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REPORT ON THE Experiments made at Sault Ste. Marie, Ont., under Government auspices, in the smelting of Cana- dian iron ores by the Electro-thermic Process. lY EUGENE HAANEL. Ph. D. Ottawa, Canada 1907. Ottawa. February 20th, 1907. Sir, I have the honour to transmit herewith the final report on the experi- ments made at Sault Stc. Marie, Ont.. under Government auspices, in the smelting of Canadian iron ores by the electro-thermic process. The report contains a detailed statement of the work done and results obtained, of all measurements made, of the analyses of the pig and slags produced and of the iron ores employed. To facilitate the comprehension of the text illustrations are gi\ on of the furnace employed and changes made in its construction and of the machinery employcfl. Plans are given of two commercial electric furnaces which have recently l)een patented. In an appendix a detailed account and description, with illustrations, are given of the recent inventions and improvements made in electric furnaces in Sweden, also an account by Professor Eichhoff. Profes.sor of Metallurgy of the Technical High School at Charlottenburg, Germany, of the advantages of the Heroult electric process of making high class steel and cost of production. 1 have the honour to be, Sir, Your obedient servant, EUGENE HAAN'EL. Superintendent of Mines. Honourable Frank Oliver, P.C, M.P., Minister of the Interior, Department of the Interior, Ottawa. INTRODUCTION In Decem»)er, 1903, the Government appointed a Commission to investi- gate the different electro-thermic processes for the smelting of iron ores and the making of steel in operation in Europe. The results of this itivestigat.on were published in 1904 in a report issued by the Mines Branch of the Interior Department, entitled: "Report of the Commission appointed to mvestigate the different electro-thermic processes for the smelting of iron ores and the making of steel in operation in Kurope. " The only experiments for the reduction of iron ores which the Commission was able to witness were those conducted by Dr. P. H^roult, at La Praz. France and by Messrs. Keller, Leleux & Co., at Livet, France. Dr. H6roult's experiment wks only made to show the possibility of smelting iron ores and no data in regard to output, etc., could be obtained. The experiments of Messrs. Keller, Leleux & Co. were more extensive and continued for a number of days. During this time two different runs were made in different furnaces, but of similar construction. The ore used was a porous hematite containing 3.21% of manganese and only 0.02% of sulphur, an ore, therefore, easUy reduced and desulphurized. The electric energy required in the first run was 0.475 E.H.P. years * per ton ** of pig iron, corresponding to an output of 5.769 tons per 1,0(K) E.H.P. days. The electric energy required in the second run was 0.226 E.H.P. years per ton of product, corresponding to an output of 12.12 tons per 1,000 E H P days. The difference in output of these two experiments was so great that Mr. F. W. Harbord, the metallurgist of the Commission, was compelled to adopt 0.350 E.H.P. years, the mean of the two experiments, as the probable energy required per ton of product. This would correspond to an output of 7.827 tons per 1,000 E. H. P. Hays. Before, therefore, a sound judgment could be formed as to the practi- cability of the electro-thermic process for the smelting of Canadian ores, it •365 days ♦♦Of 2,000 lbs. was desirable to establish with some degree of exactitude the amount of electric energy required per ton of product, the consumption of electrode, and also the "following important points referring to Canadian conditions, which were eithe; not taken up or were left in doubt by the Livet experiments: 1st. Can magnetite, which is our chief ore and which is to some extent a conductor of electricity, be successfully and economically smelted by the electro-thermic process? 2nd. Can iron ores with comparatively high sulphur content, but not containing manganese, be made into pig iron of marketable com- position? 3rd. The experiments made at Livet with charcoal as a reducing agent in substitution for coke having failed, could the process be so modified that charcoal could be sulwlituted for coke? This is especially important since charcoal and possibly peat coke would constitute home products, while coal-coke for metallurgical processes requires to be imported into several of the Provinces. The settlement of these questions was of such paramount importance for the formation of a judgment as to the feasibility of introducing electric smelting of iron ores as a commercial process in those provinces of Canada which lack coal for metaHu-'gical coke, but are well supplied with water-power and iron ore deposits, that the experimental investigation of the subject was authorized and a sum of $15,000 placed at the disposal of the Mmes Branch for the carrying out of these investigations. An agreement was made with Dr. P. H^roult of La Praz, France, who offered to design the furnace and necessarj' arrangements, to make the experiments. LOCATION ASH DESCRIPTION OF PLANT. The Lake Superior Corporation at Sault Ste. Marie, Ont., offered, on the recommendation of Mr. F. H. Clergue, the use of a suitable building in which to erect the furnace, and the power of one of their alternators free of expense for four months. At the same time the use of an office, their weU equipped laboratory, the services of their chemist and machinery necessary for the conveyance and preparing of the charge were tendered on reasonable terms As these advantages could not be secured elsewhere, the offer was accepted and the plant ordered to be erected under the superintendence of Mr. Erik Nystrom, member of the staff of the Mines Branch. A plan of the plant as first erected is given in Plate I and a section m Plate II. The raw material was unloaded from the cars and dumped either on the roof of the lime kiln room or directly into the bins provided for this pur- e, 9, a: lit ly ot Ti- nt so is lid pal ice ric ida ver ect nes vho the the lich snse iped the rms. pted Erik n m r on pur- Platel w. PLAN or EXPCRinENTAL ELECTRIC SHCLTIN6 PLANT AT Sault iS^: Maricont. Utli^i .1.1.1,1.1.1.1.1 ' EX EXPCRIMC <3£:CT/0/^ NTAL ELECTRIC SMELTING P 'SAULTSTMAf^lC, ONT. LANT — i \CTJON TRIC SMELTING PLANT rtARfC, ONT. * ■» % • m h*t '■'■'■'■■ pisifir E \ mI,I mm pose in one of the smaller rooms of the building. In the adjoining large room a motor was installed, driving a small Gates Crusher, and an elevator con- veying the charge to a bin placed in the furnace room. DESCRIPTION OF FURNACE. The furnace as first designed by Dr. Heroult (sec Plate II) consisted of an iron casing \ inch thick, bolted to a bottom plate of cast iron 48 inches in diameter. The casing was made in two sections strengthened by angle irons and bolted together to facilitate repairs, the lower section being 37 inches and the upper one 48 inches high. To render the inductance a.s small as possible the lines of magnetic force in the iron easing were prevented from closing by the replacement of a vertical strip of 10 inches width of the casing by a copper plate. Rods of iron were cast into the bottom plate to secure a good contact with the cartx)n pa.ste rammed into the lower part of the furnace. In an extension of the bottom plate a copper cylinder o (see Plate III) was in- serted and constituted the contact with the aluminium block into which the aluminium cables constituting the conductor were ca.st. This block was pressed against the copper cylinder by means of a bolt, as shown in the figure. The bottom as well as the sides of the crucible were made of carbon paste, the lining of the upper part of the fu-nace being made of fire bricks. The intention of Ur. H^rouIt was to utilize the calorific power of the carbon monoxide developed through the reduction of the ore. For this purpose an air pipe provided with holes was put in two feet below the top of the furnaces, by means of which air for the combustion of the carbon monoxide could be pressed in. The electrodes, manufactured by the Heroult process and imported from Sweden, were prisms of square cross-section with the comers cut off, 16 X 16 inches by 6 feet long. One end of the electrode was planed to fit into the steel shoe d (see Plate III), and held tight by means of wedges. The steel shoe was r.>»tpd to four copper plates, two of which were strengthened on top with steel plates and carrying a pulley. A pipe, k, was put in the electrode holder, by means of which a current of air was produced to cool the holder. This construction of the electrode-holder was adopted m theexpectation that it would permit the electrode to go down into the charge until it was practically consumed, leaving only a small stump as waste. The aluminium block into which the tables constituting the conductor were cast was bolted to one of the copper plates. The overhead work for the furnace consisted of two I Ix-ams provided with lifsht rails and a nM)veable truck wiiii two puUpys. Tho olcctrodf with its holder was supported by a chain passing inider the pulley on top of the holder and over the pulleys on the truck, one end of the chain being fastened to the wall, the other end passing over a winch operated by a worm and worm-wheel. This formed a convei.ient arrange- ment for regulating the electrode by hand. When exchanging electrode, the truck was pulled over in front of the furnace, the cables to the electrode holder Ijeing of suHicie!it length to permit such movements. ELECTRICAL MACHINERY AKD ARRANGEMENTS. The electric energy obtainable was furnished by one phase of a three phase, 400 K. W., 30 cycle. 2,400 volt, alternating current generator coupled by Ix-lt to a 300 H. P., 500 volt, direct current motor, mounted in the Com- pany's [Mwer house located some distance from the furnace building. A current of 2,200 volts was delivered to an oil cooled transformer of 225 K. W. capacity, designed to furnish current to the furnace at 50 volts. The transformer was placed in a separate room in the furnace building, close to the furnace. From the transformer the current was led to the bottom plate contact of the furnace and to the electrode contact by conductors consisting each of 30 aluminium cables, f inch in diameter. The measuring instruments mounted on a switchboard consisted of a voltmeter, an ammeter, a power factor meter and a recording wattmeter. The transformer and electric meters were manufactured by the Westinghouse Electric and Manufacturing Company. An additional -.oltmeter reading from 10 to 80 volts, supplied by the Keystone lilectric Company, was also placed in circuit to serve as a check. The voltmeter and ammeter, which had lieen mounted on the switchboard, were for convenience of observation removed to a position on the wall at the side of the electrode regulating apparatus. The recording wattmeter had to be sent to the factory for alterations and was returned too late for the experiments. In order to ascertain the correctness of the remaining instruments, the Westinghouse Company was asked to send an expert for their calibration. In compliance with this request Mr. Chas. Darrall was sent to Sault Ste. Marie. The volt and ammeter were found by him to be correct and the power factor of the furnace to be 0.919, * which finure lias heen used throughout the »'XjxTiim'iits for the caleulations of electric energy consumed. EXPERIMENTS. The experiments were carried out in the following numner: The raw material was first passed through the crusher which delivereil a product of about J inch diameter and less (a jaw crusher delivering a little larger size and not so much fines would have been more suitable, but none could be oljtained at the time.) The ore. carbon and fluxes were then weighed, mixed by hand and delivered at first to the elevator and later charged direct into the furnace by hai' .. '■»•. The numlx-r of charges used were marked down. The readings o <■'■ '" "leasuring instruments were taken every 30 minutes. In the tabic: ii m are given the average figures of volts and amperes for the time elapsed between each tapping of the iron, also the corresponding weights of slag and iron. A sample of each ca.st and slag produced was collecte The upper part of the furnace was then put in place (sec Plate II). the current put on and the furnace charged on December IHth. Air, for the combustion of the carbon monoxide developed, was pressed in and the furnace worked well for a few hours. After a little, however, the electrode started to rise and continued to do so initil an arc was established between the electrode and the upper layer of the charge, which necessitated the melting down of the material in the furnace. The heat developed by the combustion of the carbon monoxide was so great that the charge in the upper part of the furnace became sticky and would not descend into the furnace, nor could this be remedied by stoking, on accoiuit of the narrow space between the electrode and the wall. The electrode contact did not prove satisfactory. This was remedied to some extent by putting a clamp around the steel shoe d (see Plate III). Further attempt to introduce air into the furnace was, therefore, post- poned anil the height of the furnace reduced by cutting the upper section in two parts. Oti Jaiuiary 3-4. 1906. an experiment was made to produce ferro-nickel from roasted pyrrhotite; the shape and arrangement of the furnace is given in Plate III. The contact in the bottom plate proved still to be unsatisfactory and was, therefore, changed in the manner indicated in Plate iV for the subse- quent experiments. The copper cylinder was removed and a new copper piece, 0, provided with a flange on top, was inserted in its place. A number of holes, p, were bored through this flange and into the bottom plate of the furnace and filled with aluminium, no farther changes were made in this contact throughout the experiments, although its imperfection involved a loss of from i to 1 volt. RUN No. 1. A section of the furnace used in this run is given in Plate III with the alteration of the bottom plate contact shown in Plate IV. Ore treated Hematite Reducing agent t Briquettes Flux "'. Limestone The briquettes, consisting of 80% coke dust and 20% fire clay, were niiulc fr)r the inirposp of ohtaiiiinp a rpduriiiK afteiit which would not he con- -uiikmI In- tho air hlast when introihic'd and at th.- same time lessen the c.ndmtivitv of the charge. The hri.iuette machine employe.1 delivered l.ri(|ueltes 4 inches in diameter by 2i inches in height. These l)ri(|Uettes, after Iw-ins dried, re(|uired to Ik- crushed, producing a considerable quantity r.f tines, which ren.lered the charge resistant to the passagi- of the carbon monoxide formed. Hematite Analysis ok Raw Matkhiai,, 5.42'"; SS.fK) " ',',','.'...'. 2.51 " 0.61 " o.:«) " 0.16" J. 0.044" n[[\,... 0.002" Loss on ignition 2 . 4S " SiOj. . FejO,. Al/),. faO. . .MgO. . Mn. Fe=62.23% UK) 426''; Limestone sio, 1-71'; FeA AUO, 0.81 •' Cat'O:, 9^-«5" 4.40 " MgCO, p 0.004" :;< C'aO. 51.96';; MgO ..2.097o 0.052" 99.826' ; Briquettes Volatile matter. Fixed carbon . .Si0.j FejO^ A1,0:,. . TaO MgO IS 4.05';^ 69.73 " 15.26 ' 8.92 •' 0.5)0 •• 0.30 ' 0.84 " KW.OO':; The furnace was pre-heated with a low current from 11 p.m., January 5th, to 10 a.m., January 6th, when the full current was put on and the furnace charged. 9 The pompositioii of tho ohiirjjp iit first was: — On 2()0 lbs. Mri(|iu'tt('s 711 " LiiiH'stonc 120 " I'.i of these churjres were ii«es. Hri(Hiettes 70 " Limestone 80 " 26 of these charges were put into the funiaee when the run was stopped at 8.40 p.m., January 7th, and the material not melted down was taken out and the crucible cleaned. On account of the large amount of fines in the eharge the pressure of the gas developed was very great and occasionally the slag was blown out. The charge had to lie worketl down by stoking and lieeaine very sticky, pre- venting the eleetrode, which in this run was a short one, from descending. It was, therefore, decided to stop the run and put in a new electrode. During the run 11 casts were made producing 4484 lbs. of pig iron, the slag produced amounting to 3886 lbs. On account of the men employed being unused to furnace work, the current had to be taken off every time a cast was made, to enable the iron hole to be cleaneil and ])r<>|X'rly plugged. The time lost in this manner during the run amounted to 1 hour and 40 minutes. ELEn'Ric.\L Mf;.\surement». On account of imperfect contacts it was found that a loss of from 3 to 4 volts or on an average 3 . 5 volts occurred. In the following table are given the volts on the line as read on the volt- meter and the volts on the furnace, where the loss on the contacts has Ix'en deducted; the latter are adopted for calculations, since the loss through poor contacts can be remedied by proper construction: — Time. Volts on Furnace. Volts on Line. Amperes Power Faotor. Jan. 6, 10.00 a.m.. . 36 5 40 .5 ,39 ,■> 39 ,5 40 .1 .39 .5 .39 .■; 40 .) 39. ,5 40 44 43 43 44 43 43 .'XI 43 4,.'>00 4..5(K) 4..5(X) 4,.')(H) 4,.500 4,.500 4.700 4..'X)0 4,5(M) 919 10 .30 " tl.(K) " 11.30 " . 12 00 " . 12 .30 p.m 1.00 " 1 , ;io ^' 2.00 •' « Tinir. Jan. 7, 3.30 p.m... 3 00 " .. 3 30 4.00 " . 4 30 " . 5 (K) " .. .5 30 " . 6.00 " .. 6.30 " .. 7 00 " 7.30 " . 8.00 " . 8.30 " . 9 00 " . 9. 10 " . 10.00 " . 10 30 " . 11.00 " . 11 30 " . 12.00 " . 12 .30 a.m.. 1 00 " . 1 .30 " . 2.(X) " . 2 30 " . 3 00 " . 3. .30 " . 4.00 " . 4.30 " . .■5.00 " . 5.30 " . 6.00 ' . 6.30 " . 7.00 " . 7.30 " 8.00 " 8. 30 " 9.00 " 9.30 " 10.00 " 10.30 " 1100 " 11.30 " 12 (X) " 12.30 p.m 1.00 " 1.30 " 2.00 " 2.30 " 3.00 " 3.30 " 4.00 " 4 30 " .5. CM) " 5.30 " 6.00 " 6.30 " 7.00 " 7.30 " 8.00 " 8.40 " Run terminated. Vollii on Funiiii'i' 40 A 41 5 41 5 42 5 42. S 43 5 43.5 42 5 43 5 42 5 41 5 41 5 41 5 41 5 41 5 41 5 43 5 41.5 40.5 38 5 36.5 38 5 38.5 38.5 38.5 36.5 38.5 36.5 36 5 36 5 37.5 38.5 36.5 42.5 36.5 39.5 39.5 39 5 39 5 30 5 39.5 41.5 39.5 41.5 40 5 41 5 36 5 38 5 39.5 36 5 36.5 43 5 43.5 43.5 43.5 43 5 43.5 43.5 43 5 41.5 Vnitt on Line. U 45 4i 4«l 46 47 47 •16 47 M\ 45 45 45 45 45 4(> 47 45 44 42 40 42 42 42 42 40 42 40 40 40 41 42 40 46 40 43 43 43 43 43 43 45 43 45 44 45 40 42 43 40 40 47 47 47 47 47 47 47 47 45 Amperes. 4.250 4,2.W 4..'UM) 4,.M)0 4,2.V) 4,.VH) 4..'i»IO 4,(MM) 4,."iO() (..lOO 4,2.'iO 4,(MK) 4.2.">0 4,2.">0 4,.tOO 4,(N)0 4,,'UN) 4..VK) 3,.'>«H) 4,000 4.0*10 4,(KX) 4,000 4,00<1 4,2.50 4,2.'50 4,2.50 3,000 4,000 4,2.50 4,0!> i?; s lV \.uM» I'i>t iron i)r. r of ;W). -. \ ,kt ton of piK=0.:J54 SlttK 3HKfi The ratio =- « ^<«6 Iron 4484 The amount of sla»j produced wax very great on account of the use of hri i>i.iter< ax reducing material an.l the larRc amount of limestone added to the charge, in suljK,H|ueiit exp«-riment8 the limestone was decreased. The furi,ace worked cold throuRhout the run; the slag contained a large amount of unreduced oxide and consequently carried a high iK>rcentage of iron. RUN No. 2. After a new electrode had l)eei, put in, the furnace without any alterations was started up again at 12.15 a.m.. Jan. H. Ore treated Hematite Reducing agent Rrxiuettes piyjj Limestone Analysis of raw material same as in Run No. 1. The limestone in the charge was decrea.sed, the composition now being: Ore 200lhs. BnquPttfs -O ,, Lime8toi,e 13 17 of thiMf plmrKi'i* wm- put iiitn thi- funinct', whi'ii it wuh (Icciiicd to stop tht" experiment. The furiiare \vr)rkeil colil throiinhout the run iiml thi Ann priKliu-ed wait high in iron. .\t the termination of the run at I2..')(l pin., Jan. 8, the niuterial in the furnaeu wax taken out anil the eruetble cleaned. KlMTRK'AI. MKAHfRK.MK.NTM. Tbm. Hn.fi, 12 13 a.m 12 ;J0 " I (H) " 1 :«» " 2.00 ' 2.30 ■' 3.00 •' 3.30 " 4.00 " 4 30 " «.00 " 8.30 " 6.00 " 6. .30 • 7.00 •' 7. .30 " 8.00 " 8.30 " 9 00 " 9. .•!■.) " 10.00 " 10.30 " 11.00 " 11.30 " 12.00 " 12 30 p.m 12.50 " Furnace stopped • Volt. on Fumacp. Kumarc atartpd 31 ."> :tl .-1 31 .5 .34 .5 .3« ,■> 34 .'i Mi 3fl 5 3»1 5 m li Mi Mi Mi .36 .5 3« 5 36 5 Mi M i Mi 39 . '5 38 .5 41 .5 41 3 31 5 Volta on Line. 37 3t» 3.5 ;i8 40 38 40 411 40 40 40 40 40 40 4t) 40 40 40 40 43 42 45 45 35 Anip<'nit. 4,(MI0 4,2.50 4,.5(XI 4,.500 4.(NN) 4,2.50 4,INNI 4.2.50 4..V)0 4,.5()0 4.2.V) 4,2,5tt 4,2.Vt 4,2.50 4,2.50 4.250 4.2.50 4,2.50 4.400 4..5=== Watts = 37. 17 X 4583 X 0.919 156555 Pig iron produced 156555 El. horse power 746 Output of pig iron per 1,000 El. horse power day8= 391 X 1000 X 24 > hours, 30 min. 17.17 4583 391 lbs. 209.85 8.944 tons 2.5 X 209.85 X 2000 El. horse power years per ton of pig = . 306 RUN No. 6. Furnace: No alterations were made in the furnace. , ... Hematite Ore treated. . ...Briquettes Reducing agent ..Limestone Flux ^ The analyses of the raw materials are given in Run No. 1. Composition of Charoe. . 200 lbs Ore ... 70 " Briquettes ^ .. Limestone 22 of these charges were put into the furnace. 