The Iron Age 1927-05-26: Vol 119 Iss 21

THE IRON New York, May 26, 1927 ESTABLISHED 1855 119, No. Plant Planned for Future Growth Program Calls for Orderly Expansion According Definite Layout Without Preventing Maximum Use Existing Factory Space ROGERS FISKE* creased from initial $11,000 1891 over $3,- 500,000 1927, and production expanded like proportion during that time, what manufacturing space will required 1945 1963? This not inusual question; similar problem confronts every manufacturer who building quality into his product and who alert expanding his field activity both volume sales and diversity product. Answers problems this kind can found only the exercise intelligent foresight. too much expect that plans, matter how carefully laid out, will not have altered, but over period years has been the experience numerous manu- facturers that production and new lines are added with less and fewer delays the capital invested industrial company in- *Western Editor, Chicago. when some general scheme plant expansion has been laid out. excellent example provision for the future afforded the plans that were adopted the Chain Belt Co., Milwaukee, organization which has not only increased the volume its sales year after year, but has added new and diversified lines from time time. With the growth its business its Milwaukee plant had expanded until finally all available space was under roof. seemed improbable that future growth the business could provided for fac- tory location that was hemmed all sides rap- idly growing city, new site was purchased. has been improved with buildings, which, however, are not every case being used for the purposes that they will serve when the volume business demands closer fitting the complete plan production. The Chain Belt Co. was organized Levalley the No. Plant Milwau- kee Will Abandoned and Will Concentrated No. Plant, Shown the Plan View. whick present Pattern Storage are constructed = will noted that buildings now completed are be- ing used for purposes condi- tions require, and that operations will take place when the various plant units ‘ 3 7 7 om <-y AaminiStra?7 ior 7} am as ams | Mfg Boiler Roomy | | > ‘ 3 5 Core and 1509 1891 with capital $11,000. Production de- tachable chain was started room that provided only bench space. year later larger quarters were rented near the site the present No. Milwaukee, plant. 1902, property for the No. plant was acquired Eleventh and Park Streets, and shortly after that con- veyor and elevator lines were added. 1912 this property had been developed necessity demanded, and only slight attention had been given floor space requirements for the future. New Site Acres Acquired The production detachable chain called for large numbers malleable castings, all which were pur- chased during the early years the company. ‘In 1912, however, opportunity presented itself acquire malleable foundry and acres ground near the out- skirts Milwaukee. Once this property was purchased the possibility making the nucleus new pro- duction center led the acquisition, first, addi- tional acres adjoining the foundry and, later, the - The First Section the No. Malleable Foundry Building. the gray iron foundry, the machine shop and Oper. ations required for the manufacture chain the plant No. stood the malleable foundry, the annealing and tumbling building; the first section the malleable foundry, now being occupied the mixer assembly; the first section the mixer and paver building, now being used for the production conveying machinery; pattern shop and core room: and temporary boiler house. Fixed Charges Low Gray Iron Foundry The gray iron foundry was placed production building, the capital investment which has been prac- tically written off the books through the operation replacement fund. With overhead thus reduced and present capacity ample for all requirements, this com- pany setting aside pride and, saving tion cost, will continue use the old gray iron depart- ment until the urge for increased tonnage makes neces- used present for concrete mixer assembly, which later will moved the mixer and paver building purchase 35-acre tract, bringing the total holdings The purchase the malleable foundry immediately brought the question coordinating the production the old and new plants. The plan drawn provided for the use all available space plant No. and the malleable foundry, and the erection the new site such buildings, parts buildings, from time time production demanded. location for second malleable iron foundry unit was selected the new, No. plant, and portion the building was erected, which the present time used for the assembly concrete mixers. This line, added 1908, that had expanded rapidly that 1920 was necessary move the assembly opera- tions larger space. The structure now occupied will vacated when increases the demand for chain castings necessitate the use the space for its orig- inal purpose. When this occurs the mixer erection de- partment will permanently housed the mixer and paver building, portion which has been completed and now used for the manufacture conveying ma- chinery. The first product made the company was chain, previously mentioned; elevating and conveying ma- chinery were added 1900; concrete mixers were first built 1908; traveling water screens became part the line 1912. 