The Iron Age 1927-11-10: Vol 120 Iss 19

RON AGE New York, November 10, 1927 ESTABLISHED 1855 VOL. 120, No. Tendencies Material Handling Combination Systems Needed Fit Most Cases—Increasing Size Units— Financial Aspect SIDNEY KOON* situation with regard the handling materials the realization that one system suitable for all the operations most plants. Flexibility secured combining systems, some overhead, some the floor, conveyors, etc., and some other and more mobile types. Each plant presents separate problem and each are found, for the most part, varying combinations the principal mechanical methods. Generally speaking, handling systems may di- vided into four types—overhead, conveyor, vertical and mobile. The overhead system, fixed position, includes electric traveling cranes, jib cranes, telphers and mono- rails, the equivalent. The conveyor system, again fixed position and sometimes overhead, includes the the outstanding feature the present *THE IRON AGE, New York. chain type, buckets, aprons slats, screw conveyors, the gravity roller type, chutes, and special cases such where projecting lug moves carriage other unit its own wheels rollers. Vertical sys- tems, also fixed position, are primarily elevators. Mobile systems include the electric truck, tiering and other elevating machines, the caterpillar other form tractor, portable conveyors, often the roller type, lift and push trucks, drag tote boxes, dollies, motor trucks and locomotives operated steam, gasoline, electricity air over industrial standard-gage tracks. Chain and air hoists and lifting magnets form elements several the systems named. Fundamental Principles Enunciated Two fundamental principles modern materials- handling installations were stated the 1926 conven- Core Room, Showing Left the Suspended Carrier Racks Which the Cores Are Run Through the Oven Above and Baked. This the diagram page 1295 1293 4 TT | a é a | al 3 4 tion the American Foundrymen’s Association fol- lows: Increase the size the unit production. Pick load where and take its des- tination without rehandling. example the first principle—which could multiplied many times many industries—is from the practice wire mills. place the bundle rod, which the practical limit man’s strength lift off the draw-block, now use bundles 350 Even 1000 Ib. talked of. This means longer machine runs and permits one operator attend twice many blocks. the second principle, also, many instances might cited, but one will suffice illustrate the applica- tion. Two photographs and one sketch show how cores are handled, the baking, automobile shop. aor ment, course, would not adequate where frequent movements are necessary. other cases wide diversity equipment used. One machine tool builder Cleveland has over- head electric traveling cranes, tramrail system, chain block hoists operating from I-beams, electric elevating trucks, tiering machine, hand-push trucks and drag boxes, all operating the same plant, and frequently two three these conjunction with each other. this plant some the overhead cranes, high 5-ton capacity, are operated hand through differ- ential blocks, because infrequent use the places where, nevertheless, their presence imperative. Diversity again found the method handling the pieces. They may carried racks, core rooms, baskets buckets tote boxes. they may handled single piece time, either End Core Oven, Opened Show Rack Ascending Its Course Through the Oven. This the diagram page 1295 They are put the carriers, directly from the ma- chines and benches the core room, and elevated, the slowly moving mechanism, through the ceiling and into the oven. Here they are traversed back and forth until thoroughly baked and then lowered, removed for use, thus releasing the conveyors for new lot. This excellent example continuous baking, and the conveyor never stops. Contrasting Examples Practice Each the many types unit has its own partic- ular use and performs its own service the general scheme things. machine shop Philadelphia doing very heavy work uses practically nothing except the overhead electric traveling cranes, together with hand-trucks. Railroad tracks run into the plant and, when locomotive not available for spotting car where wanted, the car moved the hoist electric crane, operating through snatch block. Hand- trucks, even with heavy castings, are pushed along manual power either the broad-gage tracks in- dustrial tracks. Where too heavy for this, the crane and snatch block system employed. This arrange- 1294—November 10, 1927, The Iron Age conveyor suspended from overhead equipment, truck. various forms containers used for various purposes, many are the self-dumping type, particularly where bulk material handled where castings forgings are being delivered. Changes Unit Size Equipment Among the tendencies which have been noted the past few years has been steady increase the size the units handled. This has resulted developing electric trucks, for instance, tons capacity —practically doubling the power the equipment only three years ago. Simplicity design and the extended use anti-friction bearings have accom- panied this change. One maker heavy overhead cranes estimates that his machine tools being served these trucks are operating per cent more effi- ciently, and reduced auxiliary labor cost. one particular there has been decrease the size the unit, due special conditions. This condition true the crawler locomotive crane, which has large extent replaced the steam loco- motive crane operating fixed track. With the fixed track the limit coverage area depended upon the length the boom. Heavy loads could not handled radius ft. from the track and booms which could handle light loads that distance were inordinately long for closer handling. meet this condition the crawler crane, which can over rough ground and independent any track, has been built, with much shorter booms and capable handling heavy loads, but small radius. This has improved the flexibility operation enor- mous degree and the machine much less expensive piece equipment. These machines frequently are fitted with gasoline engines, which again has simplified many the problems control. Operation may both indoors and out, and often combination the two. Making