The Iron Age 1943-12-30: Vol 152 Iss 27

JAN 1944 DECEMBER 30, 1943 ENGINEERED AND PRECISION BUILT INTO YOUR sur- 200 and Park SIDE TRIMMER AND SLITTER five hundred feet per min- mild steel .156 inch thick- trimmed and slit with four Adjustable for various widths. Aetna-Standard engineers and builds complete in- stallations auxiliary equipment your produc- tion specifications whether you are steel, non-fer- rous, plastic, chemical industry. They will dove- tail into your present proposed facilities. Every piece equipment engineered experienced men and precision built our two modern plants. AND CHEMICAL INDUSTRIES HEAD, WRIGHTSON COMPANY, LIMITED, ENGLAND JUHN COMPANY, TORONTO, ONTARIO, CANADA ff ‘ DESIGNERS AND BUILDERS THE plus Fg > THE published every Thursday the CHILTON CO. (INC.). Entered second class matter November 1932, the Post Office Philadelphia under act March 1879. yearly North America and South America, Foreign $15. Vol. No. 27. has muffle; the ynits heat directly onto the Hoskins manufacturing Co., Detroit, Mich. VAN DEVENTER Presiden? and BAUR Viee-President General Editorial and Advertising Offices East 42nd St., New York Hayes, Production Manager. Baur, Typography and Business Managers New York New York 100 East 100 East St. Pittsburgh Bidg. Park Bidg. Chicago Chilton Bidg. 1134 Otis Bidg. Detroit Hartford Conn. RAYMOND KAY Los Angeles 2420 Cheremoya Ave. Owned and Published CHILTON COMPANY Executive Offices Chestnut and Sts., Philadelphia 39, Pa., U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President JOS. HILDRETH Vice-President @EORGE GRIFFITHS Vice-President EVERIT TERHUNE Vice-President VAN DEVENTER Vice President BAUR Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE THOMAS KANE HARRY DUFFY CHARLES HEALE ° Member, Audit Bureau Circulations Member, Associated Business Papers the Arts Index. Pub- lished every Thurs Subscription Price North America, Sout America and Possessions, $8; Foreign, $15 Single Copy, cents. Vol. 152, No. IRON AGE Editorial Overlooked Postwar Factor Technical Articles Scheduled Machine Inspection Welding Booth Curtains Made Fire Anthracite Pig Iron Effect Oxygen Enriched Blast Coke Desulphurizing Pig Iron with Acid Slags Dynamic Hardness Testing Articulated Truck Carries Blimp Fabric Carbide Drawing Dies Tubes and Tube Making Features News Front Assembly Line Washington West Coast Fatigue Cracks Dear Editor News and Markets Prompt Cancellation Promised New Plan Wage Demands Reveal Steel Firms Close Brink Army Reorganization QMC Procurement Personals and Machine Tool Non-Ferrous Metals News and Developments Non-Ferrous Metals Prices; Scrap Prices Iron and Steel Scrap News and Prices Comparison Prices Year Finished Iron and Steel Prices Steel and Warehouse Prices Stainless Steel, Tool Steel Prices Semi-Finished Iron and Steel Prices Pig Iron Prices Ore and Coke Prices Ferroalloy Prices Index Advertisers December 30, 1943 / 106 108 110 111 112 114 115 116 117 118 120 121 123 151 | ‘ ° ° : | 4 | | ; wil ° ° ° Office Ryerson now interprets modified Jominy Test re- sults terms quenched and drawn physical prop- erties for and 4-inch round alloy steel bars. RYERSON ALLOY STEEL REPORT (Fer Jomimy Test interpretation see reverse side) to your order. Jeominy Tests property IDENTIFI ere mode in the Ryerson Laboratory. This Type CATION hon due to segreganen, et Jominy End Quench Test Results ERE Heat Anclysis Carbon Pro $34 1 &. [- H Grain Size Working Temperatures Physical Properties from Jominy Tests “E and drown os shown. Yield Point Reduchon of Round of the Drow Psi Pst om Inches Ane ra + 4 + + + RYERSON ADELPHIA New Data Alloy Physicals Ryerson furnishes hardenability interpretations with each alloy steel shipment The new Ryerson Alloy Steel Report sheet furnished with each shipment alloy steels from stock. This report includes: positive identification for the steel you receive its the recommended working temperatures the steel chart its hardenability re- sponse with interpretations the physical properties after heat treatment and the effect mass the physicals and 4-inch bars. All this information makes easier for you specify your alloy steel requirements terms what the steel will rather than analysis alone. further guides you the proper heat treatment your steel obtain the best results. Ryerson engineers and metallurgists will gladly assist you any problem steel selec- tion, application fabrication. Investigate this helpful service next time you need steel from stock. Joseph Ryerson Son, Inc., Chicago, Mil- waukee, St. Louis, Detroit, Cleveland, Cincin- nati, Buffalo, Boston, Philadelphia, Jersey City. RYERSON 24—THE IRON AGE, December 30, 1943 om q 3 i | — a ‘ Inch | Round = 2 Rownd 3 lech Round Round IRON ESTABLISHED 1855 Dec. 30, 1943 VAN DEVENTER President and Editor BAUR and General Manager DIX Manager, Reader Service Managing Editor....... LIPPERT News, Markets Editor...D. WINTERS Associate Editors MacDONALD BARMASEL Editorial Assistants SCHIEN WILLIAMS BUTTERS News and Technical CAMPBELL Pittsburgh 428 Park Bidg. POST Chicago 1134 Otis Bidg. MOFFETT DONALD BROWNE EUGENE HARDY Washington National Press Technical Editor......... OLIVER LLOYD Cleveland 1016 BRAMS Detroit 7310 Woodward Ave. OSGOOD MURDOCK San Francisco 1355 Market St. Correspondents ROBERT Cincinnati PENLEY Buffalo FRAZAR Boston HUGH SHARP Milwaukee SANDERSON Toronto, Ont. RAYMOND KAY Los Angeles JOHN McCUNE Birmingham ROY EDMONDS St. Louis JAMES DOUGLAS Overlooked Postwar Factor changes people well geopolitics. The boundaries our country will not changed much after this war the geographical sense, but the mental horizons our people will greatly enlarged. And not think this psychological postwar factor making plans for doing business, will missing the boat. The cream the nation has gone will war. Armed forces eleven million people mean that some fifteen million more will probably have been uprooted from customary environments before the conflict finally over and will have been subjected experiences that will make them entirely different from what they were begin with. They will have become disciplined the hardest school hard knocks. They will toughened physical, mental and moral fibre. great majority them will have