The Iron Age 1927-09-01: Vol 120 Iss 9

THE IRON AGE New York, September 1927 ESTABLISHED 1855 VOL. 120, No. Proper Fusing Enamel Vital Plant Making Gas Stoves Coats Both Sheet Steel and Iron Castings—Japan- ning and Nickel Plating Done, Also INISH one the major problems all plants manufacturing products iron and steel and especially does this apply gas stoves. Not only must the finish artistic qualities and stand under hard treatment, but must also withstand re- peated high temperatures. Porcelain fused iron and steel has become the most popular all stove finishes and improvement the technique its manu- facture and application being made steadily. Art and science have combined make the modern stove thing beauty well unit simple and efficient utilization. This demonstrated the products put out the Detroit-Michigan Stove Co., Detroit. The Detroit Stove Works, the parent organi- zation, was established years ago. The present com- pany, consolidation the Detroit Stove Works, the Art Stove Co. and the Michigan Stove Co., said the largest manufacturer stoves the world. The Detroit Stove Works manufactured the Detroit Jewel gas ranges, combination ranges and furnaces; the Michigan Stove Co., produced the Garland range, gas, coal and combination; and the Art Stove Co. made gas and combination ranges and furnaces. These three divisions are now consolidated within the confines single plant, which has production capacity 850 stoves daily. While these three lines were, for the most part, parallel and competing, each had different designs, fea- tures and sales arguments. Today they are, therefore, being produced before, except where the manufacture certain parts could standardized for all. The one plant which the three divisions are now housed cov- ers 13% acres and includes modern, brick and fire- proof buildings. All are four stories high except the foundry and enamel departments, which are one story. The plant served with spur tracks from several rail- *Vice-president, Surface Combustion Co., 366 Gerard Ave., The Bronx, New York. 531 roads and has frontage and dock facilities the De- troit River. One Foundry Serves All Lines Consolidation the manufacture different parts for these three lines starts with the one foundry, where all castings are made. All enameling done single enameling plant and all press operations are per- formed one press department. After this the various parts for the separate lines are segregated and sent the one the three divisions for which they are in- tended. Gas ranges form the bulk the production this plant, more than 200,000 being produced annually. The castings made the foundry include the front and top oven doors, broiler doors, two grates, end shelf, top support, two journals (hinges), five burners, burner rests, back guard supports, manifold supports, ete. Castings for the various other ranges and furnaces are made here also. There are four cupolas, with capacity for 120 tons castings daily. Emery wheels, tumblers and sand blasting ma- chines are used the grinding department for thor- oughly cleaning the castings. After this they the tap and drill room, where batteries dri!! presses drill the proper holes and tap them with the correct threads. Among other machines, multiple drill presses hold four star burners time, and drill many holes single operation. From here the various are sent one three finishing depart- ments: japanning, nickel plate enameling. After the different finishes have been put on, the parts are stacked central, common stock room drawn, when re- quired, for assembly. Sheet Steel Forms Many Parts Items which sheet steel the base originate the press room and for the gas range include legs, range body, body top, high shelf top, high back and ends, al Row Spraying Booths Enameling Department. oven and broiler door panels and linings, stove linings, drip and broiler pans, splashes, back guards, etc. The great size this press room can gaged from the fact that more than 125 power presses are located here and approximately 450 different active dies. The pressed steel parts, did the castings, then one the three finishing departments, depending the finish each destined have. Standard equip- ment and standard practice are utilized the nickel plating room. Some innovations practice and im- provements over accepted apparatus have been made the japanning and enameling departments. Raw materials for the different enamels are re- ceived separate room, compounded, burned and Battery Nine Modern Enameling Furnaces Fired with Gas. Enamel carried the buckets overhead. ground. The enamels are then stocked quantity ready for use the sprayers dippers, may the case. The ground coat dipped and the two white coats are sprayed. Two large vats, sunk that the tops are just level with the floor, serve this depart- ment. There are some spraying booths, all equipped with air-pressure sprayers. All material moved trucks. Porcelain Finish Fused The different coats are burned temperatures which fuse the enamel and produce beautiful, porce- lain finish. There are nine gas-fired furnaces built brick, suitably stayed and insulated and equipped with One the charging carriages appears foreground 532—September 1927, The Iron Age 7 ~ speed forks, electrically operated doors and automatic temperature controls. These furnaces, each ft. long, ft. wide and ft. high, are the muffle type. Each furnace heated with eight burners firing under the muffle, which carborundum. This muffie heated incandescence, which turn heats the furnace radiation. this way coats enamel are burned tem- peratures varying from 1400 1600 deg. Fahr. from The economies effected this installation are real- ized few enamel furnaces. Fuel economy had from the gas-air proportioning device, well the method heat radiation. These two methods also reduce the heating periods and increase the ca- pacity the units, thereby effecting material saving labor. Furthermore, special and expensive labor for enamel burning replaced common labor, using automatic temperature control. This device also elim- Rear Enamel Furnaces, Showing the Compressor Equipment Used (Above) Main Assembly Line for the Stoves, Operating Continuous Conveyor (Below) spirates the right amount air for perfect combustion