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T T O P E , e n e r g y a n d e n th u s ia s m a r e a t t r i b u t e s o f y o u t h . C h e m ic a l i n d u s t r y is e v e r y o u n g . C h e m ic a l e n g in e e r i n g is o n e o f t h e m o s t y o u t h f u l b r a n c h e s o f a p p l i e d s c i e n c e . I t h a s b a d i t s g r e a t g r o w t h a n d d e v e l o p m e n t in t h e d e c a d e t h a t h a s j u s t p a s t. I t f a c e s a n e q u a l l y i n t e r e s t i n g a n d e x c i t in g f u t u r e a s i t s m a n y p r a c t i t i o n e r s p u s h f o r w a r d w i t h t h e i r p r o g r a m s o f r e s e a r c h a n d d e v e lo p m e n t.
N o w , a s w e m o v e i n to t h i s b r a n d n e w d e c a d e o f t h e ’4 0 s , is a n a p p r o p r i a t e tim e to g iv e s o m e t h o u g h t to t h e p r o b l e m s w e h a v e b e e n c r e a t i n g d u r i n g o u r m o r e o r le s s r e c k le s s y o u t h . W e h a v e g e n e r a te d a t r e m e n d o u s a m o u n t o f e n th u s ia s m w h ic h , i f p r o p e r l y d i r e c te d , c a n b e m o s t h e l p f u l — y e t i f m is d ir e c te d , c a n g iv e u s a n a w f u l h e a d a c h e in t h e
y e a r s to c o m e .
T o d a y , a p p r o x i m a t e l y 1 2 ,5 0 0 o u t o f a t o t a l o f 8 5 ,0 0 0 e n g i n e e r i n g s t u d e n ts a r e s tu d y i n g c h e m i c a l e n g in e e r i n g . A n a n n u a l c r o p o f m o r e t h a n 2 ,0 0 0 — p e r h a p s e v e n 2 ,5 0 0 — g r a d u a t e c h e m i c a l e n g in e e r s is a n i m m e d ia t e p r o s p e c t . H o w to a b s o r b th e m i n t o o u r in d u s t r i e s a n d p r o f e s s i o n is n o s m a ll p r o b l e m . T h e r e a r e p r o b a b l y n o t m o r e t h a n 1 ,5 0 0 n e w j o b s a v a i l a b l e e a c h y e a r i n s t r i c t l y c h e m i c a l e n g i n e e r i n g w o r k , i.e ., in d e s ig n , c o n s t r u c t i o n a n d o p e r a t i o n o f p r o c e s s e s , p l a n t s a n d e q u i p m e n t in t h e c h e m ic a l p r o c e s s i n d u s t r ie s . T h is m e a n s t h a t a s u b s t a n t i a l p r o p o r t i o n o f o u r y o u n g e n g in e e r s a r e g o in g to h a v e to f in d p l a c e s f o r th e m s e lv e s i n o t h e r t h a n t h e o l d e r lin e s o f t e c h n i c a l w o r k . T h e y h a v e g o t to c a r v e o u t c a r e e r s i n s a le s a n d m a r k e ti n g , p e r s o n n e l , p u b l i c r e l a t i o n s a n d a d v e r t i s i n g — i n s h o r t — in a n y c a p a c i t y in w h i c h t h e i r c h e m i c a l e n g i n e e r i n g t r a i n i n g c a n b e u s e d to g o o d a d v a n t a g e .
T o s o m e w h o w o u ld d r a w a r a t h e r n a r r o w d e f in i t io n f o r t h e p r o f e s s i o n , t h i s c o u r s e m ig h t b e r e g a r d e d a s i n v o l u n t a r y d e s e r t i o n f r o m t h e r a n k s . Y e t i s n ’t i t e x a c tl y t h e s o r t o f b r o a d e n i n g o f b a s e t h a t h e lp e d t o p u t m e c h a n i c a l e n g i n e e r i n g i n t o t h e d o m i n a n t p o s i t io n i t n o w h o l d s i n t h e e n g i n e e r i n g p r o f e s s i o n a s a w h o l e ? M e c h a n i c a l e n g in e e r i n g g r e w s t r o n g i n n u m b e r s a n d i n f lu e n c e b e c a u s e i ts m e m b e r s w e r e r e s o u r c e f u l a n d f le x ib le e n o u g h to a d a p t t h e m s e lv e s to m a n a g e m e n t a n d a d m i n i s t r a t i v e r e s p o n s i b i li t ie s r a t h e r t h a n to s t i c k s t r i c t l y to t h e e n g i n e e r i n g o f m a c h i n e s a n d m e c h a n ic s .
F o r t u n a t e l y , m o s t o f o u r c h e m ic a l i n d u s t r i e s h a v e a l r e a d y r e c o g n iz e d t h e v a lu e o f t h e s e r v ic e s o f f u l l y t r a i n e d c h e m ic a l e n g in e e r s in a n e v e r w i d e n in g v a r i e t y o f j o b s . O u r u n i v e r s it i e s a n d c o lle g e s h a v e b e e n q u i c k t o s e n s e t h e n e e d f o r t u r n i n g o u t m e n w e ll g r o u n d e d i n f u n d a m e n t a l s — e d u c a te d n o t a s i n c i p i e n t s p e c i a l i s t s , b u t t r a i n e d t o t h i n k f o r th e m s e lv e s . A f e w i n s t i t u t i o n s a r e a l r e a d y c o m b i n i n g c h e m i c a l e n g i n e e r i n g w i t h
c o u r s e s in b u s i n e s s a d m i n i s t r a t i o n . M a n y o t h e r s p r o v i d e i n c i d e n t a l l e c t u r e s t h a t h e l p to p r o m o t e a n a p p r e c i a t i o n o f t h e m e a n i n g a n d i m p o r t a n c e o f n o n - t e c h n i c a l w o r k in r e l a t i o n to t h e s t u d e n t ’s m o r e s p e c ia li z e d t e c h n o l o g y .
O u r e n g i n e e r i n g s o c i e t i e s , t h r o u g h s t u d e n t c h a p t e r s a n d j u n i o r g r a d e s o f m e m b e r s h i p h a v e e n c o u r a g e d l a r g e n u m b e r s o f y o u n g e n g i n e e r s to j o i n in t h e o r g a n i z e d w o r k o f t h e p r o f e s s i o n . L a t e r o n , m a n y o f t h e s e m e n h o p e a n d e x p e c t to q u a l i f y f o r e i t h e r t h e a s s o c i a t e o r t h e a c t i v e g r a d e s o f m e m b e r s h i p . S o m e w ill b e d i s a p p o i n t e d i f t h e s o c i e t i e s i n s i s t o n n a r r o w c la s s if i c a t io n s t h a t w o u ld l i m i t m e m b e r s h i p to o n ly t h o s e e n g i n e e r s e n g a g e d in p u r e l y t e c h n i c a l p u r s u i t s . A b r o a d e r v ie w s h o u l d a n d p r o b a b l y w ill p r e v a i l e v e n t u a l l y .
S E L F -S T A R T IN G J U N IO R S
T O D A T E t h e m o s t i m p o r t a n t a c h i e v e m e n t o f t h e E n g i n e e r s C o u n c il f o r P r o f e s s i o n a l D e v e l o p m e n t h a s u n d o u b t e d l y b e e n i t s c o n t r i b u t i o n t o e n g i n e e r i n g e d u c a t io n i n t h e U n i t e d S t a te s . T h e w o r k o f a c c r e d i t i n g c u r r i c u l a c a r r i e d o n b y t h e l a r g e c o m m i tt e e s , f o r m e r l y u n d e r t h e c h a i r m a n s h i p o f P r e s i d e n t C o m p to n o f M .I .T . a n d w h ic h a r e n o w h e a d e d b y D e a n P o t t e r o f P u r d u e , h a s b e e n o u t s t a n d i n g . I t m u s t b e c o n t i n u e d , f o r i t i s b a s i c to t h e w h o l e p r o g r a m o f p r o f e s s i o n a l d e v e l o p m e n t . H o w e v e r , m a n y fe e l t h a t i t is p r o b a b l y d e s i r a b l e t h i s y e a r t o s h i f t e v e n m o r e o f t h e e m p h a s i s o f E .C .P .D . to t h e C o m m itte e o n P r o f e s s i o n a l T r a i n i n g , w h i c h is t h e o n e t h a t is c o n c e r n e d p r i m a r i l y w 'ith y o u n g e n g i n e e r s in t h e f i r s t f o u r o r fiv e y e a r s o u t o f c o ll e g e . T h e w o r k o f t h i s c o m m i tt e e , w h i c h s t a r t e d o f f s o a u s p i c i o u s l y a fe w y e a r s a g o u n d e r t h e l e a d e r s h i p o f t h e l a t e G e n e r a l R e e s , is n o w b e i n g r e v i t a l i z e d b y h i s s u c c e s s o r , D e a n E s h b a c h o f N o r t h w e s t e r n . I t h a s a b i g j o b t o d o , b u t f o r t u n a t e l y o n e t h a t a l r e a d y h a s a g r e a t i m p e t u s b e h i n d it.