Operation Flexible and Automatic Flexibility has been emphasized recent years what required the lowest cost and the most Bare Pieces Bare Pieces Molding (Below) Show- ing Handling Shakeout Sand and Castings. Each man takes his molds from the mold conveyor, swings them the shak- ing grate and dumps them, throwing the bottom boards back conveyor. Sand falls through the grating and the castings are shaken down the cooling conveyor expeditious manner, and flexibility the individual unit, its control, its ease operating around ob- structions and its applicability narrow spaces pre- viously thought unsuitable for such equipment. The flexi- bility the system has taken the form particularly adapting various types units various classes service, and welding together the entire category equipment provide the most serviceable and the least expensive operating conditions. Automatic control has come the fore and prob- ably due occupy larger position the future than has yet been attained. Cases are not isolated where overhead system has push-button control start load, switch off without further attention into predeter- mined part the plant, stop the desired position and even, occasion, discharge the load that point and return the empty container. Some these automatic systems have intricate switching mechanisms for switching the articles into the different stations for assembly manufacture. Others include automatic elevating and transferring schemes. They have been applied such heavy ser- vice transformers and motors weighing hun- Unloading Ba ke d Preces dred pounds the unit. Customarily, however, this method not largely employed manufacturing proc- esses, though might readily find use when delivering material ovens stockrooms, otherwise where certain bulk has handled. Speed Determines Capacity Synchronizing various operations has been at- tained through developing definite, carefully chosen speed progress and making other movements live it. While this speed may more than would considered normal, its regularity and relentless preci- sion have operated advance the average speed, through cutting down what previously was occasional lost time. this way greater production has been secured from the same total man-hours and, reason the help afforded the men the conveying system, without added fatigue. Rest periods may imposed such system inserting occasional empty container, space, between active elements. Higher speeds are attained the newer systems, AYOUT Carrier Conveyor System Sheet Metal Plant (at Left). Pieces taken from carriers hand are dipped and then hung the chain con- veyor drip. they are taken off hand and placed another carrier for passage through the oven End less Chain Conveyor Ng and oadirg spend Trays Over eg ORE Baking (Above) Means Continuous Chain Load- ing and Unloading Core Room Below the Oven. The conveyor does not stop and all parts the equipment are kept and refer photographs however, than were ever before employed. Where the operator rides the carriage the speed may reach 600 ft. minute, while 300 ft. has become fairly com- mon. instance how work speeded mod- ern equipment afforded large warehouse Ohio. Here, motor-driven carriers riding overhead tramrails are used taking orders for widely dis- similar goods out storage. The circuit 1200 ft. covered minutes, despite numerous stops place material the carriers, for the traveling speed uniform 300 ft. minute. Formerly, when similar carriers were pushed hand along the floor, took minutes complete the same circuit. Four men were required, against two now, handle the work each carrier; and three the new carriers are doing all that five the old ones were doing. This means six men, place twenty. Design and Manufacture Equipment the manufacturing side electric welding com- ing rapidly into use. Some companies are making more use than riveting. other cases, yet only experimental stage. There The Iron Age, November 10, 1927—1295 i Oven B Japanrnire Vat A A Hai (Ta hakirg COs 75 Conveyor Flask 7 Shakir 7 { vey Crate | ; \ \ Molding Machine: 7 doubt, however, that will expand greatly the near future, both its use and the general con- fidence with which users will view it. Complete Change Method Approach Within the past dozen years there has been entire overturn the method getting the materials- handling problem. Formerly was the practice supply equipment asked for the purchaser. some cases, course, modifications were proposed and accepted. Today, however, the inquirer’s statement his needs taken merely starting point. The materials-handling manufacturer then makes inde- pendent survey, with the background his own expe- rience. This places upon the problem equipment engineer familiar with such analyses wide variety cases. almost always results radical changes the original proposition. coming more and more recognized that the proper time attack the materials-handling prob- lem before the factory built. Sometimes whole section the floor new factory the conveyor. with the remainder the floor, but built into the design give the best possible oper- ating results. not few cases the operating elements, including the arrangements for handling materials between the operating units, are designed mechanical whole. Then, when this has been completed, the building designed contain this mechanism. This method attack regards the building merely housing for the operating elements. Interrupted Operation One plant making large line pressed metal parts for automobile and other use interrups the con- veyor system the dipping vat for japanning. The diagram shows the general layout this equipment. Pieces are brought overhead tramrail carriers, taken hand from those carriers and dipped the vat and then hung another carrier, which moves the left over the drip area. From this second carrier, which operated endless chains very low rate motion, the pieces are removed hand and placed again upon suspended carriers the overhead system, and identical with those which brought pieces originally Newport Rolling Mill Co., Newport : y | iVewport, workman large board man saw 1296—November 10, 1927, The Iron Age impress upon its em- ployees the responsibil- ity each man has for pre- venting Ky., recently used novel device. the