The Iron Age 1933-08-24: Vol 132 Iss 8

THE IRON AGE 24,1933 Editor Consulting Emeritus Managing Pittsburgh Detroit Boston Cleveland Chicago Washington Cincinnati CONTENTS Dry-Quenched Coke for Blast Furnaces. Construction and Equipment Buying THE IRON AGE PUBLISHING COMPANY FRANK, President GRIFFITHS, Secretary BAUR, General Advertising Manager PUBLICATION OFFICE: Corner Chestnut and 56th Sts., Philadelphia, Pa. EXECUTIVE OFFICES: 239 West 39th New York, Y., Member, Audit Bureau Circulations ADVERTISING STAFF Member, Associated Business Papers Emerson Findley, 311 Union Bldg., Cleveland B. L. Herman, 675 Delaware Ave., Buffalo, N. Y. H. K. Hottenstein, 802 Otis Bldg., Chicago Published every Thursday. Subscription Price: Peirce Lewis, 7338 Woodward Ave., Detroit United States and Possessions, Mexico, Cuba, $6.00; Charles Lundberg, Kent Rd., Upper Darby, Del. Co., Pa. Ober, 239 West 39th St., New York W. B. Robinson, 428 Park Bidg., Pittsburgh W. C. Sweetser, 239 West 39th St., New York Cable Address, ‘‘Ironage, N. Y."’ D. C. Warren, P. O. Box 81, Hartford, Conn. SEVENTY-NINTH YEAR SERVICE THE METAL WORKING INDUSTRY Canada, $8.50, including duty: Foreign, $12.00 year. Single Copy Cents rate 4 itm 7 2 j A, i q 4 3 | 4 4 om d ~ ssidle — ~ - | For knock-down and drag-out service...day after day...con- sider the Cletrac Galion Motor Patrol, prod- uct the Cleveland Tractor Company. This job knows roads, much less good ones. Over the roughest kind ground...into ditches and out again...turning, twisting pushing.. None but the best steels will stand its service. And none but Agathon Alloy Steels are used the upper transmission shaft, main drive shaft, planetary pinions, main drive pinions, rear wheel shaft and other vital parts the Cletrac Galion Motor Patrol. CENTRAL ALLOY DIVISION, MASSILLON, GENERAL OFFICES 4 THE IRON 24, 1933 Page ie, “ = ote Vad SEE ~ 24, 1933 Pst} ; oe Vol. 132, No. 8 Ambrosia— mixing ambrosia, that fab- ulous food the gods which confers wrong ingredient may turn into devil’s brew. Witness what now emerging from Nira’s melting pot. For period years and within few weeks ago, the relations between capital and labor had been steadily im- proving. Arbitration was fast becomin accepted the means settling dif- ferences. Strikes, lockouts and “labor troubles” were progressively decreasing. Even the privations depression did not detract from the growing spirit mutual good will. Today, labor disturbances are evi- dence nearly all industrial sections. Capital and labor are further apart to- day than they have been many years spite the almost universal granting shorter hours and higher wages. Wrong ingredients have evidently been poured into Nira’s ambrosia unskilled hands. Professional labor organizers have in- troduced harmful ingredient the form insistence upon union domination ns, industry. Social experimenters and theorists have added their poisonous portion con- vincing large number people that un- limited wealth and wages can produced like conjurer’s rabbit from industry’s hat. would indeed calamity for all into devil’s brew through the actions few visionary fantasts self-interested machinators. re large. HAMMOND General Electric Co. power for steel-mill main rolls was practically unknown thirty years ago. Even quarter cen- tury back there were motors any size used, and these were all direct-current machines. general, steel mill men looked upon them experiments and were means convinced that electric motors could successfully drive large bloom- ing, rail, billet, other mills, say nothing doing economically. Under these circumstances, build huge new steel mill, larger than any existence, and that mill place absolute dependence for driving power electric motors greatly exceeding capacity any motors previously built, required great deal cour- age, faith, and engineering judgment. Any company taking such ad- vanced step, was evident, would un- doubtedly earn the status pioneer. Such honor was achieved the Indiana Steel Co. (later part the Illinois Steel Co.), subsidiary the United States Steel Corpn. was organized for the express purpose building and operating new and extremely modern steel plant the southern shore Lake Michigan. The site was chosen for economic rea- sons, the waterfront two miles afforded the best facilities for the de- livery ore. The ground area cov- ered thousand acres sandy wild- erness, wholly uninhabited the time, swept chilling winds and in- fested ferocious sand fleas. was desolate spot when, the early spring 1906, construction work was started what was the largest rail mill the world. From the outset the electric drive was planned for all roll trains and for the billet mill which was also part the plant. This once raised the question motors ex- ceptional capacities and dimensions Engineers the General Electric Co. expressed their confidence that motors could designed handle this type drive, and accordingly two commercial orders were placed with that com- pany. The first order specified three induction motors 6000 hp. and three others 2000 hp.; the second order, placed few months later, covered three more motors 6000 hp. and two more 2000 hp. These two orders together embraced the total electric drive equipment for the main roll drive. the General Electric designing engineers was immediately apparent that they were confronted with new 8—The Iron Age, August 24, 1933 ~: Home Vinal, Electric construction foreman, and the construction crew men most lux- urious building ..Epic Story The problems design. motors such large capacities had ever previ- ously been demanded. was the largest steel mill electrification record that time. The whole enterprise was fairly athrob with pioneering aspects—a perfect embodi- ment the spirit progress, which these engineers knew inseparable from electrical methods industry. The comprehension all this aroused the technical enthusiasm young Howard Maxwell, the designing engi- neer whose lot fell handle the bulk the engineering involved this proposition. Early their mathematical calcu- lations and their experiments with small motors and models Maxwell and his associates concluded that was practicable introduce the idea fractional, instead integral, number slots per pole per phase, for