S. D . KIRKPATRICK . . . Editor JAMES A . LEE...M a n a g in g Editor THEODORE R. O L IV E .. . . .A s s o c ia te Editor HENRY M. BATTERS... M a rk et Editor JOHN R. CALLAHAM A s s is ta n t Editor NORMAN G. FARQUHAR. .A s s is ta n t Editor LESTER B. PO PE... A s s is ta n t Editor
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ENGINEERING
A U G U S T , 1 9 4 3
War Lesson No. 1 ...
EDITORIAL FOREWORD
G lass Cellulation Produces Lightweight Insulation.
By NORMAN G. FARQUHAR
95
98 Liquid Chlorine S y stem s... 102
By WILLIAM H. MAGEE
Making Apple Syrup, a Glycerine and Sugar Substitute. . . . 104
EDITORIAL STAFF
Infra-Red Penetrates Many Process Industries.. 105
By E. H. ROBINSON
N ew Approach to Continuous Reactor Design-II...107
By A . BROTHMAN, A . P. WEBER a n d E. Z. BARISH
Corrosion of Iron b y A m m onia... m
By HUGH J. McDONALD a n d MORRIS FELLER
Fallen Animals, A Little-Known Process Industry 112
By W . MERLE ROBINSON
Fluorescent Method Detects Leaks in Process V essels 116
By FRANKLIN CATLIN
Alcohol for W ar and Postwar... n g
A CHEM. & MET. REPORT
Salicylic Acid and S a licyla te... 132
A CHEM. i MET. PICTURED FLOWSHEET
C h e m .
&
M e t . P l a n t N o t e b o o k . . . . . 1 1 7 F r o m th e L o g o f E x p e r ie n c e ... 1 6 7 P ro c e s s E q u ip m e n t N e w s ... . . 127 M e e t in g s a n d C o n v e n t io n s . . 1 73 C h e m ic a l E n g in e e r in g N e w s . . 139 N e w s F r o m A b r o a d ... 186 N e w s F r o m W a s h i n g t o n ... . . 141 C h e m .&
M e t . B o o k s h e lf ... 197 I n t e r p r e t i n g W a s h i n g t o n ... . . 145 C h e m ic a l E c o n o m ic s a n d M a r k e t s . 2 0 7 N e w P r o d u c ts a n d M a t e r i a l s . . . . 151 C u r r e n t P r ic e s ... 2 1 3 P e r s o n a lit ie s ... . . 159 N e w C o n s tru c tio n ... 2 1 6A n in d ex to a d v e rtis e rs w ill b e fo u n d on p a g e 344
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From
To
S ig n e d
G R I N D I N G S C R E E N I N G
C R U S H I N G
C y lin d ric a l m ills.ball o r r o d m e
d ia , b atch o r contin uo us type.
V ib r a t in g & ro ta ry screens, w e t
& d r y — la rg e st line in U. S.
Jaw , g y ra to ry , roll & ham m er crushers — f o r o re & rock.
HERE ARE FOUR O F THE M O S T
ivwr,
Unexpected Breakdowns?
Labor Shortage?
Me n
W
antedNO EXPlRIENCt
HtCtSSWt't
H o w m a n y o f yo u r key m achines were d e s ig n e d f o r 2 4 - h o u r - d a y se rvice ? G o o d point to check to d a y l
D o e s p a rt o f yo u r p r o c e ss use m en n e e dlessly? Rem em ber, proce ssing is
a machine industry!
WHICHEVER IT IS —
M
E N m u s t w o r k t o g e th e r b t h a n e v e r b e f o r e to wir w a r . . . a n d s o m u s t m a c h i n e !I f f a i l u r e o f m a c h i n e s to t o g e t h e r p r o p e r l y i s a t t h e ro y o u r w a r t i m e p r o c e s s i n g p r d r e m e m b e r t h e r e ’ s o n e com ] t h a t
specializes
i n m a k i n g c h i n e s “ t e a m u p ” . . . A llis - C h a h Collaboration of specialists is basic in A -C Cooperative Engineering.A U G U S T 19J,S • C H E M I C A L & M E T A L L U R G I C A L E N G I N E E R 1
CHEMICAL
t m e t a l l u r g i c a l
ENGINEERING
ESTABLISHED 1902
A U G U S T , 1943
S. D. KIRKPATRICK, Editor
OUR WAR LESSON N O . 1
V
V H E N th e com plete h isto ry of th is w a r is w ritte n , one of its m ost in te re s tin g a n d d ra m a tic c h a p te rs w ill deal w ith th e c o n trib u tio n s o f A m e ric a n sc ien tists a n d en g in eers. T he little know n b u t h ig h ly im p o rta n t w ork b ein g done on w a r p roblem s in u n iv e rs ity and in d u s tria l re se a rc h la b o ra to rie s wil 1 some d a y m ake an am azing re c o rd o f achievem ent. M eanw hile, te n s of th o u san d s o f m en an d w om en, in te r r u p tin g th e ir careers in science a n d in d u s try , a re g iv in g u n s tin t- ingly of th e ir tim e a n d effort. W h a t ’s to become of this w ork a f te r th e w a r? A re we going to close th e book, as we d id a f te r W o rld W a r I, a n d let someone else w o rry a b o u t th e science a n d technology of national d efen se?Some of th e e m in e n t m en who a re hig h in th e councils o f th e Office of S cientific R esearch a n d D evelopm ent believe i t w ill be difficult, or im possible to hold su ch a n o rg a n iz a tio n as th e irs to g e th e r once the w a r is won. T h ey sa y t h a t th e c o u n tr y ’s scien tists and technologists are w illin g to accep t coercion an d re g im e n ta tio n o n ly as lo n g as th e ir services a re im m ediately n eed ed by th e a rm e d forces. A f te r th a t th e y w ant to s c a tte r to th e f o u r w inds, to p ick u p th e ir peaceful p u rs u its , to fo rg e t a b o u t th e ir w a r w ork—
except p e rh a p s to w rite some books o r p u b lish some scientific p a p e rs on su b je c ts 110 lo n g e r u n d e r secrecy orders.
All th is is a v e ry n a tu r a l re a c tio n to a v e ry u n n a tu ra l s ta te of affairs. T he sc ie n tis t is an in d iv id u a l.
W hile he m a y s h u n p e rso n a l p u b lic ity , he w a n ts an d u su ally d e m a n d s c re d it f o r h is p ro fe ssio n a l achieve
m ents. H e is o fte n a n id e a list, se n sitiv e to criticism of his m otives. H e rese n ts th e idea o f h is w ork being p ro s titu te d to w h a t some one m ay call an unsocial or in h u m a n ita r ia n end.