J u n i o r e n g i n e e r i n g g r o u p s , f o l lo w in g t h e p a t t e r n d e v e lo p e d a n u m b e r o f y e a r s a g o b y t h e P r o v i d e n c e E n g i n e e r i n g S o c i e t y a n d i n c l u d i n g a l l b r a n c h e s o f t h e e n g i n e e r i n g p r o f e s s i o n , a r e s p r i n g i n g u p i n v a r i o u s p a r t s o f t h e c o u n t r y . A c tiv e a s s o c i a t i o n s r e s t r i c t e d t o y o u n g e r c h e m i c a l e n g i n e e r s i n t h e N e w Y o r k , P h i l a d e l - p h i a - W il m in g t o n , C h a r l e s t o n , W . V a ., a n d N i a g a r a F a l l s a r e a s , a r e s e t t i n g a f a s t p a c e f o r t h e i r e l d e r s t o f o llo w . O t h e r g r o u p s a r e in p r o c e s s o f f o r m a t i o n o r a c t u a l l y u n d e r w a y . T h e y p r o v i d e a n o p p o r t u n i t y f o r s e l f i m p r o v e m e n t a n d i n s t r u c t i o n t h r o u g h e x te n s i o n c o u r s e s in n e a r b y u n i v e r s it i e s o r t h r o u g h o t h e r a d u l t e d u c a t i o n a l a g e n c ie s . M o r e i m p o r t a n t , t h e y o p e n t h e w a y f o r p e r s o n a l a n d p r o f e s s i o n a l d e v e l o p m e n t t h r o u g h a s s o c i a t io n s , g r o u p d i s c u s s i o n s , p l a n t v i s i ts a n d o t h e r c o n ta c t s w i t h t h e p e o p l e a n d t h i n g s t h a t a r e o f i n t e r e s t t o y o u n g e n g i n e e r s . A n y h e lp w h i c h a n y o f u s in t h e p r o f e s s i o n c a n le n d to th e s e j u n i o r e n g i n e e r i n g a c t i v i t i e s i s d i s t in c t ly w o r t h w h i l e .
O P P O R T U N I T I E S
S O M E y o u n g c h e m i c a l e n g i n e e r s o f o u r a c q u a i n t a n c e h a v e q u e s t io n e d w h e t h e r i t is w o r t h w h i l e to t a k e e x a m i n a t i o n s f o r p r o f e s s i o n a l p o s i t i o n s in t h e F e d e r a l C iv il S e r v ic e . A s a c o n s e q u e n c e , a g r e a t m a n y y o u n g m e n w h o m i g h t m a k e e x c e ll e n t w o r k e r s f o r t h e g o v e r n m e n t
a n d w h o m i g h t p r o f i t s u b s t a n t i a l l y f r o m t h a t s o r t o f e x p e r i e n c e a n d s p e c ia l t r a i n i n g a r e n o t a v a i l a b l e t o t h e g o v e r n m e n t a l d e p a r t m e n t s t h a t a r e p r o s e c u t i n g e n g i n e e r i n g a n d s c i e n t i f ic r e s e a r c h .
T h e o r g a n i z a t i o n o f th e f o u r R e g i o n a l R e s e a r c h L a b o r a t o r i e s o f t h e U . S . D e p a r t m e n t o f A g r i c u l t u r e h a s s p o t l i g h t e d t h i s p r o b l e m . T h o s e a g e n c ie s a r e g o i n g to n e e d a l a r g e n u m b e r o f a d d i t i o n a l c h e m i c a l e n g i n e e r s d u r i n g t h e n e x t s i x t o t w e lv e m o n t h s . T h e s e p o s i t i o n s w i l l r a n g e f r o m t h o s e f o r b e g i n n e r s w i t h t h e i n k o n t h e i r b a c h e l o r ’s d i p l o m a s s c a r c e l y d r y , u p t o t h e m o r e e x p e r i e n c e d m e n w h o c a n b e c o m e l e a d e r s o f r e s e a r c h a n d d e v e l o p m e n t g r o u p s . A l r e a d y a n u m b e r o f v e r y c a p a b l e m e n h a v e b e e n n a m e d . B u t n o t e v e n a ll t h e s e n i o r p o s t s h a v e y e t b e e n f ille d . F e w o f t h e j u n i o r w o r k e r s h a v e y e t b e e n s e l e c te d b e c a u s e t h e n e w l a b o r a t o r y b u i l d i n g s w i l l n o t b e r e a d v u n t i l n e x t s u m m e r o r f a l l .
S o m e y o u n g m e n g e t i n t o t h e g o v e r n m e n t s e r v i c e a n d s t a y t o o l o n g . M a n y o t h e r s h a v e s e r v e d b r i e f l y w i t h m u t u a l p r o f i t to t h e i r e m p l o y i n g b u r e a u s a n d t o t h e i n d i v i d u a l s th e m s e l v e s . C e r t a i n i n d u s t r i e s a r e , i n f a c t , i n c l i n e d t o l o o k o v e r t h e g o v e r n m e n t s t a f f s a n d s e l e c t t h e m o s t p r o m i s i n g y o u n g m e n t h e r e f o r l a r g e r r e s p o n s i b i l i t y in t h e i r o w n o r g a n i z a t i o n s . S o m e ti m e s y o u n g m e n o f g r e a t p r o m i s e in t h e g o v e r n m e n t s e r v i c e a r e t e m p t e d a w a y t o o s o o n b y t h i s t e c h n i q u e . T h e r e i s , h o w e v e r , a h a p p y m e d i u m b e tw e e n s t a y i n g t o o l o n g a n d l e a v i n g p r e m a t u r e l y .
T h e i m p o r t a n t p o i n t is t h a t a y o u n g m a n w h o t h i n k s t h a t h e m i g h t l i k e t o g e t t h e e q u i v a l e n t o f g r a d u a t e t r a i n i n g i n t h e g o v e r n m e n t o r g a n i z a t i o n s h o u l d m a k e h i m s e l f e l i g i b l e b y t a k i n g t h e a p p r o p r i a t e e x a m i n a t i o n . T h o s e w h o l o o k f o r w a r d t o t h a t p o s s i b i l i t y , w h e t h e r th e y e x p e c t 8 2 ,0 0 0 o r $ 4 ,0 0 0 p o s t s , c a n w e l l p l a c e t h e i r n a m e s o n r e c o r d w i t h t h e C iv il S e r v i c e C o m m i s s io n , W a s h i n g t o n , D . C ., r e q u e s t i n g t h a t t h e y b e n o t i f i e d o f e x a m i n a t i o n s w h e n a n n o u n c e d . T h e p u b l i c s e r v i c e d e s e r v e s to g e t s o m e o f t h e w o r t h - w h i l e t a l e n t o f o u r p r o f e s s i o n .
( M o r e a b o u t o t h e r o p p o r t u n i t i e s l a t e r ! )
3 IA T T E R S O F E T H I C S
L A S T Y E A R , a t t h e s u g g e s t i o n o f P r e s i d e n t R u t h v e n o f t h e U n i v e r s i t y o f M i c h i g a n , t h e s t u d e n t s o f t h e E n g i n e e r i n g S c h o o l a t A n n A r b o r s t a r t e d a s e r i e s o f s e m i n a r s o n p r o f e s s i o n a l e th i c s . L e d b y a n u m b e r o f t h e m o r e e x p e r i e n c e d f a c u l t y m e m b e r s , t h e s e v o l u n t a r y g r o u p m e e t in g s o r p a r l e y s , a s t h e y w e r e c a l l e d , a t t r a c t e d a s m a ll b u t i n t e n s e l y i n t e r e s t e d a u d i e n c e t h a t w r e s t l e d w i t h a c t u a l c a s e s t u d i e s o f e t h i c a l p r o b l e m s a r i s i n g i n t h e d i f f e r e n t f i e l d s o f e n g i n e e r i n g . I m p a r t i a l o b s e r v e r s r e p o r t t h a t t h e e n s u i n g d i s c u s s i o n s w e r e e x tr e m e l y i n t e r e s t i n g a n d h e l p f u l to a ll c o n c e r n e d . P e r h a p s t h i s i s s o m e t h i n g t h a t h a s p o s s i b i l i t i e s f o r a p p l i c a t i o n e n t i r e l y o u t s i d e o f e d u c a t i o n a l i n s t i t u t i o n s . G o o d e t h i c s a r e n o t s i m p ly a m a t t e r o f i n h e r e n t b e l i e f o r i n t u i t i o n a s t o w h a t is r i g h t o r w r o n g . T h e y i n v o l v e f a c t u a l k n o w l e d g e o f a c t u a l p r a c t i c e s a n d p r o c e d u r e s , o f p r i n c i p l e s t h a t c a n b e t h e b a s i s f o r j u d g m e n t a n d d e c i s i o n . W e s t r o n g l y s u s p e c t t h a t t h e c h e m i c a l e n g i n e e r i n g p r o f e s s i o n a s a w h o l e c o u l d b e b e n e f i te d b y f r e q u e n t a n d f r a n k d i s c u s s i o n s o f e n g i n e e r i n g e th i c s .