entrance the plant through with curtain covering it. the curtain was the caption, “The who can keep you from getting hurt this curtain.” ing the curtain the work- himself mirror the carriers the overhead-rail system are pushed hand from place place, from the loading locations and through the oven, would seem feasible arrangement have that same system operate over the dip vat and drip area, and thus run the car- riers japanned articles into and through the oven without the manual rehandling Considered Investment One phase the whole subject which has never been sufficiently emphasized lies the financial end the matter. This ties not only with cost account- ing, but also with the question investment equip- ment. not merely case knowing how much the different operations have cost, compared with the pre- vious cost doing the same work; there also importance knowing what return may had upon given investment mechanical contrivances installed supersede manual effort. Many plants will not install $5,000 handling sys- tem unless they can see clear-cut saving much the initial cost single year. However, that equipment should save $2,500 manual labor during the year, and should depreciate require maintenance the extent $500, evident that has paid per cent return upon the investment. This same measure return may expected during several ensu- ing years and this particular case the equipment would fully paid for months. After that would continue earn rate the order $2,000 year long its useful life lasted, over and above all expense. Obviously, banker entering into negotiations finance company, lend money upon going con- cern, should impressed with equipment with such possibilities. Comparing two plants, one which had the equipment while the other the work was done hand, the banker would more ready advance money upon $5,000 materials-handling machinery than upon equal amount last year’s canceled pay checks. asking for 100 per cent return year, manu- facturer demanding far more than, general, can obtained from any other investment has ever made. Certainly asking much more than most his customers can obtain through what they buy from him. 34 Upon rais- reflection Draws Attention Accident Prevention Work ‘= ~ 4 High-Speed Continuous Rod Designed for 100,000 Tons Year 2200 Miles Day—Quick Change from Old Mill NEW Morgan billet mill and rod mill were re- cently completed and put operation the South works the American Steel Wire Worcester, Mass. The rod mill said roll wire rods faster rate than they were ever produced before either America abroad. Where the previous max- imum delivery speed was 3500 ft. rod minute, the new mill will roll 4000 ft. minute. Capacity output hr. 2200 miles wire rod. Annual output about 100,000 tons. The mill replaces two the old rod mills the Worcester plant. The third will rebuilt, and when operating will bring the total annual production rods all sizes and shapes South works 150,000 tons. This new mill the first the United States pro- duce rods 400-lb. bundles. also the first the world roll coils this weight small size No. which means diameter 0.177 in. fact, the Worcester works the only plant this country draw wire from rods small this. Heavy-tonnage products—barb wire and heavy fenc- ing and the like—are not manufactured Worcester, but are centralized the company’s plants the Mid dle West. The Worcester works given over spe- cial wires, many them demanding the highest grade raw materials. These include such products watch springs, music wire, and the flats from which safety razor blades are fashioned. Quality and uni- formity are essential. The new mill accomplishes these things. Its rods are much more nearly round than the old mills, they have less scale and the bun- dles are better shape, which not only expedites wire drawing, but cuts down important way the amount scrap. Moreover, the cost manufacture has been reduced compared with the cost inferior rods the plant which the new mill replaced. Adaptability Billet Mill Unusual The billet mill unusual two respects: slight adaptation the spacing the roll stands makes possible roll standard copper ingots well blooms. The copper ingot will heated furnace, while the steel bloom rolled from the initial heat the ingot, now customary plants making small billets. The other distinctive feature provision for rolling, shearing and cooling slabs, in. thick and in. wide. vertical mill has been provided edge slab sections various widths. the new billet mill will therefore possible produce steel and copper bil- lets several sizes and wide range slab sec- tions, without changing rolls guides. These new mills have their historic and sentimental side. They assure Worcester the permanence the manufacture, from raw material, the intermediate product from which wire drawn. This plant now the only steel-making plant the State Massachu- setts. The first continuous mill America was installed Worcester 1869. was Bedson mill, one this type being operation England. soon the Washburn Moen people learned engineers were sent abroad observe it, and the result was the plac- ing order Ichabod Washburn. The Worcester mills, then operated the Washburn Moen Mfg. Co., and now the American Steel Wire Co., have been rolling wire rods the continuous process ever since. JOHN NELSON Installation modern rolling mill the site old mills built many years ago involved many prob lems not encountered new site. included not only new sewers, foundations, buildings, cranes, miles electric cables and wires, transformer houses, electric sub-stations, miles water and oil piping and changes railroad tracks, but also removal thousands tons old machinery and foundations, and blasting several thousand cubic yards granite ledge. excellent example what can done intelligent cooperation, the staff South works made the following record conversion old plant new: Plant down Friday night, July rolled billet mill about m., Aug. 10; first wire rod (No. rolled and coiled reels, Aug. 27. Ingots in. square, weighing 4400 lb, are reduced the blooming mill 5-in. square blooms. The old billet mill took 4-in. blooms. Because the fewer passes required it, the capacity the blooming mill cor- respondingly increased. The billet mill has six stands 18-in. rolls, which