are attained in the pickling of metals for the removal of scale or oxide by the use of a compound which was perfected in the mills of the Ellwood Ivins’ Tube Works, Philadelphia. It has been in use in the works for time, but until recently was held as a shop secret. It has been named Edis Compound. The compound is shipped in the form of dry cakes or lumps which are dissolved in water almost up to the boiling point. It is essential that the solution be very hot, and when being worked about 200 deg. should be maintained. To accomplish this end, the Research Mfg. Company suggests that the free end of a live steam pipe be inserted into the pickling tub, letting the steam condense in the solution. Where the tubs are very long the pipe may be tapped in several places. A piece of copper pipe should carry the steam into the solution. It is also recommended that the tubs be covered, as this serves to keep the solution hotter, though this is entirely a measure for economy. It is pointed out that it is desirable to make the covers in sections to permit of easier handling. The solution is applicable to iron, steel, brass, copper, etc. tube some fi - 1520 THE IRON AGE NEW OXYGEN GENERATOR Filter Press Type with Special Cell Arrange- ment and Insulating Diaphragms A new machine for the electrolytic production of oxygen and hydrogen has been placed on the market by the International Oxygen Company, 115 Broadway, New York City. This machine differs in appearance very materially from the one illus- trated in THE IRON AGE, Aug. 17,1911. That type roughly resembles a large iron pot, while the new type of generator its outward appearance looks very much like a filter press, such as is used in many chemical industries. The new generator is bipolar type and among the features upon which special emphasis is laid are an auto- matic water feed, the prevention of mechanical mixing of the gases, the use of a special type of electrode to decompose the water with a nickel anode and an iron cathode and a diaphragm of as- bestos fabric to insulate the cells. The new generator consists of a series of metal- lic plates, clamped together in a heavy frame, each plate being insulated from the other electrically and also separated by the diaphragm of porous fabric. Each pair of electrodes forms a closed cell which is filled with a solution of caustic potash or soda. The electrodes are carried on two steel rods and are clamped together by a heavy screw Known as th commen | New Oxygen and Hy- drogen Generator of the Filter Press Type, One of the Electrodes Used and the Gas Domes, Water Con tainer and I ndicators working in the rear support. A ball thrust bear- ing is interposed between the end of the clamping screw and the rear end plate and is relied upon to do away with the tendency of electrodes to ride up from the side bars under the pressure of the clamping screw. The electrodes are of special design, the anode side being covered with nickel, while the cathode is of commercially pure iron. Vertical corrugations on the surfaces the electrodes are relied upon to facilitate the flow of the electrolyte into the cell and the release of the gases. There are two open- ings at the top and bottom of each electrode com- municating by a cored channel with opposite sides of the plate, those at the bottom being for the water intake and those at the top for the gas off- December : Nt take. In this way each half of the cell h independent water intake and gas outlet, is emphasized eliminates the possibility « gases mingling in the cell. The diaphr: are of especially prepared asbestos fab a packing rim of rubber all around the e rests in a recessed groove on the face ot trode. Special insulators are used to insulat: trodes from the side bars and nipples of ; ber inserted in the water intake and ga shoulders of the electrodes serve to su; the rubber packing rims surrounding phragm. When the electrodes are clamp: sition these nipples meet one another, thus an insulating tube in the interior of the » take and the gas off-take. The gases rising from the electrodes an: ing the gas off-takes contain a small percent I the electrolyte and to eliminate this an insu section consisting of two pieces of heavy giass ' ing clamped between iron flanges is placed gas off-take to intercept and drain off the en‘ moisture. From the gas off-takes the gases pa* through the gas domes into the purgers. (5 are closed cast-iron boxes partially filled v ter and the gases escape from below the sur! the water, pass upward and emerge thr supply lines to the gas holders. The pu! relied upon to remove any entrained fluid gas and cool it and also act as a watt valve preventing any excessive pressure of tne & holders from being transmitted to the press! system of the