2 VOL. 47 • C H E M IC A L & M E T A L LU R G IC A L E N G IN E E R IN G • N o. 1 J A N U A R Y 1 9 4 0
O U R P L A N S A N D O B J E C T IV E S
C H E M . & M E T .’S r a is o n d 'e tr e h a s r e c e n t l y b e e n s t a te d i n t h e s e w o r d s :
T o p r e s e n t th e c h e m ic a l e n g in e e r s ’ a m a z in g a c c o m p lis h m e n ts , e x p lo r e th e i r r a d ia n t h o p e s , e x a m in e th e i r th o rn y p ro b le m s .
P r o d u c tio n , th e s e a rc h f o r n e w p r o d u c ts , th e in v e n tio n a n d a p p lic a tio n o f newr a n d b e tte r p r o c e s s e s a r e a m o n g th e m o s t im p o r ta n t th in g s in th e l if e o f c h e m ic a l e n g i
n e e r s . A n d w e tr y to b e a th o r o u g h , c a n d id in v e s tig a to r o f t h e i r s w iftly c h a n g in g field s o f o p e r a tio n .
I n le r n a tio n a l a ffa irs , g o v e rn m e n t, th e e c o n o m ic s o f n a tio n a l p r e p a r e d n e s s , th e p r e s s u r e o f h o m e a n d fo re ig n m a r k e ts n o w m o v e in on th e c h e m ic a l e n g in e e r a n d h is in d u s tr ie s w ith r e le n tle s s a c tiv ity . C h e m . & M e t. is in th e th ic k o f it. F o r th e m e a s u r e o f th e im p a c t o f th o s e fo rc e s on c h e m ic a l e n g in e e r in g is th e e x a c t m e a s u r e o f th e i r im p a c t o n C h e m . & M e t.
I t s e d ito r s s e e k to in c r e a s e th e o v e r-a ll efficiency o f p r o d u c tio n a n d m a n a g e m e n t in th e c h e m ic a l p r o c e s s in d u s t r ie s b y e x a m in in g N O W a ll th e n e w e le m e n ts o f e x p e r ie n c e t h a t b e c o m e a v a ila b le , b y s tu d y in g N O W a ll th e f a c ts p e r ti n e n t to th e i r e c o n o m y , so t h a t u n n e c e s s a r y d u p lic a tio n o f e ffo rt m a y b e m in im iz e d , so t h a t p r o g r e s s m a y b e a c c e le r a te d , so t h a t h e lp f u l k n o w le d g e m a y b e m a d e w id e ly a v a ila b le m o re s p e e d ily .
M o n th -b y -m o n th , y e a r-b y -y e a r, C h e m . & M e t. p r e s e n ts th e h a rd -to -fin d f a c ts a b o u t c h e m ic a l e n g in e e r in g a c h ie v e m e n t a n d d a y -b y -d a y p r o g r e s s fo r th e b e n e fit o f c h e m ic a l e n g in e e r s w h e re v e r th e y m a y b e.
P r o j e c t i n g t h a t p u r p o s e i n t o 1 9 4 0 , w e p l a n a n u m b e r o f w o r t h w h i l e i n n o v a t i o n s . F i r s t o f a l l w i l l b e a s e r i e s o f C h e m . & M e t. R e p o r t s , p r e s e n t e d a s e n g i n e e r i n g s t u d i e s t h a t w ill b e fille d w i t h u s e f u l d a ta , c o n t a i n i n g t h e k i n d o f i n f o r m a t i o n t h a t c h e m i c a l e n g i n e e r s n e e d m o s t to h e lp t h e m in t h e i r d a i l y p r o b l e m s . T h e y w i l l b e d a te d , i n d e x e d a n d c la s s if ie d a n d p e r h a p s p u b l i s h e d l a t e r in r e p r i n t f o r m s o t h a t r e a d e r s m a y u l t i m a t e l y o w t i
a c o m p le te w o r k i n g l i b r a r y o n s u c h s u b j e c t s a s : 1. P l a n t S e rv ic e s — L ig h tin g , S a fe ty , M a in te n a n c e , B u ild in g C o n s tru c tio n , e tc .;
2. U n it O p e r a tio n s a n d P ro c e s s e s — A ir C o n d itio n in g . M a te r ia ls H a n d lin g , P o w e r T r a n s m is s io n , A u to m a tic C o n tro l a n d I n s tr u m e n ta tio n ;
3. C h e m ic a l E n g in e e r in g E c o n o m ic s— R a w M a te r ia ls , P a c k a g in g , M a r k e tin g , D is tr ib u tio n T r e n d s , e tc .; a n d
4. C h e m ic a l E n g in e e r in g O p p o r tu n itie s — T h e s ta tu s o f c h e m ic a l e n g in e e r in g a n d o f c h e m ic a l e n g in e e r s in a w id e r a n g e o f in d u s tr ie s , th e n u m b e r a n d k in d s o f jo b s a v a ila b le , th e lin e s o f p ro m o tio n , re s p o n s ib ility , tr e n d s , u n s o lv e d p ro b le m s , etc.
S e r i e s A , N o . 1 o f th e s e r e p o r t s a p p e a r s in o u r c u r r e n t i s s u e . A s f a r a s w e k n o w , i t r e p r e s e n t s t h e f ir s t a t t e m p t to g a t h e r a l l t h e p r a c t i c a l i n f o r m a t i o n a n d u s e f u l d a t a
n e c e s s a r y f o r a b a s i c e n g i n e e r i n g s t u d y o f t h e i m p o r t a n t f u n c t i o n o f a d e q u a t e l i g h t i n g o f c h e m i c a l p l a n t s . N e x t m o n t h ’s r e p o r t , t h e f i r s t in t h e s e r i e s o n e c o n o m i c s , w i l l i n c l u d e a n e x h a u s ti v e s t u d y o f c h e m ic a l r a w m a t e r i a l s a n d t h e v a r i o u s f a c t o r s a f f e c ti n g t h e i r a v a i l a b i l i t y . T h e r e i n w i l l b e p r e s e n t e d in e v e n m o r e u s e f u l f o r m , t h e d a t a o u r r e a d e r s h a v e g o o d r e a s o n to e x p e c t to f in d i n a 1 7 th A n n u a l R e v ie w a n d S t a t i s t i c a l N u m b e r .
A w a r e o f t h e i n c r e a s i n g i n t e r e s t in S o u t h e r n d e v e l o p m e n t s a n d t h e n e c e s s ity f o r s u p p l e m e n t i n g a n a l r e a d y i n te n s i v e s t a f f c o v e r a g e , C h e m . & M e t. a n n o u n c e s t h i s m o n t h t h e a p p o i n t m e n t o f a S o u t h e r n E d i t o r . E a r l e M a u l d i n , a n e x p e r i e n c e d i n d u s t r i a l e n g i n e e r a n d e d i t o r , w ill h a v e h i s o ffice s in A t l a n t a , G a ., f r o m w h i c h b e w ill r a d i a t e in a ll d i r e c t i o n s o f S o u t h e r n c h e m i c a l p r o g r e s s . M a y w e s p e a k f o r h i m y o u r i n t e r e s t a n d c o o p e r a t i o n in o r d e r t h a t C h e m . & M e t. m a y b e t t e r s e r v e n o t o n ly t h e S o u t h b u t a l l o f c h e m ic a l i n d u s t r y ?
