The Iron Age 1941-05-08: Vol 147 Iss 19

CAPITAL BASE METALS BEHAVE LIKE NOBLE METALS HOLDEN BATHS é ings. Built for iy For High Speed, Quenching, Tempering treatment. Annealing brass shells. Electrode, Three Phase. FURNACES AND Calrod Unit Write HOLDEN Equip- ment Up-Cut Shear Ma- Galva nizing Leve and Inner Covers. Automatic Automatic ght Gauge § 4 i ay - New LEAD-ZINC Uni Editorial 8000 Tanks for Hitler Technical Articles Much More Steel Foundrymen Prepare for New York Meeting Gates and Risers Top Pouring Methods for Non-Ferrous Castings New Equipment Features the Assembly Line Washington the West Coast Fatigue Cracks News and Market Reports News Industry Machine Tool Activity Personals 128 Non-Ferrous Market MAY 1941 Obituaries 130 Scrap Market and Prices Comparison Prices 132 Construction Steel VOL. 147. NO. Summary the Week 133 Iron and Steel Prices The Industrial Pace 134 Warehouse Prices District Market Reports 136 Sales Possibilities U VAN DEVENTER President and Editor BAUR Vice-President and General Manager Products Advertised Index Advertisers Managing Editor Editor Copyright, 1941, by Chilton Company (Ine.) Machine Tool Associate Editor Editor F. J. WINTERS Art Editor Washington Editors MOFFETT JAMES ELLIS DIX, Manager Reader Owned and Published CHILTON COMPANY (Incorporate Resident District Editors Advertising Staff Publicati Pittsburgt Chicago Robert 621 Union Clevelana Executive Offices ert Chestnut and Sts East 42nd St. Cleveland Detroit Hottenstein, Otis Bldg., Chicago U.S.A U.S.A Leonard, 100 East 42nd St., New York Peirce Lewis, 7310 Woodward Ave., Detroit Editorial Correspondents Ober, 100 East 42nd St., New York Robinson OFFICERS AND DIRECTORS Buffalo Cincinnati Warren, Box Hartford, Conr JOS. HILDRETH, Vice-President Boston San Francisco EVERIT TERHUNE, Vice-President LEROY ALLISON Newark, $6.00: Canada, $8.50; Foreign, $12.00 year. Single copy, cents. HUGH SHARP JOHN McCUNE Member, Audit Bureau Circulations Milwaukee Birmingham Member, Associated Business Papers ice-President Indexed the Industrial Arts Index. Pub WILLIAM BARBER, Treasurer SANDERSON ROY M. EDMONDS lished every Thursday. Subscription Price JOHN BLAIR MOFFETT, Secretary Toronto. Ontario St. Louis United States and Possessions, Mexico, Cuba, JULIAN CHASE, THOMAS KANE, CHARLES HEALE HARRY DUFFY | 4 140 it) 144 146 52 154 217 Wee 4 38—THE IRON AGE, Moy 194! THREE WAYS WORK THIS PROBLEM STEEL your steel requirements clearly and fairly before your regular source. Explain exactly what you need and when you need it. try get corner steel. SECOND...Determine the physical property re- quirements for each job. List that may used necessary. your immediate requirements with steel from warehouse reserve stocks. save time send open needed sizes may sold while the quotation being made. You know this method entirely safe through the Ryerson one-price missing but can provide prompt shipment most all steel products from our nearest plant. When you have problem application, substitution, fabrication procurement phone, wire write us. will glad work with you. Joseph Ryerson Son, Inc. Steel-Service Plants at: Detroit, Milwaukee, St. Louis, Cincinnati, Cleveland, Buffalo, Boston, Philadelphia, Jersey City. | if i | | | | | } 8000 Tanks for Hitler coal strike was called the first day April, commonly known April Day. The date was appropriately chosen. The effect the strike upon the steel industry was not immediate, because existing backlogs coke and pig iron, modest though they were. But the third week April, the operating rate the steel industry had dropped from 100 per cent, the last March, per cent. The following week, that ended May had dropped two points per cent. will require probably least two weeks more get steel produc- tion back 100 per cent again, because furnaces both for pig iron and coke have had shut down and you cannot stari them the drop hat, even such sizable hat that worn Coa’ Dictator Lewis. Roughly figured, the conscientious objectors the coal industry have set the steel industry back average points for period least four weeks. Our capacity for ingot production 100 per cent rate some 1,650,000 tons. drop one per cent weekly production there- fore means loss 16,500 tons. drop five per cent over period four weeks means irreplaceable loss 330,000 tons. lot steel. MAY 1941 This estimate ours very conservative one. Republic Steel, for example, states that its own loss will aggregate 100,000 tons alone. This loss irreparable and irreplaceable industry that work- ESTABLISHED ing 109 per cent capacity. What does mean? 1855 The loss 330,000 tons steel means the equivalent the steel re- quired for first class battleships. the equivalent more than one quarter the steel required for our entire two ocean navy program. represents enough steel make over 8000 medium tanks 16,000 fifty- ton steel freight cars. represents more steel than the automobile indus- try will save during the remaining months this year curtailing car output per cent. But coal goes into more than steel. Coal back the making all capital goods, and the capital goods index has declined points during April. Coal back carloadings that for one ton steel alone four tons materials must transported. And freight car loadings have declined drastically April. Statisticians may say that these are seasonal declines but there are “open seasons” during all out defense program. the emergency great are being told daily, and every minute counts the battle Democracy, then has been nothing less than plain treason permit the shutting down our mines for even one day. have handed Hitler nothing less than handicap our potential usage the equivalent first line battleships 8000 medium tanks. And that handicap might easily let him win. V4 4 ¥ More than Years Research —in Every Pound Inland Steel Inland Steel Company has always an- ticipated the exacting requirements the metal working industry producing finer, more uniform steel. For over years, Inland research has been directed this objective. When Inland started its first mill, 1893, every then known scientific method was ap- plied making its products. first, research centered making better harrow teeth, plow beams, merchant bars, etc. the years have passed, Inland not only