1926 the Stearns Conveyor Co., Cleveland, came under the control the Chain Belt Co. the purchase all the capital stock. transfer production from Cleveland plant No. contemplated, but ultimately plant No. will dis- mantled and plant No. will become the sole center production Milwaukee. the beginning 1927, plant No. still housed 1510—May 26, 1927, The Iron Age sary the erection new gray iron foundry site selected plant No. Layout Plant No. Well Planned The original malleable foundry building, which several additions have already been made, extends along the east property line plant No. and was the starting point for the location other buildings. the west stands the annealing and tumbling build- ing, which can extended the south. The com- pleted one-half the proposed new malleable building, now occupied the mixer assembly, located the annealing room. Ultimately the hard iron partment will located the south end the an- nealing building. The flow product will from about halfway lengthwise the two malleabale dry buildings the hard iron department, then through the annealing section proposed soft tumbling, sorting and inspection department, which extend east and west form close working unit with new machine shop and new chain building. Between the two malleable iron units and south the annealing building stands three-story structure can Sand Tle then baked gas-fired ovens. The core room usually light and well ventilated. The second used metal pattern shop, and the first serves pattern and core storage The projected gray iron foundry building parallel with and the west the new foundry. switch track will serve both buildings. nee hich in next units the west will boiler doubled size building the north. hoisted the roof this building and spouted tainers the third floor, where the cores are mace Parts for Conveyors Are Now Fabricated the Mixer and Paver Building. Later shapes and plates will fabricated here for both conveyors and concrete machinery the completed plant will central location with respect all buildings, and pattern shop and storage building Mixer and Paver Building Will Adjoin Machine Shop The mixer and paver building, which less than one-sixth has been erected, the extreme west end the group. The new machine shop will extend east and west along the north end the mixer and paver building. The chain building will built near and parallel the north property line. rough casting receiving and storage room will constructed the east end the machine shop and the line flow castings from the foundry units. machine oper- ations are completed, parts will directed either the mixer and paver building the chain building, required. _At the present time the bulk machine work mixer parts performed plant No. and those parts are then sent plant No. where they are assembled the building which will ultimately house the No. malleable foundry. With the erection the new machine shop, the mixer department will properly with the conveyor department, for the reason that will its appropriate place the scheme flow materials and because mixers and conveyors alike require considerable amount structural fabrication, which can provided for one Present Arrangements for Assembling Mixers The building now used for mixer erection di- vided into three north and south bays. material- receiving track extends into the south end the west bay, and temporary shipping track enters the south end ‘the middle bay. Structural material stacked the southwest corner and, used, travels north, first from stock the layout department, then the shears and the fabricating shop. This west bay served series jib cranes, each being 1500 capacity. Heavy mixer parts are stored the north end this bay. The north end the center bay occupied store room. Structural parts assembled are moved from the west bay the center bay, section which used assembly and riveting shop. Parts for large concrete mixers move south for final assembly the center bay, which served crane. The north end the east bay reserved for unit assembly. Small-sized mixers are built this bay, the final assembly being provided for the south 4 Conveyors are assembled the High Bay the Mixer and Paver Building The Age, May 26, 7 i i 7 i 4 ¥ 7 3 end, where complete gasoline engine units are stored. 5-ton crane provided the east bay. The design the building such that can readily converted the malleable iron castings, planned. Engineering Department Temporary Location The mixer and paver building, now occupied the conveyor department, will ultimately 300 ft. wide 600 long, and will terminate the north end the new machine shop. The bays extend north and south and are designed that the outside bays will high and the four intermediate bays will have comparatively low roofs. utilizing the building for its present pur- poses, was decided provide space close hand for the engineering department. Accordingly, one section the proposed machine shop was erected and fitted office space. With the expansion the plant now planned, the space occupied the engineering depart- ment will become part the projected machine shop, and the engineers and draftsmen will moved the second floor administration building, which will erected later date. The present engineering building designed that alterations, other than re- moving the temporary walls, will unnecessary making part the machine shop. The Conveyor Department Now Organized The existing conveyor department consists one high bay the east side and two low bays, all which are headed the north end cross bay, which used for steel store room. The concrete The Low Structure the Foreground Will Become Part the New Machine Shop. gineering department. DEFECTS METALS Loss Strength and Remedy Suggested for Intercrystalline Embrittlement the result investigation, covering several years, discover the causes of, and possible, reme- dies for that puzzling defect metals known crystalline brittleness,” the United States Bureau Standards has found that the only certain protection reduce the stress the metal point below its yield point and eliminate corrosion the surface. One the most characteristic properties metals, especially the common and more familiar ones, that ductility. The gradual change metal while ser- vice from condition relatively high strength and high ductility one low strength and high brittle- ness, the substance retaining many other essential respects, however, the appearance the metal its initial state, very disconcerting and often grave source danger. Such change generally known “intercrystalline brittleness” since can shown that the change consists essentially weakening the “bond” between the constituent grains the metal, the individual grains themselves being very little af- fected, all. Such change not infrequently results from corrosive attack. Intercrystalline brittleness resulting from simple corrosion can usually associated with the existence certain contaminating substances the metal which may, however, present only the extent few hundredths per cent. cases, however, pronounced intercrystalline embrittlement can brought about certain corrosive reagents even metals very high purity, the case with lead. 