patented venturi tube proportioners. The tempera- tures are controlled and maintained py- rometer controls. Two track tables double forks are supplied for loading and unloading. The system fir- ing product the Surface Combustion Co., New York. = inates wastage due uncontrolled irregularity heats and burning periods, which always occur when human labor depended upon. Immersion and Baking Japanning The japanning department has six gas-fired ovens served with three dipping vats and overhead traveling conveyors. The vats containing the liquid japan are The Iron Age, September 1927—533 | = | about ft. square and ft. deep, and are sunk that the tops are level with the floor. The paris japanned are hung racks suspended from the over- head conveyors. soon the racks are loaded they are lowered into the vats, that the work im- mersed, after which they are raised and the excess japan allowed run off. Racks and work are then run into the ovens and baked temperature around 450 deg. Fahr. for approximately min. These ovens are each ft. long, ft. wide and ft. high and are heated indirectly. Separate com- bustion chambers, provided for each unit, are equipped with four gas burners. The heated air forced into the ovens electric fans, through ducts arranged give free circulation and even distribution through- out the ovens. The burners are supplied air from lb. pressure, which inspirates gas atmospheric pressure, through patented venturi tubes, proper pro- portion for complete combustion. While this type oven does not lend itself well automatic control, material economies are effected the system heat circulation and method propor- tioning the fuel and air mixture. The system fir- ing here, also, Surface Combustion product. The three different lines stoves have three differ- ent assembly departments housed two separate build- ings. These assemblies, similar the final assembly automobile plant, consist long, traveling slat conveyors. The different parts are stacked inter- vals along both sides and, the stove bodies travel along, men put the different parts. the end the line the gas range connected gas pipe and tested. The crating, labeling and shipping these three lines are done three separate departments. Large Shipment Rolling Mill Equipment Roll Sheet Bars, Skelp and Strip Steel from Large Ingots Without Reheating the largest shipments rolling mill ma- chinery, recently made from Pittsburgh, consisted continuous rolling mill roll stands and gear reduction drives designed and built the Mesta Ma- chine Co. and shipped from its plant West Home- stead, Pa., the Bethlehem Steel Co. plant Sparrows Point, Md., where will put into operation. This mill will installed directly following 46-in. reversing blooming and slabbing mill, also designed and built the Mesta Machine Co. and put into opera- tion last year. The complete unit, consisting the blooming and slabbing mill and the continuous mill recently shipped, will produce slabs, blooms, sheet bar, skelp and strip steel direct from the ingot one heat without necessity for reheating during the rolling process. operate the continuous mill its maximum capacity 25,000 hp. will required, and for the bloom- ing and slabbing mill 20,000 hp., making total 45,000 hp. required for the complete unit. General View Assembled Mills and Erecting Floor and Partial View Train Leav- ing Works 1927, The Iron Age The magnitude this equipment can further visualized the fact that the maximum size ingot rolled the blooming and slabbing mill will weigh 44,000 lb. ingot this size rolled into slabs; the maximum size slab produced being in. These slabs sheared into suitable lengths are trans- ferred another mill rolled into plates. Ingots rolled the blooming and slabbing mill, which then follow through the continuous mill, weigh about 15,000 each. These ingots will re- duced the blooming and slabbing mill 8-in. cross section for sheet bar production, 22-in. cross section for the production wide skelp and strip. The 8-in. the 22-in. billets, the case may be, will further reduced the continuous mill sections approximately in. minimum for sheet bar and in. minimum for skelp. Emerging from the continuous mill reduced sec- tion speed 1300 lin. ft. per min., the product p will sheared new type electrically operated flying shear into merchant lengths, varying from ft. ft., may required. One ingot, reduced its minimum size this mill, will make strip steel in. thick, in. wide and nearly mile length. After being sheared into proper lengths, the bars are piled mechanically bar piling machine located directly line with the mill. They are removed from the bar piling machine crane and placed storage yard for cooling, after which they are loaded into railroad cars for shipping. | = i i Factors Affecting Total Carbon Steel Important Results from Study Six German Blast Furnaces—Silicon Con- tent and Crucible Temperatures Affect Carbon Content CONTRIBUTION from the Breslau Institute Eisen, April 28, 1927. the influence blast furnace operations affecting the total carbon the pig iron made. The ordinary range total carbon fluctuation pig irons about 1.50 per cent, and far definite laws have been discovered fixing the relation between total carbon and the other elements iron, well with the conduct the smelting process itself. Blast furnace operation has not yet advanced the point actual prediction resulting total carbon content the iron made. And yet this highly desirable view the call for either high low percentages this element. exact knowledge recarburization phenomena would, therefore, seem prerequisite dealing with this question. Iron the Liquid Phase Important far, studies have been mainly made the mat- ter with iron the solid phase, whereas this only secondary importance blast furnace opera- tion. Recarburization with iron the liquid phase far greater import regards the final total car- bon achieved. The items considered are the con- nection between crucible temperatures and reactions and the solvent ability the iron the one hand, and the influence had upon the reactions the car- bon already taken the iron passes down, the other. these there must added the effect slag composition, time given for the reactions and blast temperature. Six Blast Furnaces