19 The furnace worked very badly throughout this experiment. The electrode came up and the material in the furnace had partly to be taken out or melted down. The furnace in this case, lined with bricks, prevented the current or part of .xame from passing through the charge to the sides of the crucible, the whole current lieing forced through the charge, slag and metal to the b .') 00 .5.30 B 00 « 30 7 00 7 30 8.00 8.30 9 00 9. "JO 10 OO 10 30 11.00 n 30 12 00 J.in. 13 12 30 1 00 1.30 2.00 2 30 Time. ' Volta j on Furnace. Volts on Line. 3 00 3.30 4 00 4 30 .5 00 5 30 10.45 p.m. Furnace started . " 42. .5 46 " 41.5 45 " 44.5 48 " .38.5 42 " 38.5 42 " 38.5 42 " 38.5 42 " 40.5 44 " 38.5 42 " 35.5 ,39 " 38.5 42 " 36.5 40 " 3«.5 40 " 36.5 40 ' .^5.5 39 a.m. I MaterinI in . .36. i 40 " I furnace being I .34 5 ,38 " I melted i' .38. 1 42 " I down I .34.5 .38 " Furnace stopped from | 2.00 to 3 OO for cleaning of crucible. " 34.5 .38 " .32.5 .30 " .37.5 41 " .37.5 41 " 34.5 38 ( Material in furnace ( being melted down.: " Furnace stopped. | Amperes. 3,.«)0 4.000 4,2.V) 4,000 4,2.'50 4,.50O 4,500 3,700 4,.'500 5,000 4,.500 5,000 5,000 5,000 5,000 5,000 .■^.(KK) 4..'i(HI 5,000 4,000 5.000 4..500 4,0(H) S.tXM) Power Factor. 919 The furnace was stopped at 10.45 a.m., Jan. 13, and the material left in *anie taken out and the crucible cleaned. -r an .js;srs=rrrs:s^i"--^-^ lis! Sf X t- W V o IS II &5 S ^ u 5 fi - - 0) a> 01 " - s> o e 71 M 9 r, 3 S Si:'- Is iS S S I S ■19 lli k2 a o J5 X -a -^ c o S - S s s s S B ■Jl Total length (.f run 7 hoiiw, 45 min. Effective length of run 7 hours. 25 min. .Mean volts on furnace :19 06 .Mean amperes 4452 I'ower factor 919 Watts = 39.06 X 44.52 X 0.919 1597H2 I'ijf iron obtained 1115 Km. 1597H2 El. horse power 214. 18 746 Output of pig iron per 1,0(X) El. hors<. |x)wer days = 1115 X 1000 X 24 s.4;n ton.s 7.41 X 214.18 X 2000 El. horse power years per ton of pig = . 321 Slag 575 The ratio = = 0.516 Iron 1115 The magnesite h.icks were badly eaten away up to the level of the slag hole on account of the slag produced being fairly acid. RUN No. 6. FuRN'.\tK. To facilitate the descent of the charge, the lining of the furnace was maile cylindrical (see Fkte V.). the diameter of the crucible being slightly larger. .\round the crucible a lining 4 inches thick of carbon paste was rammed to protect the brick lining from the slag. Ore treated Hematite Reducing agent Bricjuettes Fl"^ Limestone The analy.ses of the .aw materials are given in Run Xo. 1. The furnace was pre-hcated ironi ).0(t p.m., Jan. 16, until 11 a.pi., Jan. 17. when the furnace was cliar^ed. Composition- of Th.^rgk Ore 200 lbs. Briquettes 70 " Limestone 40 •• 13 of these charges were put into the furnace. From now on each cwt wm numbeml t.. enable a pmper reror.1 to he kept. Kl.KfTRI«AI< Mf.AHIHK.MKNTi*. TiiiH' Jan. 17 II <)0 a.ni.Kumaroitarted. II (Ml 11 30 " 1'.' (H) " 12 :«» p.m 1 (K) •• 1 :«t •• 2 (M) • 2 30 " 3 (M) '• 3 30 " 4 00 " 4 30 ' ."» (M) ■• .1 :«) •' « (10 • 30 •• 7.(KI " 8.00 ■• 9 00 " !»■.'.'> " I Material in ! nii-llMl down. Kurnace stoppi-d. Voll« 1 Vnltx on i on Kum»r<<. I.iw. 4fl » SO 37 S 41 aa r, 40 I .nt f, 42 1 :«» s 40 ma 1 40 1 :w .1 40 i 37 5 41 a» a 43 , 37 !i 41 i 3H S 42 38 .'i 42 1 3A S 39 3fl 5 40 37 S 41 37 .'i 41 37 5 41 37 a 41 32 .'. 3« Anipcrp*. 4.000 4,2.tO .'V.OtNl 4,750 4,750 4,500 4,750 5,0IX) 4,750 4,7.V) 4,7.50 4.A25 5,000 4,800 5.000 5.000 4,875 5,000 5,000 Power Factor. ttl9 Cast No. Time when Cast. Jan. 17,2.00 p.m. .■J-IO " 6. h. 40 m. • Efftftivp Marhine Icnitth of stopped, j run. 3h. Om. 3 h. 40 m 6 h.40 m, I Qiulity Pift Iron of Pig ohtained. Iron. 425 lb«. (ai lbs. Orey I.OSAIba. Ratio olitamed. Iron. 156Ib». i 3fi7 293 lbs. I 4«i4 449 lbs. 1 425 The electrode started to come up after 7.00 p.m.. At 8.00 p.m., 200 lbs. of cnide ore were put in, which brought the electrode down a little. It wa.s. therefore, decided to melt down the material in the furnace and start agan. with a charge containing considerably less carlwn. At 9.25 p.n.., a cast wa.s made and the materia! left in the furnace was taken out. Plate V. EXPOVCNIM. ELECTRIC FURNACE RUNS G-7 ^ ■•-»> I ^ Cut .\o. Pig Iron »lil»inwt. lUI lh«. IIKMIIm. .\vfm»r Voltii oil fllltinrr AvrrBKr niii|M>mi. l^iMfr Kni'tiif Avrni(r>- wmi- Avrnicr h.l. h7 ■2\^ 'W :«7 III 4NI0 l»lll.'tK< is.i <« l» ill! v. Oiilv tukitiK iiitn iM-coiiiit t*n' two caHU rrfiTrcd to uliovc. thi> fiillowini: fiRunvtun nbtaitipil: i^i'iiKth iif niii Mi'ttii Vdlis on fiinmro Mi'iifi amiMTci^ power fartor Wiittw :{S X 4»HM» X »Hl I'ijt "HI ohtaiiicil 16:i7K4 Kl. Iiorso (Miwrr 74(J Output of pile irofi ixr 1,0(10 Kl. h.irxc |>«.«. nliiy.- 105fl X 10(K) X -'4 •> hour^, 40 mill :is 4t'>*) II H •-'!'• .1.-, >« •>.");! tons « 67 X -'19. lo X 2000 Kl. horiw jKiwcr v«'nr JUT Ion of pig :jlo An.vi.ymw UK I'ui Ikon Phcmitkd. Cnat Xo. Hi. 2 .W RUN ITo. 7. 021 («! Toltti Ciiriion. 3 SO Furnacr: Xo altpratioiis were made in the furnace. Ore treated Hematite Reducinjt agent riricpiettes flux LimeHtoiie The analy.ses of the raw materials are giyen in Run No. 1. After the termination of Run No. 6 the crucible wa« cleaned out and ihe furnace afjuin started up at 9.45 p.m., Jan. 17 Composition ok ('HARiiK ^ 20() lbs. Ore „ Briquettes '^ ,^ Limestone 17 of these charges were put into the furnace. The pits iron obtaini-d from the first two ca.sts was white, full of hoU's and hish in .sulphur. In order to produce a better iron the carlx.n in the charge was increa.sed, the com- position now Vj<-infi: Ore ^»"»r- Hriciuettes ^ ^^ Limestone .After 8 of these charges had been put in the furnace, the composition of the charge was changed to: ,. -M) lbs. Ore Hriquettes ^' ^^ Limest2 3 3 •I 4 .5. ft. » 7. 7 S. H. 9 9 10 10 II II 12 12 I I •i 2 3 3 •I 4 .■) « fl. 7 7 N 8 9 9 9 10 10 II II 12 .Ian. 19, 12 . 4.'i p.m. Furnace started. (K) " 30 " 00 " ;«» " (HI " .30 n.ni 00 '• :«» " 00 " 30 " 00. •' 30 •' 00 " .30 " 00 " .30 " m " .30 " 00 " :«i " 00 " 30 " (K) " .30 •• (Kl '• 30 ■• (H) ■• 30 •' 00 " .30 00 .30 00 .30 00 .30 00 .30 00 30 00 .30 00 .30 00 .30 00 .30 4.'5 00 .30 " 00 " 30 " (K) " .30 a.m. Knrnnrp «t<>pp«Kl. p.m. Run N'o. 7 tprminatnl Volt* on Furnace. Volts nil IJnr. .30 .'> 40 30 5 40 311 .5 40 ;i» .5 43 .36 .5 40 .3M 5 42 :j« 5 40 40 5 44 .W 5 42 37.5 41 36 5 40 41 5 45 42 5 46 3« 5 40 .30 5 40 :«i .5 40 M h 40 40 » 44 39.5 43 3K 5 42 39 5 4:« .39 5 43 40 5 44 42 .■■. 46 3N.5 42 42.5 46 3« 5 40 41 5 45 37 5 41 37 5 41 37 5 41 37 5 41 .3« 5 40 40 5 44 :{K 5 42 .3« 5 40 .36 5 40 .38 5 42 .39 .5 43 38 5 42 .30 5 43 .39 5 43 37 5 41 .36 5 40 .36 5 40 36 5 40 X', a 39 34 r, .38 .36 5 40 .36 5 40 35 5 .30 21 5 25 II r, 15 Ampf-rcs. 4.7.'>0 4.500 4..5(KI 4,(MNI 4,.'ilKI 4,.'MN) 4,IXMI 4,INX) 4,(NI0 4,.MK) 4,7.50 4..VXI 4,(MN) 4,INX> 4,.'i0«> 4,.'>IM) 4..'>(X) 4..V»> 4..")00 .'i.lHIO 4..')00 .l.tMKI 4,2.'iO 5.(H)0 .5.IXX) .5.(HNI .'-..(XHI 5.. 0.769 513 8 9 45 " .. i •••■ 3 .50 7(W Half grey, half 405 .571 white ■24 houn. i '20 min. 23 40 400A 2nm 6.3;{ Material in fumaeo inelt- e. 12 *a.m 2 3o 331 ( irev l»i (I .577 Cast No. Pii! Iron obtained. Average Volts on Kumace. Averane Amperes. Power Kacti . ; Averap? 1 Watts. Averane KI. Howe Power. 3 4 5 7 s .501 llw. 4.55 •• 911 •' 7-23 '• 707 " 709 " 37 62 38 25 39 .50 38 37 38 .36 .37 00 4344 42S1 4.389 4844 .5(XI0 .5000 919 1.501S.5 1.50477 1.59.3-20 170799 176-264 170015 •201 32 •201 71 213 .5ti •228 9.5 236-28 •2-27 90 4006 lbs. .38.18 4643 9t9 1629-23 218 40 Effective lenp;th of run '^^ l"""^- -t^' '"'"■ Mean volts on furnace :{S IS Mean amix-res -*®"'-' Power factor "''*** Watts = 3S. 18 X 464H X O ftl9 16'292:{ Pig iron obtained ^^^ "'"• 162923 El. hor?° power 218 . 40 746 Otitpiil of pJK iron jHT 1 .(HK) Kl. Imrne power day.s = 4IMHI KXN) X 24 9 29«toii'< l^f >if/r!>''fiim-cryH«rperioii<>f piK -*tREMKXTS. ,lan. Xi. 9 .■*) a.m. <» ■!.-> •• 10 no " It) .«» " 11 (XI ■' II .w ■• \J 00 r." 3o p.iii I (10 1 ;«i •' 2 (M) " 2 30 " 3 (K) " 4 00 Funiarf «tart«l a 00 .1 .10 « 00 A 30 Msrhinr stopped from 3.20 to ^.m. fixing Heptrodp holder. Maohinp sfopjuil from; 4.00 to 4.30. fixinRi cover on electrode, I 41 S » s a» s a» s 42 s 35 5 as s as 5 41 S 3S .5 3s a 36 .I 37 .1 an h 4.1 4,000 44 4.280 42 5,000 43 4,S00 43 4,750 40 4,500 43 4,.'50O .W 4,.'50O 40 4,000 m 4,500 ¥, 4.500 4*1 5.000 *t 5.000 919 42 4..W0 ., 40 5,000 " 41 8,000 " 42 4.800 l'L.\TK VI. n CXPCnnCNTAL ELECTRIC FURNACE RUNS 8-12 Sec^fon cc •Jl» jBn.'.23 7 00 7 30 s.oo 8 30 9 (N) 9 30 10 (XI 10 30 11 00 11 30 12 ()0 Jan. 24 12.30 1.00 p.m 1 30 2 (X) 2 30 3.00 3 30 4 (K) 4 30 5 00 5 30 6 00 f> 30 7 (X) 7.30 8.00 8.30 9 (X) 9.30 10.00 11 tX> Factor 41 5 45 919 37 5 41 5,0 40 5 44 4..T .30 « 00 0.00 Marhine iitopped from .VIO to .5.1.V cleaning and plugging iron' hole. p.ni "(Material In fumarei " < l)einK melted down ' " Kumaee stopped. •.ir> .39 .IK :« 42 42 41 :«i 41 41 .3« .3« .39 .3« :<9 39 ax 30 .30 37 .37 .39 .3« .3« .38. .39 :» .38 37 ■Mi Volt« on Line. .30 .30 40 4«) 42 43 42 42 42 4A 40 4S 40 4.1 4.'5 42 40 43 411 43 43 42 40 40 41 41 43 40 40 42 43 43 42 41 40 Amprm. •VOOO .vntM) a.inH) 4JM) 4.7.50 .').(NN) .1,000 .5,(MM) 4..VK) .1,(KI0 l.-KK) 4.7.W 4..100 4. mm 4,7.iO r,,(HH) n.tnm a.inm 4.7.10 4.7.10 .".,000 .1,000 .l.tMIO 4,800 .l.iNNI 4,7.10 ■1,000 .1,0(K) .1,000 .1,(K)0 .1,(KK) .1,0(M) .1,(MH) .1.000 Po»rr Factor. HI ('Mt No. I Time When Curt. ' Kffertivr Msrhinr lenitth o( ■toppeti rmu. 10 Jan, 23, 1 40p.m 11 I 7 :» " 12 Jan. 24, laml2u.iii 13 14 15 1« 17 IH 19 » 21 22 23 24 25 20 27 28 2« Jan. 24. Jan. I Jan. 2(> tl l.lani. 11 15 " 3 4(lp.ni 7 -.m ■■ 2 (l.'>a.ni . 5 .W " 9 00 '• 12 30 p.m. 4 10 " 7 40 " II 05 " . J 00 a.m. .-. 05 '• . H 00 •• . II :« " . . 45 p.m. ,^ 0.5 " . 13-29 ■26-'29 I (I3h. 5min. 1 "lioura. 15inin. 5 inin. aomin Ih. 2Sm. 20 min. 5 mill. 2h.40 m. 5 min. •TO Jan.Jti, (100 p.m. Qllnii'v l*i| I roil of Pig ohtttincd Iron. Slac (•titaiiird h. III. 4 l<> 5 U ti 20 «0 25 11 55 .55 min. lU. 515 739 1002 4 15 r>.-.s 4 45 7->o 4 20 854 3 25 .540 5 5 77S 3 50 7.W 3 S «70 3 30 504 3 40 A06 3 10 .502 3 23 719 .> .« .525 3 5 .501 2 50 712 3 35 701 3 .f 10 •20 700 652 11130 2605 While White with hole- 372 560 111)0 White 4-22 ti.56 • in-v 155 Grey .56.5 44H .56.5 469 ■'22 '167 '.14 .vs: J94 261 2H9 372 274 •227 a-i49 1162 40 Ratio Man Iron. 7.'.' 76.". 1 1.57 6tl O H4t 661 74H 72t'> ti:«.5 427 44U 527 685 461 II .-ifiO .VJl 4a5 .531 3UI 411 570 436 2.59 R.\W M.\TERIAI. Ch.KRCED. Number Composition Chante. of 1 Additional Material. Total. of Charges. Ore. Bri- quettes. Lime- Ktone. 1 Hri- 1 Ore. quettes. Ore. Bri- quettes. Lime- stone. 4H 40 26 lbs. •200 •200 •200 Dm. 60 65 6.5 lbs. .50 .55 .50 1 Uw. ll>«. 1^200 ' 60.5 30 lbs. 9600 8200 .58a5 11)8. 2HW) 2600 1720 llM. 2400 •2200 1300 L_„: 23605 7200 .5900 When the furnace was stopped at 6.00 p.m., Jan. 26. it was partly filled ^vith material. Of this 906 11«. were taken out, but there st.U remained some in the crucible. Cut .No. in II » 13 U 15 IH 17 IK 19 30 '.'I 22 23 24 i!i M 27 28 -29 ilK Iron obtaim-d. Ibx am 739 1002 SAN 7N» K-H 77H 7.ta 670 S04 «m 719 .12.^ AOI 712 701 7«) M2 l.'»-29 2tl-2« .10 1 1 130 2ll«.'> LM Averagp \'iiltii (in .«♦ Ill .is .«» 10 27 37 :»7 ;« 17 ;i9 0.1 40 .V) 37 10 M, \!l St M) 37 «) .•Hi M .17 (17 m 07 41 III) .{- .HI 37 .3;i 38 .50 37 97 ;« 79 37 CNI Avrraitp { Power I ' Ayeruftf AmperpK Kiirfor. W«tl«. 1 44+.', 919 lAlWHA i'Mt '* 1 07189 *MU *« 168387 — -~.-— ~ — — . 4781 " 104193 4.388 " I.Vfllls I7(W " 1 088 48 l.'i.lfl " 1118827 477.1 " 1I1280.J 4H.17 .17I-.7 llill>2«) 4>.1» 4U4.'I 4958 4929 .'lOOO " 4910 • • 402.1 • • 4893 .. 492.1 •• .1000 *• 4812 919 4800 .KNM) 919 919 172081 100419 100441 1710.39 10.'i.i8M 1001.1.1 173107 17420.1 172492 lli8U.V« 1 7IHI07 IH7912 1 7.t.'4!l I7IHII.1 Avemip- Kl liorw Power. 214 43 224 II ^2.1 72 '220 09 206 .32 220 ,34 220 31 218 23 210 11.1 231 47 223 08 223 11 2:10 08 219 01 222 72 2.32 12 2:« .19 231 '22 220 48 2.17 14 0|ll(HII (if I'ilt Irrm iM-r lURI K. II P dayii. Tiiiiii 91 7 91 8 41 I* 44 9 .V> 10 4.1 8 40 8 42 10 07 11 27 7 7.1 10 20 8 J,S 11 .M 9 72 8 41 12 92 10 10 11 73 II 98 •22.1 ON 9 822 2:<2 23 II M2 •2-27 90 9 00 TakioK th.. figures for (V.s 1:1-29. thus ,-\u,uu.t'ug tho tl.n.. first u...l Hi. a.st Cast, wh,M. tl... nmtonal in the furna,-. hn,\ u, U- „u.|t..,l .low,, th.- results an- the followiiig:- Kffi'ctivc length of run. 6(J hours. 2.5niiii. Mean \olts 011 furnace :{" !»" .Mean siniixTes. . . ,„,", r^'-" f'"" ' !»ifl Watts .r,9- X 4S12 X 0.919 Ui79l> I'ip iron oO'ained j I ino'n,^ 1«7912 Kl. horx- power 74 i Otitput of pig iron per 1 (KK) K! horse power day. 11130 X KMtO X 24 60.41 X 22.5 08 x 2000 El. horse power year per ton of pig .r. () . 279 .'2.5. OS 9.822 tons MICtOCOrv RISOlUTKm TfST CHART (ANSI and l«0 TEST CHART No 2) |2j8 13? 1^ M2.2 2.0 1.8 y^H^ ^ APPLIED ItVHGE 165J Eaal Mam S(ree( (716) 288- 5989 -'a. 84 Only taking into account the last 12 hours of the run, when the furnace was working well, the results are as follows:— Effective length of run H hours. 55 min. Mean volts on furnace 38.79 Mean amperes *^^ Power factor ^-^^^ Watts = 38.79 X 4860 X 0.919 173249 Pig iron obtained 2665 lbs. 173249 El. horse power 232.23 746 Output of pig iron per 1 ,000 El. horse power days = 2665 X 1000 X 24 11 .562 tons 11.91 X 232.23 X 2000 El. horse power year per ton of pig = . 236 Analysis of Pig Iron Produced. 1 r=:r=.-=--^ - Graphitic Total Caat No. Si 1 s P. Mn. Carbon. Carbon. 4.42 10 0.50 0.110 3.42 11 0.07 0.193 3.18 12 0.05 0.149 3.13 13 14 0.02 0.34 175 0.122 0.024 0.01 14 4.10 15 0.11 0.094 3.04 16 0.01 0.133 17 0.02 0.094 3.40 18 0.02 0.173 19 0.61 017 5 01 20 21 0.79 1.05 0.055 0.021 062 0.10 3.86 5.40 4 71 22 1 43 0.008 23 0.94 0.0.30 4.42 24 1.04 0,020 25 0.97 0.043 3.00 26 0.82 094 27 28 0.79 0.90 0.044 0.022 0.067 0.12 3.80 4.64 29 0.57 0.024 4.35 30 1.03 0.019 ■ 3S Analysis of Slac; I'udDLCKD. Cast No. . Si()2 A 1,03 P2»)5 CaO M,s<) MnO Frt» ! i S I Fe 14 21 28 f.eiieral Sample 29.28 30.28 33 40 15 24 13 69 15 lO 281 0.027 o.crio 35 17 46 22 45 39 2 08 2.05 1 97 0-22 18 Trace 1 16 88' 4 79i 1 98 39 13 13 74 3 72 79 I 54 26-30 General Sample 34 12 15.00 020 45 32 2 20 " 2 3li 1 76 1 82 10-30 29.44' 13.98 0.119 1 42 62 2 29 12 7 11 0.65 S.iJ The siag obtained when produting the white pig iron was bla- k with a high content of iron and with a comparatively high content of pho.sphorus and manganese, showing cold working and resulting in a white pig iron high in sulphur. With increased temperature the phosphoric acid and oxide of manganese were reduced and the iron obtained contained practically all of the phosphorus and manganese present. RUN No. 9. FURNAPK. In this experiment it was decided to make a further attempt to utilize the gases developed. Xo change was made in the shape of the furnace em- ployed m Run No. K but an one inch air pipe was put in 12 inches below the top of the furnace. Ore treated Hematite Reducing agent Briquettes ^'"^ Limestone The analyses of the raw materials are given in Run No. 1. The furnace was : arted up at 8..30 a.m.. Jan. 30th, and when the ga.ses developed began to burn on top the blast was turned on. The heat developed by the burning of the carbon mono.xide was so great that the charge in the upper part of the furnace became fused and would not descend into the crucible. The electrode was rapidly consumed by the oxidizing action of the blast and the sheet iron covering the electrode was destroved in a few minutes The electrode had to be raised and the material in the furnace melted down twice during the experiments. Any further attempt m this direction with the furnace employed was, therefore, abandoned. M RUN No. 10. FURNACK. The furnace pinployecl for this run was the same as in Run Xo. !>. the holes, however, of the air bhist tube were plupged with flay. Ore treated Magnetite from Wilbur mine. Reducing agent Bri AI2O3 -'-56% CaO MgO 2.00^ 6.S4':{ MnO 0^^«'; PA- s 02:}' 0.0.5' J'Ojandundet 3.609'^ 100.000':; P=0.01'7o [Moisture *^ ^';'. I Volatile matter 4.54',,' Briquettes > pj^^^ ^^^^^^^ 55.36';i I Ash 39.90% ioo.oo7() 23.24 \ 14.06 [■ SiOj FejOa + AI2O3 Ash: I CaO 1 '^ MgO ''I Undet 3-* The briquettes contained 1 0.3' 39.90% sulphur 0.015% phosphorus [ Volatile matter 1 . 73' ^ Coke fines: - Fixed carbon 90.37',f I Ash 7.90% Sulphur. 100.00%, . 0.67'7o .Sand : .SiO., IVA Al.Oj CaO MrO Alkali and undet. 81.71'; oiw; 14.27'; i.wv; 1 11'; 1.22'; 100.00' The analysi:. of the limestone is given in Run Xo. 1. The furnace wa.s started up at 11.00 a.m.. Jan. :il, with a charge of position: — *" com- 9'^ 200ll,s. Briquettes ^^ ,. Limestone. ... .,. .. 2o The pig iron produce.! from this mi.xture was white, full of holes -ind Inph in sulphur. The carl.on an.l limestone were increase,!, the oompositioa ot the charge now being — ^'' 200 ll,s. Hriquettes ^ Coke fines , . .) Limestone .,,. .. A grey iron of good (luality was then produced. In order to furthermore decrease the sulphur contents, the limestone «^s St.! further increased, but the slag pro.luced became too viscous and after a few charges the limestone was again reduced to the above amount and a little .sand put in at the time to make the slag more fluid. At 9.30 p.m.. Jan. 81, a cast was tried, but the iron in the crucible was tound to hav, Some limestone was then put in and at 10.55 p m the .ron was tap,. The electrode was up rather high, however, anJ K 5 = sa » Is is ? 41 When the furnape had to Ik; stopped at 6.45 p.m.. Fcl). 1. it was partly filled with material. Of this l()j:J lbs. were taken out Only takinft into aeooimt Casts U9-4;j, diiriiiK whieh time the fiirnaee was in working conditions, the results are: — Kffeetive length of run 17 hours, iH) miii. Mean volts on furnace 37 Mean amperes .50U0 Powei factor 91ft Watt»=37 X 5000 X ftlO 170015 Pig iron obtained :U!)5 lbs. 170015 El. horse power 2"i7 . !)0 74ti Outpiit of jjig iron per 1 .(KK) Kl. horse power days -- 3105 X 1000 X 24 ft. 435 tons. 17. S3 X 227.9 X 2(KK) Kl. horse power year per ton of pig -=0.2!K). Ax.\LYsis OF I'K! Iron- Produckd. ill Cast N'o. 1 Si. S. Total Carhoii. 3.5 . 12 C = = = = 38 . .39 . 40 . 41 . 42 . 43 . : 2.54 1 3.36 ...:■ 1.61 2.49 2 91 i 2.28 3 28 3 '87 4' is 1 Ax.\LYsis OF Sl.\o Prodlcf.d. Cast Xo. Si02 ■Wh ('a( >. .Mk< ). K. ' S. 36 38. . . . 27.20 27.18 35.00 20.61 28.60 28.29 18 76 28.76 20.00 14 24 13 91 10.72 14 15 '• 0.50 2 31 1 19 91 42 80 RUN Ifo. 11. Ft'RXAtK. No alforations werr mail*' in the furnacp. ( Magiu-tite from Wilbur nunc. Ore treated ^ Hematiie (Negaunee). Reducing agent '"'"' The aiialywn of the magnetite and roke arc given in Rim No. 10. The analysi.«i of the hematite is given in Run No. 1. The furnace was started up at S.25 a.m.. Feb. .5, when 70 lbs. of VVilbur ore first were put in. the crucible not being cleaner UIO Cast Time when Cast Machine (•♦opped Effective length of run Piir 1,0(10 Kl. hur.-M- power «lay» 7ttJ X 1000 X 24 11 2B.*i totiK. 3.:w X 24a. 73 X Am Kl. hiintf iKiwcr yt-ar ix-r ton t':; 1(H) 00' ; Sulphur O.OoK'; Immediately after the termination of Run Xo. 11 the funiaee was put in order and started un at 4.40 p.m.. Feb. 5, with a charge of composition:— Ore *"' ''"*• Charcoal ^^^ " Sand 2S " With charcoal as the reducing agetit the current employed was suitable and the furnace worked well. At 10.55 p.'" ' '. 5. the iron broke through however, and the furnace had to be sh.t do«,. --r repair. The linmg around the iron holt^ was badly eaten away and when the iron broke through part of the iron casing of the furnace was destroyed. 7 charges of the alwve composition were put in and when the crucible was cleaned 676 lbs. of material were taken out. Wh( ii starting up, some material from the previous run was ver>- likely left in the furnace. 4.1 KlKCTHII AI. MKAsrHKM»:NTM. Till' voltnu'ter was diriit coiitiiMttd with the clcctnxU' unci Ixtttoin pluti' of the furnace, eliminatinK the Umn on t\w luntuelx. Timr. iVolix iin h'tirnni'i'. Aniiirni). I I'cmfr Kiii'lnr F«l>, 3, 4 4t) p.m. Fumaifiitartnt am SB n m 37 30 tl (Nl n m 3A 7 int 7 :«) 37 30 41 7 .M S I.'i H .30 ' f .Machine at ' I pnirinKiriH "K'"^ (N) 3N 9 .HI ' 40 ,19 U) on 10 ;pp«.(l Kffcctive lenfcth nf run I'lR Iron ohtainrU ;iiiality of PiK Iron MlaK jobtained Kntiu Iron 46 47 Feh. n, 7.4a p.in " «, 10..^3 p.m. . . . 20 min . h. m. .•} .1 2 no 723 (iri'v. Itw. 419 .%7« -m 46-47 hm. l.'> mia 20 m. a .W I31S (In-y. 634 il Cast No. 46 47 46-47 Pin Iron obtained lbs. 723 595 1318 Average Volts on Furnace .38.00 39 20 38.60 AveraRe Amperes Power Factor .5000 .5000 919 919 .5000 0.919 Average Wait! 174610 180124 177367 Avf Tf El. H<. . Pcwi r Output of Pi/; Iron per 1000 E. H. P. days 234 06 241 45 2.37 75 Tons. 12 U3 10 46 11 256 Effective length of run 5 hours, 55 min. Mean volts on furnace 38 . 6 Mean ampere.s .5000 Power factor 919 46 Watts=:$8.6 X 5000 X 0.919 177367 Pig iron obtained ^'^^^ ">''• 177367 El. horse power 23/ . /o 746 Output of pig iron per 1,000 El. horse power days =- 1318 X 1000 X 24 ; 11 .2.56 tons. 5.91 X 237.75 X 20(M) El. horse power year per ton of pig-=0.243 An.\ LYSIS OF Pig Iron Produckd. Cast No. Si. s. I P. Total Carlioii. 