has added greatly its physical plant, but also has greatly expanded research and metallurgical facilities. SHEETS STRIP TIN PLATE BARS PILING RAILS Inland research has given industry such valu- able steel mill products as: high-strength, low alloy Hi-Steel; lead-bearing, fast machining Ledloy; finer cold reduced tin plate; Inland was among the first offer the superior quality sheets and strip made continuous mills. Inland research has pioneered many steel processing methods and control devices which steel finer quality and greater uni- formity are made. Today, every pound Inland Uniform Quality Steel has back over years intensive research. TRACK ACCESSORIES REINFORCING BARS | 3 i Dearborn Street, Offices: Milwaukee, Detroit, St. Paul, St. Louis, Kans Much More ° extraordinary material requirements imposed the national defense program have rapidly projected industrial production record levels ac- tivity. For many years the rate steel consumption has served index measuring industrial virility always finding, whatever sponse the steel industry. Cur- rently, however, coupled with the abnormal requirements for “guns,” both immediate and prospective, the significant tonnage required Guns, that the country may have adequate defensive wea- pons; butter, that the country may maintain its expanding national economy which present living standards may reasonably satis- fied. Obviously, quirements flowing from normal national growth can and always have been covered either plant expansion the construction new plants. Current emergency re- quirements, involving known and unpredictable factors, obscure the problem that such solution may represent simplification. Equally obvious are the dangers and disadvantages all-out policy expansion. The huge capital expenditure re- quired would later, with decreased production, charges, further accentuating the unsatisfactory conditions character- izing the last decade. The diver- sion materials and equipment many kinds required would create further scarcities the capital goods division, retarding the pro- duction urgently required de- fense equipment. Following the cessation Steel, ° ° FRANK CROCKARD Engineer, New York ° quickly and inexpensively, without the building great new plants. Here are many practical ideas— some old, some new, some forgotten—which could applied within few months with considerable benefit the present defense effort. The author well acquainted with this subject. one time man- ager the Riverside department National Tube Co., later was vice-president and general man- ager Tennessee Coal, Iron Railroad Co., and later was president Woodward Co. More recently his report Brazil eventually resulted the $36,000,000 plant now under construction near Rio Janeiro. ° the precipitous drop steel ton- nage requirements would again result idle plants greatly re- duced rates activity, conceivably causing insolvency the weaker steel producers and other associ- ated industrial groups. The labor displacement these groups would result sociological debacle the first magnitude, presenting more serious problem now confronting the industry. the moment, without any de- pendable guiding instrumentality known man vaguely aware the appalling speed with which driving into uncharted field which place and time arrival are unknown. Based upon the vi- cissitudinous history the steel industry, may confidently as- sumed that the competent person- nel which has long distinguished the leadership the industry will, despite these difficulties and unde- terred dists, group pressure, doctrin- aire formulae, wisely effect reasonable balance the delicate adjustment the problems now pressing. ° ° Having briefly and inadequately outlined the case, the writer, from the remote side lines and with great temerity, submits for consid- eration the following observations relating facts well known throughout the industry. Some these mites relate the compara- tively cheap and quick methods increasing pig iron and ingot pro- duction for emergency use. Others relate probably long trends af- fecting considerations relating possible plant extensions. First, may observed that progress the steel industry others not measured terms continuously uniform rates. There are number historic periods recording gigantic strides; another such period seemingly now the making. Also, the industry has pe- riods marking predilection for specialization as, for example, the continuous strip sheet mill, in- tensive research relating slag controls, the chemical and physi- cal development alloy steels. result these important studies the consumer has been given group comparatively new materi- THE IRON AGE, May | : | | if a | | als without which the many impor- tant phases astounding techno- logical advancement would have been impossible. While the actual tonnage the alloy steels devel- oped result research repre- sent only fraction the total in- got production, also true that the production, quality, and uni- formity the larger tonnage carbon steels has been greatly im- proved result collateral re- search. the meantime, because spe- cialized research, the old depend- able blast furnace which the pri- mary source all steel production, and the Bessemer process and plant which gave the country roads, buildings, bridges and agri- cultural machinery, have been rela- tively neglected. Axiomatically, any substantial improvement affecting blast furnace operation econo- mies must necessarily extend over the entire range steel products. When Gayley 1904 disclosed the startling results produced dry blast his classic demonstra- tion the Isabella furnaces faced incredulous world. Later the remarkable increase produc- tion, decreased fuel consumption, reduction flue dust, and uniform- ity pig iron resulted the in- stallation nine plants the United States. These installations occupied much space; capital re- quirements were great; operating and maintenance costs were com- paratively high. Concurrently, the growing interest the utilization blasts furnace gas resulted the operation the blast furnace the dual role iron and gas pro- ducer source energy for driving blowing engines and plant generators. The urge for fuel econ- omy thus abated and the dry blast was consigned the limbo for- gotten