S o m u c h th e n b y w a y o f o u r o w n p l a n n i n g . W h a t o f y o u r s ? F r o m o u r v a n t a g e p o i n t , 1 9 4 0 lo o k s l ik e i t is g o i n g to b e a p r e t t y g o o d y e a r . P r o d u c t i o n s c h e d u le s w e r e s t e p p e d u p in t h e l a s t q u a r t e r o f 1 9 3 9 s o t h a t th e y c lo s e l y a p p r o x i m a t e t h e i n d u s t r y ’s a ll- tim e r e c o r d e s t a b l i s h e d in t h e s e c o n d q u a r t e r o f 1 9 3 7 . E x p o r t s , w h i c h n o r m a l l y a c c o u n t f o r a b o u t 5 p e r c e n t o f t h e t o t a l o u t p u t , a r e s t e a d i l y i n c r e a s i n g , e s p e c i a l l y to S o u t h A m e r i c a n a n d O r i e n ta l m a r k e t s o n c e d o m in a t e d b y G e r m a n y . S i n c e p r a c t i c a l l y a l l o f t h e c h e m ic a l c o n s u m i n g i n d u s t r i e s e n te r e d t h e n e w y e a r o n a r e l a t i v e l y h i g h p l a n e o f a c t i v it y , a n d s in c e f o r e i g n b u s i n e s s s e e m s c e r t a i n to i n c r e a s e , i t is o u r g u e s s t h a t t h e c h e m i c a l i n d u s t r y f o r t h e f i r s t q u a r t e r o f 1 9 4 0 s h o u l d o p e r a t e a t l e a s t 2 0 p e r c e n t a b o v e 1 9 3 9 ’s f i r s t q u a r t e r .
M o s t i m p o r t a n t o f a ll is t h e o p p o r t u n i t y f o r c h e m ic a l e n g in e e r s , y o u n g a n d o ld , to p u s h b a c k s till f u r t h e r t h e h o r i z o n s o f t h e u n k n o w n a n d b u i l d f o r t h e m s e l v e s t h a t i m p o r t a n t p l a c e in t h e s u n w h i c h t h e v e r y f i r s t p r e s i d e n t o f t h e A m e r ic a n I n s t i t u t e o f C h e m ic a l E n g i n e e r s v i s u a l iz e d 3 2 y e a r s a g o in t h i s s t i r r i n g c h a l l e n g e :
Y o u w h o c a ll y o u r s e lv e s c h e m ic a l e n g in e e rs , w h o k n o w th e s c ie n c e a n d th e a r t, w h o fe el y o u r p o te n c y a n d y o u r l a t e n t fo rc e s , y o u a r e to b la m e if y o u d o n o t d e m a n d to b e h e a r d , to s h o w b y y o u r e ffo rts w h a t s to c k y o u c o m e fro m , a n d to d e m a n d o f e d u c a to r s t h a t in th e f u tu r e th e title o f th e c h e m ic a l e n g in e e r b e c le a r , th e t r a i n i n g a d e q u a te a n d th e p u b lic e n c o u r a g e m e n t th e s tr o n g e s t.
V o lu m e 47— C h em ical & M e ta llu rg ic a l E n g in e e rin g —N u m b e r 1 Chcm ical & M etallurgical E n g in eerin g is
the successor to M etallurgical <5* Chem ical E n g in ee rin g , w hich in tu rn w as a conspli- datio n of E lectrochem ical & M etallurgical In d u s tr y a n d Ir o n & S te e l M agazine, effected in J u ly , 1906.
T h e m agazine w as o rig in ally fo unded as Electrochem ical In d u s tr y , in Septem ber 1902, a n d w as published m onthly u n d e r the ed itorial d irectio n of D r. E . F . R oeber. I t co n tin u e d u n d e r th a t title u n til J a n u a ry , 1905, w hen it w as changed to Electrochem ical
& M etallu rg ica l In d u s tr y . In Ju ly , 1906, the consolidation w as m ade w ith Ir o n &
S te e l M a g a zin e, which h ad been founded eig h t y e ars p rev io u sly by D r. A lb e rt Sau- v eu r. I n J a n u a ry , _ 1910, the title w as changed to M etallurgical & Chcm ical E n g i
neering, a n d sem i-m onthly publication w as begun Sept. 1, 1915. O n J u ly 1, 1918, the p re sen t title w as assu m ed a n d w eekly pu b licatio n w as begun O ct. 1, 1919. M onthly publication w as resum ed in M arch , 1925.
D r. E . F . R oeber w as ed ito r o f the p ap er from th e tim e it w as founded u n til bis d eath on O ct. 17, 1917. A fte r a b rie f in terim he w as succeeded by II . C. P arm clee. T e n years la te r, N ov. 1, 1928, M r. P arin elce
assum ed o th er resp o n sib ilities in the McGraw-Hill^ P u b lish in g C om pany and Sid n ey D . K irk p a trick w as appointed editor.
T h e ed ito rial staff o f the m agazine com
p rise s: Jam es A . Lee, m an ag in g e d ito r;
II. M . B atters, m ark et e d ito r; T . JR. O live, asso ciate ed ito r, M elvin E . C lark , a ssista n t ed ito r. R. S . M cB rid e, P a u l D. V . Man*
n in g , E. S. S ta te le r a n d E a rle M auldin are ed ito rial re p re sen ta tiv e s in W ash in g to n , D . C ., on the Pacific C oast, in Chicago, and in A tla n ta , respectively. [A ll rig h ts to above m agazine titles a re reserv ed by M cG raw -H ill P u b lish in g C o.]
VOL. 47 • C H EM IC A L & M E T A L LU R G IC A L E N G IN E E R IN G • N o. 1 J A N U A R Y 1 9 4 0
3
Fertilizer Practice at Curtis Bay
How Davison Chemical Corp. has achieved a balanced fertilizer industry by applying modern chemical engineering concepts and economics is told here in the first of two articles. A second article, in an early ‘issue, ivill discuss some of the company s recent advances in granulating, bagging and handling of superphosphate.
F
e r t i l i z e r m a k i n g is b e c o m in g m o re a n d m o re a m o d e r n j o b of c h e m ic a l e n g in e e r in g e n te r p r is e . I t n o t o n ly c o n s u m e s th e l a r g e s t q u a n tity o f c h e m ic a ls o f a n y d iv is io n of p r o c e s s in d u s tr y , b u t a ls o r e q u ir e s c lo s e r a tte n tio n t h a n e v e r b e f o re to g o o d e n g in e e r in g a n d s o u n d e c o n o m ic p r in c ip le s .T h e f e r tiliz e r in d u s tr y is d iv id in g in to tw o p a r ts , o n e d e fin ite ly c h e m ic a l e n g in e e r in g in n a tu r e , t h e o th e r p r i m a r ily a n in d u s tr y m a r k e tin g to a g r i c u ltu r e . B o th p a r t s a r e o f im p o r ta n c e to c h e m ic a l e n g in e e r s ; b u t, o f c o u rs e , th e m a n u f a c tu r in g d iv is io n is th e o n e o f g r e a te s t te c h n ic a l sig n ific a n c e . D a v iso n C h e m ic a l C o rp . c o v e rs b o th d iv is io n s o f th e in d u s t r y ; a n d i t is o n e of th e o u ts ta n d in g e x p o n e n ts o f m o d e r n c h e m ic a l e n g in e e r in g p r a c tic e in th e m a n u f a c tu r in g p o r tio n o f its a c tiv ity . T h e p la n n in g a n d e x e c u tio n o f th is te c h n ic a l w o rk , a s w e ll a s i ts r e la tio n s h ip to th e m a r k e tin g a n d a g r ic u lt u r a l p ro b le m s , a r e i n te r p r e t e d h e r e .
P r a c tic a lly a ll fe rtiliz e r s u s e d in th e U n ite d S ta te s a r e p r e p a r e d o n a s u p e r p h o s p h a te b a s e . T h is m a t e r i a l is u s e d a lo n e in l a r g e to n n a g e s a n d a lso
R. S. McBRIDE
E d ito r ia l R e p r e s e n ta tiv e W a sh in g to n , D . C.
a lm o s t in v a r ia b ly is th e c o m p o n e n t p r e s e n t in l a r g e s t q u a n ti t ie s in m ix e d fe rtiliz e r . S in c e th e m a n u f a c t u r e o f s u p e r p h o s p h a te c o n s u m e s m u c h s u l
p h u r ic a c id , th e m a k in g o f th is im p o r t a n t f e r tiliz e r m a t e r i a l is o fte n a s s o c ia te d w ith th e m a k in g o f s u l
p h u r i c a c id . I n f a c t, e c o n o m ic c o n s id e r a tio n s a r e m o r e a n d m o r e m a k in g i t n e c e s s a r y t h a t th e l a r g e s c a le s u p e r p h o s p h a te m a k e r b e a ls o a s u l p h u r i c a c id m a n u f a c tu r e r . H o w e v e r, t h is a c id m a k e r u s u a lly m u s t d is p o s e o f s u l
p h u r i c a c id a s w e ll fo r m a n y tilin g s o th e r th a n s u p e r p h o s p h a te , o r h e w ill b e ig n o r in g m u c h o f th e o p p o r tu n ity fo r p r o f ita b le a c id m a n u f a c tu r in g .