4fi 1.84 1.21 0.0.54 0.039 0.029 0.019 4.10 47 " RUN No. 13. FtJRNACE. The furnace was repaired and given the same shape as the one employed in Runs Nos. 8-12, the diameters of the lower cone being made slightly smaller and the diameter on top a little larger. The height of the furnace was in- creased three inches and instead of brick lining partly around the tap holes, carbon paste was used entirely, as shown in Plate No. VII. The brick Immg was made of common fire bricks on account of difficulty in obtaining basic lining material. In order to ascertain the consumption of electrode per ton of product, a new electrode was put in covered for a distance of three feet with asbestos and sheet iron. The electrode weighed when put in 937 lbs. The furnace was pre-heated from 12.00 noon, Feb. 11, until 9.30 a.m., Feb 12 when the electrode was taken out and a few loose pieces at the end knocked off. The weight of these pieces amounted to 17 lbs. and consequently the weight of the electrode when starting the experiments was 920 lbs. Ore treated Magnetite from Wilbur mine. Reducing agent Charcoal Flux Sa" 2NX 327 .•«•!» 2il4 307 405 400 .50 IMN) .56f) .50 1 400 140 10 .50 20 4.50 140 .30 3 4.'> 1.30 15 (M) 15 1.300 .390 r.o 17 .i;;) 125 20 40 6S0O 2125 ;iso I 4(K) 125 25 400 125 25 5 400 i 120 ' 25 ; 2000 600 125 2 400 ' 120 20 SOO 240 40 4 400 125 20 i 16(K) .500 SO 2 400 ! 125 25 SOO 250 50 13 400 1 125 27 ! -■- 5200 1625 351 1 i 1 211.50 6.5.55 1191 A3 -- , Output of ClMt PiR Iron Averagr Voltii on Averegp Power Average Averaxe El. Hone Pig Iron per 1000 ^. H. P. daj'H No. nbtaine8.Vt 35.70 5000 919 ltH()42 219.89 11 424 KfTi'ctive length of run 01 hours, 25 inin. Mean volts on furnace 35.70 Mean amperes 5(K)0 I'ower factor 0.919 Watts=35.7 X 5000 X 919 164042 rig iron obtained 12858 lbs. 164042 Kl. horse )M)\ver 219.89 746 Output of pig iron per 1000 Kl. horse power days=- 12858 X 1000 X 24 11.424 tons. 61.42 X 219.89 X 2000 El. horse power year per ton of pig=0 239 Charcoal used per ton of pig=1020 lbs. ('•at No. as Analyhm or Pio Iron- I'RdDrrKO. Si. s. 4«. A3. U. m. m. HI 0.1 0)1. 1 3(> 1 41 2 'a I 03 04 t (« 3 29 3 70 020 012 1)24 034 07.1 029 ()20 01.1 (rJ9 ir.>4 010 ttttiX 017 .Mn. liraphitic (■Brt)on. Total Carliun. .... 27 21 .... 20 M 70 3 .Ki 3 .W .1 IH 4 «.1 4 .11 4 tl4 3 «2 RUN No. 14. FURN.\CE. No alterations were made in the furnace and tlie same electrode as in Run No. 13 was used. Ore treated Magnetite from Bhiirton mine. Reducing agent Charcoal Flux lLimesto.,e "^Sand Ax.^l.YSIS OF K.\W MATr.KI.\L. SiO. 0.60V^ Fe.,6., 60. 74''; ) „ .. „.,.. FeC). MWAy'-^"^" .KU\ 1 48'7( Blairton ore: Cab 2.84?6 ■ MgO 5.50,':, MnO 0.13;:, PgO, 0.037'7< P -0.016';c S. .." 0.57% \ CCg and undet 4 . 923';^ 100.00 Vt- M Thi> analyxiM of the rharcoul im given in Riui No. 12, of the liineittone in Uiin No. 1, and of the Kand in UiU) No. lU. When the furnace was Htop|M>(l at 10.05 a.m., Fel). \!>. it wan filled with the ini.xture previouHly unetl, uniotintiiiK to praetieully one charne. After the motor had U'en re|mired the furnare wax started up uKuin at li.tX) p.m., Feb. 15, with n charge of rompoDition: — Ore m) 11)0. Charc" .1 125 llw. In order to reduce the contents of sulphur in the pig iron the limestone was increased. The high contents of mai^nesia made the slug very infusible and in order to clean out the crucible 50 llw. of saiul were added and^the material in the furnace melted down during Cast 74a. A little sand was afterwards added to the charge and the limestone further iiicreaseil in order to obtain a greater proportion of lime to the magnesia. Towards the dose of the run the carbon in the ch.irge was reduced, the composition now being: — Ore 400 ll)s. Charcoal 120 " Limestone 25 " Sand 6 " The iron protluced was still grey, showing that with this ore 120 lbs. of charcoal to 400 lbs. of ore was sufficient. On accoimt of the comparatively large amount of slag produced and the infusible nature of the slag, the output was correspondinglj . nailer than in the previous run. El.KfTRirAL Me,\8URKMKNTS. Time. Vo!t« on : Furnace. Volts on Line. Amperes. Power Factor. Feb. 1.5, .1 (Kip .T 30 m. Furnace Htarted. 3,S 41 3H (t 40 39 .5 3.S 42 39 400 .39 41 40 42 32 .5,(KX) 919 4 on .3.5 A .in 37 .\ (M) 3(i .i 30 3.5 ti (M) .3H () fi.30 35 7 (M) 'M 7 .30 3.5 S 00 37 K .30 9 00 '.1 1.5 .M TieiHv Feb. m, ft 10 10 II II V2 Feb.16, \i I I 2 •_> .1 3 4 4 5 5 6 « 7 7 N H » « 10 10 It 11 13 12 I 1 3 3 4 4 .1 .5 « H 7 7 8 8 9 9 10 10 11 U 12 Feb.l7 12 1 1 p.m. p.m. ' Material in i fumnce melted !■ 1 down J Maohine stopped fromi 2 2.5 to 2. 40. 1 Vollii un Furnace. 40 4:{ 40 •J» :w 3.5 3:i u 37 34 :» ;w to :m ;«i 3«i .'iO 30 5 37 37 :«i 30 .wo ;«i .37 1/ ;« .35 .34 .34 34 .3.5 :« ) .32 () 37 <) 37 38 (I 38 .38 .') .37 37 .5 38 (I 39 39 31 34 .33 34 32 3.5 31 37 .■! 36 5 35 .37 :i8 36 .l.'i 37 .39 Volla on Une. 44 47 44 4:) 40 3U A 3H Amp«'i 5,0110 Power Fartur. o.»tu 41 Xi .38 ;t9 1.5 II 41 40 40 40 41 41 41 41 40 40 40 40 39 38 38.0 .37 .38 .39 38 :w 40 II 40 5 4! II 42 42 41 41 41 5 42 .'i 42 5 35 37 :«} 37 5 35 5 .38 5 .^5 41 .'19 5 39 40 5 42 40 .39 41 43 3.INI0 5,000 IVh. Feb. 18 TImr. VolU nn Furnarc. 34 35 36 34 35 34 34 34 30 38 30 35 35 39 5 39 40 36 5 Ml 36 5 34 36 36 35 35 at 3.^ 3.% 5 33 5 34 37 38 37 38 38 36 37 40 39 38 37 36 36 36 35.0 35 36 36.0 36.0 36.0 36.0 35 36 35 36 C 36 37 38 37 35 36 36 Voltii on Um. AmiMTni. I'OWIT Factor. 3 OOs.m 3 30 " .', in 1 00 " 1 30 " 2 00 " ... 2 30 " 3 (Ml " 3,30 " 4 00 ' 4 30 " 5.00 •' 5,30 " « 00 " 6 30 •' 7 00 " 7 30 " .. 8 00 " 40 40 43 5 42 5 41 .-. 40 39 39 40 8 30 •• 9 00 " < 9,30 10 00 •' 10 30 " 11 00 " 11 30 " 12 00 " •. 12 30 a.m. . .39 39.0 40.0 39.0 39.0 .39.0 40 38 40 30 :: 1 00 " I 30 " 2 no " 2 .JO " 3.00 " 3,30 " 4,00 " 4,30 " 5.00 " 5.30 " .39 (1 '■ " 6 00 " . ... 40 41 >i 0.30 " .1 7 00 " 42 " " 7. .30 " 41 8,00 " 39 8.30 " 40 " ' 9.00 " 40 97 tkim. Volt* on FuniaiT. VnlU on Ulir. .^iiiltrn-x. I'imrr Factor. rpi). IN SOa.m m :M a\ M ■M :m Xi .'19 :w :d i Iron 87 Feb lA, 8 OOp.m Fel>. 16, 12 10 a.m. 4 10 ■ 9 (K» " 1 (K)p.m .■500 " . 9 1.5" Feb. 17, 1 00 a.m. h. m . lb*. Ilw. 1 Ji 1 Q*iM f:r*i\' •>iilX fl 'liut AN 09 70 71 . .5 min , . .5 " ... .5 " 4 .5 3 .V5 4 4.5 811 • 298 .100 6A.1 •• 10.5 2.5:1 910 " 284 : 312 802 " 301 0.37.5 804 1 " 308 .3H3 6.50 '• 244 0.373 .5.57 i " 252 ' 4.52 72 i 1.5 3 .3.5 73 74 .10 min *74a 2 20 " . 20 min | 1 | 124 | " lOfl 1 -U 7H 7« 77 78 79 80 81 82 83 10 ■• 9 4-1 " I2 4.'5p.m 4 (K) •' 7 4.5 " 11 40 ' Feb. 18, .TCKla.m 30 " 10 (H) '• .1.5 " .10 " :: ^io " .... .5 " .... ,5 " 3 .3.5 3 '2.5 3 3 1.5 3 4.5 3 4.5 3 1.5 3 2.5 3 m 644 664 622 .52.5 «j8» 6.59 6:16 608 703 313 1 48«) :m I .507 229 ' .■«« 167 31H 262 1 .380 289 4:18 281 : 441 318 1 .523 4.5.5 i 647 1 67-83 6.5 hours, 40 mill. Ih 10m 64 ii :m 111 118t« Orcy 4786 4(0 m Feb. 18, 1 OOp.m. 3 h. 410 " 283 1 890 ♦M."terial in furnace melted down. tNot inel.hiittj{ Caat \u. 7 la. ^Material in furnace melted down. NuiiiIht of chaws. 1 7 •J 1 4 ti 3 AH HAW MATKHIAl. ("HAHdKU. ('oiiiposilioii of CharRP. ( >ri'. Ihs. 4(M)* 4(K) 4(N) 4(MI 4IH) 4(HI 4IM) 4(H) 4(M) 4(M) Char- (*oal. I.iini'- slnlw. I1.S, II.S. 125 10 20 12.1 20 120 20 V'r, 20 12.') 30 12.-I 120 2.5 ♦Willmron'. Sand. Il>s. 27 Ailditioiial Mati'rial. Tolul. .50 Char- I.iinc- d. Ore. coal. Htonc. Sand. s. Ilw. lbs. lllH. Il>». 4IMI 125 27 tilHNI IM75 2.S(H) S75 70 S(K) 2.50 40 ) 4IHI 125 20 .53 ItMH) 4S() SO 12 24(H) 750 120 IS 12(N) 375 !M) ■J S(H) 2.50 ,50 (i 1 44(H) 1320 275 (Mi 20.S(K) (•.425 745 191 At the tfrniiiiatioii i>f this niii sonic materiiil was still left in the fiiriuice. Ca.st Pi(t Iron AveraKr AvfraRc Volls on '. No. i obtained Kiinmcc 1 .XnipiTcs (17 i UK I e» I 70 I 71 72 73 74 75 7« 77 78 79 SO Kl S2 (■.7-S3 S4 lb.s. 92S SI I (i.53 ttlO S02 S04 ().5() 557 (144 (itl4 (i22 525 tiS<.» (>,5i) (VKi IM)N 703 llS(i5 410 .5(HH) 17.50 .5(KH) .•«1 30 37 27 31 S7 30 35 34 25 37. (« 34 (>2 35 75 34 .57 37 07 37 50 35 3(1 3(« .5(1 37 3S 35 71 35 S« :«> 14 35 SS 4U8.5 35 (K) ! .5(HH) Ontpul of I'ower AvpraKc AvcraRc Tin Iron Kl. Horse ' per KHH) I'm'tor Watts I'ower K. H. V. days Tons. <»1() KMKIW 222 97 9.9S 1712.50 229 .50 10 39 " 139112 lH(i 47 10 74 I(i7(l2s 223 S9 10 27 •' 1.5737S 210 'M\ 11 40 " 172tM)9 231 7S 10 40 • • 1.59079 213.24 sot 104271 220 20 S.4S 1.5SS49 212 93 10 13 " i 170330 228 33 10 23 • • ! 172312 230 9H 10 77 ■ • l(i2479 217 .SO S 90 " l(i7717 224 S2 9 .SO •' 1 171701 230 24 9 10 " ! l(i4()S7 219 95 10 (>7 " , 10477(1 220 S.S 9 (is " ; laovna 222.00 10 S2 91!) ! I(i4374 220 34 10 OlS 919 l(i()S25 215 .5S ! 7 (iO N Not takiiiK into account Ctists 74a and S4, when the material in the furnace was melted down, t lie results ar<': - Kffecfive length of run M hours, ;{() min. Mean volts on furnace :{.").. SS Mean iim|M'res KIS,"( I'ower factor t) !tl!l Watts X,XS X 4!).S-) X iH9 1«4;{74 Via iron oi)taine(l 1 isti.') ll)s. 1«4;174 Kl. horse ptiwer 220. H4 74() Output of pij; iron |)er 10()() Kl. horse power day.s=^^ ll.S«.'> X KKM) X 24 _ lO.OlStons (54.5 X 22(» .U X 2()()0 Kl. horse |K)wer year |M'r ton of pig () . 27:{ Charcoal used [ht ton of pij; KWfi Ihs. An.m.vsis ok I'ni luoN I'koduckd. Cast .\(i (is. , 70. , T.i. . 75.. 7<>. . 77.. 7S. , 7it. . 50. . 51. . S'J. . (Iriipliitic i Tdtal .Mil. Curliiiii. I Carbon. :«•-' 1 .11 IJO o:m 07 -' 7-' a .54 1 !»S 0J7 0U7 oil ;< 4ii :t so .5 1.5 O-W Mr, (KM) :< (>() 040 :< :«) (UO ().'{0 10 :mo 4 itl .TO.'-. (l.iO ;{ .M 04_' fW4 .< 7:{ :{ .'-.4 («!• (»24 10 •_' 7s .{ its :j :«i 0.5-' .\N\1.YSIS <1K Sl..\(i I'lKIDli I Cast NO. 70. 7.{. 7S. Nl. ()7-,S4. .Si( U .\..|( >:, I'M ».', :t7 IS 1 1 S2 (IIS :<;< 4ti 10 40 02:{ Xi M< S <».5 (lis AA 12 S 4S (ll(> : III IS 21 (Ms Call. Mk« >. .\lt.(). IS 21 :i() .57 2(1 .5S 24 .5S .'<0 2;{ 24 Sli 2.5 so :!0 21 2H 14 20 44 Ol 01 02 02 0.5 l'.< ). 41 (i.5 (I .S2 90 42 2 20 ;» 15 2 40 2 l.J 2 (Ml 6)) RUN No. 16. FURNACK. No alterations were made in the furnace and the same electrode as in Runs Nos. 13-14 was used. Ore treated Magnetite from Calabogie* Reducing agent Charcoal and charcoal breeze. I Limestone ^•"^ I Sand Analysis of Raw Matkrial. SiO„ 3.80% Fp/)3 56 24%), FeO 25.76% i AUO3 3.73% Cab 2.00% MgO 3,42% MnO 0.27% P^Os • 0.85% P=0.371% S." 0.20% COjand undet 3.73% 100.00% Calabogie ore : Fe=o9.389; The analysis of the charcoal is given m Run No. 12; of the limestone in Run No. 1; of the sand in Run No. 10; of the charcoal breeze used no analysis was made. The furnace was started up at 3.10 p.m., Feb. 18, when 20 lbs. of charcoal first were put in and afterwards the charge of composition:— Ore 400 lbs. Charcoal ^25 Limestone -^O The pig iron produced with this mixture was white and high in sulphur. The carbon and lime in the charge were, therefore, increased and the iron produced became grey and with low content of sulphur. * Calabogie Mining Co. 61 At 3.15 p.m., Feb. 19, the machine had to be stopped for repair of the motor. The fiirnaee was cooled down considerably during this time and when starting dp again at 5.45 p.m. the iron in the crucible froze up and the material in the furnace had to Ijc melted down. At 12.40 a.m., Feb. 20, the furnace was again charged with a charge of composition: — Ore 400 lbs. Charcoal breeze 135 " Limestone 45 •■ The iron produced Ijecame gradually white and the carlxxi was, tiierefore, increased. The charcoal breeze which was .wet and consisted mostly of fines did not prove satisfactory and towanls the termination of the run a charge with 145 lbs. of charcoal (in lumps) was put in and a gi-y iron produced. El-KCTRIfWI. Me.\surements. The carbon arouinl the bolt screwed into the electrode .' ^ the voltmeter contact was partly eaten away and when putting the electrode in place this bolt broke. The readings were, therefore, taken on the voltmeter coniiocted with the main circuit and from these readings the average loss, 3.72 volts, on the contacts, ascertained in the previous run, are deducted. Time. Volt.s on Lino. .Amperes. Power Factor. Ft!. 18 3.10 p.m. 3.30 " 4.(H) " 4. 30 " 5 (H) " 5.30 " 6 00 " 6.30 " 7.00 " 7 30 " 8.(M) " S .30 " 9 (W) " 9 30 " 10 (M) " 10.30 " 11. (K) " 11.30 " 12 (K) " 19 12 .30 a.m. Furnace startml. . . 43 41 5 .38 5 41 40 40 () 38 () .38 39 41() 41 42 42 () 42 41 5 41 5 41 42 41.5 41 40 5 11.0 41 5 40 5 5,000 11 ;; (1 919 F."li 1 (M) " 1 30 " 2 00 " 2. 30 " 3.(H) " 02 Tiini'. Feb. 19 Fel). 20 Anipere«. 3() a.m. (M) '• 30 •■ 00 •• HO " (M> " ;«) " (M) ■• ;«) " (M) " 30 •■ (K) " 30 " 00 " 30 " 00 " 30 .00 .30 00 30 00 30 00 p.m. 45 ' 00 ' 30 • 00 ' 30 ' 00 ' 30 ' 00 ' 30 ' 40a.r 00 ' 30 ' 00 ' 30 ' 00 ' 30 ' 00 ' 30 • 00 ' 30 ' 00 ' 30 ' 00 ' 30 ' 00 ' 30 ' 00 30 00 30 00 30 .00 30p.i .00 Machine stopjiod from 3.15 p.m. to 5.45 p.m. for repair of motor. Material in furnace melted down and furnace cleaned. 40 5 5,(MK) 39 5 40 5 40 5 41 5 41 5 41 5 42 5 41 5 40 5 40 5 37 5 3« 5 37 39 39 () 38 38 37.0 37 37 3S 39 38.0 38.0 37 39 37 . .« 38 37 38.0 42 4,500 39 4,750 40 5 .5,000 38 5 40.0 39.0 "40.0 40,0 39.5 40.5 39 5 40 5 39 5 39 5 39 5 38.0 37.5 40.0 40.0 40 40.0 38.0 40.5 40.5 40 f( Power Factor. 91'.) in Time. Vvh. JO 1 30 p.m. :.■ (H) L> 30 3 (H) 3 30 4 (K) 4 30 .■> ()0 liiiii tcniiinatpd. Volts on AmpereH. Power Line. Factor. 3i» .■> ."i.OOO 0,919 :» 5 3S .5 39 3.S :w .i 3« 5 Mwiii volts on fiirnare during first part of run (IMO p.m.. IVi). 18. to :{.l.') p.m.. Feb. 19) :— 40.01— 3.72 36.29 Mean volts on furnace during second part of run* (12.40 a.m., Feb. 20, t< 5,0Op.m.,Feb. 20):— 39.49— :^72=35.77 Ca8t Xo. Time when Csmt 86 S7 8,S 89 90 Fel>. 18, 7 .3.5 p.m. 11.3.) " Feb. 19, 3 3.5 a.m. 6. 5,5 " 11 00 " 3.1.5 p.m. 8,5-90 24 hours, 5 min. 91** Feb. 20, 12. 20 a.m. 92 93 94 9.5 .5.00 " 9.0,5 " 1.00 p.m. .5.00 " 92-95 16 hours, 40 min. Machine .stopped 5 min. .5 " ,5 " 1,5 min. . . 2h. 30 m. , 20 min . . 5 " Effective | Quality length of I Pi)S Iron of Pig" run ol>taine 188 '• 2.50 193 " 288 323 " 401 1.S5 " 0.288 23 h. .50 m 4.520 lbs 1335lbs. . 295 6 h. 3.5 m. 1012 lbs (ircy. . . .584 lbs. .577 4 20 72w " " 299 " 410 4 . . 1695 " white. . . 2.3.5 " 338 3 5.5 765 " , •' 278 " : 0.363 4 .. .533 " (Irev. . . 80 " 0.1.50 2,5 min. 16 h. 15 m. 2,722 lbs.!. I I . . 892 lbs. .327 *Xot including Cast So. 91. **During part of this run, the material in the furnace was melted down. .s s Jj X 3S^ ^ .= e 64 I ; ; ;2g : : : : : I : : : : : iiH : sSShS — 2 : : -if sst-n — ?iacac ■ — iSiHSSSiiiS X ,-fc j . . .«ii; ■ ■ • • ■ « C ^ ''t li? C C •?? '-'5 c c • ic c >c S rt T- -^ ■ . K* IC C C "t »C ■ ■ ■ >5 eg CI C^l w cc cc « ■ ■ ; ^ sSiSSiSiSiS O M — f 1 » •£ t- O M — i S 9 US Cast Xo. PifC Iron obtained Average volts on Furnace AveraRe Amperes Power Fartor .Xverajse Watts Averafjc Kl. Horse Power Output of PiK Iron per KHMI K. H. P. (iav'H 85 R7 8« 89 90 870 784 750 670 8(M t)42 3« 17 37.78 37 34 37 11 35 «1 34 rtl 5000 919 166201 173.599 : 7 1.577 170.520 163628 156.368 •222 79 232 70 230 (Kl 228. 58 219 34 209 (Ml Tons. 10 62 1(1 34 Kl (Kl 1(1 80 10 78 8 (i.5 R'i-90 4520 36 29 5000 919 1667.52 223 .52 10 183 91 1012 34 (13 5000 919 1.56;«i8 2(W (Ml 8.80 92 93 04 95 729 (->95 7(i5 .5;i3 36 11 ; 35 59 3(i 15 35 (16 4917 .5000 •■ 163171 16;j.536 166109 16U(MI 21H 72 2I<» 21 222 (Mi 215 95 9 23 9 51 1(1 .54 7 4(1 92-95 2722 35 77 4979 919 16,3673 219 40 9 208 1st part of run. (Casts S5-90). Effective length of run -y.l hours. .50 iiiin. .Mean volts on furnace :{6 . 2!) .Mean amperes .5(XXJ Power factor 0.919 VVatts=36 29 x 5.000 X 919 1667.52 Pig iron obtained 4.520 lbs. 166752 El. horse power — 223 52 74'i Output of pig iron per 1000 El. horse power day8= 4520 X 1000 X 24 10. 1S3 tons 23.83 X 223.52 X 2000 El. horse power years per ton of pig^=0.269 2nd part of r>.. (fasts 92-95):— Effective length of run 16 hours. 15 min. .Mean volts on furnace 35 . 77 Mean amperes 4979 Power factor 0.919 Watts=35.77 X 4979 X 0.919 16.3673 Pig iron obtained 2722 lbs. 163673 El. horse power 219.40 746 M Output of pig iron per 1000 El. horse power day8= 2722 X 1000 X 24 9. 208 tons 16 25 X 219 4 X 2000 Kl. horse fM)wer year per ton of pig=()4«' ; P 020' ; s 0.17'-; ^ CO^iiml iiiuh't ;{..')44' ,' 100. (KH)'; Charcoal : Moisturp 2.20',' Volutili- iimttpr 20.60',' Fixed ("arhoii 74,40' ^ Ash 2 SO';; The analysis of the limestone is given in Run Xo. 1; of the quartz used no analysis was made. The furnace was started up at 6.20 p.m., Feb. 20, when it was filled with one charge of the mixture employed in the previous run. The composition of the new charge was: — Ore 400 lbs. Charcoal 125 •• Limestone 50 " Quartz 5 " Later the charge was changed to: — Ore 400 lbs. Charcoal 130 •• Limestone 45 " The electrode rose, however, to a position too high above the crucible; the iron became cold and the crucible filled up with a scale, preventing the charge from going down, which resulted in the very small output obtained in Cast No. 101. To reduce the excess of carbon in the furnace some crude ore was put in, the carbon in the charge was decreased and a little quartz added to the charge. The electrode came down, the output increas. .. again and a fluid .slag was produced. At 9.00 a.m., Feb. 22, the furnace had to tm lie HtcipptHi (III iirciiiiiit of |Miw(>r KiviiiK nut, the iiilft to thi* tiirhiiui* lifing lil(l with ice. Kl.K(THI(Al, Mkasi KKMKNTS. Thr voltH wprr rcml in the Hamo niniiiu-r us in tlu> pri'vioim run und '.i.7'2 volts diHlupti'd for the loss* on tlii' contin'ts. TiiiK". Vottii on Aiiip<'n'». Keh. 20, (I '20 p.m. Fumaw Htartwl. t\ m •• 42 7 00 " :«t (1 7 :}(( " 40 N (Ml '• 39 S 30 " . . , . 39 9(10 " 41 (1 9. 10 " 40 10 00 •' 40 10 ,'10 " 39 n 00 " .39 11 30 •• 40 I'J.OO " 41 .5 Feb. 21 12 30a. Ill 40 (1 1 OtI " 40 1 30 " ... 41 2 00 " 40 2.30 " 40 (1 3 00 " .39 3 .30 " 39 (1 4 00 " 40 4 3(1 •• 3K .SO" " .3S (1 .ij.30 " ,39 .5 (i 00 " 40 30 " 40 7 00 " 39.0 7 .30 " .39 K (Kl " .39 K .30 " .38 .5 9 00 " .'is (1 9 30 " 37 10 00 " .38.0 10 30 " .39 a 11.00 " 41 (1 1 1 . 30 " 41 ,5 12 (K) " ... 41 .5 12 .30p.m 41 ,5 l.(KI " 38 1..30 " 41 .5 2,00 " 42 2 30 " 42 3 00 " 41 3 30 " . . 41 4.00 " 41 .5 4.30 " 41.5 .5.00 " 11 5 .-1 ,30 " 41 .5 (i.OO " 42 .5 6.30 " 40.5 5,000 Power Factor. 919 m Tinif, VnllD nil Linr. AlIIIMTOl. I'ciWtT Fartiir. K " 42 ft I" <•'• '• 4HH "••■«> •■ 1 430 II 00 " 4.5 "1 30 ■• :::::::! 400 1^' IH) •• ;«, .-, Kill. JJ IJ 30 n.iii 44 O 1 '"» " 42 1 30 ■' 42 -'•H) •• toil •'.30 •• :«, „ 3 "X" " 37 ••<:«■• •' ; ;wo ■}<"' •• I 37 ■» *• •• I 37.0 "• •><> " ' 40.0 •'5 •■«• •' i 40 « <"<• " 41 30 " ] 41 o TOO " i 33.0 7.30 " 3,,,, >* •«> " 34.0 >*■•■«> " :».o 9"K) " 4,0 .1.INNI II 'M'.l 4,IMN) 4,N00 .t.otto ' The furnace hud to Ih> stopped after the cast at 9.00 a.m., I'el). 22. on account of power giving out. tiie inlet to the turbines iK-ing blocked with ice. Mean volts on furnace=40 . 06—3 . 72=^ 36 . 34. Cast .No. 9« 97 9N •m UK) 101 102 irej 104 105 Time when ('a»t Feb. 20 10 00 p.m. " 21 1 4.5 a.m. « (K) " 9.40 " 12 .'JOp.m .'■> 0.-> " 9.(H) '• Kel). 22 1 (K) a.m. a On " 9 110 " .Machine* stopped . l.? mill .5 min F'ffertive length of I'ie Iriiii run ohtaineil h m llw. 3 40 627 3 4.5 771 4 . t)97 3 40 1)9.5 3 10 UMI 4 1.5 •ill 3 .5.5 9«10 4 . 777 4 .. 7S9 3 .5.5 (W3 (iiial. Halio of Piif Slug /*l»ir Iron ohtaineil Iron 90-10.5 .38 hoiire, 40 min. IJrev. 20 min. .3X h. 20 in. 71.50 (Irev. Il». 1,5.3 1.5:{ 2Xi 211 119 139 .529 11.5 4SS 416 2.5.56 244 I9S I 33 ) i 30.3 j 19.S 227 .5H7 14S 61.S 609 3.57 >t T» a: < ■4 I J ■o •< i t I J 8 t: ^$ili$':;S§$$ i — 1» — M — — f I ri rl ?i I s 9 •3 » "^ c-i « ?^ ?i ^5 c^» ?5 w fi 1 .».-. sss s I 5*3 1 z 6 — eOlN — — MMflfl o :li 71 t'Mt 1 1 PtK I rem AvrraKP Vtillii oil AvrrBKC Power AvrraCf Avrmgr Kl. Honw 1 iHilpiit of , I'wiron 1 prr lOUIt So. ; oblairnl Kumarf Ainprmi Kwlor Wat)i Pomrr E. H. P. dayn Km. 1 Tom. M ' W7 M ■» AOIIO n fciU itutroti •ra 4A 1 9 19 97 771 *i :m IH7IK.>N 2-j:< N» II 01 m ««7 .« ,w i»i;i;«»H .'HI IM 9 M TO tWA :«4 «•.' HMMW JIA 09 10 ,>» IINI tMN) ;«i 7H IIHMNM Wll M 10 ,ri 101 till ,»7 .W I71N07 ;i:io ;<(i 7 49 ."2 1 IMN) :w 2H I7.WWI •i:M 7H M 71 im ! 777 :iM 40 I7044H xm .w 9 S.5 104 , 7HB M 0.1 «n^ IIN-VW J 12 M 11 i:< ins an .14 W .■UNIO ir,7.M« 211 14 9 9'.' Btt-I(M 71.V) *i :14 41«« U19 ltl«l74N ta f.i 10 014 LcnKth of run 38 hours, 20 inin. Mpbii volts on furnace 36 34 Moan ampi-ri'M 4993 Power factor 919 Watt8=:}a.34 X 4993 X 919= 166748 Pin iron obtained 71.50 ll)s. 166748 El. horse power 223 . 52 746 Output of pig iron per 1000 Kl. horse power days== 7150 X 1000 X 24 10.014 tons 38.33 X 223.52 X 2000 El. horse power year per ton of piR^=0 273 Charcoal used per ton of pif5=993 lbs. Analysis op Pio Ihon PHOorcED. Cast -No. Si S 07 1 72 007 M 1 70 008 W 2 a3 007 101 1 60 007 102 1 Q.'i 007 104 1 7.5 ()07 IDS 1 22 nofi Mn. Graphitic Carbon Total Carbon 72 .\XA1.YHI» OK Sl.Ad PKODlCKn. Cast . > Sil l_. ... .ill ^l2<). IV )5 CaO MKt) MnU l-.(» ■J. !«> 20 :<7 (W.i 4ti 22 12 :« 1(1 HI 2 14 <)•) :« ;J2 9 Sti (HI9 :{7 29 17 2.1 20 49 1 :12 1112 2s 42 .S Ki (KI9 ;{!!«) 2.5 71 24 ,S2 1 14 ia5 ;{1 N2 12 2(1 ('0,5.5 :«i 17 2.i 82 0.20 (1 :<2 1 (M 7 0.(U4 36.14 20 S2 0.14 (1 7H 1 2:{ RUN No. 17. FruNAci:. NO alterations were nuidt' in the furiiuee, l)Ul a new electnxle was put in. Ore tri>at("(l .Magnetite fniiii Calal)Of;ie niine'' Keducinc ajtent Charcoal ,,, ' Limestone I'hix I ,^ •^ Quartz .\nai.ysis ok Uaw Mati;kim.. SiO. 4.(H)'; I'Vi);, r^rt-.iv; , ^.^ )S 20'; FeO 2.5. 20'; ( .