the windings these motors, thus simplifying the shop process build- ing motors similar type but for differing speeds. The six large-capac- ity motors were run relatively low speeds, 75, and r.p.m., while the speeds all but one the five small-capacity machines were 214 The fifth the smaller group was also slow-speed unit, r.p.m. The varying speeds, momen- tary peak capacities, and control pro- visions, especially the problem quick stopping, were factors requiring unusual engineering study the de- sign these motors. When running free, that is, when disconnected from the rolls, was found that the 2000-hp. motors would require hr. come rest, and the 6000-hp. motors would require hr. The engineers developed method whereby direct current 250 volts was introduced, through ex- ternal resistance, into one phase the windings, after the motors had been disconnected from their own 6600-volt supply line. This reduced the period required bring the and min. and sec., respectively. Mechanical Fuse for Spindle Breaks Still another problem had with the necessity for some method protection case the spindle which connects the motor with the mill should break during operation. such emergency end thrust created which would damage either the mill the motor, but usually the latter. guard against this, the General Electric engineers devised what they termed “mechanical fuse” the form steel yoke with babbitted face, which bears against the end the shaft, opposite the coupling, and which would break un- der excessive strain, allowing the re- volving element the motor slide sidewise, clearing the broken spindle and relieving the thrust pressure. Two heavy bolts hold the yoke securely place under all normal strains, but these bolts have reduced tion one point, that they would give way under any abnormal pres- sure. This prevents damage either motor mill method similar that the electrical fuse, which melts under abnormal flow current and breaks the circuit. With these supplemental features, together with the capacity deliver high 20,000 hp. momentary pe me a. an | pa col ste cal hy tes cre tio sit sto til ass cid iliz liv ing Inc hor the wa loo: | can ; HIS account the beginnings the great Gary plant belated tribute pioneering the field steel mill electrification. Now, after quarter century successful performance, are set down some the details epoch-making bit engineering. retrospect, few fully realize the measures that had taken the courage that was represented placing absolute dependence electric motors size that had never been built for driving rolling mills. The consummation the project was virtually conquering the wilder- ness, far the site was concerned, and was achieved through excellent shop work the motor factories and through the high caliber the erecting personnel, who struggled against heavy odds. The trail blazing design and application proved the inauguration new era steel mill motors. peak loads—in itself important ele- ment, and one which was determin- ing factor winning friends the doubting wing the steel industry— these motors represented distinct departure from any previous types. Their size was naturally im- pressive. The largest them has and width ft. They weigh close 400 tons. The heaviest single part the rotor (with shaft and coupling) the 6000-hp. machines,— 272,000 Late 1907 the component parts these motors were the site the steel plant, ready for erection. Be- cause their size they were shipped “knocked down,” the assembling and testing done the erecting crew. The foreman the construc- tion force, Vinal, arrived the site November find small three- story hotel process building for housing his men during the job. Un- til this building was completed the assembly crew found the bunking de- cidedly rough. Vicissitudes Wilderness Construction The folk who planted American civ- ilization the wilderness seldom lived amid more primitive surround- ings than the men who built Gary, name given the town honor the late Judge Elbert Gary, long chairman the board the United States Steel Corpn. This was also wilderness—a wilderness sand, blown upon almost continu- ally chilling gales which piled the loose soil countless shifting dunes. The sand, once churned traffic, be- came instantly fine white powder, Steel Mill Motors resembling snow. was loose that men sank ankle deep, and walk quarter mile was exhausting exertion. the face whipping wind, which blew this powdery sub- stance into the eyes pailfulls, neces- sitating the constant wearing gog- gles, pedestrianism was accompanied unceasing profanity. the pro- verbial “last there were the sand fleas, whose number was legion, whose biting power was terrific, and whose presence was always reckoned with, indoors and out. Gary, Ind., 1907 The population Gary, during those first few years “staking out” and “roofing over,” was nine-tenths masculine. The men were mostly young huskies contractors’ work- men, builders’ gangs, machinery erec- tors, sheet metal workers, iron work- ers, masons, carpenters, teamsters, construction crew engaged setting the big motors. This predominantly male community, suggestive California’s gold-rush days the western Penn- sylvania oil-boom period, went about incased thick sweaters well-worn lumber jackets. For the most part everyone was goggled—and everyone shivered through the winters and sweated through the summers. The town itself, the fall 1907, consisted single narrow street en- gulfed the white sand from one building line the other. The build- ings were merely rough shacks—a few barns converted into boarding houses; odd assortment plain, square wooden structures serving stores; lunch room two the dining-car type. The most luxurious affair the community was the Gen- eral Electric hotel; the largest struc- tures, course, were the mill build- ings, which, time went on, ad- vanced steadily toward completion. Vinal, Undecorated Hero The hotel, where Vinal and his sixty men were quartered, was not far from the mill, yet walk, dur- ing the first year, from one the other was arduous day’s work, account the sand. make the trip noon addition was wholly impracticable. Accordingly Vinal hired express wagon and had hot lunches delivered every day, thus making possible half-hour noon rest