received specialized training and education far beyond what they would normally have gotten peace time econ- omy. They will have learned resourceful overcoming seemingly impossible obstacles and determined reaching their objectives. These fifteen million the cream America, will not all return after the war. But the great majority them will and they will form the backbone and the viscera this country for ten years more thereafter. And the way that they think will determine what kind country this will be, for “as man thinketh, he.” Uprooted from home environments from which normally they might not have strayed far, most these millions will have traveled over large part America and have visited the four corners the globe. They will have formed mental backgrounds seeing how other people live and act; other people other nations well many people our own. And from these exposures they will have formed ideas what they want and what they want have when they come back home. These people will know what they want and our postwar planning should directed toward making possible for them get it. They will want more than they had when they left. They will want wives and families and homes, better homes and more possessions than were had the wives and families they left behind them. They will willing work hard for these things because they have learned through the hard school war that something cannot had for noth- ing. But they will want jobs work at. And they will know what they not want. They will have had opportunity appraise both the virtues and the defects our democ- racy America through comparison with other countries. And not think they will tolerant the rackets and racketeers whatever class stripe that constitute democracy’s worst defect. When wants multiply and willingness work satisfy them hand hand, you have setting for real and solid prosperity. But not unless industry lives its postwar task producing more and better goods for more people lower prices. P | : | = = There are many types employment open machine operation, welding, stenography, laboratory work, etc. The need great that woman should able find exactly the type work for which she best suited. Perhaps Joan Could Help, Too! Have you stopped consider there place for your sister, your daughter yes, even your wife the great effort the metal working industry making help win this war? Through your everyday conversation the women your family realize the need for more production. They know about the shortage workers. They know that patriotic work, but because their place has been the home, many them are timid about going work office factory. You, worker America’s great metal industry, can dispel that timidity telling them about the many kinds jobs open women. Let them know that they are safe the factory the home; that modern Ameri- can factories are and that factory associa- tions are interesting. Talk Joan, Helen, Barbara this evening. years come they will proud the work they did help keep America’s homes safe and free. Check your local help wanted ads for specific needs your area, ask the local Em- ployment Service. INLAND STEEL COMPANY Dearborn St. Chicago Illinois Milwaukee Detroit St. Paul 26—THE IRON AGE, Detember 30, 1943 St. Louis Kansas City Cincinnati New York News WLB hearings, steel operators insisted that general price increases would necessity follow general wage rise. Since practically all contracts the steel industry have fixed prices, however, retroactive price adjustments can made absorb increased labor cost. Because joint action labor and industry members WLB voting down the compromise proposal offered the public representatives, the public members turned unite with industry defeating vote the CIO-USW petition retroactive application union demands. During 1943, 30,000 freight cars were produced. Average annual production for the five years ended Dec. 31, 1941, was 48,000. Authorization for 50,000 during 1944 has already come from WPB. Light metals and plastics will not menace the steel industry, Dr. John Weiss, industrial chemist, reported the American Chemical Society. Stimulation alloy steel production will bulwark steel manufacturers. Nor will increased use plastics hinder light metal development, Because the improved supply situation, warehouses can now handle hot rolled cold finished alloy steels NE-8700 NE-9400 Serious bottleneck the program shortage facilities for large tire casings. Cutbacks 100,000 200,000 units contemplated. Original military truck program called for about million 1944. Post-war auto tires may mounted wide rims. Although requiring anywhere from more metal per wheel, tire life increased. Smaller wheels, (which use less steel) and jumbo tires increase riding comfort, however, and also are being considered auto-makers for Increased output the Garand rifle and carbine has minimized need for the modified Springfield. Therefore, manufacture this weapon will cease Febru- ary. Remington Arms will continue make spare parts until August. Instead flat bonus asked for the UAW bargaining committee from the Wolverine Tube Division, profit-sharing program was inaugurated. Pumping free iron ore deposits under Steep Rock Lake has already begun, six months ahead schedule. When per cent the water removed, mining operations will start the "B" ore zone, largest ore body. Operations the "A" and "C" bodies will follow lake level recedes. After announcing last month that the Army was developing good dollar watch, the War Department has investigated the cost retooling for production expendable watch and found that the cost would come least $4.50. accuracy sufficient for battle use was unobtainable for forerunner much greater liquidation motive power, the Army has just released more than 10,000 commercial vehicles 1939 and earlier models, mostly trucks; 989 new 1942 passenger cars, and about new motorcycles. Export freight movement November, per cent from last year, estab- lished new record. Valued well over $1,000,000,000, approximately per cent was OPA, under orders from Congress, has banished all professors and substituted practical business men. charge the export price controls, place the quite satisfactory Dr. Harris who has gone back Harvard, business man. Not exporter restaurant man. German propaganda broadcast states that technologists have developed new structural material from waste paper. It's supposed excellent substitute for aluminum, and being manufactured large quantities. The Finns have just released detailed technical data captured Russian planes, particularly the LAGG-3, the rocket carrying tank buster. Three special rails under each wing carry rocket fragmentation bombs; velocity increment due the rocket charge 8250 ft. per sec., sufficient force the projectile through in. armor plate. This weapon has been used also aerial combat, registering hits 2000 ft. range. 