\l,():, 2 24'; Calatioftie ore: ■' CaO 2 40' ; MjlO 4.(M)'; v.,i)r, 0. !).■>' ; I' =0 41.V ; S 0.4.5''; CO2 anil unilet .5.4.5'y KM). 00' ; The analysis of the eliarcoal is given in Run 15; of the liiuestone in Run No. 1 : of the ciiiartz no analysis was made. The furnace was .started up at 9 a.m., Feb. 2(5, with a eiiarge ot com position. Ore 4(K) Ihs. Charcoal IM) " Limestone 10 " * OwiiiT. T. H. Caldwi'll, Ks(|, 73 Three of these charRcs were put in iirid th" ci)in|X)sitioii of the rhiirjic ohaiiKiMi to: — <>'■•' 4()() ll)s. ('hiircdiil ]2(( •• Limestone jd .. Two of these cliarfjes were p in. The electroile eunie up t-r. qiii< kiy ;if' r starling and the iron in the eriieil)h>, when trying to taj •■.-i, at !2.'J0 ,).ni,. was foi.nd too eold. KK) ll)s. of eruch- ore was then put in and tlie ii„: again tried at 2,0(1 p.m.. l)Ut was still too eold. At 2.:W p.m.. 10() li)s. more of enide ore were put in and th,- material in the furnaee had to he melted down. Some limest,,,,,. and car- burette l)ri(iuettes were added from time to time ami at S.:{(l p.m. the iron was hot enoujih. During tlie melting down, iron eame through the slag hoi.' every time tlie slag was tapped. The weight of the iron obtained at S:M) p.m., (Cast lOH). including that which was jireviouslv obtained tlirougli the slag hole, amounted to l:5;« lbs. The weight of the slag was G42 il)>. The furnace was again started up at 8.:{0 p.m.. Feb. 20, with a charge c.f composition: — ^•■e m) lbs. Charcoal jU^^ .. l.imeston(> 4.") •• Quartz r, .. to insure an excess of carbon iH-iiig present. After the furnace was in work- ing condition the carbon was reduced and later the limestone was reduced and the (juartz omitted, a pig iron with low contents of sulphur still being produced. During the night of Feb. 27 a few charges with Wilbur ore were put in by mistake. A very infusible slag was produced and the electrode started to come up on accoimt of the e.xce.ss of carbon used in the.se charges. Crude ore was put in and quartz added to the charge until the furnace was again in its projier condition, when the composition of the charge was made the same as the one employed before the Wilbur ore was put in. Kl.KCTKK AI. .MkaSIRKMKVTS. In this run the connections for the voltmeter were made in the same manner as in Run Xo. i;j. one voltmeter being connected with the electrode and bottom plate of the furnace and the other put in the main circuit. 74 Time. Feb. 26. 8 30 p.m. Furnace started. 9.(H) " 9.10 " 10. (H) " 10 30 •' 11 00 " 1130 " 12.00 " Feb. 27 12.30a.m 1 (M) " 1.30 •• 2 (K) " 2.30 " 3 (H) " 3 30 " 4.(K) " 4 30 " .■> 00 " 5.30 " 6.00 " 6.30 " 7.00 " 7.30 " K.OO " 8.30 " 9 00 " 9.30 " 10 00 " 10.30 " 11.00 " 11.30 " 12.00 " 12 30p.m 1 00 " Feb.28 1 30 " . 2.00 " . 2 30 " . 3 00 3. 30 " . 4 00 " . 4 30 " . .1 00 " . 5 .30 " . 6 00 " . 6 30 " . 7.00 " . 7 30 " . S.OO " . 8 .30 " . 9 00 " . 9.30 " 10 00 " 10 .30 " 11.00 " 11 30 " 12.00 " 12.30 a.m.. 1 00 " 1 30 " 2 00 " 2.30 " Volts on Furnace. Volts on Line. .37 40.5 38 41 5 .39 42 38 41 .39 42 39 42 40.5 44 .38.0 41 ,38.0 41.0 36 39 36 :" ') ,34 37.0 36 ,39 ,37 5 40 36 39.0 38 41 36 39 36 39.0 35 38 .37 40 ,38.0 41 ,37 40 5 37 40 5 35.0 ,39 37 40.5 .38.0 41 5 ,37.5 41 38.5 41 5 37 40 38.0 41 5 ,38 41.5 35 .-. 39 35 II 39 ,37 41 36 40.0 38 41.5 ,37 41.0 .37 41 ,38.0 41 36 40 ,36.0 39 5 39 42.5 40 44 39 43 38 ; 41 5 37 40.0 37.0 40 5 36 5 40 36 40.0 35.0 39.0 39 43 40 43 5 38 42.0 .38.0 41 5 37 40 5 37 40.5 38 41 .37 40 5 36 5 40.0 37 40 5 Amperes. Power Factor. 5,000 919 T» Time. Feb. 28 3 no a.m. 3 30 " 4 00 " 4 30 " 5.00 " 5 30 " 6.00 " 6 30 " 7.00 " 7.30 " 8.00 " 8.30 " 9.00 " 9 30 " 10.00 " 10 30 " 11.00 " U 30 " 12.00 " 12 30 p.m. 1 00 " 1 30 " 2.(10 " 2.30 " 3.00 " 3.30 " 4.00 " 4.30 " 5.00 " 5.30 " 6.00 " 6 30 " 7.00 " 7 30 " Volts on Furnace. Volts on Line. Amperes. 37 40.5 38 .5 41 5 37 5 41 36 5 40 1) 36 5 40 36 39 5 36 .5 40 3H 41 38 41 36 5 40 3(i 40 sr. 39 34 (1 38 34 ."WO 34 () 38 36 40 ■.in A) 39 36 () 40 39 43 35 39 33 37 .34 (t 38 33 5 37 34 38 33 37 33.0 37 35 3S 34 3ti 36 40 36 4(1 39 42 5 35 39 35 39 38 41 5 Power Factor. I 5,(M)0 I 0.919 From 7.40 p.m., nace was melted down. to 2.00 a.m., March 1, the material in the fur- Mean volts on furnace (8.30 p.m., Feb. 26 to 3.45 p.m., Feb. 28)=36."5 Mean volts on line (8.30 p.m., Feb. :j to 3.45 p.m., Feb. 28) =40 26. Loss on contacts 3 ,51 volts. Cast No. Time when Cast Machine stopped Effective ! i Qual length of Pig Iron '< of Pig run obtained i Iron ; Ratio Slag L •"*'»« obtained ! Iron l()9 110 111 112 113 114 115 116 117 lis 119 120 121 Feb. 2ti, " 27 Feb. 2S 11 aop.m 3;<0a.iii. 7 20 " 10 20 " .20p.ni 1.5 " 1.5 " 1.5 " 30 a.m. .5 (K) •• K.30 •• 11 4.5 " 3 45 p.m. .10 inin. 10 1 h. ni. 11.^. 3 5.5s 4 72.H 3 3 .50 tW3 013 •> i50 543 55 f)31 .541 3 lS(i 3 1.5 (143 3 30 733 3 30 701 3 15 (ill 4 KfJ ( irey. Ib.s. 2.57 171 37S 2.50 147 245 2(M> 114 317 317 301 290 4«0 235 .5.53 0.407 270 .3.V< SSO 0.23t> 0,493 4.32 429 474 32(i 109-121 43 hours, 15 min. 10 inin 43 h. 5 m . S.3(K3 lirey. 3265 393 122** Feb. 28, 11.30 p.m. Mar. 1, 2.00 a.m. 10 h. 15 m 112S (irey. Oil 0.541 ♦Whiter than previous. ** Material in furnace melted do»Ti. 77 ^ o X < X ■< X 2 e c S .0 • ^ K* »C *C ./ 5 X X 3K at X at ."« ar at .-x X ut 1-- L- C C O C C C 3 — n- -r -^ M *i M *i -.J ^1 ^, . »;; tc ic t^t 'C »c ».'; ic c i* S re CI rj ri CI CI ci ci c* *i 1 = 1 tit , Tl M n M »■) — M -r h. ^ a j3 1 s a Cast No. Pig Iron obtaineil Ave »ge Volts on Furnace 109 110 111 112 113 114 115 116 117 118 119 120 121 lbs. .5.58 728 tj8:i 613 513 631 .541 486 643 7m 701 611 832 38 .33 37 00 36 .57 36 91 37 00 37 17 38 (K) 36 75 .37.86 37 07 36 .57 .34 83 3J 31 109-121 8303 36 75 1 Output of Averaup Power Average .\vera){e El. Horse PiK Iron per 1000 Amperes Facior Watts Power E. H. P days Tons. .5000 919 176126 2.36 (» 9 45 170015 227 90 9 .58 168(m •225 25 9.51 169601 227 34 10 79 170015 227 90 10 10 170796 228 94 U .36 174610 2.34 (Ki 9 24 168866 226 36 8 .59 173966 2.33 19 10 18 170:«6 228 .33 11 ()() 168(W9 225 25 10 67 . 160014 214 .5:» 10 51 • 1.57(j.54 211 :« U 81 i 50( K) 919 168866 226 36 10 217 Lenjtth of niii 4:$ hotirs, 5 niiii. Moan volt?" on furnace 36. 7.5 Mean amperes 5,00() Tower factor 0.919 \Vatti<-:{6.7.T X .5.000 X 0.919 168S66 I'ijj iron o))taiiied SU03 Ib.s. 168S66 El. horse power 226 . Ii6 746 Output of pip iron per 1000 Kl. horse power days== 8303 X 1000 X 24 10.217 tons 43.08 X 226 36 X 2000 Kl. horse power year per ton (»f pij£=0 268 Charcoal used per ton of pif£=1017 Ihs. Analysis of Pig Iron Produced. Cast No. Si S P Mn Graphitic Carbon Total Carbon 109 110 111 112 113 114 115 116 117 118 120 1 99 1.75 1 .53 2 20 1.39 1.10 1.99 1.65 1.51 1.46 021 021 0.012 0.017 0.009 0.54 0.009 0.007 0.006 Oil 0.078 045 0.4.56 Trace 2.12 3 71 645 Trace 2 46 3 60 0.476. , Trace 3.00 3.70 512 Trace 3 00 3 47 0. 102 Trace 3 30 4 02 121 1 43 0.465 Trace 1.10 3.28 79 AXALVHIS (IK Sl,A<; I'HilDfCKI). (Jast No. SK), AljOj PjOn CaO MeO MnO KeO .S I'l? 36 21 15 40 014 34 4:? 13 22 2« 2(1 1 07 '15 2S 10 IS MO O.OWi 34 51 17 (M) 3N 2)i 1 55 117 41 OO (•07 OIN 25 «0 23 22 2S 311 93 IJI SSIS Iti 15 (HW 32 21 17 INI 22 39 1 17 109-1 a.' 33 (Hi 15 22 Oltj 33 (K) Iti 2 10.96';; leaOa 6o.4:u;; AI2O3 3.31';; CaO 3.92% Roasted Pyrrhotite i MgO 3 53% f^ IM% P 016% Cii 0.41% 2.23% Fe=4o SO'^ ^Ni. The analysis of the charcoal is given in Run No. 16 and of the limestone in Run No. 1. The furnace was started up at 2.15 a.m., March 1, with a charge of com- position: — Ore 400 lbs. Charcoal 12o " Limestone 120 " *.'^i'^Py^^°''.''' i"""" .^'"11 """ ""'"^^ "'^a'' Sudburj-. Ont.. and was finely crushed and roasted at the Lake Supenor Corporation's plant at Sault Ste.Marie for the production of Bulphunc acid gas. The roasted ore was afterwards briquettel with some lime. Thf ftTro-nitkol pijt producfd was very low in sulphur. The limestone and clmrfdal in the charKc were uradiially dotTcasod until the composition was: — On- 400 lbs. Charcoal 105 " Limestone 40 " When decreusinn the limestone in the charge, the silicon in the pig in- creased. l)tit the sulphur was still very low. The lurjie amount of slag pro- duced naturally decreased the output and for a conmiercial production of ferro-nickel i)ip from this ore, when the silicon contents have to be kept Ix'twcen 2 and '-ia'/c, necessitatinu further addition of lime, the output will tlecrense still more. After the conclusion of the exjK'riments the plant was bought by the Lake Sup«'rior Corixiration, and the furnace was employed for the production of ferro-nickel pig during several months. The results then obtained are given later. Elkctrh'.\l Me.\surkmkxts. Tlie .same electrode and connections with the voltmeters as in the pre- vious run were employed. Time. Volts on Furnace. Volts on Line. Amperes. Power Factor. Mar. 1. 2 1.1a 2 .30 3.(H) 3 30 ni. Furnace started. .}8.0 37 37 38 37 36 .5 36 36 .5 36.0 37.0 3.'i.0 3.5 36 .37.0 37 3.") .5 35 36 38.0 39.0 38.0 37 38.0 42 41.0 41 42 41.0 40.0 .39.0 .39 .I 39 41 39.0 .39 40.0 40 40.0 39 39 40.0 42 42.5 41.5 40.0 41.0 5,000 t( 11 11 it 0.919 II 4 00 II t.r;o (X) II II 5 M) II ft 00 II •) .30 II 7 (M) II 7 .30 S 00 II II 8 30 II 9 00 II 4 30 II 10.00 10 30 11.00 11.30 12 00 12..30p 1.00 1.30 II II II II « .ni II II 1 HI Tiim-. Ml..- Miir. I, ■-' (Kl|>.lli. 2 HO ■ ;t (HI " :» ;to ■• I (H) • 4 .il) " ."• IM) •• a :«» •• « (Kl •■ ti ;»(» •• 7 (Ml •• 7 .«) " 5 (HI " s ;«i " )l (HI " 9 ;«> ■■ 10 (HI •• to .{(I ■• n (HI •• n :«i • IJ (HI ■ 1-' :«i!i.m. . 1 (HI " . I 3(1 " . J (HI " -' 3(1 " . :r(H) ■• 3 30 " . 4 (HI ■■ 4 30 • . .1 00 •• 5 30 •■ . (» (Ml • (i 30 ■• 7 (Ml •• . 7 30 ■• . 5 00 •• . S 30 • . 9 00 " . 9 30 •• . 10 00 " 10 30 " . 11 no " . 11 30 " . 12 00 " . 12.30p.m. . 1 no " , 1 .30 " 2 (Ml " . 2 .30 " . 3 no " . 3 .30 " . 4.00 " . 4 30 " . .5.00 " . 5.30 " . 6 00 " . B.30 " . 7 00 " . 7.30 " ., 8 00 " .. Voll, Volt. oil on FiitiiMci'. I.inp. :iN 11 (1 .17 Id (1 .'iM.O '1 II (1 .3A.0 i Id d :« .1 ! :iii .-. 3.'5 (1 • :v.) 11 ■WO ; 4(1 :w ' 42 ;« 42 .37 4(1 .-1 :<.i :«) 4011 : .«> (> , 39 .-) .3.5 .i 39 (1 .3.) :i8 .3b ■39.5 .^i 39 .3:1 .5 .37 5 34 ■37 5 .3(1 40 .37 40 5 .3H ■39 36.0 .39.0 .37 40 .36 (1 ■39 .35 ■39 36 40 .37 40 5 38 41 .36.5 40 38 41 37 40 .35 .38 5 .37.0 40 (1 .36 39 (> .35.0 38 .36.0 ■39 .35 ■38 5 .35 5 39 35.0 ■38 5 .36 40 .36 n 40 .37 41 .37 40 5 37 40 37.0 40 .37.0 40.0 .AiiiIH-rr*. I'iMM .I.IHHI (I ill!! I Tiinr. K ■ ■ ■ - r.r ■ Volt. Ull iiman-. VollH IHl Unp. Mar.'.', K 30 p.m. . . 1-' 76 64 34 5 Xi 31 5 ■.V> 35 .3(1 :<(i (1 :» (1 34 34 •M (I 34 3(1 35 5 ;«• 37 3(i (1 35 (I 35 34 (1 3(1 (I 3(1 (1 .XI (1 .34 (1 34 Xi ;« .33 31 .3(i volts ;iK 3(1 5 3S (1 39 :<9 II 4(1 (i 4(1 II .39 II :«« II ;«» .39 5 ;«) (1 40 39 5 4J 40 40 39 39 3.S to 40 40 (1 3M .3N (1 .37 (1 37 3tl .', 3.0 .39 5 9 (HI " 9 ;«i • 10 (HI " 10 30 " 11 (HI " 11 .30 " l.',(HI •• .Mar. 3, 12 3(la.iii 1 (HI " 1 ;«i •• •J (HI •• •.•:«) •• 3 (HI " 3 30 •■ 4 (HI ' 4 :«) ■' 5 (H) '• 5 .30 " fi (HI •' (t :«i •• 7 (HI " 7 30 " H (HI .S 30 " 9 (HI ■' 9 .3(1 '• 10 (HI •• 10.30 " - 36 11 (HI " 11 10 ■• Runt- IIP; •(■. .Moan volts on furnace = -Mean volts on line L<).«s on contacts fast No. Time when Cast -Machine stopped Kffeotive lenitth of run 123 124 125 121) 127 128 129 130 131 132 133 134 135 .Mar. 1 Mar Mar. 3 (i. 15 a.m. 10 15 " 3.10 p.m. K 10 '• 1 15 a.m. 5 25 " 9 15 " 1.15 p.m 5 10 " 9 30 " 1 .55 a.m. 7 40 " 11 10 " m .1 mm 5 min 20 min h 4 4 4 4 5 4 3 4 3 .55 55 5 10 .50 15 20 25 .30 Ainpvri'K. 5.(HHI Powpr. Faetor. 019 Quality Hatio I'iK Iron of I'iii Slag _^'IL obtained Iron ohtaiiUHl Iron Ibx. .54(1 514 .596 717 (iI2 .50.5 .500 47(i .541 filO (534 677 408 (irev. Um. 377 .3.32 472 4S(i 512 410 371 .362 .338 .5.54 345 .344 157 690 646 I) 792 t>78 (I 8,36 811 0.742 0.760 0.624 0.908 .544 .508 385 123-135 .56 hours, 55 min. 35 min .56 h. 20 m 7336 (.irev. .5060 0.6S9 •IS I I i fi ' ?x •3 — ?i fi ri — — •) — a u < s a: X H s s j; 5 s s X o» " ' " 1 Oiitpiil III Ciut Pi(f Iron .\ vrnitfi- VnltM nil .\viTtl«<' ' Power .\vi'niici> .Vvi-ragp 1:1. llon»' I'Ik Iriiii IMT IIHMt No. (ilitaiiMHl Kunmii' .\iii|N-rra Fkrtor Wntta I'llWIT K. II. 1'. -— - « 22:5 2N « .w \» .VKI X's m IICIUIM 219 h:{ 7 12 130 474I .».'( liU iii.«mt.-, 219 M 7 ."i.'i 132 «ll(l .•».'i .sit 104914 22r -W S |.-| 134 677 ;».•• 79 l«44,M 221) 45 tl HI 135 40S ;« 411 i i 205 91 222 4H « 71> 12J-I3J 7:w« ;«i 12 .VNNI 919 7 024 I.,(71 Forro-iiickcl pin olitaincil 7;W0 lbs. 165071 El. horse rx)\vi"r 222.48 746 Output of Ferro-nlokel pig (x-r KXK) El. horse power day8= 7XiH X 1000 X 24 — 7.024 totw 56 :W X 222.48 X 2000 El. horse power year [xt ton of pip— 0.390 Charcottl used per ton of piK= 1104 lbs. A.NAI.YSIS OF FeRRO XiCKEL Pio PRODfCF.D. Cast No. Si. S. P. .Mn. Graphitic Carbon Total Carlxiii Cu. Ni. IZ"? "4^83 4.50 4 91 4.03 7 34 0.009 0.012 0.006 0.005 0.004 006 006 "0.606' 124 125 128 0.059 10 3 05 3 23 0.72 3 68 129 130 (M2 037 043 0.012 0.035 0.12 3.30 3 40 3 .38 :t.40 3 ir. 2 60 71 87 67 0.62 70 4 39 4 12 131 1.32 135 0.10 0.10 0» 2 95 2.00 2.10 4.10 1,10 3 70 M ANAtYxlit a 10 nt 11 0.1 i:i 00 10 117 l.> 07 IV •» oir.> 00.1 (Kll ink; mi i««t M|{< 1 4H 21 H Jit .V» H« l\ <»H 47 41 ; mi 4« 10 11 .-.1 49 )UI !> 27 Miiu K.O CiiO NU» f* II 12 o 10 oo 10 O 2ll 21 i O 21 > o :ii) .ii 01 02 O 01 O 01' O 02 02 .1 .■»7 02 4 M 01 4>l 02 :. .17 02 4 .to RUN ITo. 19. FlIINACK. \n altcriitioiis wiTc niinlc in the furnace. Tlio ncitl brick lining used was l)adl.v eaten away i.y the linioy -hift ii. eiii|K)sitioii:^ — Ore 4v C N. Cox anil I.. (". Lennox. Kleetro-eheniiral and Mptalliiritiral IriiluKtrj-, Vol. IV., I)cr., liMMi. 87 THE SMELTING OF MAGNETITE. It was (•xp«Ttrd that considerable diffioulty vvduld 1m- exiK-riciued in the HnicltinK of ninjrnotite. on account of its conductivity. It was tliouglit that with the furnace in use. in which the electrode was immersed in the charge, tbi- current would disseminate itself laterally from the sides of the electro(l«' thronph the charge, preventing the current at the reducing and fusion zone from attaininj; such density as wouhl Ix- re(|uirer flux and charcoal, it was sometimes |M)ssible to cause the electrode, which to keep the current constant had by hand regulation Ih'cii elevated, to return to its normal [lositicn. In some instances, however, this method failed, es|)ecially when the furnace was clioked with fines and the fja.ses evolved esca|H"d under great pressure. Since the electric iiistallatioti did not [lermit the comixMi- sation of the tem|)orary increase of conductivity of the diarge by decrease of voltage with constancy of current, tlie electrode in such ca.se rose to the top of the furnace and it became iie( -.s.siiry to melt down the charge and start anew. If the explanation offered by Hronn is correct that the decrease of the ohmic resistance during the " Anheizungsphase" is occasioned by the more intimate contact of tlie conducting pieces of the charge due to pres,s\ire of escaping gases from the pores of the carlnm and the carlM)n dioxide evolved from the limestone, it is evident that preheating the charge, which might l)e effected by utilizing the carlH>n monoxide resulting from reduction, would i'utirely overcome this difficulty, if the rharije were xtiljicientli/ /mrous to jHrmil the (lanen ivolrrd to escape at Intr prenKiire. I'nder such conditions the electrode would maintain its normal {xisition throughoiit the o[X'ration. reciuiring to be lowered only to keep step with its consumption. The ores treated, with the exception of the hematite and the roasted pyrrhotitc. contained a high jx-rcentage of magnesia. priMlucing a very in- fusible slag. When the furnace had Ix-en miming for some time this infusible material formed a scale around the crucible, the electric energy available not IxMug sufhcient to keep it in a molten condition. The crucible and lower * " Elcctrotcrhni.si'hc Zcitsc-hriff," 1906, Heft 9. 8H part of the furnaoe were, therefore, partially filled up, preventing easy av." .~s of the charge to the reducing and melting zone. This slower feeding left the charcoal on top of the furnace exposed to the air a longer time, thus increasing the amount of charcoal required and decreasing the output. With a greater current than was available and consequent higher temperature, the formation of the scale would have been prevented and the output correspondingly increased. The electric installation at our disposal was far from ideal for electric smelting experiments. Aside from the drop of voltage due to the frequent slipping of the belt connecting motor and generator, it was impossible to increase the current Ix-yond 5.000 amperes at from 35 to 40 volts. This inelasticity of the system prevented the determination of the most suitable current and voltage for a given charge in the furnace. THE USE OF CHARCOAL AS A REDUCING AGENT. It was of great importance to ascertain whether charcoal without being hriquetted with the ore could l)e used instead of coal-coke. No difficulty whatever was experienced, in fact so admirably adapted was charcoal, when crushed to pass a f inch ring, as a reducitig agent in the electric furnace that coke and briquettes of coke with clay were abandoned and all the experiments with magnetite and roasted pyrrhotite described were made with charcoal. Some of the charcoal avail- able was of very poor quality, being little better than charred wood containing only about 56 per cent, of fixed carbon. This and the fact that a considerable quantity of the chnrcoal was consumed on top of the furnace account for the large quantity of charcoal used per ton of product. A modification of the furnace, protecting the upper layer of the charge from the atmosphere, and the use of charcoal properly carbonized would decrease considerably the amount of charcoal which was actually used in the experiments and conse quently reduce the cost of production as given. POWER FACTOR. The power factor of the furnace was found by Mr. Chas. Darrall, of the Canadian Westinghouse Company of Hamilton, Ont.. to be 0.919. This high power factor is due to the construction of the furnace casing, as pre- viously described. Since the true electric power is the apparent electric power multiplied by the power factor, it is evident that any error made in the determination of the power factor which tends to decrease its value will appear to decrease UM 89 the consumption of energy per ton of product. The large output of 12.12 tons per 1,000 electric horse-power ilay.s, i.r.. the .small amount of electric horse-power absorlx-d per ton of prf)duct in the second Livet exjx'rinieiits, was obtained in a furnace with the abnormally low power factor 0.564. Whatever doubt may \>c engendered as to the corri-ctness of the figure ob- tained for the absorption of electric energy on account of this low power factor of the Keller furnace, such doubt cannot arise regarding the figures obtained with the Heroult furnace for the absorption of electric energy in the (Jovernment experiments on account of its remarkably high jxiwer factor, 0.919. .Moreover, sinf-e the cost of alternate current generators increa.ses with increase of cap-^ \ . '■•'■naces with high [lower factors (which can utilize a high percentag •! "-ity of the generators) will t)e more economical as regards the hr»t v .m> electrical installation of an electric smelting plant than furnaces with low power factors. CONSUMPTION OF ELECTRODE. A new electrode was put in on February 11. The weig* • of same was then 937 lbs. After having u.sed the electrode for preheating the furnace it was taken out of the furnace and a few loose pieces at the (>iid knocked off. The weight of these pieces was 17 lbs. The total weight of the elec- trode when starting was, therefore, 920 lbs. In the following table the weights of the iron produced and the time consumed are given in detail : — St> 1^1 • a f I — ; :i :2 ■ h-Si — f : "^ .c S S c "r T -5 ^ i-» T 31 t a "5 -3 M ?J t- ^ . « - X t - ti II X 5 T r» ?l ft X •-- 01 ^ -r 71 •3t- ri t--r 55 7III B H ■3 :ti??i"'? ^?S = :! 5ilS 5?S '£ ! 15 3 •- ?1 M M •ir « z r- , = ?i ri .T; = £■? Tin 4. • C »?? »5 « •r T I"*; — « r^ 3C t ■'^■'X *. 2 z z 3 ■= i i I i ^ 1 "« S 5 ■■-•.= 'f OS Si I I f3 • m I'laTE VIII. 1.1 Fio. 2. -ifi- •1 Total pin iron prnsumplion of the lower part of the electrode is taken into account. In Plate VIII Fig. 1 represents the electrode when |>ut in, and Fig. 2, the electrode when taken out. Tlie shaded part in Fig. 2 represents the electrode consumed. Volume of electrode when put in: — 2X2 10 16x16x70—4 ( X 60)— 2 X — (1.25 + 2) X 16=- 2 2 16920 cub. in.=9.7916 cub. feet. Specific weight= 937 =: 1.535 62.32X9.7916 Weight of one cub. in. electrode=^).0554. The original length of the electrode was 70 in. Deducting from this the 27J in., (A+B), which may be considered to Ix' left intact (see Fig, 2, I'late VIII), we have only to deal with the remaining 43i in. The weight of piece A =94 lbs. " B + C - 310 " ** " ** D = I '* Total weight of electrode when taken out=472 Ujs. 1: Volume of piece B= 16x16X14—4 X 2X2 2 X 14=-3472 cub. inches. Weight of piece B=3472X 0.0554=192. 35 lbs. Weight of piece C=310— 192 . 35=1 17 . 