1512—May 26, 1927, The Iron Age floor the shop does not extend into room, steel being piled racks that floor. This arrangement acts noises, Which would otherwise the engineering offices. receiving and extends the full length the high bay the store room. Steel cut length Store ro¢ m and then moves the west bay, where and the lighter operations the course fabrication are performed. The parts are then moved the bay where they are formed preparatory delivery the east bay for final assembly. The office and room are located the north end the center bay small parts are stored the north end the east high bay. The two low bays are each served ton floor-operated traveling crane. The west crane runway extends over the steel store room floor, and 10-ton overhead crane mounted the high bay. Jib cranes are mounted strategic points the west and middle bays, and 2-ton traveling jib crane mounted the east line columns the high bay. All crane equipment was furnished the feger Corporation, Milwaukee. With completion all the buildings now planned for the No. plant, there will still remain available for future expansion about one-third the acres that have been taking the overflow from plant No. The plans for expansion, well the design all the new buildings, were developed Frank Chase, Inc., engineers and architects, Chicago, cooperation with the management the Chain Belt Co. now houses the en- the rear the completed section the mixer and paver building The embrittlement certain aluminum alloys the duralumin type, sheet form, and the warping and swelling die castings may also cited. metal, subjected simultaneously corrosive attack and tensile stress until failure occurs, infrequently shows the characteristic appearance noted the term “brittle.” This true for such soft metals tin and lead well the strong metals, nickel and iron. can usually shown that the in- dividual grains the metal have not been rendered brittle the combination stress and corrosion but that the attack has been confined largely the inter- crystalline “bond” that the grains are simply pulled apart without exhibiting any ductility. The tensile stress any case must near the yield point the metal. Intercrystalline corrosion elevated temperatures may result embrittlement certain cases, such the attack nickel sulphurous gases. The cracking” wrought brass and other copper alloys one the most important cases corrosion from industrial standpoint. With the ferrous metals, the “caustic embrittlement” low carbon steel the form boiler plate the industrial importance. Such material, when stressed sufficiently, usually result high stresses from severe fabricating operations, with the stresses set service and subjected corrosive solution such sodium hydroxide ilar other metals subjected stress The practical remedy for the problem along one two lines according the either reduce the stress, (internal stress plus nal load), acting upon the metal very materially the yield point the metal question, (b) inate the corrosive attacks the surface the 7 | 7 | ! —— 7 7 7 7 Urge Enlightened Selling Policy Institute Speakers Cite Improvement Morale Quarter Century Best Promise for Future— Competition Bar Cooperation not think everyone fully comprehends the very great difference between honest, fair and decent competition and ruthless, destructive com- petiti There can perfect competition and, the time, perfect cooperation.” these words Judge Elbert Gary, president the American Iron and Institute, emphasized the main theme his ad- dress before the opening session the thirty-first gen- eral meeting that body. The institute convened ill room Hotel Commodore, New York, May 20, and the audience that assembled hear the president’s remarks was unusually large. The need for greater spirit cooperation was also stressed Eugene Grace, president Bethlehem Corporation, who was speaker the banquet evening. Notwithstanding heavy investments and equipment, said, the steel industry making the same profit per ton within few cents years ago. his opinion, only necessary for the steel manufacturers reach sound understand- ing among themselves put the industry satis- factory basis. The improvement the selling methods the in- dustry the past was cited earnest for still fur- her betterment the future. Curiously the most opti- nistic expressions regarding the future came from two the men the institute, Judge Gary and Willis King, viee-president Jones Laughlin Steel who was also banquet speaker. “When think what the iron and steel business was doing the methods practised years ago, and compare that the present time,” said President Gary, know that the iron and steel business very much higher ine the present time.” tition In tne in plant s rosy picture the future was also painted Darwin Kingsley, president the New York Life Insurance Co., New York, who was the principal speaker the banquet. Unless become dull witted, asserted, shall achieve economic order far removed from the present the stars are distant from the earth. The immediate business outlook was described encouraging, prepared statement read Presi- dent Gary, published elsewhere. Included this re- port were statistics bookings and shipments the Steel Corporation. New bookings from Jan. date were disclosed being larger than for the same period last year, averaging 41,941 tons per day against 38,700 tons Judge Gary’s remaining remarks were extempora- neous and are quoted, part, follows: Praises Coolidge Administration “Opportunities for progress and prosperity this country are better than they ever were before. Every man who reads, listens, thinks and understands, must agree that proposition. “Since have known anything about the iron and steel business there has never before been time when the governmental administration was honestly, sin- cerely and actively much interested present the prosperity the people this country, and the whole people. Counsels Fairness Competitors “We have the iron and steel industry, think justified saying, big men, honest and fairminded men, men who come nearer being per- Steel Industry Strong and Hopeful a recession in c considerable nearly three years have en- natural and healthy. ertain lines, sometimes ably representative the average gree This only for the