and the same time conserving his men’s energies. During the first winter, however, the work was carried amid much discomfort from the cold, the mill buildings were not yet inclosed and the sole method obtaining heat was from number salamander stoves scattered around different points. These only heat- small area their immediate neighborhood. Vinal soon discovered additional complication. had run the hotel well direct the erection the motors. His huskies young enough boyish and most the time Vinal “daddied” them the extent keeping the larder, maintaining kitchen crew, and col- lecting the room bills, charging him- self higher rate that the men’s rate need not increased order meet expenses. His kittenish “pa- trons” had habit raiding the pantry late night and leaving very little for breakfast. They played other pranks, too, such bringing small flock geese the small hours and releasing them every floor the building, the frightened squawking awakening everyone. To- ward the end the two years Vinal was growing thin his dual job construction foreman and hotel pro- prietor. Field Machining and Assembly arising from the work itself incessant. Again and again they challenged the resourcefulness the erecting squad. The motors had never been assem- bled the shop, that certain amount machining was required when they were set Gary. Fur- thermore, the core assembly work, in- volving insertion the proper slots thousands thin laminations, was especially difficult since had done after the rotor stator frames were place and hence vertical position. When such cores are assembled the shop the frames are placed horizontally and the lam- inations can simply laid place. There were about 100,000 laminations for the armature and field each the larger motors, and seventeen men, all working close cooperation, The Iron Age, August 24, 1933—9 { ced the aks hod h mill the the ised ical vith inst > the un- slide ndle Two but -sec- ould ther nelts ures, liver 2 AGP 7 were required wedge them place. Although this did not involve any arduous. More vital the satisfactory op- eration the motors was the neces- sity turning the faces the rotors make the air gap conform the specifications the contract. The air gap was 0.2 in., and the limit allowable variation was only per cent. This the erection gear, rigging and turn- ing tool alongside the motors after the rotor frames were position and then turning the rotor faces the required dimension. The built-in flywheel, also, required final machin- ing the large, circular steel plates, which were bolted together produce the desired effect. Large banks rheostat resistances connected across the rotors controlled the flow current the motors. The wiring connections which these rheo- stats involved presented problem themselves. The solution was devised one Vinal’s men who used con- dulet, then comparatively new ma- terial. made exceedingly neat job, which long stood pattern for all succeeding motor installations steel mills. The pioneer character this in- stallation, which was without benefit precedents, constantly involved new methods, and even changes from the origina) designs. had been intended that all motor bearings should chain oiled, but the assembly work was not far advanced before was found desirable change ring oil- ing. The change precipitated great deal machine work each pedestal obtain sufficient clearance for the oil rings. The work was done upon bearings unusual size and with machine shop facilities unusually lim- ited. Whenever had occasion men- tion later years these Gary steel- 10—The Iron Age, August 24, 1933 mill motors and the work install- ing them, Vinal always ascribed the success the job two factors—the excellent shop work the factory and the high-class personnel his erecting crew. found when started this assignment that the motors had been designed with the utmost intelligence and that the shop workmanship was the highest or- der. for his own force, the slack times which then prevailed permitted him recruit superior men for all departments the work. Although but few his crew had ever previ- ously had experience assembling and erecting electric motors, neverthe- less had skilled workers for every task and was never obliged feel concerned regarding the type man whom placed positions re- sponsibility. Start Operations Quietly Dramatic the end 1908, just years ago, the erecting job was nearing completion. The motors for the rail mill were erected first, that all the major problems were worked out and settled entirely that part the job. The billet mill motors, being merely duplicates the others, were set half the time. The execu- tives and engineers the General Electric Co. became apprehensive to- ward the end that the installation would not completed within the around the beginning 1909 Vinal was getting disturbed messages this effect. But these did not bother him, for knew exactly where stood. finally turning over the motors for operation was time with margin some days spare. The final operating test came Feb. 17, 1909, the date which the first rail was rolled. All machinery was then place for operating the mill, including, course, the elec- trical equipment. the rail mill, the largest the world, stood the six OUTH mofor room the billet mill the Illinois Steel Co., Gary, Ind., March, 1910. electric induction motors, three 6000 hp. and three 2000 hp. the billet mill were five more electric motors equally large those the rail mill, three 6000 hp. and two 2000 hp. These motors drove the blooming mill stands, which were various capacities. The elec- tric power plant, nearby, was com- pleted, with electric generators 2500 kw. capacity each, them alternating-current design and the other two built for direct-current work. These units were driven gas engines, representing achieve- ment plant economy the engines were powered the gases the blast furnaces, which otherwise would have been dissipated the open air. the day the operating tests, high engineers the General Electric Co., well visiting engineers other electrical concerns, and con- siderable number steel men, gath- ered Gary see the motors put permanent service. was new ex- perience all around. These were the largest electric motors existence that time, and was far the