good things. Progress since that time air conditioning methods has led the simplified modern plant. very compact design requires much less space, less capital expenditure, great dependability, attractive op- erating and along with little supervisory con- trol. The bulky brine coils and their containing chambers used Gayley have been replaced simple concrete chamber which the air cooled and the moisture condensed contact water sprays. All entertainment effec- tively eliminated static baffles. These sprays maintain deg. dew point, indicating moisture 42—THE IRON AGE, May content about 2.85 grains per cu. ft. There are, therefore, de- frosting de-icing periods with the accompanying loss energy due the partial insulation caused ice the former brine coils. The ponderous reciprocating steam engines, required ammonia com- pressor drives, have been replaced either steam turbines electric drives, with very close automatic regulation either type. (See Fig. 1.) Three successive installations (with the fourth under construc- tion) the modern dry blast plant fected before compression, have thoroughly demonstrated their de- the Birmingham district. The re- sult this demon- stration means for controlling the fundamental condi- tions necessary the blast furnace long cherished conceptions from dreamland the world stern realitv. The steel ever increasingly indebted Gayley for his early masterlv ap- preciation the broad significance blast control. His dramatic dem- onstration unfortunately the times. has remained neg- lected tool extraordinary impor- tance, ranking with the mixer, but await the development plant, the pressure more rigid specifications, and more compre- hensive appreciation the disturb- ing effects mutables—including free air influencing iron and steel operations. making moisture comparisons between northern and southern areas well-known fact that the humid and dry seasons the North have their turning points during April (humid) and October (dry), whereas the southern areas the humid season extends over longer period. This appar- ently favorable balance for the southern area with reference dry blast operations not supported Gayley’s figures. While the north- ern humidity lower during the dry season, the per centage varia- tion moisture greater than during the humid season. Gayley Isabella reduced coke consumption and improved quality dry blast furnace compared with sister free air furnace, al- though the winter was unusual dryness. attributed the results furnace regularity which the zone fusion was stead bouncing and down the bosh, alternately building and removing scabbing material which interfered with uniform furnace operation, including quality iron. Since power charges represent the principal operating cost, will found through much the dry sea- son, unlike the Gayley cycle, the present design the compressor will often idle, free air frequently contains less than 2.85 grains per cu. ft. (the minimum moisture at- tainable with direct sprays). order uniformly maintain this desirable moisture constant would necessary use only suf- ficient energy (steam) for humidi- fication instead dehumidification. Per Cent More Production crease iron production per cent for given furnace and reduce annual fuel consumption amount. Expressed differently, the application dry blast hypo- thetical group furnaces equal capacity would produce tonnage equivalent additional furnace. Decreased fuel consump- tion would relieve coke oven re- quirements. Realization these objectives would secured with lower capi- tal, much less time, and decreased operating labor requirements. much, then, for relatively cheap, quickly available method securing additional emergency pig iron requirements. However, regardless emer- gency requirements, there are other considerations tance indispensable further met- allurgical progress. These may briefly stated below: (1) Reduced fuel and limestone requirements. Primarily coal con- servation measure protecting the high grade coking coal deposits. More strictly this may regarded economic rather than metal- lurgical consideration. affects final costs here included. (2) Increased physical tempera- ture the pig iron, permitting the use lower silicon metal, shorten- ing the blow and decreasing con- verter loss. (3) Decreased ladle skulls. (4) Decreased scruff. (5) Lower sulphur the pig iron. (6) More uniform regularity sulphur and silicon the pig iron. 4 ‘ (7) The use controlled pig the mixer would level chem- ical variations mixer iron, add- ing (as guide the blower) in- creased significance “mixer where the iron does not always “mix.” and open hearth prac- tice, long current, which the characteristics the pig iron are not more rigidly controlled lead the well-known primary causes irregular steels induced vari- ations silicon, sulphur and metal temperature. The well-known complexity the open hearth slag metal system with its interrelationship nu- merous variables which there are comparatively slight variations, re- quire precise operations the greatest possible control these mutables. Present rigid chemical and physical specifications endless type tailored steels tend increase the production mis- fit heats. Such heats represent per- fectly sound steel, but they just not meet the specifications; and un- less they are remelted they must stocked and rehandled for later dis- position, which frequently promptly possible. minimizing the production such heats essential uni- formly maintain such oxidation conditions that the several deoxi- dizers will regularly produce inter- changeable steels the particular type desired. Effectuation requires close silicon control the type slag required controlled without subsequent bath additions, operation requiring both time and lime. The second step ad- justment pertains sulphur regu- lation which also another time, lime consumer. The importance sulphur content and its segrega- tion because its deleterious influ- ence rolled products has been ac- centuated the enormous increase flat rolled products. These ele- mentary facts are well known that any elaboration The justifiable conclusions relating the use controlled pig iron the open hearth are: Decreased melting time; decreased lime; de- creased fuel; ries; decreased