4 | . O eC. a 1943 OMEONE has said that “the price Liberty eternal vigi- lance.” The same may said machine maintenance war pro- duction shops. Productivity plant must, because the war, sustained the highest possible level. Machine and machine parts replacements take weeks and often months, and there have been situations which the re- placement critical parts and ma- chines has been almost impossible. Consequently, the proper and ade- quate maintenance every tool and every piece equipment prime importance under such conditions. offset machine breakdowns and eliminate down-time production machinery because parts the Bell Aircraft Corp., through its Plant Engineering Department, es- tablished about seven months ago Machine Inspection Division. This division has complete charge ma- chine equipment inspection, and this job adequately and more thor- oughly has set “cycle inspection system.” The system operates such manner that every machine pro- duction inspected thoroughly varying frequencies, depending upon its importance the entire production set-up and upon its fragility. With slightly more than 1700 machines the Buffalo plant, where all produc- tion work done, this means that every machine thoroughly gone over about once ten days, and such sheet metal forming press, which there only one the shop, riveting machines, screw machines, and other similar equipment are inspected two, three, four, even five times during that period. present, there are nine plant facilities inspectors who work under the direction chief inspector. Three inspectors work the first shift, three the second shift, and two work the third shift. The chief inspector, order keep touch with all in- spectors working all shifts, starts before and works after his main shift work. Preparatory the inspection sys- tem the division made inventory machinery the entire plant. Every machine and piece equip- ment was identified name, manu- facturer, location the plant, Bell Aircraft Defense Plant Corp. num- machine inspection record made for all the 1700 pieces produc- tion equipment the Bell Aircraft Buffalo plants. The position card the card file determines the cycle inspection for each given machine. Where more fre- quent inspections are necessary specific equipment, duplicate cards are made and positioned the file that card for the inspection the specific equipment Fora 31-5 DESCAIPTION Location MANUPACTURER MACHINE INSPECTION RECORD BELL ¢ INSPECTION CYCLE volts CYCLES IF TROUBLE [8 FOUND, MAKE OUT PLANT ENGINEERING REQUISITION - OTHERWISE CHRCK U}F LIST BELOW. Items to be Checked inspected By 28—THE IRON AGE, December 30, 1943 Inspection Dates ber, and details concerning the motor equipment. Also, cycle inspection was determined for each machine. This information was tabu- lated machine inspection record cards, shown Fig. which are kept permanent file the chief in- spector. These cards were then sep- arated into three groups, according the type machinery: (1) Metal cutting equipment; (2) press and forming equipment; pickle, wash, rinse, and paint tanks; compressors; and (3) conveyors, elevators, station- ary lifts and cranes. lift trucks rolling stock are included the inspection set-up, this stock ser- viced the garage. Inspection Cycles With one card for each machine the files, was found difficult maintain the desired “inspection cy- cles,” for those machines that must inspected more frequently dupli- cate machine inspection record cards were made up. The plant, divided geographically into three parts ac- cording the number machines each location, permitted the filing the cards machine location each sector the plant. Thus, the dupli- cate cards were spaced the filing system such manner that cards were removed from the front the file, machinery inspected more frequently came for inspec- tion desired. Prior the beginning each shift, inspection orders, shown Fig. are made for each inspector ma- chine, and are given inspec- tor the start each shift. The inspection these machines con- stitutes his assigned work for the day. The inspection orders are taken from the machine inspection records, begin- ning with the first card the front the file and working toward the back. These orders used the in- spector, which there types according the three group- ings the machinery the plant, list the machine and have specific points inspection for each machine. The inspector reports the condition each inspection point “good,” “fair,” “needs repair.” repairs are needed, details the trouble are writ indi Eve Bell this spec chie one. Mai sma par the mer has cha not ord the ber ava : a = ma anc me cor In the cle each record kept in- sep- Metal and wash, trucks the ser- ult must dupli- cards livided ac- ines ing each dupli- filing nat ront spected inspec- shift, are ma- inspec- The day. from begin- front the in- three group- plant, specific achine. tion repairs ble are THOMAS LLOYD Aid Aircraft Parts Production written the inspection order, indicated the sample order shown Fig. actual inspector’s report. Every machine piece equipment, Bell D.P.C. owned, comes under this inspection system. the close each shift the in- spection orders are turned over the chief inspector who examines each one. When conditions machine warrant repairs, the chief inspector writes small order requesting that repair adjustment made the Maintenance Department. These small orders, shown Fig. are turned over the Maintenance De- partment for the purpose making the necessary repairs the equip- ment and come back when the repair has been made and approved. The inspection order forms are then turned over the filing