Studied order obtain definite information the sub- ject, six blast furnaces were selected and complete data obtained every phase their operation, includ- ing qualitative and quantitative determination the ingoing and outgoing materials and products. The meas- urement temperatures and the taking samples are subject considerable variation. Normally the first iron colder than that the end the tap. should the furnace operate colder after such tap, and the iron collecting the crucible come down colder cor- respondingly, the first the tap may hotter than the end. Hence was necessary the tests get readings under very constant temperature conditions, and these readings and the samples taken nearly uniform time periods possible. Similarly, differences the sulphur, silicon and manganese content were found running concurrently with temperature differences. Thus, normally colder iron the first the tap contained less silicon and manganese and more sulphur than hotter iron coming out later. This condition readily explainable noting that, the furnace crucible emptied slag and molten iron, the burden comes down faster than normal, fill this void, lowering the crucible tempera- ture somewhat and retarding the reduction sili- con and manganese. With rising temperature this re- duction becomes normal again. may seen, how- ever, that uniformity temperature and composition not attainable the furnace crucible. arrive satisfactory information regarding the carbon content the iron the tuyere level, steel angles were driven into the burden through the tuyeres —the wind being shut off for the moment—and drops molten metal caught them. Repeated tests with gray and white irons indicated that the carbon content the drops this level varied from 0.10 per cent, showing that the absorption carbon the iron the shaft and the hearth the furnaces incom- Prepared from the German Dr. Richard Moldenke with comments. plete, and that additional carburization must take place below the tuyere level. Total Carbon Dependent Silicon Content and Temperature large series tests was required give in- formation the relation total carbon content furnace operation as, under normal running conditions the part the furnace, the variation total carbon but slight. arrangement the taps equal tem- perature and equal silicon content give curves which plainly show the total carbon dependent upon these. the silicon rises, the total carbon drops, and with equal silicon values the total carbon varies rising the temperature the tap goes up. Curves are given for basic, hematite ore, and for foundry pig irons, showing very regular curves illus- tration these tendencies. understood, course, that with considerable variations the other elements the iron, there would some distortion the curves. For instance, increase phosphorus sends the total carbon down. Thus, Luxemburg (high phosphorus) pig iron averages 3.6 per cent total carbon, whereas other, lower phosphorus ore foundry irons run from 3.8 4.2 per cent total carbon. The connection between total carbon content, chem- ical composition and metal temperature easily un- derstood when the process carbon absorption con- sidered simple solution. With very high furnace temperatures, the saturation point carbon may reached right the zone combustion, and this saturated metal drops down into the cooler crucible, part the carbon may separate out the bottom the crucible kish. Any iron the crucible which may not saturated will then take this kish for the purpose. Slags rich iron oxides prevent this saturation with carbon and yield lower total carbon pig iron, and upset the relation carbon tapping temperature. Lower Crucible Temperatures Mean Lower Carbon The investigations gave strong proof the inter- relation between furnace operating conditions and total carbon results. Any reaction which meant lower cru- cible temperatures promptly lowered the total carbon the iron tapped. Actual temperature reductions the furnace crucible were brought about purposely test this out. This action is, however, indirect one. Thus, forcing the ore-reduction process consumes more sensible heat and hence lowers the crucible tempera- ture, which turn lowers the absorption carbon. Also, some the absorbed carbon the iron used for reduction purposes. Similarly, the curves ob- tained the relation blast temperature and speed furnace operation showed direct connection be- tween these and the total carbon results, though the curves were very regular character. Proper Course Follow Concluding with the importance being able make low total carbon pig iron, the author states that his investigations indicated the proper course follow. Since the total carbon content the iron determined the kind slag produced and the tem- perature conditions the furnace, get low carbon necessary run slags richer silica and iron oxide, and with lower temperature ranges. The cru- cible temperature will consequently drop and the result desired obtained while still getting high silicon ranges. Wuest and Brassert have already pointed this out also. Using refractory ores and pushing the furnace, well cutting the coke and running with lower blast tem- peratures will help cutting the total carbon content, though within comparatively limited amounts. The Iron Age, September 1927—535 Finished Steel World Exports Gains Bars, Wire and Tin Plate Tend Offset Heavy Tonnage Losses Rails, Shapes and Pig Iron—Sheet Products Form Backbone American Trade PAUL TYLER* ETWEEN 1913 and 1925, although production increased per cent, the total trade the world and its total population both increased only per cent. These figures, computed the League Nations, were heavily weighted for agricul- tural production, but study iron and steel bears out even more forcefully the conclusion that world trade has not kept step with world production. Each country has become more nearly self-contained. In- tense nationalism, new tariff policies, and dislocation the old-established credit machinery have combined cause raw materials worked up, wherever pos- sible, their source. High freight rates and the interruption normal business during the war con- ributed toward the same end. The causes for this condition are particular importance. What matters that the