I t is n o t s tra n g e , th e re fo re , th a t before th e w a r our u n iv e rsitie s w ere o fte n th e m e e tin g places f o r the p ro fessio n al pacifists. O rg a n iz a tio n s like W oi'ld Peace- ways b o asted of th e p ro fe sso rs a n d college p re sid e n ts in th e ir m em b ersh ip . T he sam e s itu a tio n o b tain ed in
G reat B rita in . A d m iral B lan d y , U. ¡S. C h ief of N av al O rd n an ce, in a re c e n t a n d classic a d d re ss on “ R e
search fo r W ar, ’ te lls ab o u t a B ritish a irp la n e m a n u f a c tu r e r who in 1935 a tte m p te d to c o n trib u te £10,000 fo r an a e ro n a u tic al fellow ship at, C am b rid g e an d th ereb y ro u sed a storm of p ro te s t because he w as accused o f tr y in g to p ro m o te w a r re se arch . S u ch con
tro v ersie s w ere n o t a risin g a t th a t tim e in G e rm an y a n d J a p a n — o r in R ussia, eith er. O nly one y e a r b efore H itle r cam e in to pow er, a c h a ir w as set u p in th e U n iv e rsity of B e rlin f o r th e s tu d y of w a r economics.
G eopolitics k e p t a b re a st o f m ilita ry science a n d a d d e d to th e b r u ta l success of G erm an m ig h t in 1939 a n d 1940. W e in th e dem ocracies h a d to le a rn , alm o st too late, th a t to ta l w a r affects ev ery p a r t o f o u r econom y.
F o rtu n a te ly , the M achiavellian p la n s of o u r enem ies have all b u t failed. The ev en tu a l triu m p h of o u r cause w as n ev er m ore certa in . Y et, in a ll h o n esty , we should ask ourselves w h e th e r o r n o t we h a v e le a rn e d a n d a re s till le a rn in g lessons fro m th is w a r t h a t w ill h elp us to be b e tte r p re p a re d in th e f u tu r e . I f o u r experience th is tim e h as convinced us th a t we m a d e a m istake a f te r th e la s t w a r w hen we ab a n d o n e d all w a r research except th a t in a few h a lf-s ta rv e d a rsen als, th e n we sh o u ld s ta r t now in a p ro g ra m o f p u b lic education.
T he lay m an , w ho in th e en d d e te rm in e s bo th o u r m ilita ry a n d ed u catio n al policies, m u st be m ad e to realize th a t o u r d e s tin y as a N a tio n d e p e n d s on th e use we m ake of science a n d technology. I f in s p ite of o u r ideals we are to be ch allen g ed p e rio d ic a lly by enem ies who have p lo tte d o u r d e s tr u c tio n ,.th e n p r a c tic a l idealism calls fo r p re p a re d n e s s. I t calls fo r a re a liz a tio n th a t we m u st n e v e r a g a in n e g le c t th e th in g s th a t are m ost im p o rta n t f o r o u r n a tio n a l de
fense. R esearch is c e rta in ly one of these. I f we have le a rn e d o u r lesson w ell, we w ill in s is t on th e c o n tin u a tion of some o f th e c o n tra c ts w ith e d u c a tio n a l in s titu tions w h ereb y y o u n g m en a re tr a in e d a n d k e p t a b re a s t of th e science a n d technology of w ar.
IMPENDING CHANGES IN A.S.T.P.
%
A
rmydem ands fo r chemical engineers in the m ilitary service are so few th a t no more young men are to be assigned fo r tra in in g u n d e r the A rm y Specialist T ra in in g P rog ram . This decision was reached d u rin g J u ly a fte r a resurvey of the needs fo r chemical engi
neers in uniform .
T hat th ere is a continuing dem and for m en of such tra in in g in the chemical process industries, however, is fu lly recognized in W ashington as well as th ro u g h ou t the country. The A rm y is stu d y in g m ethods by which it m ight assist in m eeting this in d u strial need.
One proposal is th a t the A rm y should continue to tra in young men as chemical engineers through the A .S.T .P. arran g em en t w ith the u n d ersta n d in g th a t such trainees, on completion of courses, would be assigned on furloughs to in d u stria l positions. The positions w ould be those in in d u stry in which O rd
nance, Chemical W a rfa re, A ir Corps and other A rm y u n its are d irec tly interested because the research or m a n u fa c tu rin g th u s aided by young engineers would be of direct concern to th e m ilitary.
U p to A u g u st 1, no specific program had been form ulated which h ad fu ll approval of both in d u strial and m ilita ry executives. I t is hoped th a t the M anu
fa c tu rin g C hem ists’ Association can serve as a liaison between the two groups in the form ulation of a work
able scheme. Such resu lts would enable p ro p erly p re pared and com petent young train ees taken by the A rm y to go ahead w ith th e ir chemical engineering education. In cidentally, the q u a lity of the tra in in g would be guided by jo in t action of A rm y, in d u strial and educational leaders. T hus the men would be of a q u ality suited to the jobs to which th ey would be assigned. Num erous difficulties lie ahead of the com
pletion of the p ro g ra m ; b u t early in A u gust the p ro ponents were hopeful as to results.
FLUID FUEL INSURANCE
F
luidfuels can be m ade from solid m inerals. This fact has long been known. B u t we still do no t know w hat technology will best serve fo r the processing of oil shale, bitum inous coal and lig n ite when a petroleum su b stitu te is the objective. Som ething should be done about this.
A specific proposal is now being considered by the S enate Committee on P ublic Lands. The proposal is th a t a sub stantial sum be authorized fo r use of the II. S. B u reau of Mines in the investigation of m ethods fo r p roducing synthetic liquid fuels from coal and other solid m ineral m aterials. L ed by S ecretary Iekes, an im pressive group of officials has appeared before the Senate Committee u rg in g the enactm ent of this bill, S. 1243.
E xperienced chemical engineers w ill not agree w ith all of the alarm in g predictions about petroleum short- age, n o r will they accept all of the super-optim istic forecasts of success for a n y experim ents in liquefac
tion of coal u n d e r A m erican conditions. B u t th ere is am ple evidence to su p p o rt the general idea th a t m ore fu nd am en tal studies should be made. These should encompass the best proposals fo r m aking eith er gase-
ous or liquid p ro du cts from oil shale, bitum inous coal, or lignite. Investm ent in sound research w ill be good insurance against fluid-fuel shortage in the years tc come. One needs to be n eith er an alarm ist nor a p o lit
ical p ro p a g an d ist to accept the broad p rin cip le of this bill provided the m anagem ent of th e engineering studies can be le ft w ith the com petent technical staff of the B ureau.
WHICH W A Y OUT?
E
quitablepolicies fo r the term in atio n of w ar con
tra c ts a t the cessation of hostilities are alread y de
m anding increased atten tio n. Several proposals are before Congress in clu d in g a s ta n d a rd term in ation clause th a t is being developed by th e P rocu rem ent Policy Division of th e W .P.B . A recen t business con
ference held w ith the s u p p o rt of the U. S. Cham ber of .Commerce, has suggested (1) an overall term in a
tion procedure grou pin g contracts and su bcontracts;
(2) p ro m p t paym en t of 75 p ercen t of all claims w ith out a u d it; (3) avoidance of d u plicatio n in a u d its ; (4) review of both facts and law in d isp u ted cases; (5) allowances fo r costs of am ortizable facilities, postw ar conversion, losses on other contracts an d o rd in ary business expenses; (6) adoption of the prin cip le of settlem ent b y negotiation an d (7) reasonable lim ita
tions on establishm ent an d uses of reserves.