largest steel mill electrification. one knew just how well the motors would perform. Vinal himself did not know, for, although had given them successful preliminary test few weeks previously, had had opportunity test them under load. was evident that many the steel mill men present were quietly skeptical concerning the success this distinct innovation driving power for mill machinery. They, and some the visiting electrical men well, apparently supposed that when the motors were started the voltage would applied gradually, perhaps steps 2000 volts, until the mum rated voltage was reached. In- stead, however, Vinal put the full line voltage the outset, knowing that the banks rheostats would reg- ulate the flow current ‘and that . tors, 2000 nore 6000 hich elec- com- the ‘rent ieve- the rould air. tests, con- eX- the tence the otors not est load. the uietly and when rhaps maxi- full owing reg- harm could occur the motors. After the motors were running, Vinal and most his crew went into the other part the building watch the billet mill roll the steel, leaving the motors take care themselves. was regarding the quality workmanship those humming units was concerning the work his own erectors setting them up. His confidence was justified, for the mo- tors gave perfect performance, even when left alone. Still Working After Quarter Century They are still operation the Gary plant, after quarter cen- tury. They were pioneers every sense the word, setting new standards and practices steel mill operation and inaugurating great era steel mill electrification sub- sequent years. the year two im- mediately following, the General Elec- tric Co. booked orders for steel mill motors more than double the total capacity the Gary motors; and the progress such electrification was extremely rapid throughout the fol- lowing decade and later. Skepticism the steel world the capabili- ties the electric drive was pretty completely eliminated that Febru- ary day Gary. electrical circles this was termed “the greatest Years afterward writers who repre- sented electrical and industrial inter- ests other than General Electric said it: “The boldness the engineers ... has been more than justified ‘By —— ~ One the 6000-kw. induction motors process installation Gary the winter 1907-08. The design and building the slow- speed induction motors, for which there was precedent, were great and successful undertaking All American engineers interested steel mills are indebted the pioneer work done the Gary Since 1907-08 electric motors for steel mill work even larger capaci- Ascendency Alloy Steel steels continue rel- atively more important the castings field than rolled steel and forgings. Production alloy steel 1932 given the American Iron and Steel Institute 757,560 tons ingots and 41,044 tons cast- ings. all ingots (13,464,402 tons), output alloy steel ingots repre- sented 5.62 per cent; and all cast- ings (216,760 tons), those alloy steel account for 18.9 per cent. The ratios are decidedly the increase the case castings but more less stationary the case ingots. For example, ten more years ago about per cent all the ingots were alloy steel; the ratio was per cent 1928, approached per cent 1929, but was 5.85 1930, 5.38 per cent 1931 and, stated, 5.62 1932. for alloy steel cast- against the 18.9 per cent classi- fied such 1932, the proportion was 17.4 per cent 1931, and for the preceding four years averaged 12.5 per cent, while ten twelve years ago the percentage was the order The electric furnace its position the alloy field. Some 58.8 per cent all the alloy castings 1932 were electric steel, and 15.4 per cent all the alloy steel ingots came from the electric furnace. alloy ingots and castings combined, the electric furnace supplied 17.5 per cent 1932, per cent 1931, 12.3 per cent 1930 and 12.9 1929. Position the Rustless Steels survey the rustless steel in- dustry’s production for the last four years was published THE IRON AGE, Feb. 16, 1933. the results this ties than those first installed Gary have been built and put success- ful operation. But there are none anywhere greater historical renown deeper contemporary influence. *“A Review Steel Mill Electrifica- tion,” Lamme and Sykes. Association Iron and Steel Electrical Engineers, 1922. Castings analysis are compared with the alloy steel production the same four years the following percentages are obtained: Percentage Rustless Steels Total Rustless Alloy Steel, Steel, Per Gross Tons Gross Tons Cent 3,957,200 47,580 1.20 2,443,300 53,080 2.17 1,455,900 30,280 2.08 798,600 23,770* 2.97 *Estimated. Electric Rustless Alloy Steel, Steel, Per Gross Tons Gross Tons Cent 510,000 47,580 9.33 300,500 53,080 17.60 232,100 30,280 13.00 140,870 23,770* 16.80 *Estimated. The Iron Age, August 24, ae > Nes = - tion the by-product coke plant, the hot coke discharged from the oven into transfer car and tower, where flooded with about 500 600 gal. cold water per ton coke cooled. Vast clouds destruc- tive dust-laden vapors are broadcast the atmosphere and the dust gradually precipitated over the plant and adjacent territory. the ordinary present-day opera- the dry quenching, the Sulzer system, the hot coke cooled the continuous passage through the coke automatically formed inert gases. The heat collected trans- ferred circulating the gases through boiler for developing steam for plant use. This operation must naturally closed cycle, and with not more than single outlet open the atmosphere time, thus gather excess oxygen. The unit the Sulzer system in- cludes coke container, not unlike squat blast furnace. Into this, the hot coke from the coke car regularly charged, usually means skip hoist. While the inlet door the top the container open take the charge, small amount oxygen enters and quickly con- sumes any accumulated hydrogen. The remaining inert gases are circulated constant speed fans, and are evenly distributed through the mass hot coke, then passed directly through superheater, located dust cham- ber, and thence through inclined fire-tube boiler. The gas then drawn through second dust collector the lower end the boiler tubes where the remainder entrained dust dropped. The cooled gas drawn through the suction side the cir- culating fan for