depart- ment where they are checked again, changes location machinery noted the machine inspection rec- ord form and inventory sheets, and then filed according machine num- ber, that complete chronological history every machine instantly available. Each inspector carries book machine-down-for-repairs yellow tags and the event that machine must shut down for repairs, the depart- ment foreman consulted and tag conspicuously placed the machine. such instance, the department given the inspector the start each shift, having been filled out the top the in- spector knows the manufacturer, number, model, and position the plant. His report the condition the equipment sent the chief inspector who orders repairs that are necessary. These orders have different points for inspection, depending upon the group classification the equipment. This for Group Metal Cutting Equipment. The plant facilities inspection system the Buffalo parts and sub-assemblies plant Bell Aircraft Corp. only seven months old, but the benefits periodically scheduled inspection plant equipment has been one the most vital factors keeping produc- tion the plant well ahead the demand the final aircraft assembly lines. foreman writes small order for re- pairs and personally sends the Maintenance Department, where the condition and extent repairs neces- sary can explained and repair fore work quickly started. Before this tag, shown Fig. can removed from the machine, inspector checks the machine and the repairs made. When the tag removed signed the PLART FACILITIES IMSPECTION ORDER GROUP METAL CUTTING EQUI PRERT Oréer Be. Date leeued Rachise Kame Masefactered Macbise Location: Plest Sept. Bey Machiae Level Aad Brake Belts Motors iad Costrols Ledrication (O11 dad Grease! Bearings, Pivots, Ste. Coolant Pump CONTAOL VALVE Vays, Ram Vays, Tadle Ways Rem Packing Ryéro System Drive Gear Trais Spiadie, Spisdie Bearings Tract ain Chack Rack Aad Pisios Coaveyor.Chais Saad Paper Saw Guide Roller Tires Ledrication O11 Pemp Other Items: 34- Cycles Make of Motor Phase nw Report Checked By: Date: date: £74 HEL A 24 HAL COOLANT Five Repairs Ordered wre inspected By: THE IRON AGE, December 30, 4 = aa LOWER Look PAPER OLD ° ° ° 4 PLANT ENGINEERING DEPARTMENT ORDER DATE PAYROLL ACCOUNT NO. | TRADES DESCRIPTION OF WORK (Se SPECIFIC MAINTENANCE REQUESTED SY DEPT _BY = = | MACHINE NAME COMPLETED 1068 ACCEPTED BY DATE: NO JOB COSTING OVER $25 WILL BE DONE ON THIS ORDER. MACHINE DOWN FOR REPAIRS LOCATION ! ! Time | DATE | START _TIME MACHINE WENT DOWN SHIFT: INSPECTED SY SHIFT: | _ CAUSE OF FAILURE REPAIRS NEEDED REPAIRED BY: BY: 406 ACCEPTED: FOREMAN: Time OOWN POSTED BY: 30—THE AGE, December 30, 1943 3—The front (top) and re- verse (bottom) sides the small order form are shown here. description the work and material required repair, well date, cost materials, time repair, and similar perti- nent information required filling out the card. From these records, cost maintenance given piece equipment quickly available. inspector and the department fore- man, and turned over the chief inspector, who records down-time charged machine repair. When breakdown caused red rather than yellow down-for-repairs tag attached the machine. This immediate visual indication faulty operation machine and has had notice- able psychological effect the worker. This red tag identical the yellow one except for color. The immediate desirable effects the Bell machine inspection system are genuine. Better maintained ma- chines work accuracy and improve work quality, well re- duce production costs and the number interruptions. Less obvious but less important are such factors re- ductions rejections and conserva- tion power. Inspectors are thoroughly trained under the supervision the chief in- spector before being placed the job. Furthermore, each inspector works long enough one the three parts the plant become familiar with the equipment installed therein. Then, the inspectors are switched around different sectors the plant as- sure them full knowledge the plant equipment and they are also switched around the type equipment they 4—Both sides the ma- show that very complete informa- tion required every machine cates breakdowns result normal operations while bright red card indicates that faulty operation caused the machine down-time. These cards are af- fixed conspicuously the chine while down for repairs. | me TOTALS | MATERIAL ‘ un sel MATERIAL — in ers ins col po: no pe: lay hief time liate ition tice- the stem ma- and re- nber re- inspect. This latter serves the two- fold purpose permitting them get and more complete knowledge different types equip- ment and act double check one another. addition inspecting just plant machinery and equipment assigned them daily, the inspectors diligently watch for failures other fields, such broken concrete the floor; bare electrical wiring; leaky air steam lines, etc. Reports maintenance such faulty conditions overhead and underfoot are one the unrecorded services this division. The reception the machine in- spector both supervisory personnel the plant and production personnel has been quite gratifying. Both work- ers and supervision the plant have come respect the efforts the group, and the manner which they report mechanical troubles the inspectors, results their efforts continue expand the demand for their services. Benefits Plan specifically enumerate value the benefits derived from such maintenance plan practically im- possible, -of the fact that there are many variables. Opera- tors handle machines differently; fig- ures for the past three six months against equal period could not take into consideration that machines are now older; actual operating times the machines over two such periods would not identical; and other similar factors make such compari- son speculative best. However, conditions that are continuously being brought light because periodic and regular inspection that would otherwise unreported long the machine actually operated, are known have eliminated breakdowns and long idle periods. Workers are equipment defects because first, may mean some time off and, second, the blame might laid them. Foremen and lead men depart- ments have too many other things check-ups and file reports