P e r h a p s n o n e o f th e f e r tiliz e r c o m p a n ie s h a s g o n e f a r t h e r t o w a r d th e m o d e r n c o n c e p t o f b a la n c e d in d u s tr y th a n th e D a v is o n C h e m ic a l C o rp . w h ic h h a s i ts p r i n c i p a l p l a n t o n C u r tis B a y , B a ltim o r e , M d . A d e s c rip tio n o f t h a t p l a n t a ffo rd s a n o p p o r tu n ity fo r i n te r p r e t i n g t h e n e w t r e n d s w h ic h
h a v e r e a l s ig n if ic a n c e fo r m a n y firm s a n d m a n y c h e m ic a l e n g in e e r s w h o d o n o t th in k o f th e m s e lv e s a s c o n c e r n e d w ith e ith e r s u l p h u r i c a c id o r f e r tiliz e r q u e s tio n s .
A c id P la n t O p e ra tio n
S u c c e s s f u l m a n u f a c t u r e o f e ith e r a c id o r s u p e r p h o s p h a t e is to d a y n e c e s s a r ily a la r g e - s c a le b u s in e s s . T h e s m a ll m a n u f a c t u r e r o f t h e s e c o m m o d itie s u s u a lly is a t a g r e a t e c o n o m ic d i s a d v a n ta g e . T h e c a p i t a l r e q u i r e d f o r m a t e r i a l s h a n d li n g a n d th e s k ille d s u p e r v isio n f o r b o th s u p e r in te n d e n c e a n d g e n e r a l m a n a g e m e n t p la c e d is p r o p o r tio n a te ly g r e a t b u r d e n s o n a n y p l a n t o f s m a ll o u tp u t. T h e C u r tis B a y p l a n t is ill u s t r a ti v e o f b o th la r g e - s c a le effi
c ie n t o p e r a tio n a n d th e te c h n iq u e o f b a la n c i n g v a r ie d p r o c e s s e s s o t h a t a t a ll tim e s a n e c o n o m ic w h o le is a c h ie v e d .
S u l p h u r i c a c id is m a d e a t t h e D a v is o n p l a n t b y b o th t h e c h a m b e r a n d c o n ta c t p ro c e s s e s . G r a d u a lly th e p l a n t h a s b e e n s h if tin g o v e r f r o m a ll c h a m b e r u n its b y in s t a l l a t i o n o f c o n ta c t p r o c e s s e q u ip m e n t, p a r tl y to s u p p l a n t a n d p a r t l y to s u p p le m e n t t h e
4 VOL. 47 • C H E M IC A L & M E T A L LU R G IC A L E N G IN E E R IN G • N o. 1 J A N U A R Y 1 9 4 0
c h a m b e r c a p a c ity . A t p r e s e n t th e r e a r e tw o c h a m b e r a c id u n its , o n e w ith 20 c h a m b e r s a n d th e o th e r w ith 10.
T h e D a v iso n p l a n t h a s n o t a d o p te d o u ts id e w a te r c o o lin g fo r i ts a c id c h a m b e r s . T h is p r a c tic e is n o w fo l
lo w e d b y m a n y o th e r c o m p a n ie s w h ic h s e c u re th e r e b y a g r e a t e r c a p a c ity in p o u n d s o f a c id m a d e p e r d a y p e r c u b ic fo o t o f c h a m b e r s p a c e . U n d e r B a ltim o r e c o n d itio n s o f th is p a r t i c u l a r p la n t, h o w e v e r, th e c o m p a n y fe e ls t h a t th e c o s t o f m o re le a d f o r th e w a n te d c a p a c ity is le s s t h a n th e c o s t f o r w a te r-c o o le d c h a m b e r o p e r a tio n w o u ld b e . N itr o g e n o x id e s fo r c a ta ly s is a r e fo rm e d b y a m m o n ia o x id a tio n (s e e C h e m . & M e t., O ct., 1929, p . 6 1 4 ) .
T h e r e a r e a ls o tw o c o n ta c t u n its , a n d a t h ir d o n e is n o w b e in g in s ta lle d . T h e c a ta ly s t u s e d b y D a v iso n is p l a t i n u m o n s ilic a g e l. T h e p r e s e n t c a p a c ity is a b o u t tw o -th ird s c h a m b e r a n d one- t h ir d c o n ta c t a c id , m e a s u r e d in to n n a g e . B u t w h e n th e n e w c o n ta c t u n it is c o m p le te , th e r e la tio n s h ip w ill b e a b o u t 5 0 -5 0 .
A c id p l a n t s c h e d u lin g a n d o p e r a tio n o f s u c h v a r ie d a c id e q u ip m e n t m ig h t s e e m to b e a d is a d v a n ta g e , b u t a c tu a lly i t is n o t. T h e a v a ila b ility o f s e v e ra l ty p e s o f e q u ip m e n t p e r m its
r e a d y c o n tro l a n d a v a r ia tio n b e tw e e n 6 0 d e g . B e. a n d s tr o n g a c id . T h e f o r m e r is, o f c o u rs e , m a d e b y th e c h a m b e r p ro c e s s fo r u se in s u p e r p h o s p h a te m a n u f a c tu r e . T h e l a t t e r is m a d e p r im a r ily fo r s a le . A d ju s tm e n t b e tw e e n th e tw o s tr e n g th s a n d th e tw o a p p lic a tio n s is o n e o f th e in te r e s tin g c h e m ic a l e n g in e e r in g a c h ie v e m e n ts o f th is w o rk s .
V a r ia tio n in o u tp u t o f e a c h a c id m a n u f a c tu r in g u n i t is p o s s ib le w ith in f a ir ly w id e lim its . M o s t efficien t o p e r a tin g r e s u lts , h o w e v e r, a r e o b ta in a b le a t c e r ta in d e fin ite r a te s o f o p e r a tio n w e ll e s ta b lis h e d b y t h e e x p e r ie n c e o f th is c o m p a n y . C h a n g e s in a c id r e q u ir e m e n t d o o c c a s io n d e p a r t u r e s fro m th is o p tim u m fo r e a c h p l a n t , b u t t h e d e p a r t u r e s a r e m u c h s m a lle r a n d le s s f r e q u e n t b e c a u s e o f a n in te r lo c k i n g o f th e tw o sy s te m s . T h is is th e w a y th e a d ju s tm e n t c a n b e m a d e .
S u p p o s e t h a t a s u r p lu s o f low - s tr e n g th fe rtiliz e r a c id is a v a ila b le . I t is n o t n e c e s s a ry to slo w d o w n th e c h a m b e rs . T h e s u r p lu s is s im p ly p u m p e d o v e r to a n a rs e n ic -re m o v a l u n it. W h e n p u rifie d th e r e , it is m ix e d w ith c o n ta c t a c id o f a b o v e n o r m a l s tr e n g th in o r d e r to p r e p a r e a m a r k e t a b le p r o d u c t o f j u s t th e d e s ir e d c o n c e n tr a tio n , u s u a lly e ith e r 98 p e r c e n t
o r 66 d e g . B e. (9 3 p e r c e n t) a c id . T o p e r m it th is b le n d in g i t is o n ly n e c e s s a r y t h a t th e c o n ta c t u n its b e o p e r a te d f o r th e m a k in g o f a s u p e r - s tr e n g th p r o d u c t.
S in c e th is v a r ia tio n c a n b e m a d e o n th e c o n ta c t u n i t w h e n it is o p e r a tin g a t w id e ly v a r y in g r a te s o f o u tp u t, th e r e is p r a c tic a lly c o m p le te c o n tr o l o f th e r e la tiv e q u a n titie s o f d if f e r e n t s tr e n g th s o f a c id m a d e , w ith o u t a n y s u b s ta n t ia l lo s s in efficiency.
S u lp h u r S u p p ly
N o t th e le a s t o f th e a d v a n ta g e s o f th e d e e p -w a te r lo c a tio n o f th e D a v iso n p l a n t is th e a v a ila b ility o f a v a r ie ty o f s u lp h u r - b e a r in g m a te r ia ls a s w e ll a s s u lp h u r . U n d e r o r d in a r y c o n d i
tio n s th is p la n t u s e s p r i n c i p a l l y a S p a n is h p y r ite s b r o u g h t in s h ip lo a d lo ts d ir e c t fro m S p a in to t h e u n lo a d in g p ie r a t C u r tis B a y . B o a ts u p to 2 6 -ft. d r a f t c a n b e h a n d le d .