generator. In operation the generator is filled w:' - iber 30, 1915 De caustic potash or soda and an electric cur- admitted at one end plate which passes on the plates and the solution to the other the generator. In its passage it decom- the water in the solution into oxygen and en, which are released from opposite each plate and pass into the gas off-takes. gases are released, the solution is replen- rom the two supply tanks or domes on the f the generator. These have glass water dicators and pipes descend from the tanks water feed manifold, which branches into pes connecting independently with the two intakes and also into two risers leading to lependent gas domes. As the oxygen and en are carried into these domes as generated, ed water tank discharges distilled water 1 a float-controlled valve to the solution tank front of the generator. The apparatus is ed so that the fluid level is maintained auto- ly throughout the system, the two independ- iter intakes to either side of each electrode ny relied upon to prevent mingling of the oxy- ven and hydrogen through the water supply. This rangement for feeding the water, it is pointed ises the pressure throughout the generator balanced and makes the water feed propor- to and under the control of the rate of gas ition. two independent water supplies, one to side of each diaphragm are subjected to the pressure due to the hydrostatic head in the n tank which is relied upon to eliminate cir- n through the diaphragms due to unequal res on their two sides. The gas pressure is controlled by the hydrostatic head in the dome through the two independent risers from the water- anifold and as the pressure is the same in the t both gases in the individual cells it is pointed at there is no mixture of the gases and the ng of the pressures on the diaphragms is as- Gas and water pressures are predetermined nstant in all cases. A signal whistle is provided to give notice when ution falls below the prescribed level. Glass ‘ight-feed indicators on the solution tank and the mes show the fluid levels and the rate at the gases are being generated. The fluid the body of the apparatus is shown by gage glasses connecting with the electrodes at intervals ng the generator. several different sizes of generator are built, the lustrated having a daily capacity of 3600 cu. oxygen and 7200 cu. ft. of hydrogen. This is equal to fifty of the old unit type cells, e floor space required, 75 sq. ft., is only one- f that required by this number of unit cells. rrent required is 320 amp. at 120 volts. ew Holder for Spring or Prong Dies nts have been recently granted to the J. M. ter Tap & Die Company, Pawtucket, R. I., cov- new holder for spring or prong dies. The feature claimed for the use of these holders is Spring Dies Designed to Support the Tool by Lo- gs on an Adjustable Ring That Is Firmly Locked to the Holder THE IRON AGE that they support near the outer ends of threading dies and mills or other tools made in the form of what is commonly known as prong, spring or acorn dies. In this way, it is emphasized, the twisting of the ands or prongs which occur by reason of lack of sup- port is eliminated. The holder consists of an adjustable ring with a set of lugs which fit in stops in the body of the holder and are firmly locked in place. In addition these lugs or stops engage the back of the prongs near the outer end and are relied upon to keep the prongs firmly in place while they are being subjected to the strain of cutting material. prov ide a Truck with Special Lowering Device The Steubing Truck Company, Cincinnati, Ohio, is now manufacturing a lifting truck with many features claimed to be new. It is of the four-wheel type of all- steel constructior A very interesting feature of the Platform Without | g a Load Upon It truck is its bar-steel construction, which not only adds to its strength, but enables the manufacturer to build it in any length or width required. Another point upon which emphasis is laid is a special device for lowering the lifting platform quickly without placing a loa, on it. The lever lifts the platform and load by a hook, as was the case with the three-wheel truck illustrated in THE IRON AGE Sept. 23, 1915. The hook automatically disconnects to permit free use of the lever and steering mechanism. The front wheels can be turned com- pletely around with the platform in either the raised or the lowered position, permitting easy handling of the truck in cramped quarters or making sharp turns. On account of the lever being free, the truck can be guided under the platform at will. The truck is equipped with a hydraulic check for lowering the loads. By pressing a foot lever the load is released, allowing it to be lowered automatically under control by the hydraulic