reduce the 5-in. blooms 2-in. bil- lets. The Edwards flying shear cuts them 30-ft. length, produce the coil rods. There are two cooling tables, one beyond the other. One may used for copper billets, one for steel. They are located the new billet-storage building, which runs right angle the mill and 400 ft. long and ft. wide. Its entire floor served traveling crane. The cooled billets, gathered from the cool- ing tables bundles with chain, are conveyed either the rod mill storage piles. closed Finishing Roll Trains Are Separate The rod mill follows the general line all Morgan double-strand mills, except that the rod finished separate trains rolls. This means that, while two billets pass side side through the roughing and in- termediate rolls, each the two finally enters sepa rate train rolls. The arrangement split-finishing makes safer mill operate and also permits rolling smaller and more nearly round rods than possible mill rolling double line rods all the way through. and intermediate rolls have their constant speeds. The finishing rolls are driven adjustable- speed motor, control which the hands erator perched above pulpit. His duty keep the speed the finishing rolls synchronized with the flight the rod comes from the intermediate rolls. They must not running too fast when they receive the rod. Nor must they run slowly not able take care the quick-moving metal when reaches them. mill where rods constant size are rolled this auxiliary control might not necessary. But this new mill specialty mill, designed produce various rod sizes. Each the two trains finishing rolls deliv- ers its rod automatic reels the laying type, Washburn Moen invention many years ago. Each train has two such reels, which are inclosed. catches the rod, coils the required high speed and then collapses, permitting conveyor move the bundle onward for the cooling. Thus the two reels al- ternate use, one coiling while the other delivering. highly important that wire rods have little scale possible. this mill they are made pass slowly, conveyor, through long water-cooled muffle chamber. This ascends rather steeply. Cast its upper face are many trays opening one into the The Iron Age, November 10, 4 7 ; 4 | 4 i ‘ = other. These are kept filled with running water, which pours from taps into the upper tray and cascades down from one tray the next. Because the conveyor tightly inclosed, oxidation minimized. Emerging from the chamber elevated plat- form, the coils are still hot, though longer red hot. The remainder the cooling done the open air. Passing the platform hook carrier which moves snail’s pace, and this each succeeding coil trans- ferred action lever. makes long journey before delivers its cooled load, for doubles upon it- self again and again, its total length being 675 ft. The rods are the air for many minutes before they reach the railroad car upon which they are deposited for de- re 10, 1927, The Iron Age a OOLING Tables and Storage Build- ing the New Billet Mill South Works. sec- ond cooling provides for copper rods bars livery South works mill storage, for trans- fer North Central works. All air entering the motors the new mills fil- tered. All bearings are made for stream lubrication and the oil which lubricates them filtered every min. Each big motor has its “break-shaft,” de- signed give under extraordinary strain. Power required drive these mills and auxiliary equipment applied through electric motors, which total 7645 hp. These replace eight steam engines which provided the power for the old mills. fact, abandon- ment the steam plants was necessity, that the new mills might erected congested place like the South works. All the area occupied the steam plants OD-COOL- ING End Works with Water Cooled Cham- bers and Hook Conveyor. the conveyor the final cool- ing, the air, takes place low tures Mill South American Steel Wire Co. with Ca- pacity 100,- 000 Tons Year. Safety ing the roll trains are noteworthy was required. The result ample room not only for the mills themselves but for the storage semi-finished and finished material. The steel mill somewhat departure from established custom, not because electrically driven throughout, but because receives its power from outside the works. Most the current comes from far distant hydroelectric stations the Connecticut and Deerfield Rivers. times low water power comes also from steam plants Providence, Worcester, Bos- ton, Fall River and Connecticut cities. The New Eng- land Power Co. furnishes the current, which enters the plant 13,200 volts and there transformed 2200 and 600 volts, which operates the motors. MERICAN Wire Co. New 18-In. Billet Mill South foreground the Edwards flying shear, cut billets required length with- out stopping their rapid run Were this outside power from any single source would not have been considered dependable. plant this sort continuous operation indispensable. Cut- ting off power might have costly consequences. But South works less than four miles from the New Eng- land Power Co. substation Millbury, where current received from many sources, both hydraulic and steam. Ten high-tension lines converge there, traveling over six separate rights way. Power from Millbury passes the works over four feed wires, carried three sepa rate pole lines over two rights way. The chance these power sources failing simultaneously consid ered negligible. And, final resort, two additional cables connect with the local electric light company. The Iron Age, November 10, 1927—1299 J 4 = @ 1 — Blast Furnace Coke, Centrifugal Pipe and Steel Mill Boiler Plant Discussed Before Steel Institute ESIDES the two papers “The Evolution the Wide Strip Mill,” Stephen Badlam, con- sulting engineer, Pittsburgh, and “Techno- logical Problems the Steel Industry,” Forbes, assistant the president United States Steel Corporation, New York, there were four other papers presented the annual fall meeting the American Iron and Steel Institute the Hotel Commodore, New York, Oct. 28. Abstracts and discussions the papers Mr. Badlam and Mr. Forbes were published THE IRON AGE Nov. Brief abstracts and discussions the remaining four papers follow. Behavior Coke the Blast Furnace JOSEPH URNACE operators often find difficult relate the physical and chemical properties coke its behavior the blast furnace, and result satis- factory standards coke quality have been developed. The failure define clearly the properties coke doubt partly responsible for retarding progress some measureable property the coke with its performance the blast furnace. [The author’s paper printed pages thor- discussion the meaning combustibility and methods measuring it, the investigations the United States Bureau Mines the penetration and combustibility coke, size combustion zone and size coke, fast-burning coke and other Mr. Joseph’s summary and conclusions are fol lows: 1.