another cycle. When the system first started small portion the air converted into mixture carbon monoxide and carbon dioxide, the percentage each depending the temperature that particular time. However, the oxygen the encased air quickly consumed and mixture inert non-combustible gases remains. typical analysis this gas after charging coke is: 10.9 per cent; per cent; CO, 6.6 per cent; 12—The Iron Age, August 24, 1933 uenched Coke for the FRANKLIN MILLER Chief Engineer, Midland Tube Pipe Co. Bound Brook, under per cent; balance. The possible loss coke through burn- ing has been determined average 0.04 per cent, entirely negligible quantity. Since the coke charged the container regular intervals and im- mediately after pushing, the entrance temperature the coke closely ap- proximates 1800 deg. Preceding each charge, the outlet door opened and charge cooled coke dumped from the container, through coke rakes, and sufficiently low tem- perature handled rubber-cov- ered belt conveyors. The pressure drop gases through the entire unit equal about in. water gage. The power consumption for the skip hoist about 0.25 Kwhr. and fans about 2.5 Kwhr. per ton coke cooled. plant capable cool- ing 1000 tons coke per day will oc- and plant for 4000 tons per day probably occupy space 105 ft. Benefits Realized Dry Quenching foremost interest the blast furnace operator the fact that dry quenched coke clean coke, and though has been said, “if good coke not made the ovens, cannot made the wet quenching screening station;” yet dry quenching does clean the incompletely dis- tilled pieces now common, and de- livers cooled coke free from “nigger black pieces. The rough surface coke makes particularly attractive breeze and dust when wet and for this reason makes breeze separation screening more difficult, and complete removal impossible. certain amount breeze adheres each individual piece coke, and falls off only when the mass dried out, and that usually happens only the furnace. This fine coke serves useful pur- pose and carried out the blast furnace gas, and from which must removed spraying scrubbing. The quantity this useless fine coke approximately per cent the dust blast furnace gas. The recoverable heat from 1800 deg. coke about 1,000,000 B.t.u. per net ton. the dry quenching system about per cent efficiency attained, and practice, from reports covering long periods, there shown output over 1000 lb. steam per net ton coke cooled. This steam credit perhaps the greatest economy this system, and alone justifies the plant installation. The maintenance and repair costs the wet quenching system are large comparison the original cost such equipment, and with its elimination figure better than $0.02 per ton coke can reasonably charged off. The wet quenching stack and its equipment have short life (about years) due destructive vapors; and the coke car itself, even shorter life, primarily due the excessive expansion and contraction strains set within it. addition, the cost pumping water (500 600 gal. per ton coke quenched) well the large amount make-up water necessary, figure largely these economies. The removal fine water-soaked breeze basins, sumps and piping another maintenance feature which elimi- nated the dry-quenching process. plants supplying market for domestic coke worthwhile saving will observed due.to the lesser amount crushing required, and thus also less breeze produced. Due the lack moisure domestic sizes, about per cent more efficient heating. Dry and wet quenching plants selling domestic trade the same locality have agreed per cent figure, and this has forced the wet quenching plant supply 2140 lb. coke the house- holder the same cost the dry quenched coke plant’s net ton 2000 Owing the more efficient com- bustion, uniformity size, and in- herent strength dry quenched coke the blast furnace, there crease the coke rate per cent better. This decrease will liberate large amount coke for making more pig iron for sale the domes- tic market. the furnace can take it, this increase pig iron may amount tons per day per fur- nace. Or, the case that the sur- ~| q 1 ‘ i \ a St W le or | Furnace ned, ring per eam omy the costs are rinal its $0.02 stack life ictive the ke-up fine ttling elimi- for saving lesser and Due mestic more wet agreed has ant house- dry 2000 com- coke cent liberate making domes- take may yer fur- sur- a quenching offers large economies the blast furnace plant, according the author, who reviews what has been done the field date. His study costs and savings should helpful. Dry quenching, word, from the ovens forcing inert gases through it; blower keeps the gases moving continuous closed cycle which the heat extracted delivered tubular steam-raising boiler and the cooled gases are returned abstract heat from incoming fresh supplies coke. plus coke could absorbed the domestic market, would turn revenue about $150 day per blast furnace. plants where coke evens are fired producer gas there ad- ditional saving from the use dry quenched coke (through %-in. screen) about fuel per ton coke produced. This usually amounts saving better than per cent. One plant using small coke (through screen) uses 254 coke per ton coal carbonized. This plant also returns fine breeze (through in. the coke plant and uses per cent mixture with the coal for coking. Provided this breeze well mixed with the coal, the structure the coke not adversely affected. the sintering iron ore one plant using mixture containing per cent fine breeze, with coal added for fuel the sintering pans. England, one dry quenching plant sells fine breeze manufac- turers building blocks. There are several excellent methods use whereby the breeze kept out the boiler plant, and thereby earns larger credit. Records Operation That dry quenched coke used blast furnaces insures better opera- tion and noticeable reduction coke burden indicated operating rec- ords European installations, the Homecourt works, and the Witkowitzer plant Czechoslovakia. Reports from Homecourt (Com- pagnie des Forges Acieres Marine d’Homecourt) show sav- ing 4.17 per cent the blast fur- nace coke rate, owing the use dry quenched coke instead wet quenched. (Dr. Mueller, “Compara- tive Investigation Dry and Wet Quenched Coke.”) This