the con- dition the machines under their direction. One the more indirect but prob- ably most important benefits derived from scheduled inspections machin- ery and equipment with proper rec- ord keeping chronological history each machine. glance, can determined from the inspection or- der file just how frequently repairs had made individual ma- chine. and cross reference the small order card file, the cost these repairs can determined. Thus, and when the time comes curtail operations plant equipment, the most costly equipment can disposed shut down. Likewise, with much the equip- ment the plant owned the De- fense Plant Corporation, Bell Air- craft Corp. decides the future own all equipment plants, D.P.C. owned equipment can better evaluated reference the service records each individual piece machinery. Furthermore, frequently charges down-time machine are made against maintenance, the ‘ause the down-time could lack material other reasons not traceable maintenance. This eliminated entirely because the machine-down-for-repairs tag shown the time the machine went down, when went back into production, and the net down time. This informa- tion also immediately available whenever desired. All all, the Bell Aircraft system highly satisfactory. Generally, such system would mean lot tedious paper work, but this instance such not the case. This system has been devised make the handling the system easy possible, eliminate forgetfulness shop inspection personnel, and expedite the carry- ing through repairs and mainte- nance. Furthermore, and maintenance work resulting from the necessity for speed eliminated because every repair must spected immediately after completion. Inspectors also find themselves acting liaison officers between manage- ment and worker, bettering worker morale, and, consequently, bettering production. The inspector the man who makes each set-up man, each foreman and each worker understand the monetary value the machine the shop; the money value idle time; the special part each person plays the whole production set-up the plant. This has had intan- gible but noticeable effect even the short space seven months that the plan has been operation. All told, the benefits periodic and supervised machine inspection are quite substantial. pointed out, impossible evaluate them the basis dollars and cents, but they are none-the-less recognizable. the present war .effort, much asked everyone and especially the aircraft industry. The elimination break-downs production machinery more than just economical—it also the manufacturer’s patriotic duty. Welding Booth Curtains Made Fire Resistant LYCERINE an_ important constituent the preparation coatings for making substitute for asbestos cloth used curtain material for electric welding According the report the Euro- pean investigator, Abramovich (Avtogennoe Delo 12, No. fabric per cent solution ammonium phos- phate, drying and coating with three layers mixture containing: Milk casein ....... parts Water Glycerine parts Ammonia solution, 25% parts Intermittent drying periods are necessary between the application each layer. Periods hr. are needed drying done room temperature, but the time may shortened higher temperatures are used. 500 parts water glass (sodium silicate, sp. gr. 1.35-1.40) added the above mixture after homogenizing, the preliminary satura- tion with ammonium phosphate can omitted. Thin transparent can made opague adding parts zine oxide soot the above mixture. Protective curtains obtained the use this procedure were found somewhat more resistant than cur- tains fireproof tenting canvas also subjected suitable impregnation. THE IRON AGE, December 30, in- rorks with ) as- plant they Anthracite coal blast furnace fuel progressed very rap- idly from 1836 when Dr. Geissenhainer first used until 1875 when the tonnage bituminous and raw coal pig iron surpassed that made with anthracite. Here the author the history anthracite metallurgical fuel and gives the reasons for its decline. With the correction the fallacious ideas anthracite blast furnace practice, the writer looks forward renewed interest the use anthracite coal. nated the entire iron and steel industry this country; and for two decades, from the year 1855 until 1875, anthracite was the pre- vailing blast furnace fuel. Since World War however anthracite pig iron has been made.’ The prac- tice using anthracite mixed with coke blast furnace fuel continued sporadically, even recent years when the coke shortage became ex- cessive. The last recorded use an- thracite blast furnace fuel mixed with coke was 1923, when total 12,730 tons anthracite was used. During the winter 1933-34 lim- ited percentage “broken” anthra- cite was successfully used blast furnace fuel mixed with coke the production ferromanganese. Un- der such conditions the story an- thracite pig iron the United States can only historical. might, how- ever, prophetic. The superiority charcoal pig iron over coke pig iron generally con- ceded; the superiority anthracite pig iron over coke pig iron will prob- ably admitted when all the com- parative results are studied. The late Dr. Richard Moldenke* placed an- thracite pig iron next charcoal pig iron quality for foundry prac- tice. NTHRACITE pig iron once domi- *“Round Table: Carbon Pig Iron,” annual meeting, February, 1927. Anthracite ceased blast 32—THE AGE, December 30, 1943 furnace this country for two reasons: First, because creased cost, and second, because the practice anthracite blast furnaces remained frozen was during the Centennial year 1876. Neither one detracts from the intrinsic value anthracite blast furnace fuel; both causes can corrected. not only possible but probable that anthracite, properly selected and sized will again used blast furnace fuel, successfully furnaces with adjusted practice. previous the history Fuels: Their Regional Ace, Nov. 29, 1934. the production pig iron this country was divided into four dis- tinct blast furnace fuel eras: Char- coal period from 1645 1855; an- thracite period from 1855 1875; bee-hive coke period from 1875 1919, and by-product coke period from 1919 the present. Naturally there was considerable overlapping these fuels into the next era, and charcoal has continued