whole industry, undesira- This Year Last Year activity and moderate profits iron and steel industry. Within ble drive the business machine there has been marked continuously maximum speed. formerly that term was Nevertheless the business this understood, but have country merely evidence the date 30,13 36,300 with steady and rea- activities, aims, ambitions and energy full volume business. nearly one hundred and twenty previous 29.600 necessary here the millions New bookings ind well understood reasons force which will surmount and over- 41,941 8,700 have brought about this con- come adverse factors they arise ere have been changes ture’s forces otherwise; although Shipments for same nor such factors may here and there for 48.677 which may operate seri- brief periods tend slow down in- Shipments from interfere with the even flow dustrial and commercial activity. Jan. date. 47,634 which has been marked believed there has been but These figures show very sound little, any, ulative buying and encouraging situation ture recent years. has been keen competition, must expect and should wel- sane and reasonable, which ntly not the case. Competition ly; the ene its proper limitations good sitate the use steel products, for there are no Consumption proceeds daily and hour- rgies Our country is rich in resources ment and expansion our national large and people neces- fun plentiful and cheap; products; any ambitions and incentive very warranted awaiting develoy ual size. income is serving. Supported everyo drop below average de- confidence, the effort and energy service and mands will only temporary. American people, which apparent- production. furnishes added The iron and steel cannot materially restrained, the enterprise and operates whole, strong and con- will push forward constructive producer well con- dition. This more less indicated lines. All this means continuous current reports one the lead- volume business and, gener- course, there will ing steel manufacturers, which prob- al, satisfactory profit The Iron Age, May 26, ‘ | | $ 7 7 | | F fect gentlemen, can found any line any busi- ness anywhere the world; men who can appealed to, the right thing and the fair thing. But are just greedy, just selfish nature has made cannot throw stones one another. But think that sometimes competition, which have said great thing for all the people, has been carried too far, and from motives selfishness sometimes se- cure business for ourselves that really, justly and natu- rally belongs some our competitors. think fail realize that the long run, year year, month month, will get more business, and certainly will get fairer prices, act more un- selfishly, all the time consider the rights and interests our neighbors. Morale Industry Has Improved “When think what the iron and steel business was doing, the methods practiced years ago, and compare that the present time, know that the iron and steel business very much higher plane the present time; and one not engaged the iron and steel business should tell that iron and steel man substantial number them were tricksters, would resent and would defend the person per- sons because know what the morale the iron and steel business the present time compared with old times. know how much happier are and how much more prosperous are because the moral position which occupy the present time. Urges Enlightened Competition “Now not against competition. believe thoroughly and believe great thing, good thing and wise thing. believe the Sherman law. How- ever, not think everyone fully comprehends the very great difference between honest, fair and decent competition and ruthless, destructive competition. There can perfect competition and, the same time, per- fect cooperation. Now there contradiction, prac- tically, those words, competition and cooperation. When help others help ourselves; and the ordi- nary customer, although not appreciate it, when finds doing tricky things his favor, has less respect for than would have tell him, ‘We practice what preach; are sorry, but cannot it.’ tell you, believe firmly soul, that the man engaged the steel business least will more Steel Industry Must Have More YEAR ago addressing the institute President Grace the Bethlehem Steel Corporation urged the steel mills become better merchants. speak- ing the banquet last Friday night stated far could see there had been little improvement merchandising ability. think can claim for ourselves without egotism that are wonderful manu- facturers.” high degree efficiency has been ob- tained; costs have been reduced low point; group employees better compensated well compensated the steel industry, and the custom- ers the industry are well treated. added, how- ever, “We have failed give the people who have placed trustees charge their business fair and adequate return.” the period since the beginning the war, pe- riod nearly years, the annual compensation em- ployees has increased 108 per cent, hourly wages have increased over 200 per cent, the cost living has in- creased per cent, and there has been in- crease the prices commodities generally per cent. Prices steel, however, have gone only per cent, and the large tonnage products—plates, shapes and bars—have advanced bare per cent. The steel the last years has invested $1,650,000,000 for new plants, extensions, rehabilitation, ete. Yet making the same profit per ton within few cents the beginning the period, Mr. Grace stated. The leader the industry, the United States Steel Corporation, had $2,185,000,000 employed its 1514—May 26, 1927, The Iron Age and interests his neighbor. “There may some this room who preaching beautiful But you look your books year after year that money being decent, always. “And remember, while talking you the floor, talking that fair-minded. est man, who sits right there, who has neral sight the selling policies the remember that talking him and that ing him here your presence, not conversation office. But anyone only one talking to, very (Laughter and applause.) “It fact that this competition business ours carried too far; also fact that our bringing was little wrong. You older men carry your mind back years when you got o’clock the morning order get some order little later the day that you knew you were not entitled to; you justified yourselves the fact that. while you were little mean, your competitor was little worse. That not justification. talk- from the ictak mistaken. a Beginners Should Start Business Right “Here another thing would like say some— will not call them recalcitrants, will call them new beginners who are just starting out business, who consume themselves with the idea that they must something get business when they are starting that may seem little wrong because hard start. want say about that, upon that subject, the way get started, get going call it, act right, act such way that your own customers say you, like business with you because from your conversation that you are fair with your competitors and, you are fair with your competitors, you are certainly fair with your customers.’ “The steel people generally have established for themselves reputation that world-wide for being decent, square, honest, dependable, and higher position morally than they used occupy years ago. “Gentlemen, you have established for yourselves generally reputation that you not only ought proud but that you must careful live you are going maintain that reputation.” Than Investment Return business 1926 and made profits only 6.54 per cent. The General Motors Corporation, leader indus- try supplied the steel mills, had $638,000,000 em- ployed its business 1926 and made 29.20 per cent. One can’t expect the steel industry exist mere investment return, said Mr. Grace commenting this unfavorable comparison. Past Teaches Importance Concord Among Mills Vice-president Willis King the Jones lin Steel Corporation saw hope for the future the progress that the steel industry has made since was young man. that time, said, there were some iron mills Pittsburgh. Money was scarce for carrying business and making needed improve- ments. There was concord among the manufactur- ers that day, who believed running their solely for themselves. result, most the they sold their products at, below, cost. Not more than five six the survived. The steel industry today, asserted ing his remarks, the hands lot young men and only beginning achieve its end. United States Leads Per Capita Production ta Production,” Darwin Kingsley, president Life Insurance Co., New York, stated that our ork ntniut Ul} aa capita, including men, women and children, 150 cent that our nearest competitor, the Cana- and 3000 per cent the production the Chinese. The United States, said, uses more power, other human, than any other people. have discov- that the more power use, other than human the more wages can pay and the more labor will duce. People from foreign lands are impressed with three this country: our railroads, our manufactur- and industrial plants and our architecture. Amer- architecture stands out because closely related the welfare and well being our people. differs from all previous types, added Mr. Kingsley, because solved problem that had baffled all previous build- ers—we reduced weight and mass and increased strength the use steel. The world was never interesting, never much alive, never alluring the youth today, declared Mr. Kingsley. larger world than the world yesterday and larger chiefly because calls for larger men. The individual must become more and more efficient. Every man must four and five Men must think faster and decide more quickly. The time calls for men instant decision, sound mind and sound judgment. Attendance 1545 Banquet The remaining speaker the banquet was Hugh Morrow, president Sloss-Sheffield Iron Co., Bir- mingham, whose humorous remarks brought out rounds and rounds laughter and applause. The attendance the banquet was 1545. During the morning and afternoon technical papers and discussions were presented, abstracts which follow. Application Welding Steel Structure EDWARDS five-story shop building was recently erected Sharon, Pa., for the Westinghouse Elec- tric Mfg. Co. This probably the outstanding ex- ample the present time welded building con- struction. The author’s paper gave details its de- sign, fabrication, erection and cost. arrived the following comparing the actual costs this welded struc- ture with what riveted one might expected cost, find that there was saving material, due de- sign, about tons, per cent; the template making was trifle less for welded; the shearing, marking, punching and finishing would about per cent less for welded, the assembling parts for weld- ing about 100 per cent more for welded, and the welding the shop, not ineluding the use electrical equip- ment, shows cost four times that shop riveting. The raising steel the field, due extra guying for alinement, was increased about per cent, and the field welding cost, not the installation and use electrical equipment, current and training welders, was about the same the riveting would cost. Pre- vailing shop and field labor rates were paid. Standard overhead expenses are included the costs. After de- ducting the cost training welders and making due allowance for other items that were included this first job, and would disappear shop were organized for welding, the additional cost welded structure would about $10 per ton, about $8,000. The materia! saved welded design was tons cost about showing excess cost $4,200 over riveted structure, not including use and maintenance electri- cal equipment, welding wire and cost training school, all furnished the Westinghouse company. EDWARDS occupies the position assistant chief engi- neer the American Bridge Co., New York. Oxford, Y., 1864, was graduated from Cornell University 1888, civil engineering. became with the engi- neering department the Berlin Iron Bridge Co., West Berlin, When this company Conn., for several years chief engineer. was absorbed the American Bridge Co. 1900, became member the American Bridge engineering Estimates, based unit costs determined this work, indicate that the continuity feature the design whole cost more than the material saved, besides introducing into the design and fabrication some com- plicated and possibly undesirable features. Continuous fixed end support members have their place struc- tures, but before being used any great extent all engineering and cost features should