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—=1 A> 2
Topo
CM~INO

el ae
A PROPOSED PULVERIZED
COAL INSTALLATION FOR THE
OR OREO OL OO) Teh hd
E. L. Powers H. W. Norman

1921
 

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A PPOPOSEN PYLVTRIZ™D CCAL INSTALLATION
For

THE RTO MOTOR CAR COMPANY

A REPORT SUBMITTED TO THE FACULTY
oF THD
MICHIGAN ACRICULTURAL COLL™C™

BY

: Le
Ty. Le Powers. H.7. No Wan
Candidates %cr the derree of

Bachelor of Selenca
THESIS

|
CDI

tee & + 284 RS

PART tf TUT HOC TT i ee

PANT BR rcetcelov are mem tet op eaten
COAL I UCOLEIRGICAL PURIOS GoD

We RR BOLLE @ a
Dont TTY De2a eas
Pains LV ga uo is OF Loe. ean
Daaii's v Cong Maton Pees

10287 nf

We
Part 1
Introduction.

This problem wns cho§sen upon the recomndation
of Mr. W.G- Hildorf, of the Reo Motor Car Co., It is
Gnevitanle that within a few years fuel o11 will, due to the
decreasing supply, increase in price until the cost will pro-
hioit ite use in heat treat work.

Pulverised coal ig being used to some extent at the
present time in heat treat work, and is used quite extensivd y

in power plants.

In thie report we will endeavor to show the feas
ibility of the application of a pulverised coal installation
to the heat treat and power plant departments, the cost of
installation, the equipment needed, and the difference in
costs of operation of the two systens.

We wish at this tine to express our indebtedness
to Mr. W. G. Hildor® for his assistance in making available
to us the data and information that we obtained from the Keo

Motor Car Company.
Part 11

Discussion of the Use of Powdered Coal in
Metallurgical

Furneces and Under joillers.

although powdered coal has not been used aa a fui

for metallurgical furnaces or boilers for perhaps more than
fifteen years, it has been used successfully in the cement
industry for more than twice that long. As fuel o11 has
risen in price powdered coal systems have veen installed to
take the place of the o11 systems, and as coal has become
harder to obtain, stokers have deen taken out and powdered
coal burners pat in their place. a

Of course, something more is necessary, tor the
efficient vurning of powiered fuel, than the mere removing of
an oil] burner and patting in its place a powdered coal inlet,
or removing a stoker and cutting a hole in the side of the
voller setting for the admittance of a powdered coal burner.
In many cases, in order to change from gas, coal or oil to
powdered coal, it is necessary to completely redesign the
combustion chamoer of the furnace or bollier setting.

4 few words on the design of furnaces for pulveris-
ed fuel may be of interest. The primary requisite for good
results is to mintain low velocities in the furnace. The

oombustion is no less complete with high velocities, out this
will result in damage to the linings and in their erosion.
4 furnace cubical in shape usually gives the most satisfactogy
results.

fhe burners should injeot the ceal under low
preasure and should permit of varying the density of the
mixture in the purnor ituelf. Their location and number will
depend on the size of the boiler and rating required, and also
may be varied to suit the grade of fuel. High boiler ratings
such as are used in modern coiler practice can be obtained
when desired, and such over ratings should be predetermined
ané the furnace volume designed accordingly. (Hote. The last
two paragraphs have been quoted from a paper by FP.A. Scheffler
and H.C. Hurohuret, “Pulvorized Goal for Stationary Boilers"
presented at Spring Meeting of A.S.M.i. Detroit, Miohigan
June 16 to 19, 1919.

While 4t ie not absolutely necessary to redesign
the combustion chamoer in order to make the fire purn, if high
efficiencies are desired, and bigh efficiencies are necessary
if powdered coal equipment is to replace stokers and oil gw stens,
the furnace defign mast conform to the design most efficient
for vurning powdered coal.