all through the years and stil] used blast furnace fuel, but during each the four eras listed above more pig iron was made from the pre- dominating fuel than from all the blast furnace fuel; the first raw RALPH SWEETSER coal furnace being built 1845 and the last 1887, total small blast furnaces. Geographic Distribution Furnaces From the time the erection the first anthracite blast furnace, the plant” Dr. Geissenhainer, 1886 until the last new anthracite blast furnace 1891, 275 anthracite furnaces were built. Naturally Penn- sylvania led the list with 192 fur- naces; and New York and New Jer- sey came next with and fur- naces respectively. The anthracite furnaces were distributed follows: Pennsylvania v Connecticut The peak production anthracite pig iron was 2,186,411 gross tons 1890 which was 23.76 per cent the total production 9,202,703 tons for that year; there were 173 anthracite furnaces the active blast furnace list that year. The statistics the iron industry the time the introduction an- thracite blast furnace fuel are somewhat uncertain, and although the building the No. furnace the Crane Iron Co. Catasauqua the Lehigh River just above Allen- town, Pa., generally accepted the start the first commercially successful anthracite blast furnace, other anthracite blast furnaces had been built and blown before the blowing the Crane furnace July 1840. not the purpose this article to the blas the All No. Co. The was per fuel can the brin stov dow boil nac four rec pol the pig bu: tor ste an dle fa: col cor Ir no cially nace, had the rticle reconcile the various reports the erection the first anthracite furnace, but does seem rea- sonable accept the record the first blast furnaces published the year 1841 Walter John- son who claimed have gathered the data directly, but does not include the Silver Creek furnace, temporarily operated Dr. Geissenhainer 1836, and who died shortly thereafter. All the early anthracite blast fur- ° ° ° the 60-ton No. and No. blast furnaces the Thomas Co. Alburtis, Pa. The No. furnace was the last this country use per cent anthracite blast furnace fuel. the right can seen the cast iron pipe stoves for the hot blast with one downcomer bringing gas the stoves and another downcomer opposite taking gas the boilers. These fur- naces illustrate the four-square design used for all early anthracite blast fur- naces. naces were built four-square shown the lower part the Al- burtis furnace, Fig. course the recorded heavy weight air per ton pig iron was not delivered into the furnace, because leakage. Most the anthracite was trans- ported canal boats; and that was the general tempo the anthracite pig iron industry. change the burden would “come down” day after tomorrow; the blowing an- thracite blast furnace was anxious operation two three days. Sick furnaces and “furnace doctors” were standard practice. spite the slow driving the anthracite blast furnaces the mid- dle the 19th century the building anthracite furnaces went ahead faster than the building coke blast furnaces. “Prior 1854 only coke blast furnaces had been built, his book “The Manufacture Iron,” published 1854, Frederick Overman said, “But few blast furnaces work coke this country there but little prospect addition the number coke furnaces which now exist, shall devote but limit- space this subject.” 1855 the total pig iron made with coke and raw bituminous coal was only 55,705 tons compared with 340,951 tons anthracite pig iron. the eight years which began 1850 and ended 1857 there were new anthracite blast furnaces built this country; none was built during the next two years. During the 10-year period 1870-79, inclusive, more new blast furnaces were built this coun- try than any other decade, fol- lows: Number Blast Furnaces was during this decade, 1875, that the production “bituminous” pig iron (coke and raw coal) passed that anthracite pig iron. The rec- ords show that there were 713 blast furnaces the active list, 147 coke furnaces and raw coal furnaces compared with 236 anthracite fur- naces and 299 charcoal blast furnaces. Although anthracite was first suc- cessfully used Rev. Giessen- hainer New York his Valley furnace Silver Creek, near Potts- ville, 1838, had continu- ing commercial use blast furnace fuel until 1840 when David Thomas Wales started the blast furnace the Crane Iron Works Catasauqua, Pa. The valleys eastern Pennsyl- vania, the heart the anthracite region and near the local iron ores and the magnetites New Jersey, became the most active the producing centers the United States. John Peter Lesley, secretary the American Iron Association, said his book published 1859, “Eastern Pennsylvania and northeastern Mary- land the greatest iron region the Union, anthracite and 103 charcoal furnaces and 117 forges (none which last produce iron from the ore).” The momentum gathered the Lehigh Valley, Schuylkill Valley, Sus- quehanna Valley and northeastern Maryland the days anthracite still influences the steel industry Bethlehem, Conshohocken, Steelton and Sparrows Point. The blast fur- nace practice that region permeat- all the other iron sections this country and went into the iron and steel centers the whole world, but was gradually speeded from the slow pace anthracite practice. Anthracite Pig Quotations Although anthracite pig iron dom- inated the iron and steel industry this country, actual produced, from the year 1855 until 1875, its predominance the Philadelphia pig iron market lasted longer and ex- tended from the year 1850 until the end 1889. and including the year 1849 market quotations for pig iron Philadelphia were for charcoal pig iron only, but the reports the American Iron and Steel Associa- tion—Annual Statistics the Trade—for 1890 the following note: “After 1849 the standard quota- tions was No. anthracite pig iron hereafter given;” therefore from the THE IRON AGE, December 30, OWS: 192 v 9 275 acite the for mace an- are ough year 1850 1889 inclusive, the cap- tion the column for pig iron prices read follows: “Average prices per gross ton No. anthracite foundry pig iron Philadelphia.” one James Swank’s statistical reports the American Iron and Steel Trade, uses the caption “No. anthracite foundry pig iron Philadelphia.” Beginning with the vear 1890 the caption read “average monthly prices No. foundry pig iron Thus the con- trolling influence the pig iron mar- ket had passed from anthracite coke pig iron. After 1906 another quotation crept into the market report pig iron Philadelphia, and column with the caption, foundry pig iron Philadelphia” appeared. For the 1906 the average price No. foundry was 80c. ton below that No. foundry. 