world today has great surplus steel-making capacity. Changes have been wrought the character world trade. national understandings, keener. Henceforth, export even more than domestic selling, steel must considered the light the service renders. Millmen and salesmen think naturally tons and the trade experts, most them, are content copy gross tonnage figures for imports and exports represent- ing the state trade. the buyers steel, those whom the steel serves, think specifically terms 120-lb. rails, welding rod, or, maybe, auger-bit stock. Recognizing that foreign markets now are definitely buyers’ markets and that the world trade aggregate special demands, the purpose the present article analyze, according major items, the combined ex- ports the six nations which together furnish more than nine-tenths the total world exports iron and steel. The accompanying tables, since they are compiled from official figures the respective countries, can more accurate than the original statistics. Dif- ferent groupings are adopted different countries and even different reports the same country for the same year. Skelp, for example, included sometimes with pipe, sometimes with bars, and sometimes with semi-finished steel. Light structural material, similar- ly, may grouped either with merchant bars with girders and other shapes. Wire rods, since they are rarely separated from wire, are perforce mostly in- cluded under the latter category, along with nails, bolts, and, sometimes, nuts and screws. promises, the accompanying data are offered the best rough-and-ready index far available for reveal- ing general trends. Especially for such leading items rails, shapes and sheets, the figures are reasonably exact although, even the case rails, splice bars are included some with rails and others with steel sleepers, which, along with wheels, axles, are mostly included the present tabulations under “sundries.” Scrap exports, since they may ‘ 1817 Street, W., Washington. 536—September 1927, The Iron Age always segregated, have been omitted all cases. All the figures relate gross exports and hence not take account the imports into the same coun- tries under the specified categories. Where this situ- ation seems cause confusion, where the same tonnage may counted twice, once exports from one the leading countries another, and again exports from the second country, attention will called the fact the discussion the individual items. Declines Pig Iron and Alloys Examining the statistics Table for the leading countries, first find drop the exports pig iron and ferroalloys from over 200,000 tons monthly 1913 only 138,000 tons 1925-26. This falling off has been partly offset increase the exports from British India (which have grown meanwhile from under 7000 much 35,000 tons monthly), and small increase shipments from China Japan. Not long ago, the Netherlands began export pig iron, and Sweden (whose exports, normally some 15,000 tons month, consist chiefly high-grade charcoal iron), also considerable significance. Actually pig iron, commonly ballast, appears some quantity the exports almost every country the world. But since, even the aggregate, these minor shipments are not large, they not alter the fact that pig iron declining importance inter- national trade. the United States, formerly con- sistent exporter, had not imported really important tonnages 1925 and 1926, the decline would appear even greater. The reason for this state affairs simple: Pig iron too heavy far. soon the tonnage are large enough justify it, local production tends spring up. Coal and iron ore are fairly widely distributed and, even though natural conditions are far less favorable many new producing countries than older centers, almost every one these new plants appears able hold its own within the short radius its local markets—often without the added help protective tariff which, notably several British dependencies, has been generally forthcoming. Without elaborating further the general subject transportation, may now stated that the trade pig iron made principally (1) shipments from one part another Europe; (2) imports along the seaboard the United States; and (3) imports (chiefly from China and India) for supply- ing Japanese steel works. The scattered requirements the rest the world would not keep even one modern furnace blast for more than few months the year. Moreover, foundrymen all over the world are com- ing buy pig iron not much brand analysis. They are buying the cheapest iron they can get, mixing different irons and scrap, they see fit, obtain the desired results. follows then that great quantity iron can carried long distance unless can delivered cheaper than that made nearby. the same time, substitutes for cast iron. notably lighter sections steel, have kept down the demand for foundry iron, and the extensive use scrap has substantially reduced the gross exports iron for making steel. Even the movement ferroalloys—never large tonnage proposition—has fallen off because the de- velopment ferromanganese industries the United States and Canada has reduced the exports from Eng- land more than enough offset the increases from Norway. Even France exporting less alloys now than before the war. More Semi-Finished Steel The upward tendency for crude and semi-finished steel may magnified somewhat the inclusion some merchant bars the statistics which indicate increase per cent since 1913. This trend, which seems contrary that for pig iron, caused almost wholly larger shipments Continental for re-rolling Great Britain. the present writer has already noted the previous articles dealing with the several countries involved, this movement one-half, even before the coal strike which placed England import basis. Exports from France and Belgium have increased, but not enough make for German losses resulting from the transfer the mills Lorraine. short, the building boom, while has been almost world-wide, has not called for heavy steel except countries which make the steel themselves. Since steel frame buildings have withstood the earthquakes better than other types construction, Japan has been buying considerably more structural material than formerly. But the gain from this source fails balance the reduced