M any p riv ate in d u stries suffered alm ost in te r
m inable delay in th e ir con tract settlem ents a fte r the first W o rld W ar. L et us hope we m ay be b e tte r p re p ared this time.
DANGEROUS STOCKPILE LEGISLATION
A
bloc o f A v estern s e n a t o r s i s m a k i n g a n e a r l y s t a r t o n p l a n s f o r a p o s t w a r m i n e r a l s t o c k p i l e . T h e y r e c it e t h e s e r io u s d i f f i c u lt i e s i n g e t t i n g m i n e r a l s f o rAvar
u se a n d a r g u e t h a t U n c l e S a m s h o u l d n e v e r a g a i n ris k s u c h s h o r t a g e . T h e i r a r g u m e n t s a r e s o u n d , b u t o n ly i n s o f a r a s t h e y r e l a t e t o t h e n e e d f o r m i n e r a l r e s e r v e s . T h e t e c h n i q u e f o r c o r r e c t i o n s A vhich t h e y p r o p o s e is a n a p p a l l i n g d i s t o r t i o n o f s o u n d e c o n o m ic s a n d t e c h n o l o g y .T h e ir p r o p o s a l is t h a t d o m e s t i c m i n i n g i n t e r e s t s b e s u b s id iz e d f o r a c e r t a i n p e r i o d a f t e r t h e w a r i n o r d e r to s t i m u l a t e p r o d u c t i o n o f s t r a t e g i c a n d c r i t i c a l m a t e r ia l s . T h e y h a v e i n m i n d b o t h t h e p r e s e n t w a r e f fo r t a n d p o s t w a r p r e p a r e d n e s s . B u t , c l e a r l y r u n n i n g t h r o u g h t h e S c r u g h a m b i l l ( S . 1 1 6 0 ) i s a p l a n t o s u b s i d i z e m a r g in a l a n d s u b - m a r g in a l m i n i n g e n t e r p r i s e s i n t h i s c o u n t r y . I n f a c t , o n e o f t h e s t a t e d p u r p o s e s o f t h e b i l l i s “ t o a v o i d t h e w i d e s p r e a d e c o n o m ic d i s t r e s s a n d f a i l u r e a m o n g s m a l l o r m a r g i n a l m in e OAvners . . . ”
A n u n m i n e d m i n e r a l r e s o u r c e is a l r e a d y a f o r m o f s t o c k p il e . T h e p r o d u c t o f s u c h a m i n e i s o f t e n n o m o r e v a l u a b l e i f i n s o m e r e s e r v e s t o r a g e t h a n i t w o u l d b e i f s t i l l i n t h e g r o u n d a s a p r o v e n r e s o u r c e . I n m a n y e a s e s , w i t h c h a n g e o f p o l i t i c a l p o l i c y , a r e s e r v e i n a s t o c k p i l e m a y b e d i s s i p a t e d , A vh ereas a r e s o u r c e i n t h e g r o u n d w o u l d n o t b e . T h e s e a r e A v e ll- e s t a b lis h e d f a c t s . T h e y a r e f a c t s w h i c h a r e i g n o r e d i n t h e p l a n f o r
9 6 • A U G U S T 1 9 J fS • C H E M I C A L & M E T A L L U R G I C A L E N G I N E E R I N G
m ining o u t these m arginal ore reserves irrespective of cu rre n t use and needs.
The chemical process industries are am ong th e p rin cipal users of m any strateg ic an d critical m aterials, w hether produced in this co u n try or im ported from abroad. They are, therefore, directly concerned w ith any postw ar plans fo r stockpiles. P erh a p s if th e ir selfish needs as consumers w ere balanced again st the equally selfish interests of the m ineral producers, b etter legislation would result. In an y event they should be consulted.
MORE PLANT CONSTRUCTION
C h e m ic a l p la n t construction will not stop. In fact, in the stric tly chemical in d u stries it m ay be g reater next y ear th an last. This p o in t is em phasized because some readers have m isunderstood
Chem . & M et. ’sedi
torial of last m onth which sta rte d with the statem ent
th a t “ B uilding w ar factories is nearin g com pletion.”
O ur com m ent was inten ded to re fe r to general con
stru ctio n and n o t to specialized jobs fo r chemical m an ufactu ring . M any of these la tte r p ro jects are still to be built. I n fa c t some W ashington officials estim ate th a t we will spend m ore m illions on new chemical m an u fa ctu rin g facilities d u rin g the n ex t twelve months th a n d u rin g the last.
However much we spend, and w hatever the chem
icals m ay be th a t we shall plan to make, th ere still rem ains the im p o rtan t point we have freq u en tly em
phasized. C onstruction from now on should be b u ilt w ith a view to its postw ar service to A m erican in dus
try . T h at objective cannot supersede questions of im m ediate w ar value, however, b u t such consideration can an d should be taken into account so th a t both w ar and postAvar will be served to the m axim um possible extent as Ave expand m an u factu rin g facilities or as we m odernize them.
WASHINGTON HIGHLIGHTS
COAL STORAGE m u s t b e c a r e f u l l y p la n n e d . I t i s n o t e n o u g h to g e t p l e n t y o f c o a l i n t o s t o r a g e , a lt h o u g h t h a t is im p o r t a n t r i g h t n o iv . S o a ls o i s p r o p e r p i l i n g a n d v e n t i la t i o n o f t h e p i l e s , e s p e c i a l ly o f c o a ls w h ic h te n d t o h e a t in th e s t o c k p ile . E v e n t h o s e c o a ls t h a t do n o t h e a t b a d ly e n o u g h to c a u s e s p o n t a n e o u s c o m b u s t io n m a y d e p r e c i
a te m u c h m o r e t h a n n e c e s s a r y d u r in g s to r a g e Avhen in c o r r e c t ly p ile d .
ENRICHMENT o f fo o d s b y a d d itio n o f vitam in s an d nutritiA^e m in e r a l in gred ien ts is n o w r eq u ired f o r bread and certain o th er im p o r ta n t com m od i
ties. W a r F o o d A d m in is tr a tio n is also tr y in g to d ecid e h o w a ll flour u sed in the h ou seh old sh all he sim ila r ly en riched. T h u s, avc m u st e a t o u r A’ita - m ins and m in e r a ls Avhether avc w a n t them or n o t. B u t it m ea n s b u sin e ss fo r th ose c o m p a n ie s th a t m a k e s y n th etic v ita m in s a n d p r e p a r e th e fo o d m in era ls in th e sp e c ia l fo r m s req u ired . POSTWAR LABOR w ill Avork u n d e r a 3 0 -h o u r Aveek i f C .I .O . h a s i t s Avay.