M a n y h u n d r e d s o f y e a r s a g o th e R io T in to m in e s o f S p a in p r o c e s s e d t h e i r o re s w ith a d is c a r d o f p y r ite s o n to th e i r d u m p s . H u g e to n n a g e s h a v e l a i n th e r e fo r 2 0 0 to 4 0 0 y e a rs . O n ly r e c e n tly h a s th e r e c la im in g o f p y r ite s fro m th e s e o ld t a ilin g s d u m p s b e e n u n d e r ta k e n , b u t d u r i n g r e c e n t y e a r s D a v iso n h a s b e e n a b le to ta k e a d v a n ta g e o f s u c h s u p p lie s b e c a u s e o f its fa v o ra b le w a t e r f r o n t lo c a tio n a n d a b ility to ta k e f u ll s h ip lo a d s a t f r e q u e n t in te r v a ls . T h e p r o d u c t so p u r c h a s e d h a s b e e n th e m a j o r s u l p h u r s u p p ly o f th is c o m p a n y e x c e p t w h e n th e r e c e n t S p a n is h w a r o r o th e r c a u s e s i n te r r u p t e d r e g u l a r d e liv e rie s .
U n d e r p r e s e n t c ir c u m s ta n c e s th e c o m p a n y is a ls o u s in g o th e r source's o f p y r ite s . R e c e n tly C a n a d ia n o re o f s lig h tly h ig h e r s u l p h u r c o n te n t, b u t d e fin ite ly h ig h e r c o s t a ls o , h a s b e e n u tiliz e d in p a r t. A n d , a s a m a t t e r o f g o o d s e n s e , s u b s ta n tia l re s e r v e s - in th e s to c k p ile h a v e b e e n b u i lt u p b y th e c o m p a n y , so t h a t a n y tr o u b le w ith w a te r h a u la g e w o u ld n o t le a v e th e p la n t w ith o u t s u b s ta n tia l re s e rv e s .
T h is p l a n t a ls o b u r n s a lim ite d a m o u n t o f s u lp h u r . O n e s u l p h u r b u r n e r is u s e d to f o rtify th e S 0 2 g a s fo r th e p r e s e n t c h a m b e r e q u ip m e n t.
T h e n e w c o n ta c t a c id in s ta lla tio n w ill in c lu d e s u l p h u r b u r n e r s a n d i t is e x p e c te d t h a t i t w ill b e o p e r a te d e x c lu s iv e ly o n t h a t r a w m a te r ia l.
N o t th e le a s t im p o r t a n t o f th e c h e m i
c a l e n g in e e r in g a d ju s tm e n ts o f th is p la n t is th e fa c ility w ith w h ic h m o re o r le s s p y r ite s o r s u l p h u r c a n b e u se d .
T h e d o c k s a t w h ic h in c o m in g s te a m e r s d is c h a r g e in to t h is p l a n t —a r e
VOL. 47 • C H EM IC A L & M E T A L LU R G IC A L E N G IN E E R IN G • N o . 1 J A N U A R Y 1 9 4 0
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s p r e a d b y a r a b b le f o r d r y in g o n th e r o o f o f th e H e r r e s h o f f f u r n a c e . T h e h e a t o th e r w is e w a s te d b y r a d ia ti o n fro m th e to p o f th e f u r n a c e is th u s u tiliz e d to d r y th e m in e r a l.
C o m b u s tio n w ith c o n tr o lle d q u a n ti tie s o f a ir ta k e s p la c e a s t h e m in e r a l tr a v e ls d o w n w a r d fro m h e a r t h to h e a r t h t h r o u g h t h e e ig h t s e c tio n s o f th e f u r n a c e . T h e m a x im u m g a s te m p e r a t u r e in th e f u r n a c e is u s u a lly a b o u t 1 ,300 d e g . F . B y c a r e f u l a d j u s t m e n t o f d a m p e r s a n d r a b b l e s p e e d , th e d is c h a r g e o f b u r n e d p y r ite s o r c in d e r is m a in ta in e d u n d e r c lo s e c o n tr o l. T h e s u l p h u r c o n te n t o f th e c in d e r is f r o m 0.5 to 1.0 p e r c e n t S.
I t is p o s s ib le to g e t s u l p h u r lo w e r t h a n th is , b u t n o t e c o n o m ic to d o so.
E a c h f u r n a c e b u r n s a p p r o x im a te ly 28 to n s o f p y r ite s p e r d a y , m a i n t a i n i n g a b o u t 8 p e r c e n t S 0 2 in t h e d is c h a r g e g a s. W h e n f o r a n y r e a s o n i t is d e s ir e d to f o r tif y th is g a s to h i g h e r c o n c e n tr a tio n f o r in c r e a s e d c h a m b e r c a p a c ity , a m o r e c o n c e n tr a te d g a s is p r e p a r e d in a n a u x il i a r y s u l p h u r b u r n e r a n d f e d in to th e m ix tu r e in th e m a in c o lle c tin g p ip e s .
T h e S O , fro m t h e p y r i te s f u r n a c e s o r s u l p h u r b u r n e r s is d r a w n t h r o u g h a d u s t c o lle c tin g s y s te m . T h r e e ty p e s o f d u s t c o lle c to r s a r e in u s e in th is p la n t. T h o s e m o s t r e c e n tly in s t a l l e d a r e C o ttr e ll p r e c i p it a to r s w h ic h f u n c tio n w ith s u b s ta n t ia l ly g r e a t e r s a t is f a c tio n to th e m a n a g e m e n t t h a n e ith e r o f th e o ld e r ty p e s w h ic h a r e o f th e c y c lo n e o r s h e lf fo rm . T h e a m o u n t o f s u b s e q u e n t c le a n in g o f th e g a s a t t h e a c id u n i t is d e te r m in e d b y t h e e ffe c tiv e n e s s o f th e s e p r i m a r y d u s t c o l
le c to rs .
A s m e n tio n e d p r e v io u s ly , th e n e w c o n ta c t a c id p l a n t n o w b e in g i n s t a l l e d w ill u s e o n ly s u l p h u r a s r a w m a t e r i a l.
I t t h e r e f o r e w ill r e q u ir e a m u c h lo w e r c a p i t a l in v e s tm e n t s in c e n o d u s t- r e m o v a l e q u ip m e n t w ill b e n e c e s s a r y . I t w ill h a v e a w a s te -h e a t b o ile r i n s t a ll e d b e tw e e n t h e s u l p h u r b u r n e r a n d th e a c id e q u ip m e n t, g iv in g fo r th e f irs t tim e in th is p l a n t d i r e c t b y p r o d u c t s te a m re c o v e ry . M o s t o f t h e o th e r o ld e r a c id e q u ip m e n t is so la r g e ly “ s t a n d a r d ” o r ty p ic a l in n a t u r e a s n o t to r e q u i r e d e s c r ip tio n h e r e .
C le a n in g o f p y r ite s b u r n e r g a s fo r th e c o n ta c t p r o c e s s o f a c id m a n u f a c tu r e is n e c e s s a r ily so c o m p le te a s to re m o v e a ll a r s e n ic b e f o re th e g a s e n te r s th e c o n v e r to r s . W e r e t h i s n o t d o n e th is i m p u r i t y w o u ld p o is o n th e c a ta ly s t a n d r e n d e r o p e r a tio n in effi
c ie n t. T h e c h a m b e r - a c id g a s is n o t s u ffic ie n tly c le a n e d to e lim in a te a ll a r s e n ic . T h e a c id m a d e in t h a t u n it, e q u ip p e d w ith u n lo a d in g g a n tr y
c r a n e s . T h e r e a r e tw o o f th e s e u n its on th e d o c k w h e re p y r ite s is re c e iv e d . W ith c la m s h e ll b u c k e ts th e y c a n h a n d le a b o u t 2 0 0 to n s o f m a t e r i a l p e r h o u r o u t o f ty p ic a l o re s te a m e r s . T h e m a t e r i a l is h o is te d in to d o c k h o p p e r s fro m w h ic h i t is d u m p e d in to a m o n o r a i l c o n v e y o r a n d m o v ed d ir e c tly i n s h o r e fro m th e p ie r to th e p y r ite s s t o r a g e b in s . T h is s to r e h o u s e b u ild in g is lo c a te d b e tw e e n th e tw o a c id p la n t s so t h a t a s in g le s to c k s e rv e s c o n v e n ie n tly f o r b o th a n d a s in g le c o n v e y o r s y s te m c a n c a r r y th e m a t e r i a l, a g a in b y m o n o r a il, f ro m th e s to c k p ile s in to th e p y r ite s b u r n e r s w h ic h s e rv e b o th th e c h a m b e r a n d c o n ta c t p la n ts .