imports into India and Australia, where local production sup- plate. galvanized Sheets, hoops Stri Ds a// wire and pipe: / y ga ized 4 shee s hoop: strips, wire and . effect merely the working iron and steel from Lorraine ore transit from France via Belgium and Bars. 2 Dars, apes, Great Britain overseas markets. Plates The increase the exports bars due mainly Sheets, greater shipments from Belgium. would doubt- 100 All Other YHOWING Increases World Other Exports Finished and Semi- Finished Steel and Sharp Decline Comparing 1925 with 1913 Grouped Exports the Five Semi-Finished THOVSANDS Metric Tons MONTH > oO less appear even larger the increased exports from France could separated from those ingots, billets, with which they are officially reported. Concrete reinforcing bars have become great importance; consumption said have trebled the last years. Since, even markets where they are not chosen for machinery shop work (or for other ser- vices requiring resistance shock), Thomas bars are commonly considered good enough for ordinary con- struction work, there mystery about the growing trade French and Belgian bars, even while exports from both the United States and Great Britain have fallen off. The latter countries have themselves been importing increasing tonnages Belgian bars because they are much cheaper than their own products. Since angles and other light sections often are included with bars, the category for shapes represents chiefly beams, girders and other heavy structural steel, mostly unfabricated. American exports have fallen off markedly, and British shipments had been reduced Big Exporting Nations (Below) erroalloys and , plies more and more the demand. 1926, all the Continental countries registered sharp increase exports both plain and fabricated building material. Hoops and strips form another classification that not too definite. Cotton ties and barrel hoops are two important items for which the United Kingdom dominates the trade, including the baling jute India and cotton various parts the world. The substantial increase under this general head, how- ever, attributable mainly France, Belgium and the United States. The movement consists partly band iron and partly fairly heavy flat steel which commonly falls into the same classification. Likewise included this category are numerous specialties, such band-saw steel, safety-razor blade stock, steel for making steel tapes, and other flat wires, both hot- and cold-rolled. The production wide strips compete with sheets seems far mainly (Continued page 597) The Iron Age, September 1927—537 = 4 44 7 Tin plate, pe = i ¢ 4 _ 4 i A % Fig. —— q ~ Fig. 538—September 1927, The Iron Age any plant progresses and its output increases neces- sary change methods operation take care the gain production without adding costs and, possible, lower costs. The core room the foun- dry the Packard Motor Car Co., Detroit, has undergone several re- arrangements the last years, and the most recent has just been completed. previous article de- scribed the system for taking care the incoming sand and for mix- ing core sand, and this one will treat the coremaking problems proper. The core room located be- tween the gray iron foundry one side and the aluminum foun- dry the other. the back the core room, connection with the outside almost entirely shut off sand bins and sand mixing system, and the front general service building, which contains the pattern shop, offices and other departments, cuts off. consequence, proper ventilation important. take care this was necessary provide indi- rect system which would give slight excess air the core de- partment and sweep out any smoke that might come from either one the foundries. good idea the ventilation system may gained from Fig. which shows one end double set coremakers’ benches, with one number unit heaters and blowers located above it. The ventilating system takes air from outdoors, heats and blows down into pipe under the core- makers’ benches, where comes out through openings floor line. properly adjusting the dampers these pipes the best distribution air obtained. summer the same system used for ventilation without the heaters. Fig. shows series core- makers’ benches that serve roll- over coremaking machines. Jacket cores and similar pieces have large number wires and rods them and relatively small amount sand compared with the bulk the core, and for this rea- son convenience manipulation more importance than special methods for the introduction sand. shown the illustra- tion, the machines are arranged front the core benches, and the core benches serve take care rods, wires, driers, chills and other pieces necessary coremaking. the same time sand supplied from sand hopper one end the core benches, the sand being tilating Material Ventilating System, Materials Handling Methods ty — 7 — ~ and Layout Features Packard Core Room put into the core box means scoop shovel. pointed out the previous article, these benches are supplied with sand from overhead. dentally, this illustration shows interesting point regard photography. numbered tag used for indicating the kind sand used each bench, and the background each tag dif- ferent color that the operator can tell the kind sand required, both the number itself and the color. The tags with the blue background show white that the numbers them are not visible the picture. The cores are placed racks, shown Figs. and and electric lift trucks take them standard rack-type core ovens fur- nished Holcroft Co., Detroit, each oven taking two racks. The dried cores are then taken from the ovens cooling floor and later the inspection and clean- portion the floor for the inspec- tion and cores for cyl- inders shown Fig. From the racks, which are arranged along the back the the operators take off the cores, re- turning the plates and driers. They then inspect and prepare the cores for blacking. Finally, the cores pass down gravity carriers continuous drying oven. the immediate right fore- ground Fig. shown por- tion the pasting and assembly conveyor used for making the cylinder jacket assembly. Fig shows more detailed view the jacket assembly layout. the right series benches with pasting troughs which the men work while making