A ls o , i t w i l l b e g o v e r n e d b y t h e l e g i s la tio n o f a s t r o n g la b o r C o n g r e s s , a c c o r d in g t o Avell la id p l a n s o f la b o r le a d e r s. T h e s e a r e m a t t e r s Avhich c a n w e ll b e d is c u s s e d Avith p r e s e n t m e m b e r s o f C o n g r e s s Avhen t h e y a r e h o m e t h is su m m e r a m o n g t h e ir c o n s t it u e n t s .
DEFERMENT c a s e s o f c r i t i c a l c h a r a c t e r sh o u ld b e r e f e r r e d m o r e o f t e n f o r th e a s s is t a n c e o f t h e N a t i o n a l R o s te r . S h o r ta g e s o f t e c h n ic a l m a n p o w e r in in d u s t r y a n d in r e s e a r c h a r e b e c o m in g m o re o f a t h r e a t t o t h e Avar e ffo r t th a n a s h o r t a g e o f c h e m ic a l m anp oA ver in th e a r m e d f o r c e s . O ffic ia l W a s h in g t o n
w ill be v e r y g la d to h a v e e m p lo y er s r e q u est r ev iew o f d ifficu lt d e fe rm e n t ea se s b y th e C o m m ittee on C h em ists a n d C h em ical E n g in e e r s o f th e N a tio n a l R o s te r o f S p e c ia liz e d P e r s o n n e l, W a sh in g to n ,
D.
C. L o ca l h o a rd s sh o u ld a lso be u r g e d to u se th is so u rce o f im p a r tia l, c o m p e te n t a d v ice.GOVERNMENT OWNERSHIP o f a g r e a t m a n y e s t a b lis h m e n t s a t t h e e n d o f th e Avar p e r io d is c e r t a in . A b o u t 1 5 b illio n d o lla r s Avorth o f s u c h p l a n t s h a d b e e n fin a n c e d A\rith p u b lic m o n e y b e f o r e th e e n d o f M a r c h , 1 9 4 3 , a n d t h e t o ta l groAvs m o n t h ly . N e a r l y 1 0 p e r c e n t o f t h is t o t a l i s m a d e u p o f p l a n t s m a k in g
“ c h e m ic a ls , p e t r o le u m a n d c o a l p r o d u c t s .” I t i s e v id e n t , t h e r e f o r e , th a t c h e m ic a l executiA -es a r e g o i n g t o h a v e a b i g j o b o f n e g o t ia t io n w h e n postA var s e t t le m e n t c o m e s. I t w ill b e im p o r ta n t to k n o w Avho fix e s t h e p o l i c y a n d hoAv m u c h c o n t in u a n c e o f g o v e r n m e n t o w n e r s h ip o r g o v e r n m e n t c o m p e t it io n Avith p r i v a t e b u s in e s s Avill th e n b e s o u g h t . S e e t h e W a s h in g t o n N e w s p a g e s f o r so m e t h o u g h t f u l c o m m e n t b y J e s s e J o n e s .
CASEIN PRICES h a v e been raised to e n c o u ra g e th e sa le o f sk im m ilk from fa r m s. O .P .A . took th is a ction b e
ca u se o f th e u r g e n t n eed f o r c a sein in p la s tie s , p a in ts , in secticid es, glu e, p a p e r c o a tin g a n d o th er in d u stria l a p p lic a tio n s. T hu s a t le a s t on e g r o u p o f la w y e rs a n d eco n o m ists in th is u n p r e d ic ta b le a g e n c y c o n fe sse s th a t the la w o f s u p p ly a n d dem an d m u st f u n c tio n in ord er to m ove g o o d s fr o m on e u se to an oth er, even in w a r tim e.
W o u ld th a t oth e rs th ere w ere e q u a lly sm a rt.
RUBBER p r o b le m s o f l a r g e im p o r t a n c e a n d o f c o n s id e r a b le n u m b e r r e m a in t o b e s o lv e d . B u t i t is n o w eA’i d e n t t h a t b y a lm o s t s u p e r h u m a n e f fo r t o n th e p a r t o f c h e m ic a l e n g in e e r s in t h e r u b b er, c h e m ic a l a n d p e t r o le u m in d u s t r ie s , s y n t h e t ic r u b b e r p r o d u c t io n i s g e t t i n g u n d e r w a y o n a h u g e s c a le in a n u n b e lie v a b ly s h o r t t im e . W a s h i n g t o n i s d e lig h te d . I t f e e l s t h a t t h i s i s o n e o f in d u s t r y ’s o u t s t a n d in g A vartim e a c h i e v e m e n ts . I t i s e v e n t a l k i n g a b o u t h o w s o o n th e r e Avill b e p l e n t y o f t ir e s f o r e v e r y b o d y . T h is i s a b it u n f o r t u n a t e , to b e s u r e , b e c a u s e t ir e s f o r e v e r y j a l l o p y a r e n o t l i k e l y t o b e a A 'ailab le f o r m a n y m o n t h s t o c o m e . B u t t h e “ w e ll d o n e ” w h ic h o n e h e a r s s o f r e q u e n t l y in W a s h in g t o n o f l a t e i s a n h o n e s t , s i n c e r e , a n d Avell d e s e r v e d t r ib u t e .
RAYON V S . COTTON is o n e o f the s ta r co n tro v ersies o f the d a y . T h e issu e is : W ill sc ien tific f a c ts o r p o litic a l p r e s su re d eterm in e Avhat k in d o f fa b r ic
(c o r d ) is to be u sed in m a k in g h e a v y - d u ty tir e s? F o r the s a f e t y o f th ose Avho u se the v e h ic le s, all te ch n ica l m en e a rn e s tly h o p e that th e f a c ts w ill w in .
CHARCOAL p r ic e s h a v e been in crea sed m a te r ia lly u n d er th e n ew c e ilin g s e t b y O .P .A . T h is avill g iv e te m p o r a r y r e lie f to the ch a rco a l p ro d u cers, b u t it c er
ta in ly w ill a lso inA-ite v ig o r o u s n e w co m p e titio n . S o m e u ser s are fin d in g th a t certa in ty p e s o f n o n -e a k in g b itu m in o u s co a l w ill d o a lm o st a s Avell a s ch a r co a l in so m e fu r n a c e r e d u c in g - r e a g e n t jo b s . H e n c e ch a rco a l p r o d u cers w h o ta k e a d v a n ta g e o f th e 50 p e r ce n t in c re a se in c e ilin g p r ic e s m a y la te r find th e m se lv es e n tir e ly Avithout b u sin e ss a m o n g su ch cu sto m ers.
C H E M I C A L & M E T A L L U R G I C A L E N G I N E E R I N G • A U G U S T 1 9 Ą S
9 7
Glass
C ellalation Produces Lightweight Insulation
To insure a uniform product, m oisture is elim in ated from the sp e c ia lly p rep ared cullet in this gas-fired rotary d ryer at the v e r y start of the p ro cess.