W h e n g r e a t e r s to c k s a r e r e q u ir e d th a n c a n b e s to r e d in th e s e c a p a c io u s p y r ite s b in s , th e s u r p l u s is h a n d le d b y tr u c k . A tr u c k - lo a d in g s ta tio n is p la c e d a t th e l a n d e n d o f th e p i e r so t h a t th e m o n o r a il u n lo a d e r a f te r p a s s in g th e s c a le h o u s e n e e d m o v e o n ly a few f e e t to b e o v e r a tr u c k - lo a d in g h o p p e r . W h e n th e s to c k is to b e p ile d
e ls e w h e r e in th e p l a n t , a s is n e e d e d w h e n s u r p l u s r e s e r v e s a r c b e in g s to re d , th e u n lo a d in g o f th e s e g o o d s is p o s s ib le w ith o u t r e q u ir i n g a n y e x tr a h a n d lin g b e y o n d d u m p in g fro m th e p i e r c o n v e y o r in to th e d u m p tr u c k s a n d th e d u m p in g o f th e s e a t d e s ir e d s to c k p ile lo c a tio n s e ls e w h e r e in t h e p la n t.
W h e n th e p y r ite s is r e c la im e d fro m s to r a g e f o r u se , a s m a ll a u to m o tiv e c la m s h e ll s e rv e s to p ic k i t u p fro m th e s e r e s e r v e p ile s fo r r e t u r n b y tr u c k to a p o in t fro m w h ic h i t is a g a in h o is te d b y c la m s h e ll b u c k e ts in to th e p y r ite s s to r e h o u s e . W h e n o n e re a liz e s th e h u g e to n n a g e o f s u c h m a t e r i a l t h a t m u s t b e m o v e d d a ily fo r a p l a n t o f th is c a p a c ity , i t is c le a r w h y th e m a te r ia ls - h a n d li n g p r o b le m is so im p o r ta n t.
P y rite s B u rn e rs
E a c h c h a r g e o f p y r ite s f ro m th e s to c k p ile is w e ig h e d a s i t g o e s to th e c h a r g in g h o p p e r a b o v e a p a r t i c u l a r o n e o f th e 15 p y r ite s b u r n e r s . H e r e th e fine m a te r ia l, m o s tly u n d e r 8 m e s h , is f e d d o w n th r o u g h a c o a r s e s c r e e n a n d
V iew s in D av iso n ’s co n ta ct s u lp h u ric a cid p la n t sh o w in g , ab o v e, a cid coolers, a b s o rb e rs a n d h e a t e x c h a n g e rs ; a n d b elo w , o leu m a n d stro n g acu l to w ers
6 VOL. 47 • C H EM IC A L & M E T A L LU R G IC A L E N G IN E E R IN G • N o . 1 J A N U A R Y 1 9 4 0
th e r e f o r e , c o n ta in s a few p a r ts p e r m illio n o f t h a t e le m e n t. T h is tr a c e d o e s n o h a r m i f th e a c id is to h e u s e d fo r s u p e r p h o s p h a te m a n u f a c tu r e , b u t if so n ic o f t h e ' c h a m b e r a c id is to b e d iv e r te d to m a r k e tin g , it is g iv e n a s p e c ia l a r s e n ic t r e a tm e n t d e v e lo p e d a t C u r tis B ay .
P y rite s B y p ro d u c t
M a n y p y r ite s u s e r s fin d th e s p e n t c in d e r a r e la tiv e ly u n p r o f ita b le b y p r o d u c t if n o t a c tu a lly a p l a n t n u i sa n c e . A t C u r tis B a y th is is n o t th e c a s e f o r a n o v e l s y s te m o f p ro c e s s in g a n d s in te r in g c o n v e rts th e c in d e r in to a n a d v a n ta g e o u s b la s t f u r n a c e r a w m a te r ia l o r “ o r e .”
T h e c in d e r a s i t le a v e s th e p y rite s f u r n a c e s is f a ir ly h o t. I t is c o lle c te d in c u b ic a l b o x e s a b o u t 4 ft. o n a sid e , o n e s u c h c in d e r d is c h a r g e u n it b e in g fille d a b o u t o n c e a s h if t a t e a c h f u r n a c e . T h e s e b o x e s a r e s lid o u t fro m u n d e r th e d is c h a r g e s id e o f th e f u r n a c e a n d h a n d le d b y c r a n e o u t o f th e f u r n a c e ro o m to a c in d e r d u m p n e a rb y . T h e r e th e c o o lin g c o n tin u e s by o u t
d o o r e x p o s u re .
T h e s p e n t c in d e r , a lth o u g h la r g e ly iro n o x id e , is u n s u ite d fo r b la s t f u r n a c e u se in tw o r e g a r d s . I t is m u c h too fine fo r s a tis f a c to r y f u r n a c e u se a n d i t c o n ta in s c o p p e r in q u a n titie s o b je c tio n a b le to th e ir o n m a k e r . A n u n u s u a l le a c h in g a n d s in te r in g te c h n ic h a s b e e n d e v e lo p e d b y D a v iso n e n g i
n e e r s to r e m e d y th e s e tw o d e fe c ts . T h e c o o le d c in d e r is h o is te d by c la m sh e ll b u c k e t o n a tr a v e lin g c r a n e fro m th e c o o lin g p ile in to le a c h in g ta n k s o f w h ic h th e r e a r e e ig h t, e a c h a b o u t 20 b y 30 ft., b y 7 ft. d e e p . H e r e th e c r u d e m a te r ia l is le v e le d off a n d th e n s u b je c te d to a le a c h w ith w e a k s u l p h u r i c a c id . T h is p e r c o la te s d o w n th r o u g h th e m a s s a n d o u t th ro u g h th e in te r s tic e s o f th e w o o d -b e am e d b o tto m , ta k in g in th e a c id s u b s ta n tia lly a ll o f th e r e a d ily s o lu b le c o p p e r.
A f te r b e in g su ffic ie n tly le a c h e d th e m a te r ia l is w a s h e d w ith w a te r, a l
lo w e d to d r a in , h o is te d o u t o f th e o p e n ta n k s b y c r a n e , a n d th u s t r a n s f e r r e d to th e s in te r in g d e p a r tm e n t s to r a g e b in s fo r fin al p ro c e s s in g .
T h e le a c h a c id is tr e a te d w ith s c r a p iro n in a r o ta r y c o p p e r p r e c ip ita to r . T h e c o p p e r s u lp h a te in s o lu tio n r e a c ts w ith th e s c r a p iro n to fo rm m e ta l
lic c o p p e r a n d fe rr o u s s u lp h a te , th e l a t t e r in s o lu tio n . T h e c o p p e r, in e le m e n ta l fo rm o r s lig h tly o x id iz e d , r e m a in s s u s p e n d e d in th e s o lu tio n a n d is re m o v e d b y filtra tio n . T h e f ilte r c a k e a f te r w a s h in g is d r ie d in a la r g e o p e n d r y e r o v e r a n oil b u r n e r a n d th e
c o p p e r c e m e n t is r e a d y fo r s a le to a n e a r b y c o p p e r c o m p a n y .
C in d er S in terin g
T h e c o p p e r-fre e c in d e r is m ix e d w ith s u ita b le q u a n titie s o f fin e b i tu m in o u s c o a l a n d o th e r m a te r ia ls , t o g e th e r w ith j u s t e n o u g h m o is tu r e to p e r m it p r o p e r p u g g in g in to a w o r k a b le th ic k m u d m as s. T h e m ix tu r e in c lu d e s b o th fines fro m p re v io u s s in te r in g o p e r a tio n s a n d d u s t t h a t h a s b e e n re c o v e re d fro m th e h o t s to v e s o f a n e a r b y b la s t f u r n a c e p la n t. T h e m u d m ix tu r e is fed fro m th e p u g m ill d is c h a r g e d o w n in to a s in te r in g m a c h in e . T h e r e , b y c o m b u s tio n o f th e c o a l, th e w h o le m a s s is a g g r e g a te d in s u c h a fa s h io n t h a t th e r e s u ltin g p r o d u c t is s u ita b le fo r b la s t f u r n a c e c h a r g e .