Probably the main incentive for doveloping powder-
64 coal equipment has been the hopes that an inferior grade of
coal may be used in this way than a stoker installation is
capable of handling. C. F. Herington author of “Powdered
Coal as a Puel” states: “Mout of the experience hitherto obtain-e
ed has been on high grade, highly volatile, soft coals, and
efforts to burn inferior grades have often led to disappoint-
ment. It is in recent practice, and in the hands of only a
few investigators, that good results have oveen obtained from
inferior soft coals and from anthracite. <All of the most
recent developments for steam generation have been made with
anthracite culm, at one time definitely abandoned as a suit-
able fuel for powdering. Yowdered coal, like ordinary
commercial coal, should be practically free from sulphar, for
all but the most exoeptional applications.

¥. Ae Scheffler and H.G. surnhurset in their payer
atate that there are three main advantages of the pulverised
fuel equipment over stoker equipment. These advantages sre:
reliavility, cost and adaptaoility.

Firet, in comparing the stoker to the pulverised
fuel equipment, we find that the factor, relianility, depends
on two items: apparatus for preparing and presenting the fuel
for combustion, and continuity of operation of the furnace
itself. Gn a stoker installation the first of these includes
the stoker itself. Neglecting the inherent defects in any
system that presente a metal mechaniam to the action of high
temperatures, it may be admitted radily that the stoker system

ie satisfactorily reliable, with respect to its apparatus for
preparing and presenting the coal for combustion.
fhe corresponding mechanisms for pulverised coal
are equally reliable. ‘This fact is proved by their widespread
use for years in the cement industry. Lroper design oy
engineers of standing who are specialists in this line has
made negligible the danger of dust explosions, the occasional
ocourances of which in yeare past have furnished ammunition
to the opponents of pulverised fuel.

Tie second condition for reliability is the

continuity of operation of the furnace. During operation,

it has been found that the pulverised fuel installations and
stokers are on 4 par as far as this item is concerned. Hovever
the advantage seems to lie with the pulverised fuel, for several
reasons. The mechanien is altogether outoide of the furnace
hence cleaning and adjustaent and the making of the few repairs
required need not interupt the operation of the furnace. In
case of necessity the fire may ve ignited and quickly orought

to full intensity, or it may be extinguished almost inatantly.
Greater uniformity of flume ané tomperature is conducive to
longer life of the furnace lining in a properly designed rurnaces,
and to the minimum variation in turnace effigiency.

The wecond factor refers to the eost per B.f Ue dele
ivered to the voller. The various items entering into the
cost py the etoker system comprise power, repaire and miin-
tainance, labor, interest on inveutment, depreciation, insurance

end taxes.

With pulverized fuel equipment, the cost of fuel for
the drier should be added to the preceeding items. It is
clear that it would be cheaper to remove the excess moisture
from the coal vcefore it enters the fire, as in the case of
the stoker, becamse in this case the evaporation damps the
fire, increases the content of the inert gases and at the

@ame time carries off a very perceptable amount of heat.

The final factor of the cost, furnace effeciency,
which governs all of the others, regults in all respects to
the advantage of pulverised fuel for the following reasona;:

First the pulvorised fuel enters the combustion
chamber ina finely divided state, being introduced with air
at low preasure, and is approximately perfectly mixed with
air for theoretically perfect comoustion. Therefore no
exeess air is required for ourning. #ith the stoker it is
impospible to cura the fuel without excess fuel due to the
fact that it is impossible to get a uniformbed of fuel on
the grate or stoker. Furthermore if it is necessary to intro-
duce excess air with pulverized fuel it can ve done in exact
amounts. In other words the conbustion and character of the
fire ia at all times under the control of the operator.

second, in pulverised form all of the comousatiole
ie burned a condition certainly ic.poasible with lump~coal
firing either by hand or stoker. It is not unusual to fi nd

20 or 30 percent of caroon in ash refuse from grate or stoker
fired boilers.

Third, with pulvoriged fuel there are no stendo
losses with change of load or when shutting down, such 4s
banked fires.

“hird with properly designe: pulverised fuel
appratus nothing of a mechanical nature takes place in the furnace.
In astoker and grate firing not only is the mixing of the air deme
in the furnace, but the presentation of fresh surfaces of the
combustible to the air supply mst t:ike plexce by the removal of
the ash.