1907 the spread was 75c. ton and 1908 and there- after, was 50c. ton. The expressions “No. 1,” 1X” and “No. 2X” show that the quota- tions were made during the period when all foundry and mill pig irons were graded and sold “on which was not such “rule-of-thumb” method after all when the foundry- man had particular kind casting make. The metallurgical history the iron and steel industry can followed quite accurately reading the market quotations for iron and steel products. One finds that 150 years ago the quotations were for charcoal pig iron; 100 years ago was “No. anthracite foundry pig iron” and “cut nails the “Best rolled bar iron” was quoted 1844; iron rails 1847; and steel rails 1867. (This digres- sion from the subject anthracite pig iron due the romance iron and steel compressed into meti- culous reports the late James Swank when was secretary the American Iron and Steel Association, which was organized March 1855, Philadelphia.) Blast Pressure with Anthracite “The use anthracite blast furnace fuel illustra- tion the cumulative grief that comes from false theories and lack sci- entific facts.” This statement was made page 146 the author’s book, Blast Furnace Practice (New York, 1938) and repeated here for the sake emphasis. The erroneous belief that “anthracite requires three and half times the quantity, velocity and density compression blast necessary and proper for charcoal, and much greater than for coke the proportion three and half 34—THE IRON AGE, December 30, 1943 two and half” started the wording, here quoted, the orig- inal patent granted Friederich Geissenhainer, 19, 1833, for his and useful improvement the manufacture iron and steel the application anthracite coal.” any consideration the com- the air blast for charcoal, coke and anthracite used blast for charcoal, coke and anthracite used blast furnace fuels, must remembered that the blast furnace men cen- tury ago had never used anything but charcoal their furnaces. The change from charcoal, the best and most re- active all blast furnace fuels, anthracite, the densest all blast furnace fuels, was such jump blast furnace practice that the advocates anthracite had Wales get man operate the first commercially successful anthra- cite furnace plant. One charcoal iron operator was skeptical that told David Thomas would eat all the pig iron that could make with an- thracite. interesting note that the men who put the money for those early anthracite blast fur- naces were mostly merchants, pro- fessional men, bankers and wholesale grocers; not the charcoal pig iron producers. (As then, now, men outside the steel industry who are advocating direct reduction iron ore make sponge iron.) true that both coke and an- thracite blast furnace quire more air blast volume and pressure than does charcoal but not the proportions stated Dr. Geis- senhainer his patent application and repeated practically all the literature the subject World War and not refuted until 1935 (Trans. 1935, “Blast Furnace Fuels Anthracite Coal,” Ralph Sweetser). show how false theory can built and can adversely affect blast furnace practice and permeate the literature both sides the Atlan- tic, the case the blast furnace Pine Grove, Pa., will briefly told here. Vol. VIII the Transactions A.I.M.E., 1879-80, John Birkinbine, ‘an outstanding authority iron ores and vig iron that period, wrote the story his unique experience the Pine Grove furnace, where was forced use successively charcoal, beehive coke and anthracite fuel little charcoal furnace 36% ft. high with ft. in. diameter bosh; the charcoal gave out February, and beehive coke was used until the coke strike April when all anthra- cite was used for while, and then per cent anthracite and per cent beehive coke. There were three tuyeres this tiny furnace with tuyere area 47.7 sq. in., when using charcoal February, 1879. The ore was very lean, only 38.26 per cent yield pig iron, using 2531 charcoal and 2287 limestone per ton (2260 pig iron. The blast pressure was only 0.77 lb. temperature 600 deg. the rate 1896 cu. ft. per min. and 77.8 ft. air per lb. fuel. The production was tons week. Now comes the penalty false theories. When coke was used nozzles were put into the tuyeres, total area was cut from 47.7 28.9 sq. the pressure went 1.0 and took 2435 cu. ft. air per min. and 92.6 cu. ft. per lb. fuel; the tonnage dropped tons per week, and the fuel jumped 3494 per ton pig iron. Following the same false theory the tuyere area was cut 14.7 sq. in. when anthracite used; the pressure went 4.75 ft. air per fuel, and the week. This the performance re- ported Sir Lowthian Bell his “Principles the Manufacture Iron and London, 1884, but left out such seemingly trifling mat- ter the throttling the tuyeres down less than one-third the size when using charcoal. That false theory persisted throughout the 19th century and was one the contribut- ing factors the abandonment anthracite blast furnace fuel. Kreisinger (Bureau Mines, Tech- nical Paper 54) found that anthracite required only 95.6 per cent much air for combustion coke. The author has found practice same volume air burn anthra- cite burn coke the same blast furnace. One the reasons advanced for the supposedly higher blast pressures with anthracite than with coke that anthracite “entirely lacking cellular structure and accordingly much greater density, that the ratio surface exposed per unit weight only small fraction what the case coke and only proportionately small amount can burned per sq. ft. hearth area. This means that the output given furnace necessarily much smaller when supplied with anthracite than with coke” (J. Johnson, Jr., “Prin- ciples, Operation and Products the Blast The author has found that the case anthracites suitable for blast furnace fuel soon there any combustion the ~ rough gray-black surface