carefully weighed. Based the experience gained from this work would seem that the all-welded skeleton structure not the most economic one. possible that some parts such structure might welded advantage. the fusion welding process joints can made strong the base metal, and the full gross section tension member can used, with deduction for holes when rivets are used. Due the greater stiffness end connections, and the ease with which component parts can more held together, welded details compression members increase their efficiency. taking advantage these favorable factors, and with the added advantage that will obtain when sections more suited welding are rolled, there may some saving material that will more than offset the extra cost welding. Where existing structures require strengthening be- cause increased loading, material can added more advantageously welding than the expensive method drilling holes and driving rivets awkward field positions; also when additions are made struc- tures, welded connections can well and cheaply made with minimum disturbance walls and exposure occupants. Furthermore, favor welding there are other considerations that might given some weight Born The Iron Age, May 26, 4 | a 4 aside from economy, such the elimination noise riveting thickly settled communities; another some- what connected factor the possibility making welded connections, for resisting lateral forces such wind, much simpler than the present cumbersome riveted brackets that interfere with the architectural treatment exterior walls and interior Welding can used supplement riveting and will eventually find its economical place. Designers and fabricators structural steel from many years experience have learned the virtues and weaknesses rivets and know how use them make safe and economical structures. They are now seeking the fundamental facts concerning the welding art which they can base their determination strength. generally accepted those who have had any structu- ral steel welding experience that safe and reliable welds can made trained operator following well de- fined procedure control. There demand for stand- ard specifications and methods making welds the different processes. Values some unit bases for the strength welds different types should fixed. Some reliable way controlling the mechanical and personal element used making welds, and testing the completed work, should established. With these factors fixed scientific research and made available the industry, the manufacturers welding apparatus, the advocates welding method joining steel parts, and the fabricators structural steel, all co- operating solve engineering and economic prob- lem, will doubtless make great progress the develop- ment the art weldin the dustry. Discussion Farmer, the Electrical Testing Lab New York, and president American commenting upon Edwards’ paper Steel Structures,” said that there are features which must considered conn the question riveting vs. welding. The sign, the second supervision. Present structures have been worked from com mercial shapes beams and angles which, long progress years, have been developed ‘for riveted connections. possible that the fullest may had only when shapes specially designed welding become available. Perhaps the years perience which have had riveting may have duplicated welding before the greatest benefits and assurance are ours. supervision, may said that welding work, when properly done, provides unit breaking stress us high that the metal joined the welds. The question remains: How know properly This very large question. However, where weld- ing done the shop automatic machines with automatic control the quality, know. the field proficient welder can relied upon, only seen that remains proficient. Only furnish- ing him with proper materials, however, can this pro- ficiency assured. The Theory the Blast Furnace RICHARD FRANCHOT ROM strictly metallurgical standpoint, blast fur- nace operation has not changed materially since the introduction the hot blast nearly hundred years ago. While the mechanical engineer has accomplished two generations ten-fold increase productivity per unit furnace volume, the metallurgist now getting just about the same results efficiency that Sir Lowthian Bell showed some years ago. Despite the promise and implication the dry blast, the fur- nace today more gas producer than iron smelter, that say, the energy absorbed converting ore and stone into metal and slag best less than the latent energy the top gas. Assuredly, the steel plant has been forced use blast furnace gas, spite its inefficiency fuel, because method has been known which the fur- nace could prevented from producing surplus gas over its own needs. The static state iron metal- lurgy over several generations seems quite definitely related lack theoretical explanation for the fur- nace action. Exact knowledge has been lacking why the ore burden is, under present conditions, neces- sarily limited that which uses from per cent the coke and air energy and why, consequently, the furnace forced reject its top gas from per cent its energy input. The explanation seems simple enough: While the air oxygen, assisted the blast heat, developing heat available for high temperature work, the nitrogen, actively forming nitrides and carbo- nitrides, notably cyanides, absorbing good part this available heat. Nitridation thus offsets oxidation. the use high blast heats something like per cent the total oxidation energy the coke made available the hearth temperature (1500 deg. Variations gas composition the lower part the furnace, supported observations cyanide centration, indicate that often per cent more the air nitrogen fixed cyanide vapor, hence that upward per cent the available oxidation heat absorbed nitridation, leaving not more than per cent the total coke energy actually available Washington. FRANCHOT was graduated from Cornell University 1896. was born St. Albans, Va. From 1908 1918, when became captain the chemical warfare service, was the chemical manufacturing business Niagera Falls, 1919 joined McElroy, chemist and patent at- torney Washington. For the past three years Mr. Franchot has specialized the blast furnace, latterly nitrogen fixation