In Gonsidering the third factor, adaptability, it
can be shown that pulverized coal is again preeminent. The
primery feature is the posuloility of burning all grades of
fuel with out effecting the effheiency of the furnace. ‘'o burn
powdered anthracite and very low grades of fuel requires a
furnace allowing « return flow of YZame past the incoming
flame, to heat up the incoming fuel, and in a furnace of this
type, fuel containing over 5&O per cent ash has oeen burned
with high effeciency. “he stoker is vory much reatrioted
in this res pect.

The flexibility in the use of pulverized fuel
is perfect, and the fire may ve instantly adjusted to suit any

condition, any condition of overload or lower load, includ-
ing the cutting in and out of nollers. The paramount impor-
tance of this feature and the utter imposinility of approach-
ing it with stoker or grate firing is readily evident.
Futhermore, the operation and the determination of conditions
for complete comoustion muy ove made automatic, the result
being a emokeless and sootless vcoiler plant, which is
essential in modern cities.

fhus it can be seen that, taken as a whole,
pulverised fuel equipment is wuperior in every way to stokers.
Is is admitted, however, that pulverised fuel is not
applicable to every plant. John Andereon, Chief stngineer
of Power Plants, Milwaukee Xleotric Light and Railway says
“A plant of lese than £500 developed boiler horespower on
a twenty-four operating basis should not consider using
powdered fuel. The mount of coal pulverised per day, the
cost of installation, and the lavor for operating the
preparation plant, when studied show that the installation
would not be practicanle”. Refering to the cost again, we
see that the items which go to make up the cest of pulveris-
ing ares: power, repairs and maintainance, coal for drying,
labor, interests on the investment, depreciation, insurance
and taxes. Ina given locality, the cost of all these items
will inorease with the sise of the plant, exsept the lavor.
¥. Ae Schaffeler and H. G. Barnhurst say in their paper on
puiveriszed coal for boilers “* The item of labor is the greatest
variadle in connection with the pulverizing of coal, due to
the increaséd output that can be obtained in larger plants
per man employed. for example, assuming that lavor costs
forty cents per hour, ea plant that hes a daily capacity
of 100 tons, is properly dewigned and equipped, will require
apprceimately 34 labor hours to prepare the fuel and deliver it
to the conveyors, whereas in a plant having a daily capacity
of 1000 tons, 115 labor hours are required. Therefor the
labor cost would be 14 cents per ton in a 100 ton plant, only
4 cents per net ton in 1000 ton plant and as low as 21/2
cents per net ton in a plant of 6000 tons daily capacity".

Very little information is available on the use
of powdered coal in heat treating furnaces, that is relating
to the conditions effecting the efficient burning. It is
known, however, that powdered coal is used sucessfully in
all kinds of furnaces and that it is replacing o11, gas and
other fuels. It stands to reason that the same factors
would effect the ourning of the pulverised fuel in these
furnaces as under ooilers the only difference being that it
would be on a smller scale in the heat treating furnaces.
Probadly the main reason why pulverized coal is replacing oii
is due to the increased cost of the fuel o11, thus making the
cost per BTU. more with o11 than with oulverised coal. There
10

is also the argument by some engineers that the heat with
powdered coal is superior to heat with oil, for heat treat-
ing work .

fhas in general it can ce seen that powdered
fuel is superior to other fuels, for ordinary wrk, and it
is the general velief among engineers fomaliar with fuels and
fuel burning apparatus, that in the near future, pewdered
coal will be preeminent in the industrial world as a fuel.
 
Part lll.
Data.

In order to obtain as nearly correct a solution
of this proplem as possiole, we wrote to several companies
engaged in the manufacture and installation of pulverised coal
equipment, asking them for copies of pulletinas advertising
their equiyment. We stated the problem to them and asked tha
they furnish us with estimates as to the feasibility of the
proposition, the probable cost, equipment needed, and what
saving, if any, would oe derived from the use of pulverized
coal.

We corresponded with the following companies in
regard to this proposition:-

quigley furnace Specialities Vompany.
Hew York.