appears. “From all the evidence the conclusion ture sufficiently high preclude yeres This roughening the smooth inevitable that the blast possibility the furnace, total face the reason why anthracite does not efficiently perform the duty normal working condition, containing using combustible, and phenomenon demanded it, chiefly for the reason anything but incandescent fuel with that little known. that does not furnish pellets molten iron slag 2531 Anthracite Blast Furnace Lines regularly measured volume air may that the more per The “lines” anthracite blast fur- delivered into the furnace, the narrow within certain practical limits blast naces were very bad; everything through the tuyeres ... the the furnace shaft constructed, the the wrong except that the diameter cause the deficient intermittent more thorough and the more energetic rate the stockline was greater than fuel before the tuyeres the actions reduction and carbon cu, diameter the hearth the attributed interruption impregnation will be; consequently iction the better the materials will pre- pared received the zone false fusion.” Walsh shows vertical cross-section the his proposed new lines, with low 28.9 bosh and slim, “more narrow,” shaft, which looks quite modern and per has proved correct. Some small fuel; Position bell charcoal blast furnaces had adopted per when down the design with marked success, but the it.” The Antrim Iron Co.’s char- coal blast furnace Mancelona, racite 2—Section the ft. ft., built 1887-88, and Durham furnace show- 1912, has lines similar the period. This fur- record tonnage and fuel nace was first blown consumption commensurate with its 1876. This furnace working volume. 13,237 cu. but its The anthracite blast furnaces had largest daily output re- high boshes, large shaft volume, the angle strictly modern; small blast volume. These ideas, false the height bosh based false theories, were firm- 19th nearly fixed the minds the anthracite blast furnacemen, that when they went other parts the country, the same erroneous designs with them. For instance, the four blast furnaces furnace lines with large boshes the print could read upside down nthra- well right side up, far the blast diameters and shapes hearth, bosh and stockline were concerned. The fine rich concentrates the Cran- level. Again, false theories brought the downward delivery the solids berry iron ore mine North Caro- that series troubles that never the formation adhesions, scaf- were sold and only the lean lump during the period anthracite blast folds, excrescences, otherform ore was smelted the blast furnace dingly furnaces, spite the fact that obstruction the boshes the Johnson City, Tenn., because the the Edward Walsh, Jr., St. furnace walls. the forms fur- directors from the Lehigh Valley be- attention the bad shape anthra- heretofore used, and now lieved that fine ore closed the voids what cite blast furnaces and pointed out will seen that the conditions between the big lumps ore and only the remedy his very progressive favoring the formation such ad- limestone. took many years paper entitled, “Irregularities the boshes furnace walls practice overcome the errors area. Blast Furnace Process and Prac- always prevail. The authorities anthracite practice; meanwhile the gives Way Avoid Them,” Trans- generally and very properly locate anthracite blast furnaces died. maller actions A.I.M.E., Vol. XV, 1886-87, the commencement the scaffold than page 419 seq. Walsh mentions lower portion the upper Durham and Warwick Furnaces “Prin- fact that “The Transactions the portion the zone fusion. But Transactions XIV, page 833, the Institute bear witness the locate more exactly neces- John Birkinbine said “The best an- has lence scaffolds causing irregulari- sary note that these adhesions will blast furnace practice record- racites ties working, especially under the commence form immediately above our Transactions conceded soon conditions modern American prac- the zone complete fusion. that pursued Mr. Fack- says further page 429, cannot occur lower the Jr., the Durham Furnace THE IRON AGE, December 30, 1943—35 — and Mr. Edgar Cook the Warwick Furnace.” The blast furnace Durham owned Cooper and Hewitt was first blown 1876. This furnace was fully his article entitled “Durham Blast Furnace,” Transactions A.I.M.E. Vol. XIV, 1885-86. This blast furnace had “working volume” 13,237 cu. ft. and even with 2400 lb. per ton pig iron should have made about 325 tons pig iron per day instead only 105 tons, which was its largest daily average reported 1894. The peculiar shape and the high bosh the anthracite blast furnace that period are shown Fig. Although the iron ore mix contained over per cent iron yet “owing the siliceous Duham ores required 59.42 per cent limestone 2495 per ton pig iron.” one blast the furnace required 2765 lb. fuel “including blown-in week.” Mr. Fackenthal describes the two Morris up-right blowing engines “entirely too small for the capacity the furnace” and which could not run over rev. per min., limiting the air 16,000 cu. ft. min. will seen from Fig. that the bosh angle was very steep for those days, and the bosh had been lowered about ft. above the tuyeres, this furnace would have been “more nar- row” according the suggestion Edward Walsh 1886 mentioned previously. According the record the blast temperature was 960 deg. and 9.6 lb. pressure, and required 88.76 cu. ft. air (piston displace- ment) per lb. fuel. Sometimes the furnace used all anthracite but most was 81.25 per cent anthracite and 18.75 per cent Connellsville coke. The Warwick Furnace was one the most successful the anthracite furnaces but had long series “dirt troubles” and other irregulari- ties which were very frankly described the manager, Edgar Cook. This little furnace, running all anthra- cite, had only 5500 cu. ft. capacity and made little over tons (2268 lb.) per day, using 2884 lb. fuel with 45.9 per cent iron ore. com- menting Birkinbine’s article Transactions regarding the operation Chester, J., compared the work the Warwick Furnace anthracite with that the Isabella (Pittsburgh) Furnace coke, using per cent iron ore. Taylor said Isabella was making one ton pig iron for each 68.2 cu. ft. capacity and producing 220 tons p