deoxidizers; de- creased misfit heats; decreased re- jections rolled products; and de- creased preparation costs billets, blooms and slabs. While the importance con- trolled iron the open hearth well recognized may, because different metallurgical characteris- tics, exert more important influ- ence Bessemer operations. Com- pared with the open hearth, the Bessemer conversion iron pro- ceeds with lightning rapidity. acid Bessemer the only available slag (the character which de- termined the composition the metal) the silicate iron and manganese resulting from the oxi- dation impurities the iron, which respect differs with the open hearth where slag formation and regulation occurs over com- paratively long time. Acid Bes- semer slag agent the re- moval sulphur inactive. The reduction weight the Bes- semer charge following the removal impurities oxidation tends increase rather than decrease sul- phur content. Low sulphur steels the Bessemer can only the use low sulphur iron. Notable variations silicon the iron affect the quality the steel despite temperature adjust- ment coolants the converter. The sensible heat the iron which function the molten temper- ature may also cause significant va- riations bath temperature and quality the steel. The primary control these im- portant factors determined largely blast furnace operations, the product which, with existing and continuing variations, prevents Bessemer operations with “flame” and iron control. Since the introduction the process Bessemer and Mushet the only important metallurgical advance during its long history the recent development and applica- tion “flame control” which the “electric eye” photo cell more accurately and uniformly deter- mines the end point and the degree variation oxidation required regularly produce the various grades steel within the range the Bessemer process. Great Promise for Bessemer The use the photo cell has re- duced the number off heats, de- creased ferro manganese require- ments, increased ingot yield, and most importantly, means closely regulating predetermined ranges physical properties. This scientific approach the produc- tion Bessemer steel has strongly silhouetted the basic need con- trolled metal with reference both composition and temperature the further economic utilization this tool hastened and extended. survey these well-known facts indicates that the value controlled iron the Bessemer, when endeavoring secure the greatest possible advantages of- fered the photo cell, may exceed that the open hearth. The ad- vantages controlled Bessemer metal are: Decreased blowing time; decreased power; increased yield; decreased refractories; decreased THE IRON AGE, May 1941—43 m 2700 Ons of a : | off heats; decreased rejections rolled products; and decreased preparation cost billets, blooms and slabs. Other possible and desirable Bes- semer controls are herein men- tioned connection with Bessemer plant design. Another factor creased blast furnace production, fuel and greater regular- ity that relating the furnace stock line. Regarding this subject there has been much conversation, many literary contributions, and masterly field inactivity. During decade the hearth expanded from The largest hearth now measures ft. in. Concur- rently, marked advances mechan- the development and application various record- ing instruments, increased blast, higher stove temperatures, cleaner gas, the preparation, grading, stocking and charging raw ma- terials were other contributions re- sponsible for increased production and smoother working. The evolu- tion the blast furnace, including its lines and technique, the re- sult careful studies, later ex- pressed brilliantly successful ex- perimentation conducted primarily for the purpose securing more and working furnace. The notable lag progress re- lates the inadequacy the big bell with respect distribution the stock line. Mechanical top charging has satisfactorily solved peripheral distribution but with the discharge the big bell uncon- trolled forces work havoc with ra- dial distribution. The furnace en- gineer when using the conventional bell and hopper limited the use dimensions out propor- tion the increased quirements the modern furnace. Adequate increase these di- mensions result either the for- mation excessive central areas increased porosity and greater gas permeability the failure pro- tectively seal the walls with fine stock. The existing condition, therefore, somewhat similar the installation 1000 hp. boiler over 1500 hp. stoker. High stoker efficiency attained the cost low boiler efficiency per contra. Fig. and Steel Engineering, January, 1941) showing the evolu- tion the modern furnace clearly 44—THE IRON AGE, May reflects the influence this im- posed limitation. 1920 the earlier hearth-bosh ratio unity more had decreased 0.92, while 1939 the ratio further dropped 0.72. Other and larger hearths have smaller stock lines. This en- forced throat contraction leads high gas velocities, excessive dust improperly irregu- larly prepared stock, high fuel con- sumption and decreased production. For years the use the other than gas seal has been anachronism. With large hearths its continued use insufferable. The primary function the blast furnace the reduction iron ores and the production molten the lowest possible cost. The blast furnace plant, including boilers, blowing engines, stoves and coke plant requires large capital, maintenance and obsolescence charges. Other factors being equal the coke rate determines molten production. The secondary use gas producer, therefore, limits the attainment the first objective imposing the consumption the extra coke required the produc- tion fuel gas. doing, addi- tional impurities are charged the form coke sulphur, phosphor- ash and increased stone. Their removal part accommo- datingly affected the use the expensive plant required furnish hot blast relatively high pres- sures. The results are decreased tonnage, the week-end surplus furnace coke gas which not al- ways most profitably utilized, and the earlier depletion high grade coking coals. Substitution cheaper secondary coals less ex- pensive gas producing plants, the use other fuels when eco- nomically available, would furnish