the assembly. The cores are delivered the men gravity carriers, and each oper- ator performs one more opera- tions the assembly line. Above the benches can seen test jigs used making the assembly. When the core assembly com- plete, taken off and placed the vertical, gas-fired, continuous drying oven shown the rear. The continuous drying oven re- ferred has two uses. First, serves dry all blackened cores their way from the cleaning de- partment the assembly, and, second, dries the paste the assembled cores. Fig. shows the discharge side the drying unit. The cleaned and blacked cores ready for assem- where the jacket assembly made, while the pasted jacket assemblies come out the oven and are passed directly toward the front the picture down gravity car- rier. the immediate foreground there grinding rig for facing the assembly and certain other cores. The assembly then passes the left gravity carrier, indicated. The cylinder pouring molding floor only few feet from this location, and the assem- blies and other cores necessary for this floor have transported but few feet their point use. The other cores are placed special trucks and transported the molding units where they are required. The Lane Co., Detroit, acted consulting foundry engi- neer connection with the work, and the installation itself was car- ried out the Packard Motor Car Co.’s construction division. 4 bly pass the left the oven Fig. The Age, September 1927—539 | 4 ~ 1 Iron and Steel Centers France What Are the Conflicting Factors Which Have Governed Development the Various Districts ANDRE REYNAUD* RON and steel industry France old the nation. his “Gallic Wars” Julius Caesar refers the remarkable properties some small torrents the Alps for the quenching swords and many French towns contain their names, “la ferriere,” evidently derived from the Latin word rrum, The writer was born Allevard, small town the French Alps, where there steel mill still operation that claims one the oldest the world. This mill, which had been operating for long time the beginning the thirteenth century, has continued uninterruptedly the present day. The iron workers France were always highly regarded men, proud their work and their skill, which was taught father son. Metallurgy was one the very few trades that nobleman could practice without forfeiture his nobility; fact, some the oldest names France are those families raised nobility consideration the service rendered the country improvement some metallurgical operation, increase the efficiency their mill. The first iron works, were established places near fuel and water, the two essential factors. Ore could shipped the plant easier than fuel and swift torrents were necessary supply the required power. Conversion raw metal into the finished ar- ticle was done entirely under hammers, operated the running water against wheel connected with the hammer through shaft and eccentric. The fuel was first almost entirely wood. These two facts explain why the Alps were the starting point the iron in- dustry, wood and water were plentiful and addi- tion there were some fairly large deposits iron ore (siderite, iron carbonate, CO,) which were very easy work. Industry Shifts Coal Centers With the development the use coal and the destruction the forests, the iron industry moved other sections. early the fifteenth century, the great metallurgical center France was the St. Etienne district, the center the country, but was not until after several centuries that the iron and steel industry came back the place its birth, the French Alps. During the past years, the old plant Alle- vard (Société des Hauts Fourneaux Forges d’Alle- vard) particular, the electric furnace was developed and improved and the same torrents which formerly turned the wooden wheels for the blacksmith’s hammer are now generating hydroelectrically the energy re- quired plants employing several thousand workers. Three factors have influenced the location mod- ern French steel plants; coal mines, ore deposits and proximity the seacoast, that ore can brought from North Africa and coal from England. The mills thus built near the sea were great assistance during the war, when the industrial regions the North and East were under German control. The most important metallurgical districts France are: The Center, built old coal deposit, known and worked since the fifteenth century (mills specialize high quality products); the North, built the French-Belgian coal deposit, the largest the country (ore brought from the East); the East, the most important district, established ore deposit *Ingenieur des Arts Manufactures, Ecole Centrale 540—September 1927, The Iron Age and obtaining most its coal from Germany, which not more than miles distant. Some extremely good coal found also Lorraine and the Saar dis- trict. Aside from these three districts, France has some steel mills built the ore deposits Normandy, which use British coal. the Southwest also are few plants using British coal, their ore coming from Spain the Pyrenees. the South there are some steel plants the Alais coal deposit, using Algerian and Tunisian ore, but the tonnage produced these other districts unimportant comparison with the large capacity the East and the North. Alloy and Special Steels Made Center Despite the small tonnage steel produced the Center district, great interest the metallur- gist. Since early the fifteenth century, the entire district has been populated thousands iron work- ers, blacksmiths, cutlers and weapon makers. Small iron ore deposits supplied the metal, and near the surface extremely good coal was mined, suitable for forging purposes. The small rivers, like Gier and Furens, supplied the power for the small hammers then use. The activity this district was amazing and for many centuries was the great industrial cen- ter the country. Its position France compar- able Sheffield England. was this section that the first French railroad was built; here also the open-hearth process was de- veloped the Martin brothers, and was here that chromium and chromium steels were first made. Many names linked with this district, such Creusot, St. Chamond, Firminy and St. Etienne, are familiar metallurgists the world over. About 100 years