—It believed that failure define the proper- ties coke clearly partly responsible for retarding progress correlating coke properties and furnace practice. Combustibility coke has been widely dis- cussed the technical press and many views have been what constitutes differences combus- tibility and how such differences may measured. combustibility, property the fuel, dis- tinguished from rate combustion, factor controlled rate air supply, the term value relating coke quality and furnace practice. Highly combustible coke will not burn faster before the tuyeres than less combustible coke, but will burn smaller volume. The size the combustion zone, controlled largely the size the coke, affects the working the furnace with respect the furnace walls. More combustible coke shifts the position maximum nearer the walls and results concentration heat toward the periphery the furnace the tuyere level. The size the combustion zone affects the descent the stock the furnace. The predominating tendency for the material feed directly into the zone where the coke shrinking result combustion. Mechanical agi- tation the blast important, but there are data relate the various properties coke. Gas sam- ples taken from the tuyere level and observations Perrott and Kinney when forcing water-cooled sam- pling tube into the center the furnace indicate that the mechanical stirring does not extend beyond the zone active combustion. the combustion zone becomes smaller would appear more difficult for the coke move into the zone combustion. conditions the fuel bed hand-fired lab- oratory furnaces, designed determine differences combustibility, are different from those existing the tuyeres blast furnace; therefore the distance re- quired burn completely hand-fired furnace cannot taken measure the distance required accomplish this result the blast furnace. The dis- 1300—November 10, 1927. The Age tance from the grate bars required burn completely the approach saturation the gas with carbon, shown the gas composition any point the fuel bed, can used measure relative com- bustibilities, under properly controlled conditions. blast furnace conditions fixed amount air will consume definite quantity carbon front the tuyeres. Variations the carbon gasified contact with outside the tuyere zone will affect the number charges per day, when the wind remains constant. Data representing wide range operat- ing conditions and various types coke show that the average amount carbon gasified above the tuyeres surprisingly constant. Extreme cokes show differ- ence reactivity with CO, temperatures 950 1000 deg. C., but the difference for two cokes about the same type small. Conditions which control cal- cination limestone and reduction the ore before reaching temperatures which CO, will react rapidly with coke even smal! reactivity are believed fluc- tuate more than coke made under modern oven practice. Progress toward larger production per furnace has been attained increasing bosh and hearth diameters and some cases blowing more wind per unit vol- ume the furnace, but not per square foot hearth area. Hearth areas have increased about since the days hearths, whereas the volume has more nearly doubled, 5.—The use Mesabi ore presented new problem blast furnace practice, namely, that moving large quantity fine ore under the force gravity, countercurrent large volume gas. Present prac- tice seems have settled upon big bell clearance which produces dense periphery and porous center, the latter acting relief valve for sufficient gas permit regular stock movement. The dense periphery was also adopted decrease lining renewals. 6.—One important function coke decrease the resistance the charge gas flow. This function, which more important with the use fine ore, more satisfactorily performed large pieces coke low density which will retain their size until reach- ing the tuyeres. 7.—It appears that the physical properties coke bear important relation the physical and me- chanical problems presented process. Discussion means for quantitative evaluation the properties coke are badly needed, the opinion Peter Dolan, superintendent blast furnaces, Bethlehem Steel Cor- poration, Coatesville, Pa. Until these matters are cleared up, the operator will handicapped the log- —— — present supervising engineer the North Central Experi- ment Station the Bureau Mines Minneapolis, Minn., Mr. Joseph was born Beaver, Utah, Sept. 12, 1894. ated from the University Utah 1917, became chemist for the International Smelting Refining Co., Tooele, Utah. resigned this position join the Army during the war. war became metallurgical chemist the Bureau Mines ex- periment station Pittsburgh. 1922 ical utilization blast furnace cokes, and will un- able find the best operating technique for given fuel except trial and error. quoted data from three plants illustrate the present conditions. Furnace Operation Must Now Adjusted the Coke certain plant two adjoining furnaces are fed the same mixture hard magnetic ores, Lake ores and cinder. The normal production these two furnaces are respectively 425 and 550 tons per day when using coke made 50:50 mixture high volatile and low volatile coal—coke which can graded “fair.” subsequent campaign using brittle coke made one coal medium volatile content (but the coke analyzed much like the former) the production the smaller furnace was maintained without difficulty any but production the larger furnace fell 450 tons, the wind had reduced from 43,000 40,000 cu. ft. per min., high tuyere losses were experienced, much off-grade iron and excessive flue dust produced. The coke broke badly the big furnace, reaching the tuyeres pea size. another plant operating Lake ores, the fur- naces are two groups, one using coke and the other coke Coke made per cent low vola- tile coal, and per cent high volatile. For coke the proportions are reversed. The two fuels test fol- lows: Coke A, Coke B, Per Cent Per Cent Fixed carbon .... 