company also reported “that the use dry cooled coke more regular and im- proved action the furnace was evident, and trouble caused hang- ing the load the furnace was greatly reduced. Dry quenched coke ‘does not break under the heavy load the charge, the case with wet quenched coke. The formation dust and breeze pockets the blast furnace thus prevented, and more through the charge secured.” This plant with capacity cool- ing but 1000 tons coke per day de- creased the coke burden 14,595 tons year. Reports from the Witkowitzer schaft show definitely saving per cent coke consumption the Dry quenching plant the Ford Motor works England. blast furnace, and this against previous practice using mixed coke. Quoting letter from this company, find that “dry quenched coke does not change its size any great extent the blast furnace because me- chanical handling. This complete freedom the charge the furnace from newly formed breeze and small coke has essential influence upon the regularity the furnace opera- tion and the pig iron and therefore upon the saving coke. further advantage the dry quenched coke the absence water content otherwise varying which always permits charging the furnace exactly the amount carbon re- quired, which renders regularity the furnace operation and lowers the consumption coke.” this point, Schadrin “Sa In- dustrialisazizu,” Moscow, April 1931, says: had opportunity inspect Sulzer dry coke cooling plant the Witkowitz steel works. With one ton dry-cooled coke 400 kg. (882 lb.) steam are produced (200 One the blast furnaces The Iron Age, August 24, 1933—13 4 q £3 r quenched coke, thereby fuel saving per cent effected. This in- formation have found confirmed daily records operation. well the American technical ad- visors with Magnitostroi, have often asserted that dry-quenched coke lower quality than wet-quenched coke. The experience the Witkowitz works has convinced the con- trary. The dry-quenched stronger and contains less breeze and dust. “The first plants Magnitogorsk and Kusnezk will use the wet-quench- ing process. Now will necessary SALLTY VALVES PIPE make provisions. for change dry quenching for plants and build the coke ovens with view adopting the dry- quenching process. Considering the tremendous scale these plants the economies effected are bound tremendous, too.” addition, may listed the re- cently completed stalled Dagenham, England, for the Ford Motor Co. This plant will cool Iron Age, August 24, 1933 CHARGING ROPES WOT COKE CHARGING DOOR WATLA SLAL MULASURING OLV/CE coke for 500-ton furnace making single grade foundry iron. Inter- esting records should forthcoming this furnace gets into production. The data the Dagenham dry quencher are: Plant capacity, 700 gross tons coke per day; steam pres- sure, 200 lb. gage; steam tempera- ture, 600 deg. F.; weight coke per charge, gross tons. The 500-ton furnace now being com- pleted Pretoria, the Transvaal, Sulzer dry quenching system shown tion elevation. for the South African Iron Steel quenched coke exclusively. This fur- nace will supply basic, foundry and special irons. The furnaces Dag- enham and Pretoria are the first blast furnace plants which Thi Ste al nec pro Say 500 pro day porated dry quenching equipment the initial plant construction. Steam Production Data From various reports, covering con- siderable periods, the Rochester Gas Electric Corpn., Rochester, Y., the following data have been taken: Steam produced per net ton coke cooled (Blowdowns and Bleeders deducted), 942.4 This steam produced from and Steam pressure, average, lb. gage 141. Superheat Feedwater, average temperature, Average power consumed per net ton coke cooled, kwhr...... 2.37 Rochester was the pioneer the dry quenching field this country. The plant has been operation more than six years and has proven most profitable and economic ven- ture. tendent the gas department Rochester, letter the author, states: “The operation dry quench- quality coke, since produces coke which stronger and more re- sistant further handling and due the lack moisture enables better screening and sizing the coke take place. The value the steam alone produced has made the dry quencher, our case least, de- cidedly economic venture. “The use dry quenched coke re- sults production breeze with very decided advantage for the rea- son that enables all the breeze that produced used the opera- tion the coke plant and none neces- sary used boiler fuel. our plant this quite achievement for the reason that use straight high volatile coal which produces somewhat weaker coke and therefore always has been productive larger quantities breeze than usually produced most coke plants. The use dry quenching enables larger percentage the breeze used the producers and also along with the coal prior carbonization.” The second plant installed was Flint, Mich., 1929, for the Con- sumers Power Co. From report for 1932, find the following: Steam produced per net ton coke cooled (Blowdowns deducted), This steam produced from and Steam pressure, average, lb. gage 227. Set-Up For Blast Furnace Plant Assuming installation con- nection with blast furnace and by- plant, plant containing, say, three 700-ton furnaces four furnaces and the coke plant 2250 net tons coke per day, the following set-up taken typical. Coke cooled, per year, net tons.. Average temperature hot coke, Steam pressure, lb. gage 150 Feedwater temperature, deg. F... 200 Cost electric energy per kwhr., Steam value per 1,000 pro- duced, hundred Steam produced per hour, OPERATION Labor, increase rate present wharf operator that Power required operate dry quencher installation ........ 24,300 Maintenance dry quenching Boiler feedwater 2,800 Total operating expense, per Total operating expense, per 1,000 lb. steam ..... $0.0722 Direct Savings Elimination expense pumping wet quench- ing water, and reduction maintenance hot coke han- Gling equipment 24,300 Net operating cost, per year... 28,850 Net operating cost per 1,000 Ib. $0.0392 Investment, estimated cost dry quenching plant, installed Fixed charges, interest vestment, depreciation, taxes, insurance, 13.5 per cent.. 60,750 Depreciation stand-by boiler plant (already existing)..... 