65 Ite. »i Volume of olcctrfKh' roii»utnrcl= 2v'> 16X16X42 5— 4X X 42 . 5— volumc-8 of C +1)= 2 1().>1<) — volunu'H of (' + 1) cdb. incheK. W»M(iht of flectrodc eonHuniP(l= 10540 X 0.0554— 1S5. 65— 17*=381 .26 llw. CoiiHTiinptioii of I'li'ctrcKlc per ton of pif; iron pr(Klucetl=- 381.26X2000 = 17.S5 1I)B. 42711 MODIFICATION OF .XPERMEKTAL FURNACE FOR COMMERCIAL PRODUCTION OF PIG IRON. Trolmhly tin- lurnpst unit which can at prcwcnt be conHtructed on the monding on the nature of the slag to Ik- formed, leaving only the carlxin Ixtttom in electric communication with the base plate of the furnace. These suggestions are incorjiorated in the 2-shaft-fumace represented in Plate IX, recently patented. Moreover, the capacity of the crucible .should Ije adjusted to the energy employed to insure the projx-r current density for effective working of the furnace. The greater capacity insuring less loss of heat by radiation and the modification of the furnace to permit of the utilization of tliecarlMin mono.xide will materially increase the output l)eyond that ascertained by the experi- mental furnace. The experiments indicated that under normal conditions al)out 11.5 tons were produced by an expenditure of 1.000 electric horse- power days. It is, therefore, not unreasonable to assume that under similar conditions with a properly constructed plant the output i)er 1,000 horse-jxiwer days would certainly reach 12 tons. This figure has been adopted in calcula- ting cost of production per ton of pig. The protection of the charcoal of the charge from combustion on top of the furnace will materially decrease the amount of charcoal in-cessary for reduction and consequently lessen the cost of this item. This saving has. however, not been taken into account in the estimate of cost. PRODUCTION OF FERRO-NICKEL PIG. The Lake Superior Corporation has acquired the (Jovernment plant i)y purchase and has employed it for the semi-commercial production of ferrfi- nickel pig. The furnace operations were left entirely in the hands of the workmen, who had been trained during the progress of the Government experiments. The furnace worked with admirable regularity, the regulation of the electrode requiring hardly any attention, and the output was of e.\- eellent and uniform quality. On account of the value of the product, the smelting of roasted nickelif- erous pyrrhotite by the electrothermic process, as carried out with the Covern- f M ment experimental plant, admits of immediate commercial application with- out other modification of the furnace than increase of its capacity. Mr. E. A. Sjiistedt, Chief Metallurgist of the Lake Superior Powf-r Com- pany, who has had charge of the smelting operations. rept.riH regarding the production of ferro-nickel pig as follows:— " During the first few weeks of our experiment.-* minor changes in the shape of the furnace were made.also in the electrode hokler. the lime charges were purposely kept low (from 15 to 18 per cent, of the ore charge) in order to ol)8erve the influence and efl^iciency of the lime in the elimination of the sul- phur and silicon. During this time the furnace product averaged 2 700 lbs per diem of ferro-nickel with 0.01 per cent. S and Si contents, varying from 5 to 11 per cent . Returning to our old practice and running on 5o" per cent hme charge,the product decreased somewhat (vielding from .A.pril 4 to Mav .5 on an average 2,456 lbs. per diem), but the Si contents were red-^ to alx)ut 3 percent. The further increase of the lime charge tendeti to further decrease the Si contents, but at the sacrifice of the production. Finally we settled down to an ore charge of 400 lbs. of briquettes (carrying froml 5 to > 25 per cent. S). 140 to 150 lbs. limestone of the composition given in Run No. 1 and about 120 lbs. charcoal. I p to Augiist 1 aljout 168 short tons of ferro-nickel pig had thus lxM>n pro- duced. Omitting the firFt few weeks and taking into consideration onlv the four full months. April to July, inclusive, during which time the furnace w.as m continuous operation, with the exception of such unavoidable interrup- tions as were caused at the fx.wer plant and for the changing of electnxles. the following average results were obtained:— Total product 1.54 .short tons. Total working time. 114.8 days of 24 hours. Average jiroduct per working'day i . 3415 .horf tons. Mean volts on furnace 3^ .Mean amperes « j^ Power factor q' gjg -Mean electric horse-power on furnace, approx 225 Output of ferro-nickel pig per 1,000 E. H. P. days= 1.3415X1.000 ■ = 5.96 short tons. 225 During this period the following average amounts of raw material were consumed for the production of one short ton of ferro-nickel pig (of an average S5 omposiHon of about 2 75 p.T ront. Si; 01 por ront. H: 0.03 per cent P- I |if f ((III N'i iiiid H fwr rent Cu) H iHstPfJ |i.vrrMUi.«ttl..mt2f).'r(Tiit. S(j„ •• plcctrodcs '"jy ., ifli ELECTRIC FUmiACE AS COMPARED WITH THE BLAST FURNACE. The tend.>i,rv atno.ip iron tmimifactun.rs for s(,in.. tini.. has Im-oii to in- .rcase th.- ^m- and capacity of Wast-f.irnaccs until the ..|i..rinoi.s capacity of 600 u, SOO tons jxt day with a fiirnac- stack 100 fc.t hiijh lias Ix^eii reached. But for the eronoiuiral workinji of a blast-furnace ihcf is a jx.int »)eyond which the furnace can be neither increa^d nor d«T»-ased in size. It .seems to have been established that furnaces with a heigJrt of 90 feet and corres- ponding output prove the most econonii.-al. Whil,. f,„.| j.s cheap and ore of Hood quality and high iron cntent is still al-.ndant, anv disadvantages of such large units will not be felt, k nmy. however, be (.f value to call atten- tion to some of the disadvantages connected with the emplovment of large unit.s. These are a.s follows ; - 1st— Large first cost of furnace. 2nd— Excessive cost of charging machinery and upkeep of same. 3rd— I^irge expense and probable idleness through break-clown. 4th— Cost of and difficulties of making repairs, relining. etc. 5th— Serious complications resulting from scaftolding, involving loss of life and money. 6th— Financial loss res-lting from wrong coni|H>sition of charge , in- volving many tons of iron Ix-fore correction can lie made. Yet, with even these drawbacks the blast-furnace of to-dav, representing the result of a hiuidred years' experience and inventiv,- skill! must be pro- nounced a perfect machine, hardly ptTmitting further improvement, and if the electric furiuice, which is yet in its infancv. is able in its present state of development to compete with a blast-furnace under the s[)ecial conditions of cheap electric energy and high price- of metallurgical fuel, what mav we not expect of its f)erforman(v when all the calories available in an electric furnace will have been utilized by pro(M.r design, as the result of vears of experience? It i«, then for,., warcfl;. to t\w ix.int to ^H'ak of faults or di.sml vantage of a now invention, wliicli. as thry arc n-alized, iimy U- corrected, hut it is of jtreat iniportaiicc lo [x.int out any advaiitaKes a new apparatus may |)ossoss over a long-tried maehine. Tlie following are some |K)iiits in favor of tin- eleetric funiaee: — lst^()rij:uial -mull cost of furnace. L'nd- Al)s«iice of bulky or ror tly charginft nuicliinery. :{r(l Small exiK'nse involved through breakdown. 4tli i: from scaffoldinji. 6th— />*«. due to wnme conipositiwi of chnrge reduced to a minimum. 7th-lV>ad quality of iron. The fonnation of cyanides in the blast furnace IS pffectetl by the nitrogen of the blast in presence of a basic .slag, and con- currently the nitrogen combines with the ferrite to form nitride of iron the presesee of which in the iron renders it brittle. This fact ha.s only btely be«>n (JiHfovere»ti<;n as the heating agent, may lead to the intnxiuction of nitride of iron in the resulting product^ Mwl hence injuriom«ly affect the mechanical qualities of iron and steel! Thin explains what has so far l)een regarded a.* inexplicable— that certain iron and steel.»< with low .sulphur and pho«phonw show great brittleness. It is for thi.s now known reason that electrically prodwvd iron and stee! are superior to that made by the old proc«'sn. since nitr<^ n is eliminated from the prtwess. GEITERAL REMARKS. The far-reaching con-seqiience of the gratifying result^ acl.teved by these exp«rim«-nts will at once Ix' apparent. .Many of our magnetites are too high HI sulphur to Ix- handlfHl by the blast-furnace and eon.se(,ucntlv have so far been of no commercial value. Hut the very Ix'st of pi^ inui. as ha.s Ix-en »7 proven, can U- niado from ores which contain as high as 1 .5 prr cent, of sul- phur. A blast -furnace will not usually Imn.llo an ore which contains more than 0.1 per cciif: of sulphur and requires, therefore, an ore which cannot be obtained at a low figure. RcjrardiiiR the water-power retiuired for the application of thi.s pn.ce.ss It may lx> stated that many water-ix)wers exist in Ontario and (.iueln'c surrounded by iron ore fields, in localities ill adapted for the application of electric energy for any other purpose, which could Ik- developed to furnish an electric horse-power year for from $4.50 to $6.00. With such a price for the enerfry re(|uired, the small consumption of electrode. the cheapness of the ore employed and tlic jKculiar excellence of the piK iron i)roduce(l, electric smeltinK of iron ores in Canada in properly constructed furnaces, usinf? charcoal or jx-at-coke made from our peat Ixigs of enormous extent, may Ik- pronounced commercially feasible. Under the prevailing conditions in Canada it now only remains for the engineer to design a plant on a commercial scale, say of 100 to 150 tons dailv output, with all the necessary lalx)r-.saving appliances. Just as in the t-ase of the blast- furnace so likcwi.se with the electric furnace, e.xpt>rience gained will result in further economy and the day may not be far distant when the carbon mon- oxide, which is of high Calorific value and which at present as a product of the reaction taking place in the electric furnace is allowed to escape without utilization, will l)e employed for increasing the output bv something like one-fourth. When this is accomplished, the blast-furnace could not comiX'te with the electric furnace, even imder conditions where coke might be cheaix>r than at present quoted in Ontario and Quebec. With the present advance which has been made in the transniL^sion of electric energy, batteries of electric furnaces could lx> set up at various ironore deposits, which could be fed with electric energy from some centrally located wafer-power, thus effecting a sa\ ing of the transportation costs of the ore from the mine to the furnace. The following is a summary of the results of the ex|x'riments which have been made under Goveninient auspices at Sault Ste. .Marie:— 1st— Canadian ores chiefly magnetites can Ix- as economically smelted as hematites by the electrothermic process. 2nd— Ores of high sulphur content can be made into pig iron contain- ing only a few thousandths of a per cent, of sulphur. 3rd— Tlie silicon content can Ijc varied as recpiind for tlie class of pig tol)e produced. 4th— Charcoal which can be cheaply produced from miU refuse or wood which could not otherwise be utiliied and peat-coke can be substituted for coke without being briqucttcd with the ore. 5th— A ferro-nickel pig can be produced practically free from sulphur and of fine quality from roasted nickeliferous pyrrhotite. 6th— Titaniferous iron ores containing up to 5 per cent, can be success- fully treated by the electrothermic process. Tliis conclusion is based upon an experiment made with an ore containing 17.82 per cent, of titanic acid, yielding a pig iron of good (juality. The results of the introduction of electric smelting into countries possess- mg iron ore deposits and water-powers, but lacking metallurgical fuel, may be summarized as follows: — 1st— The utilization of water-powers which cannot at present Ix' profitably employed for any other purpose. 2nd— The utilization of peat bogs for the production of peat coke, to be used as reducing material for the operation of electric furnaces, and utilization of mill refuse and sawdust, for which there has so far been no practical use. 3rd— Rendering such countries independent of fuel import for metallur- gical processes. 4th— Enabling them to produce their own pig iron for home consump- tion and consequently retaining in their country the money which otherwise would have to be sent abroad to purchase pig iron in the crude and manufactured state. 5th— The development of steel plants and rolling mills using only electric energy. Wt Eftlnute for « 10,000 Horse-power Plant Producing 120 Tons of Pig Iron per day of Twenty-four Hours.* FurimiTs, contacts, overhead work. Uins, chutes, elevators Cnishers H.(X)0 l..'iOO :i(KX) :{,(KX) o.fXKJ $1IK).S(J0 I harcoal plant ^^ oy/j Power plant (assuming cost of developing one electric hor8e-powcr=$.50.00) .'iOO.tXKJ $6.i0.S(J0 t-Iectrodc plant y 0,^ Unforeseen expenditure 4.J 200 8700,000 -Amortization: 5^1 ] Depreciation: 5<;; } 15% on $700,000 $10.5 OOO Interest; 5^",' J On a production of 43,200 tons per year of :j(50 days per ton of pig iron $2 43 Cost of Production of Pig Iron per Ton. Ore (55';; metallic iron) at $1 .,J0 i*r ton $ 2.70 ;{ (XJ 2 4.S l.(X) 0.20 (I 3(i 1 00 Charcoal, one-half ton at $«.00 per ton . . . Electric energy, unionization, etc Lalwir Limestone Eighteen lbs. of eWtrvide at 2 cents p^- lb. CJeneral ex|)eu8es Total. * This estimate ia given on the authority of Dr. 1'. Heroult. fit} m ■ ) nil APPENDIX New Inventions of Electric Smelting and Reduction Furnaces. In Sweden, where ronditions in repiinl to tJie raw material for llie iron industry are in many reN|)eet.M «iniilar to the conditions in several I'rovinees of Canada, the (i; •3tion of utilizing eleetrie energy for smelting |.ur|)ose« lias lately been given eonsiderable attention. The attempts so far have In-en made to improve the induetion furnaees and at present extensive experi- ments are Ix-ing carried out in Sweden, for whieh a sum of 2(K).(J(J(J kronor (S.55,000) has Ixh-u appropriated by Stora KopparU-rgs U«-rgslag8 AktielMilng. These inventions were made by Messrs. A. Cninwall. .\. Lindl)lad and (). Stalhajie and for their exploitation a eompaiiy, " Klektnmietall," address Ludvika, Swwleii, has been formerio(ls has Ijeen |)ropo.«!ed. Tlii> low fre- (luency of the current necessitates the instalment of six-cial machinery, in- volving a heavy outlay, and prevents the connection of these fiirnnces with already installed power plants erected for orditiary purpo.ses. The position of the primary coil around the leg of the transformor sur- roimded by the bath of the metal to l)e snieltwl was another disadvantage, whieh, by the inventions described later, has l)een overcome, and the in- ventors previously mentioned now elaim that induction furnaces for coni- uieicia! production and for any charge can U' constructed. III-.' If: f =» onjilc of plmw (iiiiplarcment, c = foiiRtniil, "» = frpqiioiifv, a =-= arvn nf Kiiih of metal to Im- smplnil, / = loiigtli of l)!itli of nn'tttl to Ik- f.:iiflti'«l, u = «|Hrific K'siMtanpi- iti ohmn of the batli, ir,= itiaKiictic resistance uroiiiid the ^Pl .nd.iry (the Ijaih), " p^ " " " " primarv poil. we have for tlie tanp tit of the anfjle of pha.>.t> (li.HplaretTi.-tit:— Tang ,p = — f L.l -| From this fornn.la it ii< evident that if (<)«iv = power factor, it i^ increawd hv:— l«l— derreasiiiff the freqiU'iicy, 2nd— ini aaHinjt the ohniic resistance of the liath, 3rd- inrrcasing the magnetic resistai,' e of the two leakage fields. I)( crc«-ii,g the frequency of the eurrcnt causes, as previously explained, »o great disuilvantages that such a course ought to be avoided. The onl> means left to decrea.se the phase lisplacenient are consequently: increase of the ohmie resistance of the Imth at d increase of the magnetic re- gist.-»iu'e of the two leakage fields. Tlie invj'ntions by Messrs. Groiiwall, Liiidblad, aii.l Sthlhane to aecom- pli.sh this are fully described in the accompanying jiatent sjieeifications. -Attention is here called to the fact, howev. r. that bv giving the Imth the form of a groove.t surrounding one leg of the transformer and provided with parallel e.\fension.s in connection with each ottier, and not the customary circular form, the following advantages result from such construction:— 1st— a greater ohmie resistance of the bath, 2nd— an increased resistance for the leakage fields, on account of the closeness of the circular part of the bath to the iron core of the transformer. 3rd— A further increased resistance for the secondary leakage, because the extensions of the groove form a so-called "I/ifilar" winding. • .Xcfoitfins to T.iiKllilad. t .Sc fnrther Patent .Spooification Xo. 4 1 i 'I % i «*C»OCOfY nSMUTION TBT CHAIT (ANSI and ISO TEST CHART No. 2) 123 I2J 13.2 |Z2 1^ 1.8 ^I^U4 _^ /APPLIED IN4/1GE In B'a 1653 East Mam S(f»f ^S Rocheslef. N«« York 1*609 USA ^S f^'6) *82 - 0300 - PhoM ^5 ('16) 288- 5989 - Fo* rrr. ._l\ — — ff , "'' " '"'^"i ! »r 1*'" '^'"-^ J mA PlateX 8T0NS ELECTRIC STEEL FURNACE PLAN fCf MTii ¥, >'••. IK ■J—i i ( r t I / I ty , -I y\ ijl.'] A ■ I t * t \ » - | '.^'- I - ' ^ ^ -■ ^ - . ■' A-\A A 'undoubtedly, even for comparatively low voltage, result in considerahle difliculties and for higher voltage it will probably U- im|)o.ssible to obtain the necessary insulation, on account of the high tem|M'rature of the bath, which has a destroying effect on the delicate insulation of the primarv coil, and the u.se of water-cooling In-twj'en the coil and the bath is not likely to prove effective. From what has been said it is evident that no earlier construction of any induction furnace can without risk for the insulation Ix- direct-connected with a power-transmission of high voltage. It is only through the invention of the compensation coils, which makes the p<>sifion of the primary coil re- latively to the bath indifferent, that such a connection is possible. The accompanying Plates Xos. X-XIII of an S ton steel furnace of 7.50 horse-power at present lx>ing erected show the utilization of these inventions. The primary coil is placed around that leg of the transformer which is not surrounded by the bath, iii a specially made well, where it is exceedingly well protected from the heat and all danger to the men attending the furnace of coming in ccmtact with the high voltage transmission is excluded. The leakage field developed around the primary coil produces no direct phase displacement, as the leaking lines of force are forced, on account of the arrangement of the compensation coils, to again produce effective lines of force through the compensation coil placed around that leg of the transformer surrounded by the bath. In order, therefore, that a i)hase displacement shall 1k' produced due to the primary leakage, it is necessary that a new leakage field shall be deveioix'd around the comjxMi.sation coil last mentioned. The leaking lines of force due to tl' primary are consequently forced to pass thro\igh the air around tlie primary and also throusili the air around the compensation coil placed inside the bath. The distance which these leaking lines of force have to travel has. therefore, Ix-en greatly increased and con- Mqiunily aUo il„. iimgnrtir n^intanr.. which ihi-y havr to ovrm.nir hi ..nlor III priMhici' It phiiM- iliHphinMuiii. Ai.oth..r v.-rv . ffiTtivr »«y of .li.cn.ii».inK fh.' priman- l.-.iknp. pn,|Mw,.,5 l.y th.. iin..|,t..r. r.f.r. t.. thi- r..n,tnirti..ii of th.- trai.Hf.)rn...r r..r.-. TIiw .iiv.M.n..ii 1^ fully .Ir^rrilHtl iti jMitciit ^iMTifii ati(.ii N... J. Th.> .'ffcct of thiH iiivrnii..,, i„ ..„i„l„„»tior. with th«. rornprnHBtior. n.jl. w ih„t the hnkuiii iin... .,f f„r.T. whi.h, «« ,.l„.„dy ...xphiin,..! uIh.vc. in ..nh-r to phkIii... a phuM- .li^phi.rin.nt iniiHt paxH thronnh th.- air Inith around th.- prmiary mil iuhI th,. .•nin|„.nsaiioii poil plaml iiwiflc (h« Imth. arc fore d to p«s.M four tini.-. ihro.i^M. ihr .i.l,. MirfaooM of ihr iron cor., nnci thorrhv <-n- coiintrr a (trcnlly incn-ii.srd niannciip rpKixtanrt'. I'at.-i.l SiM-.itiration No. :t r..f..p. (o an invention ajwi intond.-d to do- croa«. th.. matrn..tir UakuK.. in irarHforin.-r furnatTH. n,i« inv,.ntioi. c-o.iM.fM of th.- u f a .hort ,-ir.-uil..d .-ondu.-for or .-ondu.-tors of low r.-swtanc.-. which an- pla.-.-d in th.- way of th.- i.-akiiiK lin.-s of f..rcn. but not in th.. way of th.- .-(T.-.-f iv,- lin.-s of for.-.- ..f th.- tran.for.n..r The invention is fully d.-s.-rilK-.! in ilu- pat.-nt s,x-ei(iratioi. un.l will in c-rtain eases Ik- used hy the inventors. Electric Furnaces for the Reduction of Orei. Trannlnrnur Furtuice. The arraiip-iiM-nts of this typi- of furnace are .lescrilx-d in patent specifi- cation N'o. 4. Th.- necessary .-lertrical machinery and arranpincnts are based on the same principles as for the steel furnac- previouslv J<.scril)ed. The parallel extensions of the groove are drawn into the hearth ..r lower part of a shaft furnace (or oth.