that connection. vice-president Ferro Chemicals, Inc., 1516—May 26, 1927, The Iron Age 7 7 7 7 Thus the for the work devolving upon the hearth. necessity burning with air large amount coke relative the iron order maintain the hearth becomes intelligible. The hypothesis that nitrogen fixation limits the the heat and hence limits the burden seems possess four elements validity: —It has sound basis fact. incompatible fact has been established. smelting efficiency systematically ex- plained the hypothesis. other valid explanation the furnace action appears available. The blast furnace has been often characterized gas producer. now appears that other functions underlie that gas producing: The furnace appears still, reflux condenser, nitrogen fixer. Small wonder perhaps that iron smelter “not sle vails avaliat io Discussion Sharp dissent from some Mr. Franchot’s conclu- sions expressed written discussion prepared Kinney and Joseph the United States Bureau Mines, which was read Dr. Herty, Jr. This paper referred tests made Southern blast furnace, which samples were taken off during the regular commercial working the furnace, three levels, study the concentration potassium cyanide the gases. The lower level was the tuyeres; the second level was in. above the tuyeres, and the upper level ft. in. above them. the upper level there was evel there was sligh higher con- centration cyanide than either the lower levels, and was much more uniform across the diameter the diam ter the furnace, being fact almost straight line. The average amount cyanide per thousand cubic feet gas this level was found 3.47 about 0.22 This figure may compared with the Ib. reported Mr. Franchot. the basis the bureau’s experiments and find- ings, the fixation nitrogen the furnace would about 0.06 per cent, place the per cent reported Mr. Franchot. producing this result, the reau’s estimates are that only 0.03 per cent the heat the hearth would thus absorbed. Disposition Missing Calories Where the missing heat units, reported Mr. Franchot 207 calories per pig iron, was believed Mr. Kinney and Mr. Joseph quite different from the disposition reported the paper presented. Instead being used fixation nitro- gen, they reported nearly per cent the unac- counted for calories having been required the heating process itself. For instance, get solid mat- ter, such ore, limestone and the coke charge, temperature 1500 deg. C., the heating elemen must supply considerably higher temperature. Other- iron would from the wise the condition would static anc produced. assume that the heating fuel 1600 deg., this differ once accounts for 162 calories calories. Operation Large Hearth Furnaces JAMES LOSE increase blast furnace output during the past few years has been such magnitude that may considered the most outstanding feature their recent development. Analysis the cause the in- creased output shows the result several factors. One the most prominent has been the gen- eral installation large hearth furnaces, which have proved beyond doubt their ability make more iron equal better quality, with more and usually with less coke per ton iron than possible with smaller hearth Another factor equal effect upon the tonnage increase has been the tendency drive the furnace the upper limit wind capacity, consistent with, and some cases spite of, the economic relation be- increased furnace loss and decreased cost above. Several reasons are found for this development. One the new installation single furnace plants built during periods excessively high construction ts. Such furnaces are usually operated picked raw materials and are pushed the upper limits COS LOSE was educated the Carnegie Institute Tech- nology and entered the employ the Carnegie Steel Co. 1910 tracer the drawing room the plant the Carrie furnaces. has been continuously employed the plant since con- then, draftsman, stock house foreman, struction and assistant superintendent furnaces. ber, 1924, was appointed superintendent the Carrie fur- naces, which position now occupies. capacity order reduce the per ton cost interest the extremely heavy investments they represent. The high tonnages produced these plants became incentive for other furnace operators reach higher outputs and resulted spirited competition between plants. Also, the large hearth furnaces were built increasing numbers different plants, was found that what was formerly considered the upper limit wind capacity longer held true and that consider- able increase could made the wind blown, and consequently higher production realized with little detriment other features operation. These conditions have resulted nearer approach maximum possible production than ever before re- alized. clear example this seen Table comparison year’s operation two furnaces equal size, furnaces No. and located the South Chicago plant the Steel Co. The perform- ances given are for the year 1919 for No. Furnace, and for the year 1926 for furnace. The comparison shows furnace have produced Septem- 3 ; good, | | ence of 100 deg. : the missing 207 7 7 7 7 7 : > enn The Iron Age, May 26, 121.6 tons more iron per day, and that was blown with 15.9 per cent more wind per minute. This com- parison indication the results being obtained the very recent campaign for higher tonnages, and shows that the full possibilities the large hearth furnaces were not realized for some years after they were developed. Table A Comp son of Two Furnaces of Equal Yea 1919 and No. Furnace Furna Average dai production, 600 otal ore, cil et 4,661 4,235 Gross coke, per ton 1,972 Net per ton..... 1,871 Limestone, Ib. per ton.. 673 over produced, Ib. Fl dust produced, Ib. per ton 257 265 Flue dust used..... 159 250 Mesaba ore, per cent 100.00 74.7 Cul feet wind per minute.. 