more readily controlled fuel sup- ply with higher heat value, permit- ting faster heating, reduced cost gas mains, regenerators and recu- perators now used preheating the air gas. Regarded only iron maker and therefore ignoring considera- tions relating the fuel value the gas, apparent that the blast furnace result defec- tive radial stock distribution and restricted throat area now oper- ated contravention the ele- mentary laws physics and chem- istry. Some the widely recog- nized fundamental requirements are: Homogeneous stock mixture; and uniformity gas composition given zone, gas temperature given zone, gas velocity given zone, gas given zone, and time. Abundant data relating therms, isobars, gas pressure, com- position and velocity confirm the regular irregularity these fae- tors. The satisfactory completion any reaction closely related the time element, which ing mass the blast furnace function volume. The excellent results attending slack eration during the depression at- test the importance the time fac- tor. Highly accelerated modern driving requires corresponding vol- umetric increase order effec- tuate preliminary reduction the sessing uniform characteristics throughout given plane the stock column, which the gas solid contact should consistently inti- mate. Under these conditions pre- liminary reactions will largely completed temperatures which the CO, equilibrium ratio exist suitable temperatures for indi- rect reduction the upper portion and lower zones the stack, mini- mizing the secondary reactions af- fecting solution loss after the fa- miliar formulae reaction which not appreciable below 900 deg. 1000 deg. The second solution loss accompanies the reaction iron oxide, These reactions not only steal car- bon but being highly endothermic abstract heat the lower and bosh sections just where heat absorption affects hearth temperature. is, therefore, the utmost economic importance effect the greatest possible reduction ore high the furnace order avoid the formation formed the higher temperature zones which greatly contribute solution loss. New Blast Furnace Bell How ineffectively this result being accomplished disclosed the careful investigations the Bureau Mines (Technical Paper No. 442, which stated, results indicate that only 24.4 per cent the reduction being done the shaft the furnace, whereas 75.6 per cent being done the hearth and bosh.” attempt secure wider throats and substantially amelio- | Ks) wit fix di: | A ' ~ ! | s . | rate, without hope securing homogeneous stock column, the writer has devised the arrange- ment schematically shown Fig. The main feature the use fixed supplementary distributor functioning secondary bell cone, coaxial with the bell. The top diameter the frustrum being larger than that the bell. The distributor suspended hang- ers, F.F, pendant from the metal dome cover, G.G. Encircling the cylindrical hopper extension the ity the core, thereby assisting more uniform distribution the ascending gases stock column improved homgeneity. The effect upon furnace lines following the use this arrange- ment its equivalent shown greater than which ft. higher than Here the diameter the distributor about equal the stock line diameter The respective areas are 298 433, increase per cent; the fa- ‘S ' ' ' ive « H 10-Tuyeres 1920 downwardly and upwardly movable barrier sleeve, attached op- erating suspension (heavy tubes), E.E, passing through gas sealed opening the cover plates. charging operations the bell dropped position The stock, flowing freely from the hopper, cas- cades over the distributor and its gas louvre the peripheral annu- lus. proper charging sequences the sleeve lowered the level corresponding with the upper plane the frustrum, forming exten- sion the hopper, preventing the flow hopper stock until the bell enters further into the frustrum, where stock flows into the central annulus during the progressive de- scent the bell position following proper quences the central stock column crater can regulated permit controlled variations the poros- 1939 2—These diagrams show the lines successive rebuilds the modern blast furnace. vorable effect upon flue duction apparent. The hearth-throat ratio has been restored the more normal value 0.85. Removal replacement made the removal cover plate G.G. Stack lines related these pro- posed proportions would for the first time demonstrate the real actual hearth capacity the mod- ern furnace before reaching that stage now known “over blown.” While these dimensions could not secured existing stacks, very substantial crease can obtained the sub- stitution 22-in. walls for the heavier walls now used. The in- creased volume resulting would gainfully utilized ore reduction, instead providing room for in- ert brick work. The long belated exploration the stack section promises results with respect cost and quality, which over all economies ranging from coke plant rolled products are large and obvious. The use the Bessemer con- verter means greatly in- creasing ingot production, either the duplex triplex process, has Top furnace eres Proposed plants for years. The production synthetic Bes- semer iron, derived from the use mixture low phosphorus scrap with the addition sufficient ore and flux required the formation adequate slag volume, has been successful operation for more than years. The smelting such mixture results enor- mously increased iron production from given stack. Here, then, are two methods which, when compared with the in- stallation additional open hearth furnaces, offer with minimum in- vestment, shortened construction time, and decreased labor require- ments flexible means cheaply and quickly increasing ingot ton- nage. The writer keenly aware that recording these well-known facts THE IRON AGE, May — | ” 9-6 / 1950 relating purely methods quickly increasing production they are rather barren humdrum. Viewed broader perspective relating proposed construction determinative influences upon long trends the steel industry they are fascinating interest and great economic importance. The term Bessemer steel here- inafter used refers steel made Bessemer converter from iron suitable chemical and physical com- position, conducted ade- quate plant controlled highly skilled