-r similar furnace). TV-.s the hearth of the shaft furnace will con.sist of a part <>f the smelting Rroove of the induction furnace and the material h.'ated .ir snulte.l in th.- shaft furiia.-e will directly drop down into the smelting bath of th. cl.ctric furnace and will there be submitted to further frcatment by m.-ans of an electric current. The sm.-lted pig iron may by m.-an.s of th.-se arrangements Ik- brought to continuously flow out from the shaft furnace into the smelting groove of tlie .-h'ctric furnace. The groove is given such cross sections in its different parts that the principal heat is d.-velop.-.! insirle the .shaft furnace. The groove outside the shaft furnace is completely bricked in, forming a closed canal. The inventors further propose to use part of the ga.ses .leveloped for heating and reduction purpo.ses in a manner similar to the one proposed bv Henri Harmet. fi j ttM PlaU XI ifmmm mmi mmm wmi mn FumiieL Pun -' I ■Hi TRANSFORMER FURNACE COMBINED WITH SHAFT FURNACE. Ski Til >\. ^^■■irill / / / / ■ / / & ^ -TT^ :-Z_ X:. / y ■/ ■ yrr-- -^^-y^ Plate XV. ' / / / .- / ,' ''///.■ ^,//. / / / . o ■-• Ac-' o 1 ). . 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Tlir J^M^. in ('tttiHi-qiii-iitly ki'jn in itmiintiou circiilaiuiii and an new jja.s JK (•oimtantly loiiui'd tlmmKli tlio rciliK'tion of the on- iiiul air t-Nchiili'ii. th<' |MT«-clita>jf of iiilroKt'ii iii tlu' Kiw will Kriif(IUt«>r<. All cxi.ritiu'titnl ftiritHOf of 6(M) to 7l»»> h p. is at pri-4fiit Ix'iiitr crcctfl in areordaticc with llii-^ itivciition, the const ruct ion of «hirh is •howii in I'loU'sN'os. XIV-XVl. Il ( ntii't FiiriKt' < . IIk" Fill, If iii\( iitors uhi) prcpiw to t-inploy a furnaci" of the contaii type for thi- din-, i si'S- Miiig nf on-s. This iiivciitioii i.-i dt'MTilx'd ill (mtcnt H[M'ri(ication Xo. ") and ono form of thppon^fnictioiMSHlmwn in I'latc Xo. XVII. The lowf: [xirt of a shaft fiirnuce is divided into two parts hy nii-ans of a wall of :..i' nvoof niuK-rial, 8o that two (trooves arc I'ormcd. whicd cNtnid thron;'|i «.p( ■. .mt" 'h tho brick J.. i mw the M. ■>•■■■ )>lopk8 or ir..' ; •. of each :'".i:- r;i..ii|.:.'h ilu' . ':■■• : ; li.icf and ■ ovi . The • ; !i> "T-d and work ontBide (he fiirnaee. The molten material electrnties for the current, connections l»ein(, i.-iajc other suitable arranf;einents with the traiismissi(„ lio. ■ prcmvc. The electric current passes fnnii one ■ i, • molten priKluct in one cf the jtronves, across t' ■ a,.' out to the other terminal through the material ir lii' charge in the furnace through its resistai.ec to thi' i smelted Holdliiiii l-'iirriare. This invention, also projHiscd hy the same inventors, consists of au electric furnaee in comhination with a series of rotating cylinders and is fully described in patent Specification Xo. 6. This invention may prov.' i>f value esfx'cially for finely divideil ores, for instance for the treatment of concentrates of the iron sands in Canada, which m this case do not need to undergo any bricnietting process. i a f J 106 Specification No. 1. Improrcmrnt in TranKformvr ''itnuirei relatimj to tke arrangement of Compcmation Coilx for the dicrcaxe of the Magnetic Leakage. Tlic jm-sfiit iiivoiitioii n-lntps to elcctrip smelting furnaces of the trans- former tyjx'. In such transformer furnaces of the construction hitherto known oi-.e of the greatest difficulties has k-en the great magnetic leak- age and the re>ulting phase displacement, which has caused the necessity of a relatively great and ex|x>tisive machinery and thus heavy original costs. Ill order to avoid or retluce these difficulties different methods have been tried for reducing the magnetic leakage. Kvery invention intended for that pur|H)se and carried out in practice has l)een based on the principle to render it more difficult for the leaking lines of force to close themselves or meet through the air. Thus it has In-en attempted to les.sen the area through which the leaking lines of force may close themselves through the air for in.stance by placing the primary coil within the area enclosed by the smelting l)ath. ITiis disiK)sal of the primary coil, however; on account of the high temperature of the smelting bath, which is placed near by, is con- nected with great difficulties, especially if, as usually is the case, the primary coil is supplied with alternating current of relatively high voltage. The pn-sent invention has for its object a device by which the disad- vaiitiigeous leakage is limited to the space within the smelting bath, inde- jH'ndant of the |H)sition of the primary coil relatively to the smelting l)ath. In order to more fully explain the idea of this our invention, the follow- ing description of it is given with reference to the accompanying schematical drawing, in which is sliowii a vertical section of a transformer furnare em- Ixxlying the present invention. 1 is the iron core of the transformer, 2 the smelting bath and 3 the primary coil, wliich in the form of the furnace shown in the drawing is located around tliat leg of the transformer core, which is outside the smelting bath. 4 and 5 are two other coils, which are nf)t connected witli the primary .source of cur- niii. Of these latter coils the one. 4. surrounds the same leg of the trans- fonncr core as the primary coil and the other. ,5, is placed within the smelting bath and surrounds the same leg of the tr:insfornier core iis tliis latter. These two coils. 4 and .j, are connected with each other in such a manner that the elect romotive forces induced in the same counteract each other. If tnese two coils have the same numlier of windings or turns, the electromotive forces imiiuid or excited in the .same should completely neutralize or nullify each other. i)ro\iiled that no primtiry leakage is developed in the transformer. If, however, not all of the lines of force generated by the primary coil. 3. pass through the smelting bath, 2. aiul the coil .5, but instead of this a part of theiri in longer or short<'r ••iirves clos*- Ihem.selves through the air. more leak- ing lines of force wili pass through the coil 4 than through the coil .5, wherefore 1"7 thr clcctroniotivo force iii(l in the former will have a value greater than that indiieed in tlie latter. In consequence of this an alternating current will flow throujili the two coils 4 and 5, connected with each other, the strength of said current lK>ing deiK-ndent on the nunilH-r of lines of force leaking around the primary coil. From this it follows that if the coils are connected with each other in the manner alnive stated, tlie coil .") will nuignetically co- may Ik* made with only a few windings, it follows that the tension induced in the same will Ix- relatively low and it is obvious tliat the insulation of the same also may l)e relatively slight or thin, whence it finally follows that the space In'tween the smelting bath and the leg of the transformer core surrounded by tlie same may practically Ik- made as small as if there were no coil. Obviously it is not necessary that the iron core 1 has the form shown in the drawing, neither is it necessary that the primary coil \)c placed as shown in the drawing, but tliis latter may Ix" located on the transformer core in any other 8uitaV)le manner. Tlie primary coil may also Ik' sulxlivided in two or more sections or parts located in any suitable manner. Xor is it n<'cessary that tlie coil 4 In- placed in the manner shown in the drawing. It may instead lie located around, aliove or underneath or in any other suitable manner near the primary coil, provided it always be so arranged that all or a part of the lines of force leaking around the primary coil '.i act in made with any suitable nimilxT of windings' and may also lie divided in several sections. "; r I IIM I«« Specification No. la. If>, jiruii nil ntn In Trniisjontiir Fiiriinrnt rrliilinil to the iirriiniirmnil oj ('Dnijii ii'-iitiini Ciiilx jitr Ihi tlirntisr nj thi Mniinclir Littkaijc. Oit of the {rrcjilf^t ilitliciltK - with tnui-fcirnirr t'liniiiccs liiis up to the imsciil liccii the fil'-al |)1i;!M' (lis;»la<'cliMlit prodiici'il hy ttn' Kt''i''nilly coii- ^^ill(•r!^^ll(' niajiiK'tic l»-i»kapp. The principle of the invention pre\ iou.-ly made liv the inventors for the (leerease of llie tna^netic leak:i<;p (see patent SiM'cilieation Xo. 1) consists of snilal>ly [ilaeed coils, charped from the outside wiili the reciuired current, in such a manner tliat their mapnetotnoti\c force comix'nsates the mafrTielunin- tive force uiih which the leaking lines of force try to force their way out from the iron core of t)ie transformer. Thi- pre i-nt invention has reference to a certain niodilicalion of that in- vention, whidi in an essential depree lacilitates its practical a|)plicatioii. on account of tlie decrea.se in the required numlxT of coils and conse(|ueiitly also the decreased uinount of copix-r required. Tlie accoriifmnyiiij; drawing shows ihi> form of the invention. I'ip. 1 is a vertical section of a transformer furiuice provided with the said itivention. Fip. 2 is also a vertk'al s<'ction of such a furnaie provided witli anotlier form of the invention. 1 and 2 are the two vertically placed leps of the iron core of the transformer, united alM)ve and Ih'Iow liy the two parts :{. 4 is the mellinp hath and '> the primary coil with its two terminals 6 and 7. S and 9 are two other coils designed in accordance witli the present invention to counteract the primary leakage. rip. I shows the terminal 1(1 for coil .S. connected with the terminal 11 for coil <). The other two terminals, 12 and 1:5, for tliese coils are intended to 1m' coiniected with an outer .-^oiirce of current. The two coils S and !> have siicli a winding, that the electromotive forces induced in same fnun the lines of force \\\ the iron cor,- are directed apainst each other. If no primary leakage is prcMluced. i.e., if all of the lines of force produced Wy tlie primary coil 5 in the lefi 1 pass also through leg 2, tlie electro-motive forces produced in coils 8 and !) are equal, (providiiiR the immlMT of windiiiKs ill the two coils are "(pial). There will lx> no difference of |xiteiilial hetweeii the terminals 12 and 13. If. on the other hand, a primary leakage is produced, then a greater iiumher of lines of force jiass through leg 1 tlian through leg 2 and consequently the currents induced in coils .S ami 9 are no longer ('(pial. .V.ssiiiiie that in leg 1 a nuinher, «, lines of force are produced and in leg 2 a nnniher, h; in such a case the electro-motive f)) r<'|)r('sciiis tlif iiuihIkt of Icukiiig liiu-s of f(»rfo aroiiiul the primary coil .") iiiid, thcrrfDro. it is evident that the (iifferenee of (Mitential imnluced U'twecii the teriiiiiiuls I'i and 1:{ l>v the primary leakage i^ eised with advantage. Tlie arrangements in this citse are shown in Fig. 2. Tlie primary coil is as U't'ore supplied with current through the terminals 6 and 7 Imt the terminal 12 of coil 8 is now connected to the terminal 7 of the primary coil and the terminal l.'i of coil 9 connected to such a |M)int 14 on tlM' primar coil that the prevailing ilifference of }X)tcntial Ix'tween ter- minals 7 and 14 will just Ix' sufficient for the coil system 8 and 9. It i^ ividentiv unt neces.sary that the i)rimary coil 5 Ix? placed as shown in the drawing. siii«* ifs {xisition is indifferent in regard to the iron core. Tlie primary eoil can also Ix- divich-d up in a nnnil'or of arbitrarily placed parts. Kvidently dso tin- coils .S and 9 can be placed in some other way than shown III the drawing and be divided up in different parts. ^^ Ill I U'i Specification Ifo. 2. Improremrnls in Tramjonmr Furmmx nltiting to the ('on»tnirlion />/ the Iron Con of Ihf Tmmjiinmr for thi ilirrmsf »/ Ihr Mdijmtk IahImiu: III clortric- cnu'ltinp fiirmu't'w of the tnmsfornuT tyiK- U'forc kiiD.ni oii.< of thi- ijniiti-st (imiciillics in pniPtice has U-n\ tlif coiisidorahlo electrf)- n.iiniiotic- leakage ami the sliiflii.c of phusrs arisiiijj ilicrcfroni. which takes plate on account of the ix)sition of the primary coil or coils with rcRprd to the s<-con(lary coil, in this case consistiiin of the smeltiiit' hath. In other transformers, for instance such as are used for the transmission of power, this dilliculty dd near to each other, for instance in such a manner that the one coil Ix' placed concentrically aromul and near to the other coil. In transformer furnaces, however, such an arranjjetueiit is. on account of the furnace construction, not possible, for even If the primarv coil and the .smeltinp bath l)e placed concentrically relatively to each other, the high temperatn: of the smelting bath makes it necessary that there should be a relatively great space l)etween the primary coil andthe smelting bath, in onler that a sufii.ient insulation against heat mav' Ik- secure.l. Therefore, in transformer furnaces other means must !« used for reducing th.- leakage, so that the iH)wer factor (cos ^ ) may not be too small, making the use of mai^sive and exp.'nsive machinery necessary. According to ol)s<>rvatioiis made by us in transformers of the construc- tions hitherto used, the leaking lines of force emanate chiefly from the edges of the sheets or lamellae of iron of which the transformer core is comi)osed. Thus when the transformer core is formed with rectangular cross section the most of th.' leaking lines of force emanate from those sides of the core which are forme.1 of the edges of the said sheets or lamellae, while only a relativelv small number of the leaking lines of force emanate from the other sides of ihe core. or. in other words, the leaking lines of force pass more easily aloi'g the -ide surfaces of the sheets of iron than across the same. This is •ilso in acconl with the theory, as the leaking lines of force which try to pass across the shj-ets of iron necessarily must 1h> counteracted or restrained by the "scrH-ning action," which the iron sheets them-selves exerci.sc. The present invention has for its object an iron core for use in trans- former furnaces, which iron core is constructed on the base of the said ol>- ^•rvations for the pur,K.se of reducing the U-akage as far as ,x.ssible Th.> principle of the invention is. broadly spt-aking, as follows: The tran^f..rmer core should 1h- so formed that its surfaces, as far as ix-ssibl.-. lx> fornud not of the edges of the iron sheets of which the transformer core cm- «ists but coiMM of .he iron sheets or lamellae of which the transformer core / 113 is formed and so arranged that wherever the leaking lines of force try to escape or emanate from the iron core tlicy are forced to pass acnmn a smaller or greater number of the said sheets of iron. In order to make our invention more plain, it is descril)ed in the following with reference to the accomimnying drawing in which, as examples, different forms of the same ar<' ilhistrated. Fig. 1 is a front view of a rectangular transformer core, constructed in accordance with this invention and Fig. 2 .shows a horizontal cross section of the same. Fig. 3 is a horizontal cross section j)f another form of a trans- former core, also constructed in accordance with this invention. According to tlie form of the invention illustrated by Figs. 1 and 2, the iron core is composed of a number of parts or sections, 1, of triangular section, said sections being put together to complete the iron core, so that the iron sheets, of wliich a certain section 1 is formed, will be parallel with that side-surface of the complete transformer core, which is formed of the same part or section. In order to prevent the production of disadvantageous currents within the in)ii ore, the several sections or parts 1 are seimrated from each other by means of a layer 2 of insulating material. To secure the effect aimed at by this invention, i.e. the "srreening action" of the iron sheets, by which the reduction of the leakage is attained, the vertical legs of the transformer core may suitably lie connected also at the corners with its horizontal parts iti the manner shown in Fig. 1. According to the form of the invention illustrated by Fie. :{. the sections 1 are formed with such cross sections that when said sections or parts 1 are put together, passages or canals .J are formed, through which a suitable cool- ing medium may l)e led for cooling of the iron core. Obviously it is not necessary that the transformer core In- formed with rectangidar cross st>ction as shown in the drawing, but it may also lx> formed with any other suitable section and it ought also to Ix' understood that the iron core may even Ik- formed by another numl)er of sections or parts than that shown in the drawing and that in such ca.se all or a part of them may l)e formed with other cross sections than the triangular one. The iron core may also be composed of sheets of iron, placed concentrically or spirally around each other, in which ca.se, however, the sheets nuist Ix' insulated from each other in such a maiuier tliat no disadvantageous currents can develop within the iron core. ^Ih v\ 114 iia Sptcillcation No. 8. Improvem'ntH in Trannformfr Furnacen relutiru} to the nrrarufcmnf, nj Shnrl-eireuUed Condiictom for the deertane of the Self Induction. The prp8ent invontion relates to iniprovenients in electric fiirtiaccs of tho ty|K' where the crucible is formed of an endless groove intended for the reception of the material to be treated, which material altiiie or tngether with other eoiidiicting mattrinlH placed in said groove forms the .secondary coil of an electric transformer. In transformer furnaces of the said type and of the construction hitherto known the disadvantage has appeared, that, owing to their construction, the self induction Woincs very great and thus they work with a relatively small power-factor (cfw ip), which makes ex|H'nsive machinery neces.sary. The present invention consists in such improvement.^ in triintiformer furnaces of the said tyix- by means of which the self indut ion ma.v Ix' con- siderably reduced. For this purpose, according to this invention, a short circuited conductor or conductors of low resistance is placed in the way of the leaking lines of force but not in the way of the effective lines of force of the transformer, in which conductor or conductors by the action of the leak- age flux currents are induced, which directly counteract the said flux. It is to Im' understood without further explanation that the said short circuited conductor or conductors may consist of an endless conductor or of annular discs or of mantels of conducting materials cut open iri one or more places and formed and arranged in a suitable manner. This conductor or conductors may be located in non-insulated condition, at a little distance from the smelting bath, so that they may. without damage, be exi>.)sed to a high temperature. The less the ohmic resistance of these conductors is and the fxreater the numl)er of the leaking lines of force that are caused to pas-s through the same, the more effective will the action of the same be. In the following this invention is descriln-d with reference to the accom- panying drawings, forming parts of this specification. In these .Ir, ...ii: ■ are shown as examples several different form.s of the invention. Fig. 1 is a vertical section and Fig. 2 a plan view of an eli-;-: • m '..-Itiur funiace embodyii'g a form of the invention. Figs. .'J. 4 and ."> im- !„,riiii!it i! plan views of smelting furnaces embodying .some other forms of the invention In the different Figures corresponding parts are indicated with the same numbers of reference. Referring to Figs. 1 and 2, 1 is the transformer core, which is surro. „'<«d by the groove 2, intended for the reception of the material to l)e treated fir the material forming the secondary coil) and by the primary coil .3. The said core, the whole or a part or parts of it, is further, accorciing to this in- vention, surrounded by a mantel 4, of conducting material, which mantel i.-f I ! « II IM rut (>|x>u at one or several |>lti«ii, for instance at 5. in onler that the effective lines o( fone of the raimforni.- may ««>l act inductively on the name. Hv mean* of this mui.tel 4, « ud by one or more annulur diMs or plates 4 of conducing material, cut op«.n at one or several places, for u tance ut .'J. so that the effective flux of the transformer may not act inducii\(ly on the said disc or discs, whde the diffused or leaking lines of force excite I'xal eddy (urn'Uts in the same, which counteract the said leaking lines of force. Obviously these conductors or dis.s or mantels may lie placed either within the area enclosed by the smelting bath, or aljove, beneath, or around it, or simultuneously in two or mon of these different manners. 