Combustion Kconomy Corporation.
1901 S. Rockwell Ste,
Chisago, Til.

Fuller Engineering Company,
Allentown, Pue

The Bonnet Company.
Canton, Ohio.

Fuller - Lehigh Company
fullerton, tie

american Industrial sngineering Co.,
Monednock ‘sullding,

Combustion Snzgineering Company,
ll sBrot.dway.
New York.
These companies offered to assist.us if we wuld
furnish them with the necessary intormation and data concern-
ing the Reo heat treat depertment and voiler room. Wo complie ‘
this data from the records of the company, personal observatio’,
ané information furnished us by the officials of the Reo Motor
Car Company.

Prints were obtained of the boiler settings, coal
handling equipment, and Jayouts of the heat treat departmente,

and poiler room.

Sets of the data and prints were sent to each of
the aforanamed companies, The data furnished the companies
is given on the following pages.
13

BOTLiR ROOM DATA SHast

Hoe of voilera - 7

Noe in batteries - 6

Type and make ~ 6 licNsaulls 1 Springfield.
Rated horsepower - 4-400; 5504 1-870
Arrangement of baffles ~- Vertical,

Dimensions of furnaces ~ Given on blue prints.

Kiné of stokers ~ Jones Std. and Jones AeCe on
Springfield.

Kind of draft » Forced.
Sige and height of stack ~ 12 ft. X 175 ft.
Vagsuum at breeching in inches of water -.75

Coal handling esuipment - sucket elevator, flight
conveyor over bunker.

Hours operated per dry = 24.

Days per year - 0

Overload carried -racticully none.

Number of men to operute and cost:-

Day shift - 2 men ~ 12 hours ~ 60 cents per hour.
Night shift - Same as day ohift.

Yo utesm used for generating electricity.
FULL Valae

Kind ~ West Vu. Cost per ton - (2.85
Grade - Mine run. Preight por ton - £4.75
Amount used per ésy (24 hours) - 80 tons avor.

Annual consumption - 24000 tons.

ANQLYS 15.

Volatile ~ 36.4% BeZeUe ~- 12000 - 14000
“2 SANA

 
ASh - 4.97% Fixed carvon ~ 57.4,
Sulphur - 1.16% Foiseture - Not determined

were
The following pvlue prints mébak be sent under

separate cover: -

Plan showing tracks ané ouildings in viainity of bnoiler room;
coal handling equipment; boiler settings of 400 H.?. McNeaull
and 870 Her. Springtield.
14

FPURNAC A Dili
Cyvaniée rots.
Purnsoes #1 = 21 © WS we UG & 24 & 26
Make = Strong, Carlisle and Hammond, RNeoullt.
Temperature - 1400 der. ¥.
Tine per heat - 14.17 minutes.
Weieht of metal per heat per furnace - 40}

Yur naces.

Yurnace #2.

Mike @- 3.0. and He 717 Rebuilt.
femp. - 1650 deze F.

Time - 55.01 min.

Wt. of met~-al per heat - 137.5}
Furnace #3 - 4.

Make - Bellevue #7.

fempe ~ 1425 deg. F.

Time - 60 min.

ft. of metal per heat - 200;

Furnaoe /5 - 6.

Make ~ 3,C and H. #4.

femp. - 1425 dog. F.

Time - 64.4 min.

ite of metal per hezt - 3512.

Furnace i7 - 7.
Make - 3,0 and He iti.

Tomp. - 1500 deg. F,
25

FURN.AC2 DaTaA.

Time - 52.24 min.
Wt. of metal per heat - Z2L0F «

Furnace #13.

Make S,C and H. }£485.

Tempe - 1525 dog. F.

Time - 5O min.

Wee. of metal per het - 625

Lead votse

Yurnaces #14 to #20 inol.
Woke - 8S, C and HH. Neoullt.
Tempe - 1550 deg. F.

Time - 36.06 min.

Wte of metal per heat - 142}.

Mext bhhree furnaces in the line of the lead pow
(ae shown on bDlue print) are preheat furnaces and are only used

internittenly.
Carourizing.

Furnace #41.