7,750 Total fixed charges, etc....... Total cost plant, per year.. from value steam 700,000 Ib. $245,000 From reduction coke rate per cent saving on 2,000 tons day, tons for 350 days, From domestic say tons day for 300 days, ton 60,000 Total revenue per year...... $368.000 (Credits for savings per cent gas producers not listed, nor credits for fine breeze). Less operating expense and fixed Total net profit, per year..... $270,650 Per cent total net profit, per 60.2 From the foregoing set-up. noted that plant this size would pay for itself well under two years. With plant smaller capacity, will, course, take longer time, probably about two and one-half years. Thus either event, one might conclude that dry quench- ing plant would prove entirely profitable venture. summary the previously noted facts, worth while quote from report recent meeting the Blast Furnace and Coke Associa- tion, Chicago district, the following statement: “The advantages the dry quench- ing method indicated the per- formance Rochester are follows: Recovery 1000 Ib. steam per ton coke cooled. Elimination clouds steam with re- sulting condensation and deterioration equipment. Elimination the nuisance clouds steam along walks and wharves. Lower maintenance cost equipment hot car, screens, belts. Lower labor cost handling coke. More uniformity size coke (except where sizing practiced). More uniform moisture. water pumping cost. Saving freight where coke shipped. More thorough screening. Several steel companies have this time plans under advisement for dry quenching installations. The dry quenching coke will popularized, both steel plants and public utili- ties, the incessant and altogether imperative demands for lower costs and elimination wasteful practice. Heat-Resisting Cast lrons Four Groups CAST irons good heat-resisting properties are grouped into four classes Morgan, the British Cast Iron Research Association. contributed paper the subject the recent conference Cardiff, Wales, the British Foundrymen. The classes are: Types white and unmachinable cast irons used because they not grow under the influence high temperatures; close-grained cast irons containing low silicon and carbon and negligible quantities phosphorus, correspond- ing with good engineering properties and sometimes having alloy additions; high silicon irons, silicon excess per cent the Silal type; and the recently developed austenitic cast irons. After white unmachinable irons, which not grow, austenitic irons, especially the high-silicon type, come next order merit, according Mr. Morgan. the other types, advises that the conditions serviee are severe and above 700 deg. C., irons the Silal type should used, provided the right composition chosen and the rate heating cooling not such make the lack ductility serious matter. When the temperatures are below 700 deg. and the conditions are not seri- ously oxidizing, the low-silicon type preferred. resist the corrosion action high-temperature oxidizing gases con- taining sulphur compounds, one must prepared, urged, use high contents chromium, silicon alu- minum the castings. For reducing conditions, especially the presence sulphur, cast iron steel, asserted, will stand high tem- peratures for any length time. the same meeting Coyle, research metallurgist the Interna- tional Nickel Co., reported Amer- ican progress the use alloys cast iron. pointed out that al- though increased strength could obtained adding carbide-forming alloying elements, was found advis- able supplement their effect the addition graphitizing alloying ele- ments, such nickel, facilitate machining. added that was firmly believed among American foun- drymen that the use alloying ele- ments iron castings was not only firmly established but that the future would see its use considerably ex- tended. The Iron Age, August 24, 1933—15 he. Ms 7 4 890,200 > ‘ ‘She > 68,500 $7,350 n “ ater temperature, average, New Rapid Determination mining titanium steels com- prises boiling the hydrochloric sulphuric acid solutions these steels with sodium-thiosulphate but gives low results. The high-chromium content the solution retains very considerable amount the dissolved titanium, even after protracted boil- ing faintly acid condition. Further, per cent the titanium present re- mains insoluble the acid after solu- tion the drillings. must filtered out, fused with preferably the lat- ter salt, and the fusion dissolved dilute HCl. This titanium then precipitated with “thio” not enough the main solution. Also these steels usually contain all the way from 0.05 0.20 per cent aluminum from the ferrotitanium which frequently has per cent aluminum it. The interference the high can prevented re- moving it, the start, from the solu- tion the mercury cathode method. this electrolysis all but few milligrams the and are absorbed out the solution the mercury. However, all the still the electrolyte with the and must removed along with the two three milligrams chromium still remaining with the titanium. The mercury cathode outfit ex- pensive. means large outlay for platinum and mercury. The latter must redistilled frequently, and glass still does not last through very many runs. not rapid method but does not require quite much the operator’s continuous attention the following gravimetric method which accurate and removes all in- terference Al, Cr, Si, and Fe. Further requires expensive ap- paratus high-priced chemicals and considerably more rapid. method often used for deter- Thirteen years ago the writer pub- lished his method which the bulk the iron removed from all steels fractional precipitation the Al, Ti, Cr, Zr, and the simple expedient adding very slight ex- cess 1:1 ammonia water the solution the iron the ferrous state. Then filters off once the non-ferrous elements. The resulting precipitates are thus freed from the bulk the iron (see Chem. Met. Eng. 20, 523, 1919, and Chemical Analysis Special Steels, fourth Edi- tion and earlier editions). modi- Iron Age, August 24, 1933 Dr. MORRIS JOHNSON Chief Chemist, Park Works Crucible Steel Co. America fication this original procedure adapted the determination the these high chromium steels and also the Al, but the latter element can run better advantage the method given for Al. The Gravimetric Method Dissolve 3.5 thin finely