117 »«"c»ocorr rkoujtion tbt cha*t (ANSI and ISO TEST CHART No. 2) ^ /APPLIED IIVMGE In S". '653 Eos! Mam Street F^ Rochester, Utm York U609 USA as ("9) ♦B2 - 0300 - Phone ^S (■' ^) 288 - 5989 - Fa>. IIH 119 Specification No. 4. Improvemmts in Electric Transformer Furnaces and Transformer Furnaces in connection with a Shaft Furnace. The present invention relates to improvements in electric furnaces of the type where the crucible is formed of an endless groove intended for the reception of the m .terial to be treated, which material, alone or together with other conducting materials placed in said groove, forms the secondary coil of an electric transformer. The invention consists of a special form of the said groove or canal, which is intended for the reception of the material to he treated, which material, as above said, during the smelting or heating process forms the secondary coil or conductor of the electric transformer. The invention further consists in the combination of two such grooves or canals with each other in such a way that the material may be tapped off from the one into the other for further treatment. The invention also consists in the combination of the smelting groove or canal with a blast furnace or other similar furnace and in a certain arrangement of the primary coil of the electric transformer or trans- formers used, and in certain arrangements of said transformers and grooves. In the use of electric smelting furnaces of the aljove mentioned type and of the constructions hitherto known certain difficulties have lx;en experienced, consisting partly therein that a great phase-displacement takes place which becomes greater the greater the area is which is enclosed by the said groove forming the hearth or crucible and partly therein that only an electric current of relatively low voltage can be used. Through the present invention these difficulties are overcome thereby, that the said endless groove (or grooves) intended for the reception of the charge to be heated or smelted and which as usual surrounds a part of the iron core of the transformer is partly bent around the said core but provided with one or more relatively long extensions formed in such a way that certain parts or branches of said groove (or grooves) are arranged parallel to each other and as near each ^ther as is practically possible. These extensions are connected with each ciher in such a way that the same together with the parts bent around the core form an endless groove or canal. By giving the groove this particular shape, the advantage is gained that it will have a great volume, but enclose a relatively small area. Besides *his the further advan- tage is gained that a higher voltage may be used than by any other construc- tion. The voltage may be the greater, the longer the said extensions of the smelting groove are. On account of the relative smallnes: .)f the area en- closed by the said groove, the periods of the alternating electric current employed may be of greater frequency, hence the electric machinery necessary will be considerably less costly than with constructions before known. f 190 An electric smelting furnace of this construction can suitably be com- bined with a blast furnace or another similar furnace in such a manner that the extensions of the groove of the electric furnace, or in general words, the parts of the groove arranged practically parallel to and near each other, are drawn into or through the hearth (the lower part) of the furnace. Thus, the hearth of the b'ast furnace will consist of a part of the smelting groove of the electric furnace and the material heated or smelted in the blast furnace will directly drop down into the smelting bath of the electric furnace and will there be submitted to further treatment by means of an electric current. Preferably two grooves of the form above stated may be combined with each other either in such a way that they belong to one and the same transformer, or in such a way that each of them is provided with its own transformer or transformers. These grooves are so located relatively to each other, that the one is placed higher than the other so that the smelted material may be tapped off from the former to the latter for refining treatment or puddling. In order to facilitate the cooling of the primary coil of the transformer and to reduce its leakage, it is, according to this invention, placed not around the part of the iron core of the transformer which is enclosed by the smelting bath, forming the secondary coil, but around one of the other parts, pre- ferably around the lower one of those parts, by which the vertical legs of the said core are connected with each other or a primary coil may at the same time be arranged both on said part and on the vertical leg not enclosed by the smelting bath, by which arrangement the leakage from these parts of the transformer is practically overcome. In the accompanying drawings examples of some forms of construction of the invention are shown: — Fig. 1 is a vertical section of a transformer furnace in accordance with the present invention. Fig. 2 is a plan view of the same seen from above. Fig. 3 is a vertical section through the line C-D in Fig. 4 of such an electric furnace combined with a shaft furnace. Fig. 4 is a plan view of the same seen from above and partly in section through the line A-B in Fig. 3 and Fig. 5 is a transverse section through the line E-F in Fig. 4. Figs. 6, 7 and 8 illustrate in the same manner a somewhat modified form of the furnace shown in Figs. 3-5. Fig. 9 is a vertical section and Fig. 10 a horizontal plan view of another form of the invention. Fig. 11 is a vertical section and Fig. 12 a horizontal plan view of still another form of the invention and Fig. 13 is a vertical section and Fig. 14 a horizontal plan view of still another form of the invention. In the several Figures the same parts are indicated by the same figures of reference. Referring to the Figs. 1 and 2, 1 is the endless groove or canal arranged in a frame 2 of brick work or the like and is intended for the reception of the Ml material to be treated. Said groove encloses as usual a part, 3, of the core of the transformer and 4 indicates the primary coil of the transformer, which coil for the purpose stated above is placed on the bwer one of those parts of the said core of the transformer that connect the vertical legs with each other. The groove 3 is partly bent around the one leg of the iron core and is provided with one or several relatively long extensions 5 arranged parallel (or practically parallel) and as near each other as possible, the said extensions being at their outer ends 14 connected with each other so that an endless groove is formed. In transformer furnaces where alternating electric two— or poly-phase current is used, the groove may also be provided with such extensions, in which case the ends of the same may be connected to a neutral point. When the groove intended forthereception of thematerial tobe treated is given the form above stated the advantage is gained, as above said, that a part (for instance at 14) of the extension of the same may be placed within the hearth of a blast furnace or another smelting furnace. Such an arrange- ment is shown in the drawings, as for instance in Figs. 3, 4, 5, and in Figs. 6, 7, 8. In these Figures 5 indicates the parts of the groove that form the extensions. Said parts enter into the hearth of the blast furnace 6, where they are connected with each other in the manner shown in Fisrs. 4 and 7. The material heated and reduced within the blast furnace may thus in smelted or heated condition directly drop down into the said groove cf the electric furnace, where it is submitted to the action of the electric current. In this case the electric current will pass through the hearth or through the smelting zone of the blast furnace, thereby generating a quantity of heat sufficient to make up for all or at least a part of the quantity of coal or other fuel that otherwise would be necessary for the smelting of the ore within the blast fu.nace. The smelted iron may by means of these arrange- ments be brought to continuously flow out from the blast furnace into the melting bath of the electric furnace where it is further heated or refined. The said arrangement of the electric furnace, viz.: that the groove is provided with extensions or parts arranged practically parallel and near each other may also be used in electric furnaces of the type called "contact furnaces" or "resistance furnaces." In some cases another groove, 9, (which may be called "fining groove") siniilar to th mentioned one may be arranged at the side of this latter, which groove, ..i such cases, forms the "steel melting groove" proper. This groove, 9, is, as may be seen from the figures 5 and 8, arranged lower than the other groove, 1, so that the smelted mass may be tapped oil from the groove 1 into the groove 9 through suitably arranged canals or the like (not shown). The said grooves 1 and 9 may have a common electric transformer (or trans- formers), as shown in the figures 3 to 5, or be provided each with its own transformer, as shown in the figures 6 to 8. The groove 1, which, to dis- tinguish it from the groove 9 in this case, may be called the "blast furnace \j in 1 groove," is suitably covered with a vault or with plates 7, of fire-proof or refractory material, so that a canal or passage 10 is formed, through which gases containing carbon monoxide or other oxidizable gases suitable for the reduction or heating of the material charged into the blast or smelting furnace may be introduced into this latter through the pipe 8. Such an arrangement permits the introduction of gases into the blast or smelting furnace in a very simple and practical manner. This construction has the additional advan- tage, that when the said gases pass through the passage 10 over the smelted mass in the groove 1, the gases absorb heat that radiates from the slag cover- ing the smelted iron in the groove. This heat may be utilized for the pro- cess going on in the blast or smelting furnace. The said gases containing carbon monoxide, which are introduced into the blast or smelting furnace through the pipe 8, are preferably generated in the manner stated in another application filed simultaneously herewith, viz.: that the gases issuing from the said furnace, which gases are latively rich in carbon dioxide, are con- tinuously led through a heating device and there heated to a sufficiently high temperature and thereafter in a heated condition led through or over a layer of carbon, whereby the carbon dioxide through the reducing action of the carbon is reduced to carbon monoxide while at the same time carbon is oxidized to carbon monoxide. The gases thus received, or a part of them, which are relatively rich in carbon monoxide, are then led through the pipe 8 and passages 10 into the smelting furnace, where the carbon monoxide either by means of air introduced in said furnace or principally by means of the oxygen contained in the material to be treated is oxidized to carbon dioxide, which together with the other gases are, in the manner above stated, led from the blast or smelting furnace through the heating device .md over or through the carbon for regeneration of carbon monoxide, which latter gas '^ then again introduced into the furnace and so forth in a continuous circulation with alternate oxidation of carbon monoxide to carbon dioxide ana decomposition or reduction of this latter by means of carbon to carbon monox-de. Canals or passages 12 are also provided for conveyance of air to the transformer for the purpose of cooling the same. It must be understood that in the case illustrated by the figures 1 and 2, i.e. when the electric funiace is not combined with a blast furnace or another similar smelting furnace, a special "fining groove" may also be provided in the same manner as shown in the figures 3 to 5 or 6 to 8. In the figures 9 to 14 some other forms of the invention are shown. According to the form illustrated by the figures 9 and 10, the furnace is provided with two transformers 3 placed each at the opposite ends of the groove 1 intended for the reception of the material. This groove may have the form shown in figures 10 and 12, i.e., its end portions partly bent concen- trically around a leg of the cores of the transformers and its middle portions arranged substantial!} parallel to and as near eaoh other as pas-sible. The in last named parts may be straight, as shown in Figures 10 and 12, or they may be curved for instance, as shown in Figure 14, or in any other suitable way. In Figurec 13 and 14 there is shown a form of the invention where two legs of the core of the transformer are surrounded by the groove in a manner that may be seen from Figure 14. By these arrangements the advantage is gained, that the core of the transformer may be of smaller dimrn. 'ons than if only one transformer is used or a transformer of which only one leg of the core were enclosed by the smelting bath, besides which the area enclosed by the groove is with regard to its capacity relatively small. If the • electric furnace is to be combined with a blast furnace or a similar furnace, these latter may suitably be placed at the middle, 15, of said groove. In some cases it may be useful to expand a certain part of the groove into a well for collecting the smelted iron or material in question, in which also the temperature may be kept lower than in other parts of the groove. Such an arrangement may suitably be provided in the forms illustrated in Figures 9-14 in such a manner that said well for collecting the smelted material be made a neutral point, for instance at 15. (See Figure 10). These latter forms also of the electric furnace may be combined with a blast furnace in the manner before stated, in w>- .. case the blast furnace or smelting furnace is placed over the neutral point (see Figures 11 and 12). The employment of two transformers for the same smelting bath or groove has the advantage that if a fa ilt occurs in one of the transformers this transformer may be cut out and repa red while the smelting bath is kept heated with the aid of the other transformer. The electric furnace, as illustrated for instance by Figures 3 to 5, or 6 to 8, works in the following manner: — 'i The ore charged into the blast furnace and there reduced by the action of the carbon monoxide is, in that part of the groove of the electric furnace which extends into or is placed within the blast furnace, heated to the smelting temperature by the passage of the electric current, reaching a temperature of about 1600° C. Into the smelted iron bath contained in said groove drops from the blast furnace both smelted iron and also partly reduced pieces of ore. These latter pieces when they have fallen into the iron bath are very rapidly reduced and melted. The smelted iron which fills the groove of the blast furnace is tapped into the other groove (the fining groove) which, as before stated, is placed for this purpose somewhat lower than the first groove. Some smelted iron must, however, be retained within the "blast furnace groovi» " in order that the electric current may not be broker The fining process is 3arried out as usual by adding scrap iron or ore to the ; -Ited pig iron. Ihe fining work may conveniently be carried out in thos-. parts of the groove that are arranged parallel to each other. When the fining work of a charge is finished, all the charge may be tapped off and the " fining groove" again chained from the "blast furnace groove." Evidently a very high de- 134 Kree of efficiency may be obtained in an electric smelting furnace, constructed as above described. In the blast furnace itself the smelting zone where he highest temperature takes place may be restricted to a small space, for the high temperature is, as described, obtained in the iron and the heat .s led from the interior of the mass outwards. This electric transformer furnace is, as before stated, from an electric point of view of a most advantageous construction. , _ , _,., It ought to be understood that even more than two grooves, each sur- rounding a leg of a transformer core, may be combined with each other m the .manner described, by means of grooves arranged parallel to and near each other. ' i : ' '! 1 ; i I« IM riff.^ Fig: 5. m FioS. '^jV/Z/MWA Fig: I \ YA 5J /♦ -D F rig. 8. m0 -z U ''^Mm.MM:d Mi Fig.9. Fig-- /O. I Mi I 13() 11 Fi Q: /5 ri^:/i- 131 Specification No. 6. Electric Contact Furnace for the Production of Metals from their Ores. For the productif)n of metals from their ores by means of the electric current, as for instance for the reduction of iron ores, furnaces have been used in which the electric current is brought by means of contacts to the material which is to be heated or melted. The heat developed by the electric current is produced in the material through its electric resistance. One difficulty with these furnaces has Ix'en the conveyance of the cur- rent, i.e., in the arrangement of the contacts themselves. Up to the present the contacts have generallj' been so arranged that either both or at least one of the electrodes have been placed inside the furnace shaft ( in a vertical or more or less inclined position) and surrounded by the charge. The gases produced by the reduction in combination with the high temperature have in such cases led to destructive corrosion of the contact. i' ! This present invention has in view a furnace-construction in which the above mentioned difficulty is eliminated. The accompanying drawing shows, as an example, a furnace according to this invention. Fig. 1 is a vertical section through line E-F in Fig. 2. Fig. 2 is a horizontal section through line C-D in Fig. 1 and Fig. 3 is a vertical section through line A-B in Fig 1. 1 is the furnace shaft, in which the ma- terial to be smelted is charged. The lower part of the shaft is divided into two parts by means of a wall of fire-proof material, so that two grooves, 6, are formed, in which the melted materials collect. These grooves extend through the openings, 2, in the brick work outside the shaft. The material forming the conductors in the parts of the grooves extending outside the shaft is in a molten or half molten condition and in some suitable manner connected with the terminals of the electric current, for instance, as shown in the drawing, by two carbon blocks, 5, which are placed at the ends of the grooves, which here are widened out and made deeper. In order to keep the molten bath inside the furnace at a constant level, the molten product, as shown in the drawing, can continuously lie run out through openings 7 into a fore-hearth 8, from which it can be tapped through the tap-hole 9. For a furnace of above described construction the continuous working from an electrical point of view will be as follows:^ The electric current passes from one of the terminals 5 through the mol- ten product of the furnace in groove 6 and across the wall 3 through the charge to be smelted and out to the other terminal through the material in the other groove. The charge in the furnace through its resistance to the current is heated and melted. 1S2 The molten material in the grooves 6 inside the furnace performs con- sequently the function of electrodes. The parts of grooves 6 outside the furnace can be made of such cross section that the temperature will be comparatively low, which enables the contacts to be made more easily. When starting the furnace a suitable electrode material of the same kind as the product to be produced is placed in the grooves 6. This class of furnace construction can, of course, be adapted for poly- phase currents. For a three-phase current, for instance, the grooves are arranged as shown in Fit,. 4 and if the shaft is circular as shown in Fig. 5. 133 Fxg. / F£ff:\ Ftg.t IwHl 4'^ .5 ■'m^/Jk>//M. 6 y Fi Q:^. 9 ii^a^r- ' , 134 Specification No. 6. Rolating Smelting Furnace. Experiments with rotating furnaces have been made during late years at several places for roasting ores, for cement fabrication and also for the production of pig iron. The construction used has consisted of one or more inclined or horizontal rotating cylinders, into which the ore is charged and slowly brought forward, gradually meeting gases of continuously increased temperature, and at last melted down in a special part of the furnace, or in a separate chamljer, ar- ranged at the side of or in the lower part of the rotating cylinder. In this part of the furnace the heat is generated by the combustion of generator gas l)y means of an air blast. The difficulty, however, has been the sintering together of the ore lx>forc it gets down to the smelting chamber, on account of the impossibility of preventing the heat, when gas firing, from rising to the higher parts of the furnace, and the consequent clogging of the relatively narrow cylinders. This difficulty can be altogether avoided by employing the construction consitituting this present invention, which is based on an electric furnace in combination with a rotating reductli.A furnace and eventually also a rotating roasting furnace. Throughout the extent of the reduction and smelting chamber combustion by means of the oxygen from air is precluded. In the accompanying drawings are shown as examples two different constructions of the invention. Fig. 1 is a vertical section of a construction, including both roasting, reduction furnace and an electric furnace. Fig. 2 is a vertical section of a similar furnace construction, but in this the roasting furnace is omitted. The furnace shown in Fig. 1 consists of a series of inclined rotating cylin- ders, 1, 2, 3, 4, communicating with each other, constructed of some suitable material. The two upper cylinder?