Muke ~- 53,C and H. xevuilt.
fempe ~- 1726 dex. Fe

Time - 12 hours.

wt. Of metal per hert inol. wt. of box - 1315.
16

FURR AC: DiTAe

Carnorizing surnaces.

Furnaces +42 to 68 incl. and +61-62-68-64. |

linkee Packard Ty ve furnace. This rofers to al
numoers xvove We

Miuke #41 - 50 inole - 3,C and H. Hevuilt.
Tempe - 1725 deg. Fe
Time - 11 hours.

Ate of metal per het ~ 14607

Furnaces #59 - 60 « 63 = 63.
Make - Packard Type “urnace.
Tempe - 1725 deg. Fe

Time - ll hours.

ite of motu] ver heat - 2625;

Purnace $70.

Bike = \merican ous “urnnoe Co.,
Tempe ~ 1425 dex fF.

Time - 75 min.

Wte of mete] par heit - 15°:

Forging urnscose

Type A
Noe of furnace of this type = 3

Tempe - £2000 dog. Fo
Wee of mterial heated per day per furnace - 850 }
Make - Buikt oy the Reo Motor Cur Co.,
17

PURILAC i Davie

ype Be
Noe of furnaces of this type - 3
Tompe = 2000 deg. F.
ite of metal . :.eated per day per furnace - 6330#

buixe - Built by the Reo hotor Car Co.,

[ype C.

lo. of furnaces cf this type - 3

Tempe = 2000 dec. ?.

it. metal hented per day per furnace ~- 680}

ike @- Built oy the Roo Motor Car Co.,

Type De

Noe of furnaces of this ty pe ~ §

Tempe = 2000 deg. F.

ite o” metal .eated per day per furnace = 2120)

ORES D RN ER ESD

Since no prints of the cross sections of the
furnaces were available, the Manufacturers name and number of
furnace has been given in all Gases where it could be found.
In the cases where this information is given, the dinensions
of the furnaces may be ootained from the Manufacturer's
catalogue. ™he inside dimensions of the following furnaces
will pe givon aos the Manufacturers name and number could not

be asvertained:
18

FURWSACS DATA.

Furnace 741 - Hearth 3* x 5 3/4! » 21/2" high.

Furnace #42 « 46 incl. - Neartn 0 1/4" 4 71/4". 1 2/4" highe
Furnace 347 -60 incl. - Loarth 7 1/4' X¥ 81/4" 1 5/4" high.
furnace 751 - 53 incle © desrth of % TE. 2! highe
Furnaces 451 ~ 62 « 64 = 64. sume ay f5l - 58.

furnaces #59 ~ 60 - 63 - 62. - Hourth 3 2/4 "212". 3 1/4" hig,

The lead pots and cyanide pots are of the strong,
carlisle and Hammond make, reouilte. A print was sent of the
cyanide furnsces. The lead pot furnaces are the same except
that they are 6 inches higher than the cyanide furnaces.

The data given on tho preceeding shoets has been
collected as carefully as possinle. In 21ll cases where possible
it is based on the records of the Neo Motor Car Company. There
was no recorded dats on the forging furnaces. Consequently the

data given on these furnaces is more or leus of an approximation.

In the forezoing shects of Gata, where the item "it.

of metal per host", is given, it refera to the iit. of metal per
hoat par furnace.

FULD OIL Daltde

Kind «~ fuel cil

Gravity - 28 - 3 ‘hiume at GO °°.’
19

Amount used per day of 24 hours =~ 5900 gal.
Amount used per year - 1,170,000 gel.
Cost per gal. - 4 l/icents.

Sir Blest Datue

The air used oy the ofl] furnaces is supplied by a
Western KEleotric Centrifugal Air Compressor. The compressor
4s of single stage type ond is driven py a 50 hep. motor,
direct connecte’. This set is dupligated oy two 25 hep. sets.

The air ig gsupvlieu at a voressure of 24 ose

The dit ecencernin-:: tho c&ipicity of the Gompresso:
uging on efficiency of 50%. The recult obtsined was 5820

cue Ft. por min. for the 50 hepe sot.