check. The different sized trucks have wheels of 6, 7, and 9 in. in diameter, and any wanted can be furnished with different models. Hyatt roller bearings are used throughout. Servs? SELL Ae a Fin s1ze Lifting Magnets with Increased Capacity The Cutler-Hammer Clutch Company, Milwaukee, Wis., has brought out a new series of lifting magnets of the general type as the one illustrated in Tue Iron Ace April 7, 1910, salvaging a boatload of barb wire and nails from the muddy bottom of the Mississippi River. This new line of magnets is char- acterized by increased lifting capacity ranging from 20 to 60 per cent, a 62-in. magnet, for example, having had its lifting power increased from approximately 2600 Ib. to a minimum of 4000 Ib. This increase, it is pointed out, reduces the number of magnets, cranes and crane operators required, and in many cases it is possible for two of the new magnets to do what for- merly required three. Same The Maryland State Industrial Accident Commis- sion has decided that a chronic ailment is no bar to the award of compensation even though the ailment con- tributed to the accident. Shop Pneumatic Devices Which Effect Great Savi A Recent Development in the Franklin Automobile Works NUMBER of compressed air devices are now in use in the works of the H. H. Franklin Mfg. Company, Syra- cuse, N. Y., maker of the Franklin automobile, for facili- tating production and thus decreasing the cost of the mo- tor cars, not to mention the lightening of the physical labor of the workmen. Some of them and the operations are here illustrated. The startling facts lie in the time saving as against hand operation, and the figures given below, ob- tained from George D. Bab- cock, production manager of ) the company, are bas: “exact fundamental tin both of the old hand and of the new machin ods, and are being regularly.” In driving trans studs and screws and wood screwing on the in No. 1, the time savin per cent. In bolt clipp in No. 2, the saving is 5 cent., and the special jaw twice as long as former]) saving in handling all « studs, screws and nuts, } is 71 per cent. The saving the fixture and pneu Dec mber 30, 1915 shown in No. 5, in driving the front axle clip nuts, as against the hand wrench is 56 er cont. The various sockets and the parts driven by kets are shown in No. 4. New Cutting Oil and Compound Filter e line of oil filters manufactured by the Rich- ardson-Phenix Company, Milwaukee, Wis., has been recently increased by a line designed especially for purifying cutting oils and compounds. Where the iIters are to be used in plants working on ferrous s a magnetic separator is provided. Means an also be provided if desired for sterilizing the thus removing the danger of scratches becoming nfected through contact with bacteria-laden oil. A number of different sizes of filter are built, the ne illustrated having an hourly capacity of 10,000 gal. operation the used oil enters the inlet a, s down through the strainer baskets b, where irge cuttings are removed and flows under the fe c. It passes up on the opposite side of this and across the top of the magnetic separator d, ere the iron and steel chips are removed. An ss chain belt causes scrapers e to travel across face of magnets and remove the accumulated These are carried into the chip retainer f, g holes covered by screens to enable the oil to n out. When the retainer becomes filled with hips, it can be slipped to one side and removed so the contents may be emptied. After the oil passes over the magnet it flows over the dam g and nto the filtering compartment in which the in- ividual filtering units are located. The lubricant tirely surrounds and flows through these units, which are relied upon to remove even the most minute particles of foreign matter. The clean oil passes into the compartment h, provided for that se, and from there a pump forces it to the erhead reservoir or directly into the oil dis- iting piping which is equipped with a relief to maintain the requisite pressure. saan 4 br y 5 ae pos aes reix eee tees iy iti Srpsurt aaah | Lt lf ¥ bi oe Uh tt ts +¥ atte Hy 4 iit phil Sit ebirip dit Terie — Drain \ New Filter for Purifying 10,000 Gal. of Cutting Oil and Compound Hourly, THE IRON AGE 1523 Collet Holder for Spring Dies A collet holder for spring dies, designed to take the place of the ordinary split collar, has recently been brought out by the National-Acme Mfg. Company, Cleveland, Ohio. Several advan- tages are claimed for the collet holder. One is that all the lands of the die are adjust- ed evenly. Another is that the collar is pro- vided with a float similar to that used on the company’s opening dies, which allows the die to cen ter itself on the work. This holder con- sists of a spring ad- justing chuck which has a bearing on die lands and over which a master holder is ad justed for the cutting size with a spanner wrench. Then with the wrench a ring is drawn against the bottom of the master chuck to hold the lat- . 