ago, the French-Belgian coal de- posit was discovered. Meanwhile, most the good coal had been removed from the mines which had been worked for the previous 400 years and, with the defec- tive methods used early mining, working the old deposits became more and more difficult. Consequently the heavy tonnage mills, making rails, structural shapes and plates, gradually shifted the north France, where the coal was better and cheaper. The steel mills the Center have had face serious problem, addition high priced coal and the difficulties working the mines. More and more, the Paris district became the greatest consuming center and Paris far from St. Etienne. Besides the district hemmed mountains, which present serious obstacle the building fast freight lines connect with Paris. Local consumption small and, since the ore mines have been exhausted for some time, ore and scrap must shipped from distant points. However, some aid the industry this district has been given the Government, which, for military reasons, does not wish have all the steel industry concentrated the North the East, where the frontier open. The national munition plants are mostly the Center dis- trict. Output Open-Hearth, Electric and Crucible Steel Another reason for the survival this district steel center that the North and the East, where the Bessemer converters can turn out thousands tons, quantity production utmost importance. the Center, where freight the big problem, only spe- cial quality material made, products which the = Paris. ore deposits shown are the Longwy and Briey districts. The mills the Briey district are marked from Nos. 14, follows: (1) Hayange, blast furnaces; (2) Pa- tural, blast furnaces, converters and rolling mill; (3) Fenderie, furnaces and rolling mill; (4) Moyeuvre, blast furnaces, con- verters, rolling mills; (5) Jamaille, rolling mill; (6) Rombas, blast fur- blooming mills, trains rolls; (7) Maiziers, blast furnaces; (8) Knuttange, blast furnaces, con- verters, rolling mills; (9) Hagon- dange, blast furnaces, converters, blooming mill, trains rolls; (10) Uckange, blast furnaces; (11) Andun Tiche, blast furnaces; (12) Thionville, blast furnaces; (13) Redange, blast furnaces; (14) Ottange, blast furnaces. The plants the Longwy district are marked from Nos. follows: (15) Longwy, blast fur- trains rolls; (16) Maubeuge, blast furnaces, Talbot- Martin (200 tons), furnaces, converters and trains rolls; (17) Hussigny, blast furnaces; (18) Gorcy, blast furnaces, furnace, converters. Berore Ore SCALE MILES H %, AFTER 1870 ++++++ACTUAL FRONTIER STEEL MILLS three great industrial dis- tricts France with iron ore and coal deposits marked are shown the map. The in- tense concentration industry the East district par- ticularly great the Longwy section, which about and embraces groups plants blast furnaces. The Center dis- trict, bordering the French was the first loca- tion the French iron and steel in- dustry. Outside these districts are few mills Nor- mandy and few the South and Southwest. The Iron Age, September | i C : JA 4 ) | o* 4 ‘ ‘ ‘ \ & CALAIS WAAST Le Navec of mousson Z NEULES STRASSBOURG | ORLEANS ln TRIGNAC 4 \ *BALE SWITZERLAND \ SENTRY =z Le Boutau cost workmanship occupies the most important place. Rails and shapes are not made, but instead the mills specialize crucible, electric furnace and acid basic open-hearth alloy steel. Most the old firms the district have purchased erected tonnage mills the North and East, but still keep their old plants running special steel. The most important these mills are: Creusot, which belongs Schneider Co.; St. Chamond, owned the Acierie Marine; Unieux, controlled the Soc. Anon. des Etablissements Jacob Imphy; Montlucon and Commentry, owned the Compagnie des Forges Chatillon-Commentry Neuves-Maisons. There are also the Soc. Anon. des Acieries Forges Firminy, producing alloy steel and malleable iron, Soc. Anon. Commentry-Fourchambault Decaze- ville and the Forges Gueugnon. these plants, the Creusot works produces semi- finished and finished rolled forged products, guns, munitions, electrical equipment, steam engines and other products. During the war open-hearth plant was built near the Creusot plant Breuil. This shop, with eight 60-ton furnaces, one the largest open-hearth plants France. The St. Chamond plant the Compagnie des Forges Acieries Marine produces quality open-hearth steel. The same company has two large works the East Homecourt and Rombas. The Unieux plant the Jacob Holtzer interests has capacity 2000 tons month, prin- cipally crucible steel, including some high grade tool steel. The Imphy works also specializes open- hearth and crucible production. The Montlucon and Commentry plants are about miles apart. The big production mill the com- pany Neuves-Maisons, and interesting add Armco ingot iron now made France this com- pany’s plants. Commentry, rolled products and tin plate are produced from the steel made Montlucon the open-hearth electric furnaces and crucibles. Large Steel Consumers North the large coal deposits, the north France very active district. this section are some the largest steel mills and many steel con- suming industries, such locomotive and car builders, machinery and equipment manufacturers, well some the largest chemical plants Europe. The steel mills are almost entirely large production units, making rails, structural shapes and heavy sheets plates. The most important these mills the north are the Soc. Anon. des Hauts Fourneaux, Forges Acieries Denain D’Anzin, with blast furnaces, converters, open-hearth furnaces and rolling mills, total pro- duction about 400,000 tons steel and 300,000 tons pig iron annually; the Soc. Anon. des Laminoirs, Hauts Forneaux, Forges, Fonderies Usines Providence, with blast furnaces, converters and open- hearth furnaces and specializing cast iron and cast steel; the works the Etablissements Arbel, with open-hearth furnaces, rolling mills and forging equipment; Soc. Anon. Metallurgique D’Hautmont; Soc. Anon. des Forges Acieries Nord L’Est; Soc. Anon. des Acieries Paris d’Outreau; Soc. Anon. Meuse; and the Soc. Anon. des Fonderies Laminoirs Ateliers Biache St. Vaast, the Pas- de-Calais. All the plants and mines this district were dam- aged and some partially