Hote; ~ Che Swinsfield poiler montionod in the boiler
data sheet is now veing installed, so none of the data in re-

gerd to fuel consumption, eto., refere to this boiler.
Part IV.

Analysis of isticates.

In the following ps.es we will give the sup-
etance of the reports furnished us py the several companies
we corresponded with in regard to this problem.

The first proposal considered will be the one
furnished by the cuigley Furnace Specialties Co., The
proposal is the most carefully prepared and is given in the
greatest detail of any of the several we hive received. The
suostunos of this report will be givon in detail.

Analysie of the other reporis will ve given
using this one as a basis of comparison.
21

wuigley furnace Bpecialtieu Company.

We propose to furnish to the Reo Motors Company the
following equipment for pre paring, distributing ané vurning
powdered ooal at their plant.

The powdered coal our&fang equipment is for use in
connection with
7 - Boilers.

70=- Smell Hosting rurnaces.

10 = TON KILLING Lal?

 

le special track hopper constructed of heavy steel plate
with reinforoing ond etiffening angles which will have an open-
ing at the top for receiving the coal 12 ft. oy 12 ft.

The necessary treok girders will be supplied as well
as steel grissloy bars with 8" x 8&8" openings placed below the
track girders.

A suitaole opening will be provided in the vottom
of the track hopper for connection to the reciprocating feeder
which regulates the flow of coal to the orusher.
ie Sheet steel connection vox provided with onnecting
engles for attaching the reciprocating feeder to the track
hopper.
le Reoiprocating feeder for regulating thed Ylow
of coal to the orusher, which will be oconstruoted of stee)
Rae

plate properly reinforced where necewsary and provided with
driving mechanism, etc., for operating same.
le Steel plate chute connection between reciprocating
feeder and crusher.
le Single roll 24" x 24" coal crusher will be supplied
for reducing the size of the coal to 11/4". The crusher will
be of heavy substantial design with reduction gearing, fly
wheel and safety devices, such as spring releases, shear pin,
etc., to safeguard the machine incase of the introduction of
some hard foreign substance. The roll shaft will be extended
on o.e end to which will be attached the necessary sprocket
for driving the reciprocating feeder.
le Sheet steel cover suitable reinforced will pe
provided for covering the pit vetween the track hopper and the
crushed cosl elevator.
le Sheet plate chute for directing the coal from the
discharge of the crusher to the boot of the crushed coal elevator.
1. Chain and bucket elevator having a capacity of 50
tons per hour for elevating the crushed coal to the belt conveyor
with magnetic separator pulley which in turn discharger . to the
crushed coal odin.

This elevator will be constructed of sheet steel with
connecting and stiffening angles and Will be made @ust-tight.

The necessary reduction geaping at the elevator head

will be provided also the take up in the pnoot and power will be
25

transmitted from the motor to the idler shaft at the head of
the elevator by means of gocring.
le Small @tructurs] steel platform with hand rail
will be supplied for attachment at the head of the crushed coal
elevator.

chis platform will give accéss to the elevator head
ané will also serve as a osse for the motor wht h operates the
elevator.
le = : 24" pelt conveyor with mignetic separator pulley
et delivery ond to conduct the coal from the crushed coal
elevator to the crushed cos] bin. The conveyor will be totally
enclosed in a sheet steel housing provided with inspection
@oorsa. Idler pulicy and take up will bo furnivhed. Framing
for walkway will be attached to the atructural work of the
conveyor housing.
le Mognetic sepurator pulley 12" dia. by 20" face
Operating with direet ourrent will be provided. Thies palley
is to separate tramp iron from the coal. A reject spout of
fron from the separator to the floor will be pravided, together
with steel pinte ohuto from the pulley to the orushed coal bin.
The necessary chain drive with sprockets for operating the
belt conveyor will be provided.
le Serew conveyor for deliverin; the orushod coal into
the storage bin. |
le Crushed cosl pin, having s oapaoity of 100 tons.
Bin will be constructed of suostantial steel plate with suitable
etiffening members and rigid structural steel support will be
supplied for sustaining the crushed coal nin apove the fire-
box of the dryer.