the arts conver- sion, teeming, heating and rolling. This limitation perforce excludes some steels which may have passed through Bessemer converter. Bessemer characteristics, including great stiffness and high tensile strength for given carbon content, ready weldability, machin- ability free cutting, its satisfac- tory behavior the draw bench, and its special wear quality wearability, shafts axles, are superior qualities not com- bined other steels. These char- acteristics distinguish Bessemer steel unique material inher- ent worth. differs from open hearth steel cold sponse. Corrective adjustment composition and ments present problems search. Technical discrimination respect- ing appropriate application, coup- led with aggressive sales activity would reclaim much lost tonnage. Other increments magnitude based price consideration would result the displacement open hearth steel when physical require- ments could equally better served Bessemer. Bessemer steel greater uniformity and higher quality, including the now possible reduction the phosphorus con- tent below present standards, when and required, will further extend its field. The vigorous development American acid paralleling the extraordinary growth the basic Bessemer Continental Europe and England would conserve national fuel sup- plies and afford reciprocal economic advantages producer and con- sumer domestic export markets. The earlier consumer demand for low phosphorus steel was served the adoption the open 46—THE IRON AGE, May hearth process. Because the large tonnage back flow scrap generated the converter during its dominancy, and adequate raw material supply vas cheaply available costs less than pig iron. The larger invest- ment blast furnace and coke plant was unnecessary. this base the open hearth was built and now rests. The future scrap trend uncertain. certain that the ex- tinction the Bessemer process which produces more scrap than consumes, would decrease the scrap supply, bringing further unbalance. The continuing expansion the electric arc induction furnace will further decrease open hearth supply. The use the electric fur- nace the production special carbon grades steel areas af- fording cheap assemblage raw material and the distribution the resulting rolled the same area presents new steel trend. This trend will further encouraged stimulated the availability cheap current gener- ated Federal power plants, and cheap fuel distributed natural gas oil lines. The increasing use alloy non-corrodible steels not helpful scrap proved methods protecting steel surfaces either with metals pig- ments will further contract scrap flow. Much, perhaps all, the large steel exports during the war period are beyond domestic scrap reclamation. Apparently the era adequate cheap supply scrap ending. this so, considera- tion the Bessemer process, either connection with the production Bessemer steel its use du- plexing, importance this time. Ore Supply Increased One the factors contributing the decline the Bessemer proc- ess was the anticipated compara- with these changed and changing conditions will found that the ore tonnage avail- able for Bessemer use greatly increased. Bessemer steel can be, and now commercially produced from iron carrying 0.30 per cent phosphorus. The Tata Iron Steel Co., Jamshedpur, In- dia, for years large producers adopted the Perrin process which iron containing 0.30 per cent phos- phorus blown acid Bes- semer converter. The blown dropped from considerable height into the casting ladle, containing very basic molten slag. Dephos- phorization immediate and satis- factory—0.03 0.035 per cent phosphorus. Their arranged nates the use the open hearth previously required duplex oper- ations (Yaneske, British Iron and Steel Institute, September, metal containing 0.150 per cent phosphorus was reduced 0.06 per cent, the use dry dephos- phorizer consisting per cent lime, per cent scale, and per cent fluorspar. their 8.5- ton heats carrying 0.100 per cent phosphorus the use 500 per heat this mixture reduces the phosphorus content per cent. The resulting steel possesses, among other desirable qualities, characteristics superior either open hearth standard Bessemer, making valuable for special ap- plications (Gordon Yocum, Metals Tech., T.P. 1265 January, 1941). This adaptation the acid Bes- semer converter the use non- Bessemer iron comparatively new development which more ex- tended experience will bring fur- ther refinement and wider applica- tion. There is, however, large potential ore tonnage Bes- semer grade which will later available standard Bessemer practice, will indicated. probable that the next dec- ade will witness the peak high grade Lake ore ciencies will replaced the beneficiation the billions tons low grade ores. The large depos- its lean magnetites will with magnetic concentration yield high grade Bessemer ore. Important de- posits magnetite other regions Other ores the hematite class available either magnetic concentration after roasting, pres- ent hydraulic methods, entirely new concentrating techniques. The gradual replacement, this manner, the present large pro- duction high grade ores will the aggregate require huge capital expenditure more than casual in- terest with respect the capital structure integrated companies. These capital charges augmented the costs will manifestly increase ore — | cos pel dit —~ po 0 | costs the mine. Partially com- pensatory credits will flow from transportation savings and econo- mies effected the blast furnace the use beneficiated ores. Ad- ditional compensatory credits much larger significance, during and following the inevitable trend outlined, are those lower steel cost (operating and capital) made possible expanded Bessemer duplex operations. pendence scrap market vagaries would weighty factor mar- ket stabilization. Basically, the proposal resolves into defensive cost policy. the extent that steel costs are reduced, the industry would the same de- gree gain protection against inter- market competition other metals synthetics. The past performance the Bes- semer process requires apologia other than note that was born and reared without benefit that efficacious modern tool known’ research. Refinements the Bes- semer