entirely destroyed during the war, that they are just beginning now operate normally. Largest District the East The position France one the great steel pro- ducing nations the world largely due the East district. For long time the ore deposits Lorraine were known, but prior 1878 nobody been able produce good iron from this ore. The old iron workers called diminutive for mine, expression contempt for this low grade ore. After the war 1870 Germany took the rich plain Alsace, but left France the greater part the iron ore. few years later, Thomas and Gilchrist, two young Eng- lishmen living Paris, developed the basic Bessemer process, and this ore deposit, previously unexploited, be- came once one the most valuable the world. The ore the surface and easy work, that such quantities can extracted that supplies not only France but also the greater part the British and German industry. Boats can loaded near the mines and the ore shipped water the Ruhr and Welsh furnaces. Under present conditions more than 20,000,000 tons year can extracted. Since the war France has recovered all this deposit and part the coal mines. Some coal mined Lorraine, but the tonnage coke produced there insufficient supply the demand, that most the fuel has purchased elsewhere. The logical place the Ruhr, from which can easily shipped river Lorraine. Fifty years ago there were only few small plants this region, but the recent industrial development extensive. The high phosphorus content the ore becoming less objection the quality the steel and has been found that the high phosphorus pig iron easy melt the basic converter, the phos- phorus, burning, supplies much the heat required keep the metal molten. addition, the phosphoric acid the slag gives high commercial value fer- tilizer. One district, especially interesting, formed the three provinces Savoie, Haute Savoie and Isere. There neither coal nor ore this section, and the transportation difficult, but this district, which the Alps, has abundance “white coal” hydro- electric power. This cheap electricity used the Southeast various industries and the Alps for electric furnace production electric sheets, ferro- manganese, ferrochromium and other ferroalloys. The plant the Compagnie des Forges Acieries Electriques, Paul Girod Ugine Savoie ex- ample what electricity can steel mill. this plant, which operates nine electric furnaces, four rolling mills and considerable forging equipment, there not single boiler. The torrents nearby supply all the power for heating the furnaces, driving the mills and producing compressed air for the press and ham- mers. Lowest and Slowest Locomotive Ever Built 542—September 1927, The Iron Age THE 4-ton gathering locomotive here illustrated mentioned the lowest and slowest this type ever built. meets the demand for motive power for working thin seams in mines. It has an overall height « in. and speeds miles hour when operating ductor cable and miles hour when operating from the trolley. was shown the Baldwin-Westing- house mine locomotives exhibit the recent American Mining Congress. Some the features its design include semi-magnetic control, bar- springs and ball bearing motors. One these locomotives with drum type control now used the Er- skine Coal Co., Staunton, Va. Reversing Blooming Mill Practice Drafts for Heavy Ingots—Small-Diameter Rolls for Proper Economy—Proportioning Roll Passes cost steel ingot form, reduction handling costs and ingot-mold consumption. This may said hold good for all ingot weights likely em- ployed “tonnage” plants. not certain that heavy ingots produce better even good quality finished products. But probable that some com- parisons made the past, when the fundamental im- portance casting conditions and mold proportions were less realized than nowadays, have tended ob- scure the issue. NCREASING the unit weight ingots reduces the view the tendency toward casting heavier in- gots, necessary examine more closely the effect this tendency blooming-mill practice. The use heavier ingots entails heavier and more expensive plant and greater maximum capacity the driving unit. This results increased capital cost, and con- sequently higher standing charges, whose incidence can lessened only greater output. Therefore, un- less large market exists for the products the mill, acting powerful inducement raising its output the maximum, the more costly plant required for the heavier ingots tends increase the overall rolling costs. Large Ingots Reduce Working Costs the operating side, however, any increase the weight ingot decreases the working costs re- ducing the power used for auxiliary services, well for the main rolls. The proportion usefully ex- pended work idle work increases result the reduction the number reversals per ton, and idle running the ends passes. thus evident that, with any given installation, the greatest efficiency will attained when the heaviest ingots that the plant can deal with are employed. Proportions the ingot, important from the point view quality, are less from that rolling efficiency. the energy expended cogging function the elongation worked to, highly ad- vantageous cast ingots long possible rela- tion their mean cross-section. Dr. Kiesselbach emphasized this point article und Eisen 1920. Table gives the proportions ingots used some modern works, and shows the variation the ratio length mean cross-sectional area. Another important advantage which accrues from the use heavier ingots the reduction the weight crop ends produced per ton, and the consequent in- creased yield. Blooming mills are occasionally called upon preliminary shaping heavy character, such as, for example, large beam blanks. There least one plant where reversing blooming mill regularly rolling large-, medium- and high-carbon rounds (12 in. in. diameter). These are subsequently sliced special rotary shears into disks for feeding rolled- The author manager engineering department, Bright- side Foundry Engineering Co., Sheffield, England. The article taken from his paper read before the American Society Mechanical Engineers, local meeting Cleveland. previous portion the paper appeared THE Ace March page 638. steel-wheel mills. [See THE IRON Sept. 16, 1920. pages 704 Limits Size Bloom