After drying, the cu llet is ground in a la r g e b a ll mill
N O R M A N G . F Ä R Q U H Ä R A ssista n t Editor, Chem ical & M etallurgical E ngineering
--- C h em . & M e t I N T E R P R E T A T I O N - ... ... ..
Of the m a n y products d e v e lo p e d during the la st y e a r or so, F o a m g la s, Pittsburgh-Corning's c ellu la r g la s s , is o n e w h ich w ill b e w id e ly u sed in the y e a r s to com e. W hether for air-conditioning of b u ild in gs, for co ld sto ra g e fa c ilitie s or for in su lation of industrial equipm ent, there w ill b e nu m erou s a p p lica tio n s for this lig h tw eig h t insulator w h ich a lso p rovid es re sista n c e a g a in st g a s , m oisture, fire and verm in. Its production a n d properties are d escrib ed here for our r ea d ers—
Editors.G
l a s s , a l r e a d y w i d e l y u s e d in the field o f h ea t in su la tio n , n o w o f f e r s a rem ark ab le, n e w c ellu la r in s u la tio n m a teria l o f ab ou t th e sa m e d e n s ity a s co m m ercia l b a lsa w o o d or cork. P ro d u c ed by th e P itts b u r g h - C o rn in g C orp ., th e n e w p ro d u ct k n ow n a s F o a m g la s is m a d e b y a chem ical r ea c tio n so m e w h a t a n a la g o u s to the r a is in g o f b read d o u g h w ith y e a s t.C erta in o x id e s in m o lte n g la s s rea ct w ith a sm a ll q u a n tity o f c a rb o n to m a k e carb on m o n o x id e and d io x id e g a s e s w h ich a r e tr a p p e d w ith in the g la s s a n d fo rm t in y sea led a ir ch am b ers n u m b erin g m ore th a n 5 m illio n in o n e cu b ic fo o t.
S in c e its str u c tu r e is cellu la r rath er th an p o ro u s, F o a m g la s is im p e r v io u s to both w a te r a n d v a p o r s, a p r o p e r ty n ot a v a ila b le in a n y oth er
k n o w n m a ter ia l e x ce p t som e o f the o r g a n ic cellu la r ru b b ers. T h e com b i
n a tio n o f in o r g a n ic g la ss, th e v a p o r - tig h t c ellu la r stru ctu re, lig h t w e ig h t, h ig h c o m p r ess iv e stren g th and p o te n ti
a lly lo w m a n u fa c tu r in g c o sts is r e sp o n s ib le f o r P itts b u r g h -C o r n in g ’s e n th u siasm a n d w illin g n e s s to incur h e a v y d e v e lo p m en t c o sts in s p it e o f w a r tim e d ifficu lties a n d h azard s.
P r o b a b ly th e b e st k n o w n a p p lic a tio n o f F o a m g la s is its u se a s th e b u o y a n t elem en t in s e v e ra l ty p e s o f flo ta tio n a p p a r a tu s f o r th e U . S. N a v y . H o w ever, it is e x p e cte d th a t th ere w ill be m a n y oth er u s e s f o r th is n e w p ro d u ct in o u r p e a c etim e eco n o m y . O ne im p o r ta n t field w h ich F o a m g la s h a s a lr e a d y in v a d e d is th a t o f lo w -tem - p e r a tu r e in su la tio n w h ere its p erm a n e n t r es is ta n c e to w a te r is a v ita l
fa c to r . I t se e m s lik e ly th at F o a m - g la s w ill b e u sed a s a s tr u c tu r a l in su la tin g ele m en t in p r e fa b r ic a te d wall, floor and r o o f se c tio n s f o r th e b u ild in g s o f th e fu tu r e . E v e n u n d er to d a y ’s co n d itio n s m a in te n a n c e e n g in e er s are fin d in g it an id ea l a n sw e r to the very r e a l p ro b lem o f g e t tin g a n insulated r o o f th a t w ill r e ta in it s o r ig in a l re
s ista n c e to h e a t tr a n s fe r w ith o u t re
q u ir in g fr e q u e n t r e p la c e m e n t or re
p a ir s. I n th is u se it is becom ing cu sto m a ry to la y sta n d a r d b u ilt-u p r o o fin g o v er 2 in . or m o re o f th e glass.
F o a m g la s w ill s u p p o r t its ow n w eight in a n y t y p e o f w a ll c o n str u c tio n w ith o u t d a n g er o f c r u sh in g or packing, w h ich m a k e s it id ea l f o r b u ild in g up s e lf - s u p p o r t in g p a r titio n s or curtain w a lls o f so lid in s u la tin g m a ter ia l. It sh o u ld n o t, h o w ev e r, be u sed fo r load- b ea rin g w a lls.
T h e Chem ical p r o c e s s in d u str ie s w ill b e q u ick to find n e w a p p lic a tio n s in co n n ectio n w ith e q u ip m e n t, su ch as s tills , co lu m n s, a n d o th e r h e a t ex ch a n g e a p p a r a tu s . On o v en s, fu r
n a ces a n d o th er h ig h tem p eratu re u n its, F o a m g la s ca n b e u s e d fo r hot- sid e te m p er a tu r e s u p to a b o u t 1,0 0 0 deg. F ., p r o v id e d th e se r v ic e condi
tio n s do n o t im p o se su d d en o r violen t therm al sh o ck s. T h is p e r m its its use in a la r g e n u m b er o f p r o c es ses in vari
ous in d u stries.
9S A U G U S T 1 9 .’, S • C H E M I C A L & M E T A L L U R G I C A L E N G I N E E R I N G
DEVELOPMENT OF THE PROCESS F o r a b o u t fifte e n y e a r s p r io r to 1 9 4 1 , o n ly in te r m itte n t in te r e s t in th e p r o c e s s f o r m a k in g c e llu la te d g la ss h a d been sh o w n b y in v e s tig a to r s in F r a n c e , E n g la n d a n d th e U . S . A . H o w e v e r , e a r ly in 1 941, a se r io u s d e
v e lo p m en t p r o je c t w a s b e g u n b y the P it t s b u r g h C o rn in g C o rp o r a tio n a t a n e w ly co n str u c ted p ilo t p la n t in P o r t A lle g a n y , P a . H e r e , su ch r a p id s tr id e s w e re m ad e th a t in a f e w m o n th s c o n str u c tio n w a s s ta r te d o n a f u ll- s c a le p la n t a lo n g sid e th e e x is tin g g la ss b lock fa c to r y .