di- vided drillings heating them ml. 1:3 and ml. maintaining the original level the acid additions boiling water (boiled remove air and maintain the near boiling temperature during solution). Raise the liquid boiling toward the end the dissolving oper- ation make sure all particles steel are decomposed. The foregoing requires, normally, about one hour. from sulphurous solution and the manner given the method for (Aug. 17, 1933), the method fractioning different from the procedure. Dilute the solution the steel with 100 ml. boiled Then add 1:1 filtered ammonia water until the hydroxide formed begins redissolve rather slowly. Then dilute the solu- tion with boiling water volume 350 ml. Next add 1:1 ammonia water until the pale blue precipitate and the hot solution smells distinctly ammonia. Avoid large excess this time light brown film, may greenish film, will form the surface the hot liquid and there still some excess Stir 1-in. diameter ball ashless paper pulp and filter out the and and some once, through 12.5 cm. ashless, rapid and double filter papers; No. good grade. Let the precipitate drain. Rinse all solution out the beaker the filters. Use two funnels each 800 ml. beaker. Then wash the papers and mixture pulp and precipitate ten times with cold water. Dissolve this precipitate off the HCl. Wash the acid taste out the filters with cold H.O. Peroxidize the solution and washings. Boil the peroxidized solution ten minutes, filter it, wash the precipitate with per cent solution exactly described peroxidizing for this series methods, ex- cept that the precipitate and pulp from the peroxidation are washed only twice stirring filter full the water wash. Also account the considerable iron that unavoidably co-precipitated with the Cr, best now scrape care- fully most the precipitate and pulp back into the peroxidation beaker with the small porcelain spoon used the shooting into the solution when peroxidizing it. (See method.) Then rinse the remainder the precipitate—all but stain iron into this beaker from the two funnels. Avoid too strong jet and proceed carefully prevent tearing the papers. This transfer the pulp and precipitate its beaker rapid. and precipitate, pouring the acid around the beaker walls dissolve any adhering precipitate. Warm the mixture acid and pulp until the latter white and the hydroxides are dissolved. This whole operation re- quires only few moments. Cool the solution and dilute 350 (leaving the pulp it) with This operation much quicker than dissolving the precipitate filter and then washing the same free acid. Next, repeat the peroxidation, boil- ing min., filtering the precipitate and some the same filters, again, and on, until the filtrates longer show more than slight tinge yellow. This may require four peroxidations but, the fourth filtrate shows only this trace color, three peroxidations are usually suf- ficient. unless the iron remaining the filters with the excessive. actual timing, requires hr. dissolve two tests, make the frac- tions, and four peroxidations re- move the Cr, using 3.5 18-8 steel with Ti. the iron co-pre- cipitated with the and that greatly interferes the peroxida- tions separate the chromate from the and residual iron. The original set double filters the two funnels, per each test, will last until the final peroxidation mad iron boili off ash for fron and then care milk tent! fain ized then heat boil; analytic methods, particularly for rustless steels, have been devel- oped Dr. Johnson. Methods for ascertaining carbon were detailed THE IRON AGE Feb. 21, 1931; new one for molybdenum was described the issue July 13; the rapid determination aluminum was covered Aug. 17, and here outlined rapid procedure for titanium. The series will completed taking the oxides aluminum, silicon and chromium. Publication permission the Executive Department the Crucible Steel Co. The gravimetric method herein described for titanium based the writer’s fractional separation whereby Ti, Al, Cr, and can separated from the bulk the ferrous iron the simple expedient adding 1:1 ammonia water the reduced solution these elements. proposed this scheme years ago. The following facts are brought out: reliable gravimetric determination aluminum can carried through Nitralloy types, duplicate, hr. less time. 2—An accurate analysis the 18-8 steels and other types high-chromium steels for titanium can accomplished duplicate hr. less time suitable modification the hydrogen peroxide color method. This technique has been successfully applied the determination highly alloyed chromium steels for more than year his laboratory. The analysis made the presence the intense color the high chromium. 3—An accurate umpire method described for the gravimetric analysis Ti. The scheme can carried through. duplicate, plus one control, total hr. expensive chemicals, metals, apparatus are needed. made and the titanium and residual iron are dissolved off with ml. boiling HCl, and filters and pulps are washed until free acid taste. These washed filter papers are now burned off the weighed crucibles and the ash held. The solution and washings the final peroxidation precipitates the hot HCl are now ready for the separation the away from the residual “thio.” Proceed follows: the solution and washings add ml. per cent solution, which will first turn red and then begin decolorize the solution warm. Continue add the NH.OH carefully until the solution becomes milky with the hydroxide, the present the extent several tenths per cent. When the solution smells very faintly SO. and nearly decolor- ized and, perhaps, few small brown bubbles ferric iron are showing, then add ml. extra H.SO; and heat boiling. Next add sodium-thio-sulphate and bring boil; then produce cloud white Add just enough the latter cause the sulphur coagu- late; e., the and Ti. Then boil very slowly volume 450 ml. for min. hr. Filter this mixture and double 12.5 filters, mixing some ashless pulp—about %-in. ball. One funnel per beaker enough. Wash times with ml. per 500 cold water. Ignite this paper and precipitate the same crucible with its ash that has been held. This ash constitutes the total plus several milligrams that are carried out with the the “thio” precipita- tion. Also some will