- , 1 and 2, constitute the roasting furnace and the two lower ones, 3 and 4, the reduction furnace. The upper end of cylinder 1 communicates with a charging apparatus, 5. for the ore. The lower end of cylinder 2 and the upper end of cylinder 3 communicate with another charging apparatus 6 for the carbon and eventually for such material as may be required for the reduction and smelting processes. In the Icwcr end of cylinder 2 a tuyer 7 (or eventually more than one) is inserted for the introduction of air into the roasting furnace. The lower end of cylinder 4 communicates with a suitable chamber 8 constituting an electric smelting furnace, in which the charge is melted. In this chamber or in the lower part of cylinder 4 one or more tuyers, 9, are in- serted for the introduction of reducing gases, which may be generator gas. The electric furnace can be of any suitable construction, as, for instance, a transformer furnace or a contact furnace. 13S In the accompanying drawings the electric furnace is a contact furnace of the following construction: — I In the lower part, 10, of the furnace chamber. S. are arranged two grooves, 11, (one only shown in the Fig.), extending out.side the furnace and connected with the contact blocks, 12. The electrodes in this case are formed (during the continuous working) by the molten material in these grooves, which convey the electric current respectively to and from the furnace. The ends of the grooves connected with the blocks 12 are suitably made wider and deeper in order to obtain a lower temperature in these parts and in order to keep the molten material in the grooves at a constant level these grooves are provided with tap holes, through which the melted product continuously flows out into the fore-hearth 15 and from there is tapped through the tap hole 16. The rotating cylinders are on the inside provided with longitudinal projections 17, which during the rotation agitate the material and insure a better e*Fect of the gases. These projections can be formed by bricks laid in the lining. !: With this furnace the working process is as follows: Ore in suitable form is charged through the charging apparatus 5 and passes through the rotating cylinders 1 and 2, constituting the roasting furnace, and is there meeting hot air, pressed in in sufficient quantity through the tuyer 7. The heat required for the roasting of the ore taking place in cylinders 1 and 2 is derived from the combustio: .)f the combustible gases coming from the reduction furnace by the previouslij heated air passing into cylinder 2 through the tuyer provided for this purpose. The amount of air pressed in is regulated in such a manner that no sintering together of the ore can occur. The ore after being roasted drops from cylinder 2 down into the stationary hopper 18, where it is mixed with carbon and other required material. The mixture then pa.sses through the cylinders 3 and 4, constituting the reduction furnace, where it is met by the hot reducing gases pressed in throvigh the tuj-er 9. In order to prevent too high a temperature in the reduction furnace, no air is here let in, but only reducing gases suitably pre- heated to a temperature of 800°— 1000° C. The preheating of the gases can be accompli.shed in an electric heating apparatus, as shown in Fig. 2. The highly heated material drops from cylinder 4 down into the furnace chamber 8 and is there smelted by means of the electric current, as previously described. The electric furnace can also be used in combination with only a reduc- tion furnace, as is shown in Fig. 2. The principal difference in this construc- tion from that represented by Fig. 1 is that the cylinders 1 and 2 constituting the roasting furnace have been omitted. The ore is charged together with carbon and other required material through the closed charging apparatus 18 and passes through the rotating 136 cylinders 3 and 4 down into the furnace chamber 8, as previously described. With furnaces thus constructed, a considerable saving in carbon can be effected, by forcing the gases developed to continuously circulate through the furnace system. This can be accomplished by means of an exhauster, 20, which draws the gases from the charging chamber 18, through pipe 19, and presses them through pipe 21 into a heating apparatus of suitable con- struction, where the gases are heated to a temperature of 800°— 1200° C. From the heating apparatus the gases (or only part of same) are pressed through pipe 23 and tuyer 9 into the smelting chamber 8 and further through cylinders 4 and 3 back to the charging chamber. In this case only enough carbon to combine with the oxygen of the ore needs to be added. The excess of gases resulting from the reduction can be used for other purposes. The gases which circulate through the furnace system will, when the furnace has been in operation for some time, consist i.early entirely of carbon monoxide and dioxide. The carbon dioxide is reduced by the carbon in the lower parts of the furnace to monoxide, which in the upper parts of the furnace again is oxidized to dioxide by the oxygen of the ore. Possibly part of the carbon dioxide is also dissociated in the smelting chamber 8 into carbon monoxide and oxygen. The heating apparatus for the gases can be of any suitable construction, but preferably such that the heating is done by electricity. Such an ap- paratus is shown in Fig. 2. In a chamber, 22, of a suitable material are a number of tubes, 25, of conductive and firj-proof material, arranged in such a manner hat *he gases which are to be heated are forced to pass first through and later around the tubes before being conveyed to the furnace. Another method, which perhaps is preferable, is to let the gases first pass around the tubes and then through the whole length of the tube system, when a higher temperature can be obtained. The rotating cylinders, in order to facilitate the passage of the ore, can be made conical. In the constructions shown, both the roasting and reduction furnace consist of two cylinders each, but it is evident that instead of two only one or a number of cylinders can be employed. When treating a material which only needs roasting, for instance for the production of copper, the whole um^ce system is arranged as a ro: ing fuma-je, i.e., air is pressed in through tuyer 9 instead of reducing gases. (See Fig. 1). I3N IM Result! obtained with ^tbe H4roult Steel Funiace at RemKhcid in Oennany. At the meeting of the \'erein Deutscher EiRenhiittenletite at Diisseldorf on the 9th of December, 1906, I'rofegsor EichhofF, of Charlottenburg, read a paper* on the manufacture of electrical steel, in which he reviews in a general way the progress made in the application of electricity to steel-making, and describes and criticises the principal furnaces employed. With regard to the H6roult system he gives the following statements: — The plant at Remscheid was started on the 17th of February. 1906, and has, since the 22nd of March, l)oen operated by the Srm Richard Lindenlx'rg, G.in.b.H. The demand for the steel has l)een so great that it has proved necessary to double the plant and an additional furnace and rolling mill consuming 1,400 h.p. have been ordered. I'p to the present the electric furnace has been running continuously without any interruptions for more cxtonsivv- repairs. The VVellman furnace used for preheating and smelting of the raw material has caused some interruptions, which, however, when necessary experience has been obtained, will be avoided. No change of the hearth in the electric furnace has up to the present been required and the roof, which consists of one layer of small bricks, lasts over 100 charges. The electrodes last from 70 to 80 hours with a consump- tion in height of about 1 cm. per hour. The average power consumption is about 250 K.W. and the consumption per ton steel, '.iHa K.VV. hours. .Since up to the present the plant has been unable to meet the demand for steel, it has been impossible to exjjeriment with other classes of steel and soft iron not included in the Firm's line of manufacture. One experiment was made, however, with silicon steel and the results obtained showed that only a very small percentage of the silicon was lost. On account of these few results obtained. the investigation made by the well known experimenter L. Guillet in Paris, the results of which were read by him at the Congress for Technical Chemistry in Rome, 1906, will perhajw be of interest. * From Stahl und Eisen, 19<»7. No. 2. EXPERIMENTS MADE BY L. GfTILLET WITH HEROULT STEEL. I'NiroiiMiTY or CoMPoamoN im the Ingot. I i 1 1. Soft Iron. 3. 8l«el. Larue Iiidot. Small Larue Ingot. Small Ingot. ; Top Mid- dk Bot- tom. Middlp. Top. Mid- dle. Bot- tom. Top. Mid- dle. Bot- tom. Carbon Silicon Mannmne . Sulphur Phoaphonu . 0(184 03« 233 019 . 008 069 034 2.30 020 008 0.068 070 038 030 240 230 (tt2 022 0009 008 1 015 1.016 ion o.?oi 0.144 148 021 0.019 0.010 0.009 1.023: 1 018 0.103 0.098 0.158 0.151 03l! 0.020 O.OIOi 0.011 1 013 100 0.150 on 1 033 0.101 0.146 019 0010 EXPERIMENTS MADE BY L. Ol'lLLET WITH HEROULT STEEL. 1 Elongation in % of Contraction strength in % of c Mn Si S p m original length original crow section. 0.044 0.075 or: 0.007 39 00 30.00 ;o.6 0.089 0.076 0.003 0. 5 0.006 36 00 31 00 74.6 0.107 105 0.040 0.018 0.010 38.00 33.50 73.6 0.140 0.320 0.140 0.006 0.012 43.00 30 00 55.0 0.230 250 0.220 0.006 0.015 49 00 28.00 49.0 0.293 320 0.05U 0.009 0.024 53.00 26.00 48.0 207 .380 0.060 009 026 48.00 28.00 59.0 0.285 0.480 0.465 021 010 57 00 28.00 50.0 700 0.125 a35 0.015 0.007 68.50 18.00 40.0 0.880 080 0.148 006 OOd 86.00 13.00 29.0 1.19 0.110 065 004 003 69. 50 17 00 36.0 1.30 0.160 0.129 0.017 006 76.20 18 50 23.0 1.38 190 090 on oa-i 82.90 11.00 23 1.49 0.187 148 0.007 009 73 30 15 00 2».0 hi Ul i m 9n^ 9?,^ ^nn nnn ee mno smy w* 3S hiss 89Sj a;99 399 ^'■4 ee>n ece loee eee ^!ii ?saS ?.^,?\ P,n^ !^8!7 ■n KJMifl «>«« en<» r»«^ s s!i;:s a?.'?! ^n^ :?!$» N«fl WWIO xi/9a> Nusai •rtQai IS ^ I I a o iMi »!!; !;SS ii^SiS $!r3 S!?9 i i I 6 i; i So eSe oSo S3§ oSl ee ooo 6b bob oee ese oss feSS S 8 S S ~ 2 3S" bos bob obb 8 "55 »»"53c oujifl o?)0 ec^o «!? S^I; &§Z! S"^— h!2S ooo ooo ooo wSJ3 S3s! SS3» wccM n^n n^to oo oeo ooo ooo oco f"? a "SO bb bbb 3SS OOO ooo n ^ n T^9 Ti 2S?2 oo ooo ooo ooo OOO '3oS^8 <^) p»)«3<{ Xitaiojjun saidoiSB ny i 1 0. •c3 So s S it !l .3 R .3 a ■c ESI IS? B ^ _ ^ _ D. J) "JJ o. «i "3 a. «i u S-i 04 alu a^l slu li M The Bourre of the matrrialu fur thoK«« twitp in not «tat«J. hut vrry likfly thry were ohtaiiii'd (roni the work* in France and date Iwok to a tinw when till' procemi had not rrachcil it* pniiont development. The inve»»tinationi» by (iuiUet correKpond partly with the remiltH ohtained ut Remncheid, viz.:— that l»y the HMnilt procewi a steel can lie produced fully comparable with and with the followinn advantanes over crucible itteel:— J —With eipial toughnwH it permit* of a carbon content from 20 to 40% higher and consequently offer* u greater resistance to wear. 2— Very hifr'n ela»tic limit and contraction. 3— Freedom from blow-hole*. 4_St«'l completely deoxidixeil and containing no emulsion of silica or munganous oxide. .l—Tlie presence of copper and arsenic ha* no injurious effect, so long us practically no sulphur is present. fl—.Sep-egations of phosphorus and sulphur do not occur. 7_The steel forges Ix-ttcr and stands a higher heat better than crucible steel. 8— A cost of pnMluction far Ix-low that of crucible steel. 9— Independent of the raw material. 10 — Manufacture coupled with less exertion for the workmen than that of crucible steel. 1 1— A purity excelling nearly all crucible steels. 12 — The process makes it possible to produce any kind of alloy steels. Steel produced may be '"pt for hours under a neutral slag without changing its quality and a part of the heat may be worked over to another gradp_a matter which is of great importance to steel founders. The steel may be allowed to chill and be melted over again without hurting its quality. Cont of Prodtiction. The cost of production varies greatly according to conditions and the quality of the raw material. i«a ProfpMor Kirhhoff hu ronipilnl thf followiiiK tablm of the pnwrr Biid time rci|iiir(>nt npi>rationN, acNuniiiiK the inipiinwt rtM of wpiyhlM of rhargi'H: — TIMK RK^t'lKKI) Kt>H oPKHATIONS, IN MINITJX Xo. 1 ■i 3 4 H tl 7 H U 10 II 12 i4 I A Id Wrifiht of Charitr In liR. AOO Rrpairc'hrarth.roidrharRF. 10 RpfBir of hearth, hot rharitp N CharipnK, <^l Drawing olT fint ulaic. <'oll li S IN Tt i.VS. • ■i No. 1 1 Wciiiht of t'hariLte in k';. 100 l.",00 JIlOO :l:n;H liruc-^ Cold ehaitic ilin'.vinu dtV ,l.-,i; twiir. Coldcharp'. ilri'wii:- (iff shiLMiiiic. . ^ Kor ('iiii.siiniiitioii of 1 iicniv ,«<•(■ :iil- Ml l:il.-) It-SO JIJO jMlO I'lO ; 3 4 on ■100 1 I.Vl l.-.,s.-. isjo lOSO .'.'so -'IXO :ioso :i:)NO l.">:to lOJO 1 r, 7 Iciwin;; lalilc Hot (•liarp'.ilriiwiiii.M.IT.vlMitiwic!' Ho! cliar^'i', ilrawiiii; olT slai; onci- Hot clmrw. only otic sla« l:i.-).s -•:{so i :u7o lo.io 'r,r,2()' S(i20 f I.VjO ■-•770 i :i7oo l7-'0 li.lOO lOIJO Id lO.V) ■.UJil 1 I.MO .■).S|0 SJ.'JO 12(iJ0 11 IJ > Coii.«iiiii|i|ion of I'licr/v, ~m- lullow- J in;.' tahlc. j f 10 t I 5 c o JS UH •^i — ^ 1^ if '£ i! i! £ * ■? 5i S H ri .= 53 -■ is- C I * X I a — M >5 X ri tJ 2 r- IT--? E — >i; ri y. x S -r ^5 rt ?i ^1 — — MM M M 5- i = V £f. .— C i * 3: K "■ ;: tcs = = 3 =-r iz2-.= .= =r 5 » H 5 2 M t--r — rt ^ ?t 5 y. c « t- "? 5 ?i c r- 0-. — M M M ?i M « '^ O C C 'T '* r- — S 3J -J — — M M ri ^? '.' X L" -1 M -J M — -J — -i IS -r M M PC Pt -r ;5 2-M ■rJi i Eta 5 S iiit;! fite- a om uii -^ H 5.g I ■r 3 i s C '-* i -r X "-t c — 5 -t t- M M r- ?. X r- 1- 5 3C fJM = -2 S r» irf X « c cc rt •)• -r irt ffl ^ 3: X t* M r» X s «; M ec — o> « X -i »S«x 5 ^ ^ — t^ t ui ; g >i. S«fl M X P ?1 cc 1" «t W5 :b t* c CSC = c ut — !>. -t iS »C M « M -t « t- 111^ .1 I f SECTION A-B M 'mi' mm 'J!>-r'iih\'-"i>!'i:*1W. "SECTION K-L ^^^^^ PlatelVM )N C-D \ SECTION E-F SECTION G-H \' «... *. f..i W^-''«n;i:-s5:: 5ECTION M-N T.»%#«-^ J^rf- ' 1 i; <■ ■ > i -, 1 h- P-i -J : J" 1 H 1 1 1 • K i i ■i 1 H , • i; ' \^ ii ' V ^ 1 '^ 1 *> V k ■ f 1* J/ ^ ■/ ' ^ 1 '. « ^— ! IT ' 1 ■* 1 •! 1 H Fi \ ' 1 T ..„J i:^ ELECTRIC FURNACE .\ I 147 'I'lif opiTiitidii (i| [\\f funiMcc calls for two rncn and one hoy. Wlicn cnhl niatriial i-' rliartrcil "lit' or iwo cliarirci- arc r('(|iiirf(l. acr'onlinj; in ilic si/c of tlic fmiiacc. Tlic ciihsiiliilitioii of clcctiodcs laiidos lictwwii "•) ccMt^^. and oiii' ilollar with a colli charp'. ami ■_'.') to til' cents with lii|iiid cliarnc. The \vast(>, with the |i\ircst lu'oduct. is C ,' in cold clmrniiiji and :5 to 2V ,' with lirpiid charfic The .iiiisiunptioM of linic and ore is not greater than liy otlicr | iroci-sscs and thcri' is a savinj: in fcrro-inani;aiicsc and fi-rro-silicon. The cost (if repairs and the consiiinption of refractories are lunch lower than l)V the open hearth process. Improvement in Electric Furnace Construction suggested by R. TumbuU.* This furnace is shown in sections and i)lan in I'late Will and consists of a snieltiiiR irroove comiiiiinicatinj: thioiifih shoots with a central shaft. The electrodes carrying the curroiit arc suspended vertically tictwccii the shoots ill the siucltinfi groove, the Ixittom of which is made of carbon paste in coiuiunnication with niic of the teriuinals for the current. The top of the central shaft is arraiisied in sucli a manner that the na^v:' (or part of same) devch>|K'd tliroujih the reduction of the ore are utilized for the preheatinjj of the ore and the calcininfr of the limestone. Till' ore, liincstoni' and other rei|nircd shifi-huildini; material arc cliarp'd into a rotatinj; cylinder, in whidi the jias is liiTiif hy means of an air blast, tlic iiuantiiy of air beiii); re;;ulated so that a suitable temperature is obtaincfl. The gases rcsultiii<; from the comijustion arc drawn out through a cliimncv hy means of which the pressure in the funiacc i.s also to some extent rcsiilatcd. The carbon is charged throujili a 'losed charging r.i)paratus aid in tlic furnace sliaft mixed with the ore and slag-building material. The l)ottom of the .shaft is m-ide in such a manner that the charge has an easy descent through the shoots into the smelting groove. Electric Smelting Plant in Canada. Thefirst electric smelting plant ill Canada for the production of pig iron and later of high grade steel and steel castings is at present under construction. This plant will \>e located at WcUaiid. Out., on a i)iecc of ground facing the Welland Canal. The first installation will consist of one 3,000 h.p. furnace of the latest type brought out by Dr. H6roiilt and his associates. Tliis furnace is ex- pected to produce 35 tons of pig iron [X'r day, wlien not utilizing the gases produced by the reduction, and 40 tons wlien the gases are used for preheating * Worked out and drafted by E. Xystrom. M.E. UN illlil Ic.lMclioM. Tlu' IMiwcr will Ik- l'unii>lir,l l,y tlir Oiitilli.. Tower (■„., „f Niiicani I'l.lls.M'M v..li;m.M.fl2,(MK) volts. ;ui(l ili.'ii tniMsfoniMMl to the n-- (|ilir('l"onmr-. riiiiiisli,.,! I,y tlir l':u'k:ir.l Coinpaiiy. of St. CiithnriiicH. Oiil.. will lie of il il ami water eoo|,.,l iy|M.. of 7."»() K.W.Caeli, ami arraiised' with taps oil the seeoiKlaiy >i.l.' to allow a faiip' fioin :«) to 41) volts oinlic ''•'' •'"'■>■ ''"l"' I'lininee is .iiTaiiiieil in siieh a iiiaiiiier that a thfee-phasr cillTeiit can U'eiiiplovfil. This first fiirnaee \\ill he used for the purpose of (leliioiistratiriK that pi^ iron can he eomnieicially produced hy the electro-thermic process even at such an unf.noral.le -ite as Welland. wliere the pri(r of [Muver is hiu'li and the nearest ore supply about i:.t) miles distant. Some of the or<> used will l«. hrou>;ht from I'ort .\riliur, eontainiii>: as hi-h as l\< ; sulphur. Other ores of a v.-ry refractory nature will also Ih' used, the inlentioji of tli.' promoters licin»r to einph.y e\elu>ivcly Caiuidian ores. Tlie first furnace will 1«" followed hy a second one of prol.a.hly larjror capacity. A Heroult steel furnace will he put (h.wn at the same time and tlie entire production of the second furnace will he used for the mainifacture of hijrh trade steel castinjis. which are at present not luaile in Canada, and also for a limited inimlH'r of ordinary steel castinjjs. Tlie leclrodes will he manufactured hy the Heroult secret process, a plant with a capacity of IS electrodes iht week heiii-r constnicted. The organization of this demonstrative i)lant is due to the effortsof Mr. H. Turi.l.ull. Canadian representative of the Heroult imursses and furiuicos, and also to .Mr. H. H. Wolff. American representative of same. These RentU'- men. alonn with some friends also interested in the above processes, are in- vestiun their own i)rivate capital in the enterprise, thus proving tliat not only are they certain of the results that can he obtained hv thi.s new process, bii't are iiowh'adiuf; the way for otl,(.rs bytakinjr the'.irst risk and buildinji the first commercial jilaiit. Electric Smelting Plant in the United States. At Haird. alifr.rnia. an electric smeltiu}.- i)lant for the production of piR iron is at present under construction and is expected to be in operation in :\Iay, 1907. The first installation will be a 2,000 h.p. furiiaco with a guaranteed out- put of 20 Ions tons per 24 hours. If successful, this plant is to be onlarce.l to a capacity of 600- cSOO tons per day. The ore which will be employed is a very rich majjnetite, containing only a very small percentage of sulphur and phosphorus. The reducing ageiiV will he charcoal and for the production of the charcoal a plant has alreadv been erected. 149 Electric Steel Works. Franre. fS(X'i<^t6 KlcctroiiH'tallurKi'i"'' Fruiii-uiso, at I^i Praz ; one 41KJ li.p. H<'"-')ult fiirnai'c. Si)ci<'tt' (Ics llautf KMinicaux it Forncx d'Alluvard, AUcvard ; Iwii .VMt lip. furiiarcs Imilt, two Imlldiiin. S(H'U''ti; lUw Hants rimriieaux. Form's el Acit'-rics dii Suiit-(lii-T:iiii. Sniiit Jiiery; one llt'roiilt furnace liiiildin^;. Jacol) Holtzcr & Cii', I'liit'ux; one Keller furnace. Societe .\nniiyme Elect ri>inctallur)ji'iiie I'gine; oneGirod furnace Schneider & Cie, Creusot; one iiul;icti >n furnace. S]xiin. Viiida di' rrigdita c llija, .Araya; due Kjellin furnace. (liini'iiii/. Richard I.iudeiilMMf;, ijenisclieid; two Fleroult furnaces. X. Krupp, l']sseu: one (lin furiiac<'. HoecliliiiK, N'olklinpcn a. d. Saar; one (iin furnace. Switiirlnml. Aligenieine Calcium Carbid OpssoU, (iurtnellen; one Kjellin funiaci'. Cicorce Fischer. Schaffhausen : one Wroalt furnace ImildiiiK- Komi Tcrnioeldtrici Stassauo, Turin: one .Stassaiio furnace. Arsenal of Turin, Turin; one Stassano furnace. Enf/hind. Vickers. Sons A Maxim, Shcffielil ■ one Kjellin furnace. Swci.cn. Aktieholaget Hi^roult's Klektriska Stal Kortfors; one H. Plate E. 3 I it m