Sheet steel cover will be provided for to tally
enolosing vin.

Ruck and pinion operated gute will ve supplied
and attached to the bottom of pin and the necessary mechanism
and hand chain for operating this gute from the floor will be
supplied.

linnd railing will ve provided on the side of the
erushed col bin.

Se Stock tester gauges will oe supplied for determin-
ing the amount of coal in bins.

Le Sorew feeder will oe supplied to regulate the
Flew of coal from crushed coal bin to the dryer. Hecessary
sheet steel chute from the feeder to the dryer inlet will

be furnished. Sprocket and chain and ratohet drive for operation
of the feeder will ve included.

Le Doubjo shehkl dryer which will reduce the surface
moisture of the ool from 10% to about 1% at the rate of 10
tone per hour. ryer is of the semi-indireot type with central
flue, substantial girth gear and rae.uction gearing for rotate
ing the shell. fhe two riding rings attached to the shell
will be supported on self-aligning rolls. ‘hell will be 70"
dia. 35° long.
Flaine Satie

 

 

 

 
25

The necessary fireoox castings, ouckstays and
grates will be supplied. Shell will be bolt driven from
the countorshaft.
Le Countershaft, complete, with pulleys and hangers
for trunumitting power from tho motor to the dryer and sorew
feeder. Sorew foeder end countershaft supports will be fur-
nished for attschment to the framinz; of crushed cosl bin.
le Auxiliary stuck, which will ve urtached to the
fireoox for shortecirouiting the products of comuustion from
the firebox when shutting down the dryer.
le Cyclone separator with chute and exit st&ck and
etructural steol support will ve supplied. The products
of comvustion from the firebex of the dryer will pass through
the dryer shell and thence to the fun, cyclone collector and
to the atmosphere.
Le Struetural steel plutform fcr supporting the
exhauster furnished with the dryor &xs well as the motor for
operating it and the dryer.
le Housing for the dischurge oustings on the dryer
will be inoluded which will form ohute to the voot of the
Gried coul elevator.
le Recording thermometer with wcuple and recording
dial to rogister the temperature at the cutlet of tho dryer.
le Dried cosl e&evator, ly.-ing u caymcity of 55 tons

per hour will bo furnishocd. Dried coil elovatcr will oe of
26

the same general type as the crushed coul elevator. Steel chute
will be supplied for discharging the dried ooal to the dried
coal conveyor.
Suitable eteel framing will be supplied upon which

motor which drives the elevator will be mounted.

Le Small steel platform will ve supplied to give socess
to the heads of elevator hearings ,etc.

Le Sheet steel dried cosl bins will oe supplied hav-
ing a capacity of 3 tons each. Bins will oe properly reine
forood with atiffening memoers. aA rigid structural steel

frame work Will se supplied for supporting the dried coal

bins. Dust-tight manhole frame of special design will ove
attached to the steel plate cover of exch oin for giving

access to inside of bing. At the bottom of each bin a rack

and pinion slide gate vill be supplied for shutting off the
coal to pulverisers. ‘tock tester gs. ges for determining the
amount of coal in binu will be supplied.

Le Sheet steel chutes will be furnished for directing the
coal from the dried col oins to ulvorisersa.

a 5 roller lowside nills including exhausters for the
sir separation of the ooul and the necossury galvanised iron
piping from the mills to the exhausters and from the exh-ucters
to the cyclcne separators und fron tne oyclone se peretors osok

to the milis. The primary cyolone ccollecteps of vhich there

Will be two will vo supplied, tozether with tro seconcary
Collectors.
“7

Be Structural steel platZorms for supporting the
exhansters furnished with the mills.

Ze Structural steel su ports for cyclone collectors
furniahed with the mille.
Le Struotural steel pletZorms will be supplied for

supporting the motors which drive the pulveorizers and exhausters.
20 Seta of sheet steel chutos will vce furnished { or
conducting the coal from the powdereé coal vine to the slormeg
tank unit.