process the work treatment steel were unknown producer and user. Bessemer plant pattern de- signed vears more ago. be- lated recognition these condi- tions should secure for the Bes- semer the very reasonable request that now given precisely the same treatment profitably corded the open hearth; namely, research modernized plant bility facilities required eco- nomically applying the more recent technological findings, further development and utilization dictated research. Pending this development will impos- sible intelligently approximate the probable limits Bessemer production. The support given the open hearth, extended the acid Bessemer process, should result the renais- sance comparatively neglected process which the much more wasteful basic Bessemer, with its huge English and Continental ton- The production good steel any known steel process requires raw material suitable and uni- form chemical and physical charac- teristics. The sensitivity and im- portance controlled Bessemer operation has been briefly mentioned connection with the controlled iron. The obligation and responsibility ful- fillment this primary require- ment obviously rests with the blast furnace department. The Bessemer takes over the accurate determi- nation molten temperatures, and the correct weighing all materi- als used the converter ladle. The acid Bessemer offers the fol- lowing recognized advantages: (1) Decreased capital require- ments for the production given tonnage. (2) Decreased ingot cost. (3) Facility with which open hearth production can greatly boosted duplexing during peri- charg- ing device permits wider throats and sub- stantially ameliorates designing modernized Bes- semer plant improbable that the huge Pierce- Smith converter used copper practice can sat- isfactorily adapted steel prac- tice. Size limitations the con- ventional type are mechanical rather than metallurgical. The use 45-ton basic Bessemer converter with the accompanying larger slag volume has been German practice since 1931 (Hoesch-Eisen Stahl- werke, Dortmund, Westphalia). 50-Ton Converters There should experimen- tal formidable problems the development 50-ton acid con- the homogeneity the stock column the blast furnace. ods requiring extraordinary out- put open hearth ingots. (4) Production flexibility, per- mitting wide daily variations output, with less dislocation lev- eling labor quota. (5) Greater adaptability the production small special heats compared with the open hearth. (6) Ability supply steel mar- kets requiring the particular quali- ties possessed various Bessemer grades. (7) More uniform soaking pit heating practice because syn- chronization converter and bloomer. open hearth heats disturb uniform heating con- ditions. plies. (9) Compact plant. (10) Short preparatory period required reach capacity follow- ing periods idleness. verter. The use such vessel would reduce charging and pouring time for given tonnage. Larger heats would reduce the number different sets physical work- ability levels per unit produc- tion. This desideratum would more closely approach open hearth prac- tice consolidating two 50-ton heats the same grade 100- ton casting ladle. eliminating this needlessly weak spot caused the present small heat Bessemer practice would possible, with the assistance flame and other controls, more quickly develop greater technical consumer appre- characteristics Bessemer grades, and more discriminating but wider application. Other problems design relate blast connections and considera- tions relating blowing costs which constitute important item “cost above.” The costly pres- THE IRON AGE, May ig | | Q | | a by | sure drop occurring the con- verter disk valve, trunnion and wind pipe, ranging from rep- resents drop about per cent the initial pressure. The use two trunnions generous diameter instead one conventional design, larger valves improved design and larger blast pipes the wind box are obvious correctives. Independent blast line each con- verter with by-pass connection the spare converter will permit con- trolled blast pressure, which im- possible when using common line. Another energy loss results from maintaining blast pressure ex- cess that required the ferro static head and the necessary dy- namic action the blast. The proper distribution additional tuyeres for the same blast volume will reduce excess pressure, while the activity the increased tuyere area will also reduce blowing time. Incidentally, the adoption this modified tuyere plate crease output some Bessemer plants now pushed for emergency production. Wind box leakage irregular and indeterminate volume an- other source loss, preventing more accurate estimation the time blast volume required fol- lowing established end point. Additional field data should derived relating the optimum length tuyere, order reduce bottom refractory costs time lost bottom changes. The present design tuyere orifice de- fies all considerations efficiency known man nature. delicacy the essential ther- mal control the molten metal necessary straight-line humidity and temperature constants the blast. The modern dry blast spray system used controlled blast furnace operation equally avail- able for converter use. For the control blast temperature suggested that the neglected con- verter gases used heating serving feed water heater. The waste gases from such plant their passage through brick checker system, serving heat reservoir, would the use metal recuperator, preheat tion the total volume required. automatic mixing valve used blast furnace practice, admitting 48—THE IRON AGE, May the heated air into the main blast line would maintain uniform but very moderate blast temperature. High blast temperature would in- crease scrap carrying capacity permit the further reduction sil- icon the molten. Until the effect high temperature upon trunnion bearings and tuyere life could determined, the moderate straight- line temperature objective could realized without affecting converter practice. The use commercial oxygen and when becomes economically available could advantageously used during the early portion the foreblow, decreasing blowing time and silicon requirements. The converter tilting mechanism must all times have sufficient