85.0 Shatter test, per cent in..... Furnaces using coke have 18-ft. hearths; they make 600 tons pig per day with 200 flue dust per ton pig. Furnaces using coke have 18-ft. in. hearths; they make only 575 tons pig per day and produce 400 lb. flue dust per ton. Upon being gradu- the close the was assigned his present position. member the iron and steel committee the American Institute Mining and Metallurgical Engineers and belongs the American Society for Steel Treating. awarded the Johnson, Jr., award for 1927, the and i Mr. Jose ph was third plant uses surplus coke made another iron company. The coke producing company gets 500 tons pig iron day out its furnace rated 550 tons; the operator says the coke “too soft.” This same coke sold another furnace, when used stack rated 250 tons, able produce 325 tons pig iron daily. Such occurrences led Mr. Dolan conclude that the best coke use one furnace and for one ore may not nearly the best when charged under differ- ent conditions. The main thing get the coke the tuyeres sufficient quantity and proper condi- tion the work, and the speaker said that the best way insure this condition regularly screen out the fines and charge properly sized coke. Cooperative Tests Carnegie Steel Co. Commenting upon the excellent work already done the Bureau Mines, Maccoun, superintendent Edgar Thomson blast furnaces, Braddock, Pa., said that only through the intelligent help the whole in- dustry could the many remaining problems coke solved. Realizing that ill-defined “quality” and “combustibility” coke have the greater influence furnace operations, the Carnegie Steel Co. organized the blast furnace and coke oven cooperative committee look into the matter. This committee has already investigated many problems and verified disproved the solutions running extended campaigns the ovens and blast furnaces. instance, Mr. Maccoun that was one time agreed that better coke would have more vola- tile matter. Consequently the normal coking tempera- ture 1850 deg. Fahr. was reduced. But the blast furnaces using this material immediately developed serious irregularities. Evidently lower coking tem- perature wrong. Then higher temperature was tried, with improved blast furnace performance. NATIVE Indiana, Mr. Kintner received his technical edu- cation Purdue University from which was graduated 1894 electrical engineering. little later became assistant Professor Fessenden the Western University Pennsylvania and succeeded Professor Fessenden professor engineering. worked many investigations Hertz, X-rays and other similar phenomena. Following the war, negotiated sale the West- inghouse company the company’s patents radio apparatus, and after spending about two years with the Westinghouse company assisting its radio developments, was appointed manager the research department, which position still holds. The Iron Age, November 10, 1927—1301 J 4 3 a | q a 4 a > 7 . the end was demonstrated that the higher the coking temperature, the harder the coke which could made from 100 per cent charge high volatile coal. This fuel turn permitted more wind the blast furnaces, higher tonnage and more uniform iron. Similar correlated experiments have enabled the ovens make extremely good coke from coals ormerly thought worthless. has later been proved hat the coking temperature should vary directly with the fusion point the ash. Slate must eliminated from the coal, because the coefficient expansion slate and coke are quite different. slaty coke the blast furnace causes much cross fracture and produces much That this problem not yet completely solved indicated Mr. Maccoun’s remark that some cokes, which should graded “good” all preliminary tests, still break badly the furnace, thereby slow- ing down the output, and making much top dust. The speaker also presented data supporting Mr. Joseph’s contention that the zone intense activity near each tuyere, that the most rapid movement funnels discharging into these zones, and that move- ment stock down the center the furnace fre- quently extremely rapid. Venturi tests the air en- tering different tuyeres normally operating fur- nace show fluctuations from mean much per cent, these fluctuations lasting for short time in- tervals. This indicates zones intense and varying activity each tuyere. Mr. Maccoun also emphasized the well known fact that the charging routine has great influence the distribution sizes furnace. Fragmentation coke the furnace must avoided, and the Carnegie Steel Co. has extended experimenta- tion under way discover whether careful sizing coke will able control this factor. Knowles Glow Tube and Similar Recent Developments RACTICALLY the whole this paper consisted demonstration some the recent advances made possible the development the vacuum tube. The apparatus demonstrated consisted the main tubes and circuits through which the tubes could energized, together with two-part loud speaker con- nected with Victor talking machine. One industrial use pointed out was the vaporizing and condensation va- rious metals obtaining materials the highest chemical purity for the purpose studying their prop- erties. The transcontinental telephone has been di- rect result this line development. The speaker pointed out that, while amplification only possible multiply the number stages indefi- nitely and thus obtain magnification even 100 million. The loud speaker development was referred possible future replacement for orchestras cafés, small theaters, dance halls, and possibly even churches. KINTNER The Knowles grid glow tube was demonstrated, with particular reference the approach airplane. operates sound definite, predetermined pitch number vibrations second. means this opera- tion, flood lights automatically may turned field facilitate landing the plane. These would then turned off only manual effort, even though the sound the plane’s engine disappear. What was