T h e n ew p la n t c o n sists o f a o n e - s t o r y b u ild in g c o n ta in in g a p p r o x i
m a te ly 5 0 ,0 0 0 s q .f t . o f floor sp a c e . I t i s o f m odern c o n str u c tio n w ith a ste e l fr a m e on r ein fo r ce d co n crete fo u n d a tio n s . F lo o r s a re a lso co n crete, w a lls a r e o f brick , g la s s block a n d corru g a te d a sb esto s, p a r titio n s o f tile , and r o o fin g o f tar a n d f e lt o v er g y p s u m p la n k in on e p o r tio n a n d w a te r p r o o fe d co rru g a ted a sb esto s o v er the fu r n a c e s . T h ree c o m p lete p r o c e s s u n its h a v in g a co m b in ed c a p a c ity o f a b o u t 2 5 ,0 0 0 b d .ft. p e r d a y h a v e b een i n s ta lle d in o n e -h a lf o f th e p la n t, the la y o u t h a v in g been p la n n e d to p e r m it in s ta lla tio n o f th ree a d d itio n a l u n its w h en e x p a n s io n is req u ired . A t p r e s e n t a ll th ree u n its arc r u n n in g a t c a p a c ity r a te w ith th e ir e n tire o u tp u t g o in g in to e sse n tia l u ses, m a in ly fo r flo ta tio n a p p lic a tio n s f o r th e U n ite d S ta te s N a v y , an d a s a lo w -tem p er a tu r e in s u la tio n m a ter ia l.
R AW MATERIALS
T h e tw o e sse n tia l r a w m a ter ia ls u sed are a s p e c ia lly p r e p a r e d fo r m o f c u lle t a n d fin e ly d iv id ed carb on . T h e fo r m e r is o b ta in e d fr o m th e p r im a r y m e ltin g fu r n a c e in th e a d ja c e n t g la ss b lock fa c to r y a n d sto r ed in b u lk , w h ile the la tte r is rec eiv e d a n d sto r e d in 1 0 lb. p a p e r b a g s. P a r tic u la r ca re is e x er cise d to p r e v e n t f o r e ig n m a tter, e s p e c ia lly o f a n o r g a n ic n a tu re, fro m c o n ta m in a tin g th e c u lle t, a n d to th is end a s p e c ia lly c o n str u c ted sto r a g e s p a c e h a s b ee n p r o v id e d w ith in the p la n t. O th erw ise, im p u r itie s in the batch w o u ld a ffec t th e c e llu la tin g r e a c tio n a n d th e p r o d u c t w o u ld be im p r o p e r ly fo r m e d w ith b lo w h o les a s in im p e r fe c t m e ta l c a stin g s.
PREPARATION OF BATCH T o in su r e u n ifo r m ch em ical r ea c tio n s in th e fu r n a c e , th e c u lle t is th or
o u g h ly d ried a n d g ro u n d . D r y in g is a c co m p lish e d in a co u n ter-cu rren t r o ta r y -ty p e d ry er, co n stru cted o f steel, a n d fired b y n a tu r a l g a s. T h e d ryer is f e d b y m ea n s o f b u g g ies k n o w n as
“G eo rg ia b u g g ie s” w h ich b r in g the c u lle t fr o m sto r a g e a n d ch arge it a t a r a te o f a p p r o x im a te ly 60 lb . p e r m in.
D r ie d c u lle t d isch a rg ed fro m th e d ryer is p ic k e d u p b y b u ck ets on a b elt e le v a to r a n d carried to the c u lle t h o p p e r , a n e le v a ted ste e l b in u sed f o r a n in te r m e d ia te s to r a g e a n d fe e d e r s u p - p ly .
G r in d in g the c u lle t a n d m ix in g th e carb on w ith it are co m p leted in on e
c o n tin u o u s o o p e r a tio n in a la r g e b all m ill d riven b y a 1 5 0 -h p . m o to r th ro u g h a sile n t ch a in d riv e. A b a tc h -w a y fe e d e r c o n s is tin g o f a s m a ll s te e l h o p p e r in sta lled o n sc a les a n d f e d fr o m the c u lle t bin d isc h a r g e s 1 5 0 lb. to the ball m ill th ro u g h a sc o o p fe e d e r a t in te rv a ls o f five m in u te s. T h e carb on is w e ig h ed m a n u a lly a n d f e d to the m ill in a r a tio o f le s s th a n 1 p e r ce n t o f the g la s s c h a r g e. T h e b a ll m ill it s e lf is a ste e l sh ell 8 f t . in d ia m eter by 1 4 f t . lo n g , lin e d w ith 4 to 5 in . o f b u h rsto n e. T e x a s flin t p eb b les a b o u t 2 in . in d ia m e ter a re u sed to g r in d th e m ix tu r e a s it tr a v e ls dow n th e le n g th o f th e m ill in a p e r io d o f a b o u t five h ou rs. A p p r o x im a te ly 95 p e r ce n t o f th e fin a l m ix w ill p a s s th rou gh a 325 m esh screen , th e la r g e r p a r tic le s b e in g r ecy cled f o r fu r th e r g r in d in g .
A f t e r g r in d in g , a n o th er b u ck et e le v a to r p ic k s u p th e m ix ed b a tch a n d d isch a rg es it to a ste e l b a tch b in w h ere it is a v a ila b le f o r th e firin g o p e r a tio n . A v ib r a tin g fe e d e r c o n v e y s th e fin e ly p u lv er iz e d m ix tu r e to a u to m a tic w eig h sc a le s w h ich a re lo ca te d n e a r th e f u r n a ce e n tra n ce. P a s s in g u n d er th e sc a les is a r o lle r c o n v e y o r b r in g in g m old s w h ich c a rr y th e c h a r g e th ro u g h the fu r n a c e . T h e m o ld s a re m a d e o f
¿ -in . s ta in le s s s te e l in tw o se c tio n s c o n s is t in g o f u p p e r a n d lo w e r h a lv e s a n d are ta p e r ed in b o th w id th a n d le n g th to f a c ilit a te r e m o v in g th e b lo c k a f t e r firin g. E ach m old is a lso co a ted w ith a d e x tr in -k n n lin m ix tu r e to b eep the p o w d e red g la s s fr o m s tic k in g to it A b atch of ab ou t 10 lb. of the fin e ly ground cullet
an d carbon is m ea su red b y th e se autom atic w e ig h s c a le s, dropped into sta in le ss s te e l m olds an d fed
to the firing fu rn a ces
A fter firing for ap p ro x im a tely three hours, the b lock s a re "stripped"
from the m olds b y "strippers" and im m ed iately p la c e d in a n n e a l
in g leh rs for a thirty hour h ea t treatment w h ich is c lo s e ly con trolled b y instruments
C H E M I C A L & M E T A L L U R G I C A L E N G I N E E R I N G • A U G U S T 1 9
9 9
w h en h ea ted . A c h a r g e o f a b o u t ten p o u n d s se e m s to j u s t a b o u t cover the b ottom o f th e m old , b u t p r o d u ce s a F o a m g la s b lo ck w h ich , a fte r trim m ing, m e a su r es 6 in . x 1 2 x 1 8 in.
CELLULATION
T h e fu r n a c e in to w h ich the ch arge is fe d o n a r o lle r d riv e is a b o u t CO ft.
lo n g a n d g a s-fired b y m ea n s o f 80 se p a r a te b u rn ers. T h is la r g e nu m ber o f b u rn ers is n e c e s sa r y to in su r e u n i
fo r m ity o f te m p er a tu r e , on e o f the m o st im p o r ta n t p r o c es s c o n d itio n s.