4 Collet Holder for Spring Die ter in place and lock with a Spring Adjusting Chucl the adjustment. The Designed as a Substitute for th . : Ordinary Split Collar backs of spring dies used for. the holder are slotted to receive two pins which are relied upon to hold the die from turning in the holder under the cutting strain and further assure the permanency of the adjustment. This does away with spotting spring dies, which is necessary when a collar is used. The collar is built in five sizes, to accommodate spring dies of cutting capacity from % to 1 in. One holder will accommodate spring dies of several different cutting sizes. if Et Pp Lf\| | Hf a eH PT = h 7 a “is a rs <1 lycra Me ' “ : } ‘} pal ; pa ae ’ pid ood ae 3 ae EY om Equipped with a Magnetic Separator , 1524 THE IRON AGE December 3) 1915 - Ornamental Wire Fence Machine principle of a micrometer is set on the adju . : j . f : The chasers are held from side play by ecce: A machine for weaving ornamental fencing for ing screws, which are tightened against th: door yards, parks and boulevards and industrial the chasers after an adjustment to cutting establishments where something a little more beau- been made. \ tiful than the standard type of wire fence is re- Two important advantages are claimed fo: e & ‘ quired, has been developed by the National Fence One is that it can be used for short-cut threa A Loom for Ornal tal Wire Fencing Consisting of Twisted Horizontal Wires and Inserted Arched Picket Machine Company, 827 Grand River Avenue, De- the time which might be saved by an opening troit, Mich. The output of the machine consists of too small to be of advantage. The other advantage horizontal line wires or cables made of two strands that it involves a smaller investment than is of wire twisted around each other and holding trans- fT 2" opening die and answers the same — ; verse strands spaced at intervals throughout the being claimed that with its use the same resu ait : at , ; s : accuracy and approximately the same results fence. The machine takes the wire from @ seri€S duetion can be attained as with an opening di: of reels, as shown at the right of the accompanying pointed out that this die has an advantage over illustration, and delivers the completed fence rolled as shown at the left. re The machine is automatic in operation, the wire ie being fed through the machine, the spacing of the 1 pickets gaged and means provided for varying the : spacing of the pickets to change the mesh of th: fence. The machine also has a twisting head and forming device to enable an arched intermediate picket to be formed and introduced in a portion of the fence fabric. The arch of this picket is divided f by alternate pickets. \ The machine is operated entirely by power, the bet consumption, it is stated, being not more than 2 hp. The capacity of the machine is 1500 ft. of ‘different heights of ornamental fence per day Threading Die with Adjustable Chasers i ; New Die of Simple Construction Having ; A new adjustable chaser die has been brought out rometer Adjusting Ring for the Cl by the National-Acme Mfg. Company, Cleveland, Ohio. This die has few parts and is made strong for heavy- dies in that it is sharpened much easier be duty work. The chasers are set in a one-piece body. chasers are separate pieces that can be taken They are adjustable for tight or loose fitting threads ground and the substitution of a new set of chasers by a ring which carries a hardened dowel pin against makes a new die. It is made in eight sizes, the backs of the chasers. A gage that operates on the capacity from 5/32 to 5% in. i ma lustrated articles will be found on pages 1560 and 1561) mber 30, 1915 THE PRICE OF CASTINGS Why Maker and Taker Should Discard Buying by the Pound Only BY H. M. RAMP* wo great questions in the foundry business are. the cost of castings and the price of castings. These represent two vital phases of the industry, the manufacturing end and the selling end. Volumes have been written about cost reports and cost keeping, about organization and equip- ment. Fortunes have been made and lost in labor- saving devices for this industry. Concerns have been wrecked and reputations blasted by holding the cost sheet of castings so close to the eyes that it obscured from the horizon of vision the fact that the price of the casting also rests partly with the producer. It is not that too much attention has been paid to cost or progress or development of the industry, but rather that too little effort has been expended in marketing the product. FOUN