stated the largest amplification any known de- vice single stage was also shown, the shape silver-lined sphere operated the approach the human hand means light signal. was used the demonstration move back and forth Willys- Knight car behind the speaker’s stage, the movement being controlled the free motion the operator’s hand the air over the sphere. was this same de- vice which Judge Gary used last spring starting from his office New York the operation large blooming mill near Pittsburgh. (See THE IRON AGE June last, page 1809.) Iron Pipe Centrifugally Cast Sand Molds JAMES NLY the last two decades does the sand mold appear have been considered connection with centrifugal casting, and until the development the process now under consideration one was able overcome the difficulties which confronted him. The reason for using sand mold obviously de- sire preserve those qualities which have made cast iron pipe the standard pipe for water and gas mains throughout the civilized world. The centrifugal process gives certain fundamental advantages: the degree bachelor civil engineering and master arts, Mr. MacKenzie was graduated from the University the South 1912. was born 1891 Brooksville, was employed the American Cast Iron Pipe Co. Birmingham chemist, and since that time has had various operative and research assignments with that company, becoming chief chemist 1915, which position now holds. member the American Foundrymen’s Association, the American Society for Testing Ma- terials, the American Ceramic Society, the American Chemical So- ciety, the American Electrochemical Society, the American Mining and Metallurgical Engineers, and the Iron and Steel Insti- also cooperative analyist with the United States 1302—November 10, 1927, The Iron Age In 1912 he MACKENZIE section and soundness section. The combination, therefore, centrifugal casting and the sand mold gives the same time sound, even casting true gray iron structure with consequent strength, resilience, machinability, and resistance corrosion. history the new process given the author. complete description the process was published THE April 15, 1926, page 1055.] Microscopically the iron is, pit-cast pipe, pre- dominately pearlitic. Combined carbon will average j \ > per cent, which, with the usual analysis 1.60 per cent silicon, 3.50 per cent total carbon, and 0.70 per cent phosphorus gives only pearlite, graphite and the binary phosphide eutectic, the latter being about ten times the phosphorus, per cent. author presents photomicrographs the iron cast the old and new process.] Fine graphite arranged whorls characteristic the centrifugal pipe, beginning almost immedately the outer edge and growing very slowly the inner surface. The pit cast close structure both edges with graphite tending globular form, while large area the middle decidedly flaky. The struc- ture, when consisting fine leaflets, this case, markedly superior physical properties the flakes. The pearlitic matrix gives maximum resilience without tendency brittleness, and will noted that the phosphide small discrete particles, which not interrupt the continuity the pearlite. The iron used, melted very hot, intrinsically stronger than that commonly used the old process there not the difficulty casting encountered the old method with superheated metal. Slow cooling per- mits the iron develop flexibility with strength and the superheating serves dissolve graphite nuclei present colder melted irons. The advantages superheating cast iron have been recently demonstrated Professor Piwowarsky Aachen, Germany, who showed that heating cast iron sufficiently high temperature the graphite nuclei are dissolved and not form again until the freezing point the liquid reached. then too late for form coarse particles. This principle physical chemistry, long known science, has been only recently applied the metallurgy cast iron, but very probably responsible for some the increased strength obtained this product. This process peculiarly adapted the production special materials small quantities, alloy additions per cent being easily made the iron the individual foundry ladles. Thus, the use chrome, nickel, copper other alloys, tubes excep- tional strength, flexibility, resistance abrasion Steel Mill author described new boiler plant the South Mills the Aliquippa Works the Jones Laugh- lin Steel Corporation, Pittsburgh. explained that account the abundance cheap fuel the boiler house was not equipped “to capture and hold the last B.t.u.” but goes far economical from finan- cial standpoint and possesses reliability, simplicity and flexibility well adapted carrying steel mill load satisfactorily. The plant contains single row five boilers 1900 nominal horsepower operate normally about 200 per cent rating. The boilers are fired NATIVE Westchester County, Y., Mr. Mekeel was gradu- ated from Haverford College, after which went work for the Cambria Steel Co., Johnstown, Pa. was employed that company the construction its plant Lorain, Ohio, which now unit the National Tube Co. Jones Laughlins, Ltd., Pitteburgh, Cleveland, and the Jones Laughlin Steel Co. successors, has been employed for the last years, the last which has been the chief engineer the Jones Laughlin company. was employed successively the Cleveland Rolling Mill Co., and their successors, the American Steel Wire Co., special corrosive agents may made any desired quantity. MacKenzie this point discusses quite fully the comprehensive series tests made Prof. Talbot, University Illinois, which presented the 1926 annual meeting the American Society for Test- ing The outstanding merit this product that gives homogeneous, sound, close-grained iron, which tough, strong, resilient and easily machined. shows approximately per cent greater strength than ordinary sand-cast pipe both bursting and trans- verse tests. shows greater resistance impact and greater bending ability. true gray iron and possesses the granular structure peculiar gray iron, which has most successfully resisted corrosion the past, may expect that the new product, account its slightly greater density and homogeneity, will better this respect. Discussion John Capron, research engineer, United States Cast Iron Pipe Foundry Co., called