E n te r in g th e fu r n a c e a t a tem p era tu re o f 1 ,2 5 0 d eg . P ., the g la s s a n d carbon m ix tu r e is su b je cte d to a co n tro lled th ree-h o u r h e a tin g . A s th e m o ld s p a s s s lo w ly th ro u g h th e fu r n a c e on ca st a llo y ro llers, th e te m p e r a tu r e is first in c re a se d to a m a x im u m o f a b o u t 1,550 d eg. F ., th en lo w ered a g a in to 1,150 d eg. F . n e a r th e p o in t o f d isch a rg e.
A s p e c ia l d ev ice a u to m a tic a lly co n tro lled b y p h o to e le c tr ic c e lls c om es in to p la y h ere a n d su b je c ts th e m old to a te m p er a tu r e o f 1,350 d eg . F . f o r th ree m in u te s b e fo r e r in g in g a b ell to n o t if y th e o p e r a to r th a t th e m old is r ea d y f o r r em o v a l fro m th e fu r n a c e . T h is final b o o st in te m p er a tu r e c a u se s the s ta in le s s ste e l to e x p a n d s lig h t ly and se p a r a te fr o m the F o a m g la s w h ich h a s n o w b low n u p to fill the m old . A t th is p o in t th e F o a m g la s B lo c k c lo s e ly r e sem b les a b la ck m a ss o f fo a m , a n d its d e n s ity h as c h a n g e d fro m a b o u t 5 0 lb.
p e r c u .ft. to 1 0 lb. p e r c u .ft.
T h e m o ld s a re m o v ed o u t o f the fu r n a c e on r o lle r s to th e o p e r a to r s, or
“ s tr ip p e r s ,” w h o a re r e a d y w ith a sb es
to s g lo v e s to “s tr ip th e m o ld s” and
Physical Properties of PC Foam glas
S p ecific'G rav ity ... 0.17 (10 to 11 lb.
p er C u. F t.) K (C o n d u ctiv ity a t 70°F .)____ 0.45 B .t .u ./ H r ./
S q .f t./° F ./I n . K (C o n d u ctiv ity a t 300“F .) .. . 0.70 B .t .u ./ H r ./
„ , S q .f t./° F ./In .
Coefficient of
E xpansion (°F.) ...0000046 Specific H e a t ... 16 to .19 B .t.u.
p e r lb. p e r °F.
C rushing S tre n g th ... 150 lb. p e r sq. in.
M odulus of R u p tu re ... 90 lb. p er sq. in.
Im p a c t S tren g th (C en ter D ro p -in crem en t m ethod, on 8* x 1 0 ' x y th ic k specim ens
su p p o rte d on a 1 2 ' s p a n ) 66 f t.—lb.
A bsorption (24 H r. Im m ersion
in W a te r )... 0.4% b y Volume—
2% b y W eight (All a t surfaces) Air In filtratio n or
P e rm e a b ility ... 0 C a p illa rity ... 0 Volume Change w ith
M o istu re ... ... 0 Standard Sixes and Packing
Pieces p e r A pproxim ate G lass size carto n w eig h t P er carto n 12 x IS x ...2 ... 12 3S.0 lb.
1 2 x 1 3 x 3 ... S 37.51b.
12 x IS x ... 6 41.3 1b.
12 x IS x 6 ... 4 37.01b.
A v ie w of the n e w F o a m g la s p la n t at Port A lle g a n y , P en n a . T y p ica l of g la s s plant construction is the h u g e monitor w h ic h p ro v id es ven tilation lor the hotter parts in the b u ildin g. A lso in e v id e n c e are the w a lls of
g la s s b lock s m a d e in the ad ja c en t plant
p la c e the block s in a leh r f o r a n n e a l
in g . D o o rs and ro llers on fu r n a c e s and leh rs are c o n tro lled b y p u sh b u tto n s c o n v e n ien tly lo ca ted n e a r the o p e ra to rs.
T h e str ip p e d m old s are p la c ed on a ro ller c o n v ey o r and carried back to the lo a d in g sc a les via a s p r a y b ooth . In th is booth each m old is th o r o u g h ly c lea n ed and s p r a y e d w ith th e d ex tr in - k a o lin m ix tu re describ ed above. To p r o te c t the o p e r a to r o f th e sp r a y a p p a r a tu s fro m fu r n a c e r a d ia tio n an in s u la tin g w a ll o f F o a m g la s b lo ck has b een in sta lle d b etw een th e fu r n a c e and s p r a y booth.
ANNEALING THE BLOCKS A n n e a lin g F o a m g la s block s is a c
co m p lish ed in gas-fired r e c ir c u la tin g leh rs 1 1 0 f t . lo n g an d o f a h ig h ly s p e c ia l d e sig n . On a ste el w ire b elt 1 0 f t . w id e, tw e lv e block s u p o n end a re ca rried a b r e a st th ro u g h a tem p e r a tu r e g r a d ie n t fr o m 1,0 5 0 d eg . F . to 1 2 5 d eg. F . T h e tim e req uired f o r a n n e a lin g v a r ie s, o f cou rse, w ith th e th ic k n e ss o f th e sla b s a n d th e ra te o f co o lin g , w ith a m a x im u m cycle, u n d er p r e s e n t o p e r a tin g co n d itio n s, o f a b o u t 30 h ou rs. One o u tsta n d in g p o in t in th e d esig n o f th e leh rs is the 2 6 -in . fr e e tu n n el h e ig h t w h ich is u n u s u a lly la r g e f o r th e g la s s in d u str y a n d g iv e s g r e a tly in crea sed ca p a c ity . G en er a lly , th e d ifficu lty o f m a in ta in in g u n ifo r m te m p er a tu r e a t a ll p o in ts in th e e n tir e e ro ss-se etio n o f the leh r n e c e s sita te s k e e p in g th e tu n n el h e ig h t to a c o n sid e r a b ly sm a ller d im en sion .
FINISHING A ND PACKOUT A n n e a le d r o u g h b lock s o f F o a m g la s fro m th e leh rs a re m a n u a lly loaded
o n to sk id p la tfo r m s or tr a v e lin g c o n v e y o r s f o r d e liv e r y to th e fin a l trim m in g m ach in es. H e r e each block is in d iv id u a lly c u t a n d sh a p e d , first in a fa c e trim m er a n d th en a n e d g e tr im m er. T h ese trim m ers cu t the b lock s by m ea n s o f r o ta tin g w h eels, th e fa ce trim m er b e in g e q u ip p e d w ith two 3 6 -in . ste el-c en ter e d carb oru ndum w h eels. T h e b a se s iz e o f th e blocks is 6 in . x 1 2 in . x 18 in ., h u t th e y are e a s ily slic e d o n a h a n d sa w to p ro d u ce les se r th ic k n e ss e s su ch a s in ., 3 in.
o r 2 in. S ta n d a r d card b oard cartons are u sed to p a c k th e fin a l p ro d u ct fo r s h ip m e n t a f t e r an in s p e c tio n o f each b lock h a s b een m ade.