ca- pacity quickly the vessel order avoid tuyere filling caused increased area tuyere ex- posure. must also able handle the vessel under any condi- tion unbalance caused lining erosion kidney accumulations; otherwise the elapsed time from end point pouring position would introduce intolerable time vari- ant seriously affecting the precision flame control. Spacious provision should made for reladling and when nec- essary, other requirements fol- lowing research developments relat- ing post converter operations the further refinement the bath. Bessemer plant consisting two 50-ton converters and spare produce approximately 5000 tons steel per 24-hr. day. The production such large tonnage the concen- trated Bessemer area will require very radical modification the pouring methods now used either the Bessemer open hearth plant. After pouring, the heat will promptly conveyed ladle trucks carrying insulated ladles teem- ing hall. Obviously the several possible methods, each arrangement will determined the preferences the engineer and the Bessemer man- agement. Any arrangement should embody the known but not always realized essentials for the produc- tion sound ingots. Without de- laying converting operations, should possible permit the ladles remain standing long enough thoroughly complete ladle reactions and effect the greatest possible elimination non-metallic inclusions, after which teeming one plurality teeming tracks and stations would follow. These teeming tracks should sufficient number permit the teeming low high carbon steels their respective tracks: Also, for molds, standard, special slab molds. doing, greater dis- crimination could exercised the assignment mold track stand- ing time before delivery the stripper. Bessemer teeming station facilities should permit the utiliza- tion the costly experiences and the ever increasing finesse the open hearth and electric furnace the production sound steel. The use tundish favor- ing environment would decrease the ferro-static pouring head, decrease mold splashing and liberate some gases now carried into the molds. tundish would di- minish the curse too fast teem- ing improper pouring tempera- tures, the evils which are well recognized. This practice would increase Bessemer operating costs slightly, over-all costs would re- duced result fewer cracked ingots, reduced preparatory cost blooms and slabs, and decreased mill rejections. the writer’s belief that the methods suggested, some old and some neglected and some new, would permit consolidation produc- tion and quality gains extending from the blast furnace finished product. this way will found, through the lower cost mass pro- duction, greater protection the disruption the domestic and world steel markets following ces- sation hostilities. Most impor- tantly, the production Bessemer steel will have become for the first time its history scientific proc- ess and not highly skilled art. The application controlled opera- tions with suitable equipment per- mitting the reproducibility given grade steel possessing uniform and stabilized characteristics will reclaim much lost steel market. Undeveloped uses applications following lower costs and improved quality, all basic industries, will result greater profits for the producer and expanded benefits the ultimate consumer, the public. necessity exchanging production data during this period peak production, and the many extra-curricular ac- tivities offered the City New York, will undoubtedly attract record group foundrymen the 45th annual convention their As- sociation, New York, the week May 12. covering the practical and scientific advancements the industry, the information obtainable the con- vention has been prepared appeal all types foundrymen, including executives, engi- neers, research workers and man- agement. unusually imposing group experts their respective fields has been secured present papers variety interesting phases foundry work, many touching problems important the National Defense Program. The excellent facilities available Hotel Pennsylvania, convention headquarters, for the holding all types meetings, together with the fact that all A.F.A. activities will confined the hotel, will definite advantage those at- tending. Such Foundrymen Prepare for New Yor Meeting makes possible secure easily the information desired individ- ual foundrymen. the program appended herein indicates, presentation papers and committee reports will begin Monday, May 12. Gray iron, malleable and non-ferrous meetings various types well shop operation courses will held Monday and Tuesday. Wednesday, May 14, has been designated the day for the annual Board Awards lecture and business meet- ing, and the annual Association dinner. The Board Awards selecting outstanding national speaker the Awards lecturer. Sessions steel and gray iron castings will held Wednesday and Thursday with the shop opera- tion courses continuing throughout the entire four days. Scattered throughout gram are sessions general in- terest. For example, foundry train- ing, most important subject, will emphasized the apprentice training session, with Pat- terson, Federal Committee Ap- prenticeship, speaking “Appren- tice Training the Defense Program.” The A.F.A. Committee will discuss, symposium, re- lated instruction for the pattern and foundry apprentice. Safety and hygiene will dis- Roger Williams, assistant director, Inspection and Safety Service De- partment, New York State Insur- ance Fund. This meeting will continuation the series de- veloped under the auspices the Safety and Hygiene section the The four major Gold Medal awards the Association for meri- torious service are made four men who have made outstand- ing contributions the advance- ment the foundry industry. This year the awards are: The Joseph Seaman medal Charles Edgar Hoyt, executive vice president and manager exhibits the American Foundrymen’s As- sociation. The award Mr. Hoyt being made for his exception- ally outstanding service foundry industry manager the foundry exhibits since 1908, secretary and treasurer the As- sociation from 1918 through 1936, since 1936. The Whiting medal Don- ald Reese, engineer, Research Development tional Nickel Co., New York, for his outstanding cont