attention the fact that centrifugally cast pipe improves the product well the process, matter whether the rotating mold lined with refractory permanent iron mold. This increase strength the pipe due several factors, pointed out Mr. MacKenzie. Mr. Capron inclined believe that much due im- proved iron, and surmises that this done the Birmingham district the use steel scrap the furnace charge. “While sand-spun pipe stronger and stiffer than the old style pit-cast pipe, Prof. Talbot’s results show that pipe made rotating permanent molds has still greater physical values. While opinion differs the real significance these properties, the Federal Specifications Board has taken note them its “master specifications” for centrifugally cast pipe follows: Made Made Permanent Sand Molds Lined Molds Maximum secant modulus of elasticity > 15,000,000 10,000,000 Minimum modulus rupture Boiler Plant MEKEEL with pulverized coal. Unit-type pulverizers with air register type burners are used. Although they are not quite high efficiency the central pulverizer plant, they cost somewhat less and, with the low cost coal prevailing the plant, are expected produce lower over-all steam cost, fixed charges considered. Air preheaters were also ruled out because, with the low fuel cost, the improvement efficiency would not produce sufficient saving return satisfactory profit the additional investment required. Pulverized fuel burners use current air for these and their eee tee ee ee | The Iron Age, November 10, 7 transporting the powdered coal the burner and into the furnace. This “primary air” not sufficient for complete combustion, and “secondary air” drawn through the furnace front and side walls and delivered the burners individual fans. Each boiler provided with two alternating current motor-driven unit-type pulverizers and two burners having combined capacity 20,000 lb. coal per hour, which sufficient run the boiler about per cent rating. One pulverizer and burner can operated produce from per cent little over 150 per cent boiler rating. Coal conveyed the boiler house inclined belt conveyor from the main mill receiving and crush- ing plant. delivered directly into overhead pended steel bunker having capacity 2000 net ns, sufficient*to operate the boiler plant for hr. Chutes leading from the bunker each pulverizer are NEW ENGLAND’S POSITION Industrial Era Leon Alden, industrial engineer Thompson-Licht- ner Co., Inc., Boston, was the guest the Boston branch the National Metal Association Wednes- day evening, Nov. Hotel Essex, Boston. His ad- iknesses New England industry. contrary the general belief else- lustry those States has, however, certain problems vhich are fundamental and which must corrected. mind which purely regional; taxation, which retarding growth the region; general weakness selling his opinion, are state and merchandising product, because too many manu- facturers fail realize that selling has become sci- problem; general lack group effort; and, lastly, but his opinion most important ecutive appre nticeship. Mr. Alden’s remarks concerned particular branch industry, but New England industry collectively. Improved Industrial Activity Reported from New England The Whiting Machine Works, Whitinsville, textile machinery, operating close per cent capacity. The Seth Thomas Clock Co., Thomaston, Conn., has gone 50-hr. per week schedule, contrasted with heretofore. The Plume Atwood brass foundry that town now operating 55-hr. per week schedule. Transfer two-thirds the stock the Cheney Wire Works unnamed interest Presi- dent Tucker announced letter the minor- ity stockholders, which states that they may share the stock transfer $145 per share. organized 1842. The new Bath Iron Works Co., Bath, Me., which take over the major part the Keyes Fiber Co.’s interest the old Bath Iron Works, has contracts build several large yachts and soon will begin tion. The Stanley Works, New Britain, Conn., operating slightly under the 1926 schedule, but 1928 production estimates run ahead pre-war years. The Colt’s Patent Fire Arms Mfg. Co., Hartford, Conn., producing fire arms normal basis, with unusually large contracts hand. particularly active making washing machines, mo!ded products and electrical appliances. The Saco-Lowell Shops, Boston, textile machinery makers, are considering either moving their Lowell, Mass., business Biddeford, Me., the Biddeford The company was 1304—November 10, 1927, The provided with gates which may operated chains from the operating floor. The foundation for the plant presented puzzling problem. had been the intention use spread foundation directly top the slag fill, but ground drillings showed ft. mushy clay under the slag, and below that about ft. sand and gravel bed rock. bank nearby, was feared that the soft material might pushed out. was considered impracticable drive piles through the slag, and was first believed necessary excavate the clay and drive concrete wooden piles gravel, capping them with reinforced concrete mat. was finally decided drive pipe piling; 16-in. pipe was driven bed rock, after which was cleaned out and filled with concrete. The job required 158 piles, each ft. long, which called for total length about 10,000 ft. 16-in. pipe. 1: liscussion which followed his address, the subject executive apprenticeship, taxation and banking were more widely mentioned. Mr. Alden had pointed out that the Middle West large numbers young men hold important positions industrial plants, while the average executive New England past the prime years life. said there advantage taking vision into partnership with experience, and advan- tage maintaining and preserving business methods and practice the introduction young executives. was pointed out him that the young Western executives during 1919 and 1920 numerous instances proved utter failures and that such cases manufac- turing companies were seriously involved financially. was stated that Western banks put more reliance character and ability, and less collateral, whereas New England banks absorb too much the money that should rightfully into industrial profit. was also claimed that New England manufactur- ing concerns many cases are too closely controlled one two people, who absorb profits tha