T h e s in te r in g m a c h in e is a s e rie s o f tr a v e lin g g r a te s w h ic h fo rm a c o n tin u o u s lo o p fro m th e c h a r g in g h o p p e r to th e d is c h a r g e e n d a n d b a c k u n d e r n e a th . I m m e d ia te ly a f te r c h a r g in g , th e m o v in g g r a te s e c tio n s p a s s u n d e r ig n itin g b u r n e r s w h e re a n o il
flam e r a is e s th e m a s s to a t e m p e r a tu r e t h a t w ill in itia te c o m b u s tio n o f th e c o a l c o n ta in e d in th e c h a r g e . A ir fo r c o m b u s tio n is d r a w n d o w n th r o u g h th e m a s s b y a COO h o r s e p o w e r fa n w h ic h m a in ta in s a s u c tio n o n th e sm o k e d u c t, th e l a t t e r b e in g c o n tin u o u s u n d e r th e e n tir e le n g th o f th e u p p e r lev e l o f th e s in te r in g u n it.
A f te r th e in itia l h e a tin g u p b y th e o il b u r n e rs , th e c o m b u s tio n p ro c e e d s w ith o u t f u r t h e r n e e d fo r c o n tro l a s th e g r a te s tr a v e l th e l e n g th o f th e m a c h in e . A ll o f th e c o a l is b u r n e d o u t a n d p r o p e r a g g r e g a tio n o f t h e m a s s is a c c o m p lis h e d b y th e tim e th e g r a te s tu r n o v e r th e d is c h a r g e e n d a n d d u m p th e h o t s in te r off th r o u g h a h o p p e r a n d c h u te in to th e s in te r p i t b elo w . T h e g r a te s r e t u r n u n d e r n e a th , lik e a c h a in g r a te sto k e r.
I t is m o s t d e s ir a b le if th e s in te r c a n b e fo rm e d in to p ie c e s a b o u t th e size o f n u t c o a l. M u c h o f th e s in te r a s it le a v e s th e m a c h in e is l a r g e r th a n th is , b u t it r e a d ily b r e a k s u p d u r in g its f a ll d o w n th r o u g h a l a r g e g riz z ly
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s c re e n a n d c h u te in to th e w o r k in g p it.
F r o m th is it is c la m s h e lle d o u t o n to th e s to c k p ile a w a itin g s h ip m e n t to th e n e a r b y b l a s t f u r n a c e w h e re it fo rm s a m u c h v a lu e d p a r t o f th e o re c h a r g e . I n c id e n ta lly th e s u l p h u r c o n te n t is r e d u c e d d u r i n g s in te r in g to a p o in t w h e re th is “ s y n th e tic o re le - c eiv es f a v o ra b le r e c e p tio n fro m th e f u r n a c e m en .
I t is i n te r e s tin g to n o te t h a t d e s p ite th e la r g e to n n a g e o f m a te r ia l h a n d le d e a c h m o n th th r o u g h th e l e a c h in g a n d s in te r in g d e p a r tm e n t, th e p a y r o ll of th is d iv is io n o f th e p l a n t is k e p t low - A s in g le c r a n e s e rv e s f o r a ll m a t e r i a l s h a n d lin g fro m h o t c in d e r d is c h a r g e to fin a l lo a d in g o f c a r s fo r s h ip m e n t o f th e fin is h e d s in te r . 1 h e le a c h in g p l a n t is o p e r a te d w ith o n e le a c h e r p e r s h if t. T h e s i n t e r i n g u n it h a s a s m a ll c re w o n e a c h s h if t. A lto g e th e r , la r g e - s c a le m e c h a n iz e d o p e r a tio n is n e c e s s a r y to m a k e t h e b y p r o d u c ts o f c o p p e r a n d s i n t e r p r o f ita b le to th e e n te r p r is e .
P h o s p h a te R o ck
S te a m e rs b r i n g in g t h e p h o s p h a te ro c k to th is p l a n t d o c k a t a s e c o n d p i e r d ir e c tly o p p o s ite t h e s u p e r p h o s p h a te p la n t. H e r e a g a in g a n tr y c r a n e s a r e i n s ta lle d fo r u n lo a d in g f ro m th e s te a m s h ip s a t a b o u t 4 0 0 to n s p e r h o u r . T h e ro c k w h ic h is g e n e r a lly a ll th r o u g h a 4 -m e s h s c r e e n is d e p o s ite d b y th e p ie r c r a n e s in d u m p c a r s w h ic h a r e m o v e d in s h o r e fro m th e d o c k d i
r e c tly to th e ro c k s to r a g e b in s o f th e s u p e r p h o s p h a te b u ild in g .
T h is c o m p a n y p u r c h a s e s its ro c k w ith a tte n tio n to th e o th e r c o n s titu e n ts , a s w e ll a s to th e B .P .L . (b o n e p h o s p h a te o f l i m e ) . I t is n e c e s s a r y in o r d e r to m a in ta in a b o u t 20 p e r c e n t a v a ila b le P 20 6 in th e s u p e r p h o s p h a te t h a t th e r o c k u s e d s h a ll n o t b e b e lo w
a b o u t a 7 2 p e r c e n t B .P .L . g ra d e . ' F r o m th e r o c k s to c k p ile th e m a te r i a l is h a n d le d b y c r a n e in to th e fe e d
Cyclone, i n n
D a v iso n ’s su p e rp h o s p h a te b u ild in g sh o w in g g ro u n d ro c k h a n d lin g e q u ip m e n t
h o p p e r s o f th e p h o s p h a te g r i n d in g m ills . T h e r e a r e 12 o f th e s e a ir s e p a r a tio n u n its , e a c h c a p a b le o f p r o v id in g a b o u t 4 to n s p e r h o u r o f fin e ro c k p o w d e r, 87 p e r c e n t th r o u g h 1 0 0 m e s h a n d 6 2 p e r c e n t t h r o u g h 2 0 0 . T h e m ills a r e th e r in g - a n d - r o ll ty p e w ith R a y m o n d a ir s e p a r a t in g c y c lo n e u n its a n d d u s t s y s te m fo r c o lle c tio n o f th e fin es. T h e d u s t c o lle c to r s , w h ic h a r e o n th e r o o f o f th e s u p e r p h o s p h a te b u ild in g , d is c h a r g e in to th e g r o u n d r o c k s to r a g e h o p p e r s j u s t u n d e r th e ro o f. F r o m t h is p o in t s c re w c o n v e y o rs c a r r y th e fin e ro c k to t h e s u p e r p h o s p h a te a c id u la to r s .
S u p e rp h o s p h a te M a k in g
“ S p e e d , a n d m o re s p e e d ” i s th e m o tto o f th is p a r t o f t h e p l a n t . A t p r e s e n t e a c h m ix e r p l a t f o r m is so o p e r a te d t h a t tw o m e n , w ith a m ix e r e a c h , c a n a c id u la te r o c k to f o rm 100 to n s o f s u p e r p h o s p h a te p e r h o u r . T h is m e a n s t h a t e a c h m ix e r m u s t b e
c h a r g e d w ith a b o u t a h a l f to n o f r o c k a n d a h a lf to n o f a c id 5 0 tim e s p e r h o u r , a s p e e d p r o b a b ly n o t a c h ie v e d h e r e to f o r e e ls e w h e r e . T h e r e s u l t is , o f c o u r s e , a v e r y f a v o ra b le c o s t f a c to r f o r b o th l a b o r a n d c a p i t a l in v e s tm e n t in th is p a r t o f t h e p l a n t .
T h e q u a n ti t y o f a c id a n d ro c k m ix e d is p r e d e t e r m i n e d b y t h e c o n tr o l l a b o r a to r y . I n c a l c u l a ti n g th e m ix e d c h a r g e a n u n u s u a l te c h n iq u e h a s b e e n d e v e lo p e d f o r a c c u r a t e p r o p o r tio n in g . T h is t a k e s a c c o u n t n o t o n ly o f th e p h o s p h a te c o n te n t o f th e r o c k , b u t a ls o o f t h e o th e r a c id - u s in g c o m p o n e n ts . T h e r e s u l t is a p r e c is e p r o p o r tio n in g a n d e x a c tly t h e d e s ir e d s u r p l u s o f a c id in t h e m ix tu r e a s it r u n s f r o m t h e m ix e r to t h e d e n b e lo w .
I n th e m ix e r t h e tr i- c a lc iu m p h o s p h a te r e a c ts w ith th e a c id , h e a t e d to a b o u t 120 d e g . F ., a n d is c o n v e r te d to m o n o - a n d d i- c a lc iu m p h o s p h a te w ith t h e f o r m a tio n o f c a lc iu m s u l p h a te a n d th e l ib e r a t i o n o f t h e flu o rin e
S e c tio n th ro u g h o n e b a y of th e su p e rp h o s p h a te p la n t, sh o w in g g rin d in g , p r o c essing, h a n d lin g , sto ra g e a n d s h ip p in g fa c ilitie s fo r ro c k a n d fin is h e d p ro d u c t
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