51,860 Temperature blast, deg. Fahr. 1,114 1,201 yield metallic mixture 48.91 52.7 The development the blast furnace hearth, credit for which rests with the Edgar Thomson plant the Carnegie Steel Co., and later with the South Chicago plant the Illinois Steel Co., dates back over two de- cades. discussion the present features operation complete without some history the development, including analysis the operating difficulties and the steps taken overcome them. author here recites the history referred and the questions brought the fore- going paragraph]. Operation the Furnace noted the foregoing description the furnaces and auxiliaries, the furnaces are amply pro- vided for all their requirements heat, wind, filling, distribution, etc. Their lines are almost identi- cal with furnaces similar size operating, coke ex- cepted, very similar raw materials. Therefore, may assumed that any deficiencies occurring the operation the furnaces are due either the difference coke quality the method operation. All the iron produced basic pig iron and the operation endeavored maintain the silica content the iron its proper low limit increasing the burden rather than increasing the basicity the slag. This method generally recognized the most economical coke and the most productive quantity iron. Regularity the movement the furnace first importance this operation, for with fine Mesaba ores, checking and rolling result large production flue dust. Production Iron The quantity iron possible produce from given furnace dependent upon the chemical and physical properties all raw materials used. The main properties the raw materials which affect this feature operation are fineness ores, reducibility ores, size and strength coke, ash and sulphur content coke, combustibility coke, size and purity limestone, and last but not least the maintenance uniformity all materials. Table gives the average records Carrie’s large hearth furnaces over the entire period their opera- tion, and addition gives the individual records their highest average production for period one month. These productions are comparable with equal Table RB Data Concerning the Performance No. of Months Aver Coke Daily ated Prod Coke ings No. 1 Furnace average Best 734 150 No. furnace average Best month...... vee 703 1,974 103 No. furnace average Lining 689 2.126 114 727 132 No. furnace average Best month....... 752 150 1518—May 26, 1927, The Iron Age size furnaces operating soft ores and made from 100 per cent high volatile however, somewhat less than that the same ores but using coke made from high and low volatile coals. This indicates coke superior Clairton coke quality. conclusion further strengthened the the Jones Laughlin and the Weirton plar have operated both types coke. [The coke rate and the blast temperature are then discussed]. Flue Dust Produced and Consumed Carrie’s flue dust production high, the produced ranging around 400 per ton. has been used varying amounts throughout paign these furnaces. They are now using about per cent the dust produced, and found tha: attempts use higher quantities have resulted than proportional increases flue dust seems cumulative action dust product ViOn which indicates this operation that 400 per ton about the maximum dust production permissible. the production exceeds this figure for continued period inferior furnace operation results. The flu dust problem general has become serious with the present use higher winds. [At this point there full discussion movement the Conclusion Analysis the operation the blast furnace very difficult task. The chemical and physical prop- erties the burden materials impose their different tendencies upon the furnace many ways. The varia- tions existent these properties combine produce marked swings the operation, which often mask the results changes such extent that con- clusions drawn may wholly wrong. These conditions are responsible for the wide dif- ference opinion sometimes held regarding the various phases operation. Johnson, during his investi- gations concerning the properties alumina the slag, remarked that since many operators regarded acid, was quite sure was neutral, and later was able give substantial evidence prove his con- tention. Another difficulty confronting the investigator the human tendency making comparisons see only the worst his own operation and the best the other. effort has been eliminate such tendencies every way, but not all certain having attained complete success. Finally, the value making comparative analyses operations can well considered equal that costs. The theories developed explaining the detri- mental effect various factors upon the operations often become the basis for changes which result minimizing great extent the difficulty hoped that this paper may some manner prove benefit such developments. Discussion George Hohl, superintendent blast furnaces, Bethlehem Steel Co., Bethlehem, Pa., pointed out connection with large hearth furnaces using from high volatile coal that the cost sheet the real judge value any changes which may made. of Carrie Furnaces on Their Present Linings Scrap Used Cu. Ft. Net Over Wind Coke Prod. Prod. Temp. 1,851 +60 319 190 49,206 1,017 20.3 1,870 +76 186 51.626 1,178 1,871 404 233 49,690 1,848 +46 340 175 50,742 954 22.3 1,962 +28 374 116 1,918 51,251 1,049 21. q 7 ‘ duction has high reduce the unit interest harges large investment. Test runs great output are interest the management, ing what can done producing lower costs Otherwise, they have comparatively little per ton, This was reference statement Mr. Lose, not covered his paper, that the best run for one day No. furnace had produced 1263 tons iron. this amount about 820 tons, was calculated, was made from ore, the remainder from scrap. the latter, tons went into the ladles. For hard ores, Mr. Hohl considered bosh angle 78% deg. the best possible. This angle does not apply, however, any similar way Lake res. the same way, for hard ores the batter the shaft the furnace finds best from 0.6 0.75 in. per whereas greater batter better for Lake ores. reported one furnace which the batter had been reduced 0.4 per ft. cam- paign years this furnace had always proved the smoothest working unit the plant. reported lips virtually unknown with hard ore. Much Higher Blasts Coming Into Vogue Blast provided earlier furnaces was the basis limit. Today 51,000 ft. common figure, and one furnace his plant designed for 65,000 ft. large furnace with 19-ft. hearth diameter and 23-ft. sh, the furnace being 100 ft. high, much 74,000 per min. has been used for coke which can burned, and this depends upon the wind supply. one furnace the 1926 operation for month showed 514 tons iron per day and 1