T a ilin g s fr o m th e trim m in g and s lic in g o p e r a tio n s a re ca rried a w a y on a c o n v e y o r b elt to a s tir r u p cru sher in a p it b elo w floor lev e l a n d th en d is
ch a rg ed in to a h o p p e r . W h e n the h o p p e r is filled , a m o n o r a il a n d trolley h o ist rem o v e i t to a d u m p o u ts id e the b u ild in g . A s y e t th ese t a ilin g s have n o t been p u t hack in to th e p ro cess.
VENTILATION
T y p ic a l o f g la s s p la n t co n stru ctio n is th e h u g e m o n ito r v e n tila to r above th ose p a r ts o f th e p la n t w h ere m ost o f th e h e a t is c o n c en tra te d in p ro ces
s in g . I n a d d itio n , a m o d ern d u st col
lec to r s y s tem k e e p s th e e n tire p lan t e ffe c tiv e ly clea n a n d f r e e fr o m dust in s p it e o f th e f a c t th a t se v e ra l very d u s ty o p e r a tio n s a re p e r fo rm e d . A n etw o rk o f d u e ts c o n n e c ts th e sp r a y booth, a u to m a tic w e ig h m a ch in e and trim m in g m a c h in e s w ith a la r g e bag- t v p e d u st c o llecto r. T b s d u st from th is c o lle c to r is d isp o se d o f in the sa m e m a n n er a s th e ta ilin g s fro m the tr im m in g m ach in es.
1 0 0
A U G U S T 19,'fS . C H E M I C A L & M E T A L L U R G I C A L E N G I N E E R I N G
Taken from the leh rs after a n n e a lin g , the rough b lock s are lo a d e d onto sk id platform s or tra v ellin g c o n v e y o r s for d e liv e r y to the fin a l trimming m a ch in e s. Lehrs are the recirculating ty p e sp e c ia lly d e sig n e d to g iv e a
26-in. free tunnel h eig h t thus provid in g g rea ter c a p a c ity
PROPERTIES
S a w s or a n y o th er o r d in a r y c u ttin g tool a re p e r f e c t ly s a tis fa c to r y fo r sh a p in g o r fittin g F o a m g la s blocks fo r in s ta lla tio n , a n d a sim p le a sp h a lt- eem en t m ix tu r e a p p lie d b etw een b lock s p r o v id e s a b o n d th a t is se cu r e and d u ra b le. T he in o r g a n ic n a tu re o f cel- lu la te d g la s s p r e clu d es th e p o s s ib ility o f a tta ck b y verm in and a lso p r o v id e s
C H E M I C A L & M E T A L L U R G I C A L E N G I N E E R I N G . A U G U S T 1 9 1 /S .
r es is ta n c e to a c id a tm o sp h e re s a nd o th e r c o rr o siv e m a ter ia ls . F o a m g la s is n o t o n ly n o n -co m b u stib le , b u t a lso a c ts a s a fire reta r d a n t, an im p o r ta n t fa c to r w h en it is to be u sed in co m b in a tio n w ith c o m b u stib le m a ter ia l. I t s h e a t c o n d u c tiv ity , w h ich a t 70 d eg . F . is 0.45 B .t .u . / h r ./ s q .f t ./ d e g . F . / i n . , a n d a t 300 d eg . F ., 0.70, w ill n o t ch a n g e in s p ite o f th e p r e se n c e o f a n y a m o u n t o f m o istu e . O b v io u sly , th e r efo r e, in c a se s w h ere w a te r o r d a m p n e ss a c t to n u llif y th e in s u la tin g v a lu e o f o th er m a ter ia ls, F o a m g la s w ill p r o v e a boon to in d u str y .
T h e sp ec ific h e a t o f F o a m g la s ra n g es fr o m .16 to .1 0 B .t.u . p e r lb.
p e r d eg. F ., w h ile its co efficien t o f e x p a n sio n (d o g . F .) is .0 0 0 0 0 4 6 . O n the o p p o s ite p a g e is a ta b le o f th e p h y s ic a l p r o p e r tie s o f P C F o a m g la s g i v in g c o m p lete d e ta ils w h ich sh o u ld be o f in te r e st to en g in e er s w h o d e sig n an d in sta ll in su la tio n o f a n y k in d . T h e siz e s c u rren tly a v a ila b le are a lso listed .
Left— F o a m g la s b lock in a n e d g e trimmer.
Rough blocks a s th e y com e from the lehrs h a v e u n ev en fa c e s an d ta p e red e d g e s w h ich must b e sq u a red off in fa c e trim
m ers an d e d g e trimmers. The fin a l product a s sh o w n after trimming is a p er
fect block 6 in. x 12 in. x 18 in.
B elow — Tem perature control a n d r e g u la tion is centered in a g la ss -e n c lo se d room cen trally lo ca ted in the p la n t. H ere a battery of recorder controllers operate, the furnaces an d leh rs a n d forem en chart
variou s tem peratures in the p ro cess CONTROL
C en tra lly lo ca ted b etw een th e ro w s o f fu r n a c e s a n d leh rs is a n elev a ted g la ss-in c lo se d co n tr o l ro o m in su la ted w ith F o a m g la s . H e r e a r e in sta lle d v a r io u s record er co n tr o ller s f o r the g a s b u rn ers on each fu r n a c e a n d lehr.
N u m er o u s a d d itio n a l te m p e r a tu r e s are read on a n in d ic a tin g p y r o m e te r by m ea n s o f a se lec to r sw itch a n d p lo ts a r e m ad e o f th e tem p era tu re o f the F o a m g la s b lock s a s th ey m o v e th ro u g h th e leh rs. T h e se p erm a n en t reco rd s a d v ise each s h if t fo r em a n o f w h a t h as h a p p e n e d on th e p r e v io u s s h if t , and a lso p r o v id e in fo r m a tio n w h ich is in v a lu a b le in q u a lity co n tr o l w ork. B y lo c a tin g this room c en tr a lly a b o v e the o p e r a tin g floor, a g o o d v ie w o f the e n tire p la n t is o b ta in ed , a n d a co n sid e r a b le m a teria l s a v in g w a s m a d e in th e in itia l in s ta lla tio n o f le a d w ir e f o r the th erm o co u p les. T h e c o m p a n y ’s r esea rch a n d f a c to r y co n tr o l la b o r a to r ie s a re h o u sed in a s e p a r a te b u ild in g n ea rb y . A c o m p r eh en siv e p r o g ra m o f fu r th e r resea rch on c ellu la r g la s s is u n d erw a y , d irected tow ard 'fin d in g n ew w a y s to m ak e th is u n iq u e p r o d u ct, a n d th e s o lu tio n o f th e p r o b lem s c o n n ected w ith the p r o p e r a p p li
ca tio n o f th e m a ter ia l to the m a n y co m m e rcia l u ses a lre a d y en cou n tered .