 

le 6 BC aC lus Qabl. Gilles
1 Sheet steel powdered Gosl oin, having © capsotity

of 6 tone will be furnished und will oe properly roinforced
with stiffening angles where required,

le sheet steel cover will be attached to the bin
and a manhole frame and cover of special duste-tight design
will be attached to the top plate cover of vin for giving
access to the bin.

le Stock tester gauge will be furnished for de-
termining the amount of conl inthe Din. ‘To the bottom of
the pin will ve attached dust-tight gxte of specisl constrw -
tion fa@r shutting off the coal from the blow tank.

le Plexinle connection voostreen tho powdered <osl okn
and plowing tank will oo included.

le cuostantial ris;id structura, utee] framework fo

Supporting the powdered 0021 vin will be furnished.
28

1. Patentod powered co:.1 trune ort vlowing
tunk will bo supplied 6° dia. and 13" high. Tank will be
on paple of receiving 5 tons of powdsred gosl xt one charge,
and the shell will be puilt of subutantial steel plete
properly caulke! and rivitte4. juick-opening inlet vélve
will ve attached to the to, heed of vlowing tenk with necessary
mechanism for manipulating the vaive from the floor.

@resaure cruge, o:faty valve, air inlet control
Valvo and air pressure recucing valve will be supplied.

Slowing tank will ve oullt for a working pressure
of 1002 per 84. inch.
Ze 4" piutonted flanged hand-oporuted cm] awitch-
ing valves for distrivuting tho powdered coal from transport
line to bine Lever end hand chain for operating these viilveus
will ve furnishod.
le Indilostin; osletform scule with stoel pistforn,
lurge indiguting disl and tere beom wi}J1 ba furniohed with
this unite Ulsul will be divided gs0 as to reea in 1003
divisions end will record up te 10,2007. i this ma as
all the powdered coel is saceurstely welched and charged

against euch powdere: con] bin .t the furnsces.
weenveccccc sO cccvccccnces

9 06061 ladders to cive access to the vericus

platforms end elevator heuds will be furnivhel.
le Signal aystemconsiuting of a panel with push
buttons, lights and annunciator for the milling plant and smal
panele with light and push oatton:= on each din utation.

All necessary boltin:;s for operat ing the qgbove
specified machinery will ve furnishei.

PecesccvesesQCODencccccsccese

 

 

 

DINMILWT a NO SEIN en
for
J- ollors
40 Sheet steel hoppers, & having 2 cepaucity of

16 tons each and © huving s camoityz of 20 tons oach with
18 discharge openings. A m.nhole frume of weoisl douizn
will bce attuched to the stvol cover cf ouch hopper. Hoppers
will be provided with steel eGvers end will oo mide &ut-
tisht. 16 extension castings will ve furnishgi.

18. Dust-tizht gates of wpeci:l oonstructionwl DT oe
supplied.
4e Stock tecter geures will oe wupplied for 4 termine

ing the amount of coal in pvins at any time.

8. Vont pipos for ettachment to top plates of hoppers.
4. 4'2" dia. cyclone collectors of speciul constrwtion
will be supplied for use in connection with the cc mpres ed

air trany port system, to::ether with exit otvcoks and dictri bute

ing ohutes.
4. 3tructursl ctcel supports for cyclone colleotors.
18. Powdered ooe)] feod controllers, oaoh having ¢

wankinum ouppoity of 1250;- powdered ooel per hour. ‘hes feedrs
ere substantially devisgneé and sre provided with teo sh tters
operated from the outside by mans of wheel or hand chain

wheel, so that the amount of cosl fed by each can be

readily regulated oy the furnace hester &8 would be the case
with of1 or gua.

4. Controller drive countershafts with bearings, cto,
will be su plied.

18.6 Controller drive wprockets and chains will oe
furnisheé.

ld. 5043 of coal und alr pipes to vurners.

18. Yowdered Coc] ournere of 8 peoisl design will be
far nished.

18» Powdered coul turner sup ortbe

2 eriraery 64r vlowors, 1 &ving & aupality of 5000

Cue £t. ond one hi:ving a oupscity of 2000 cue fte per mine Ut
6 Of—6 Wedsuure Oadh.
Qe Secomery air blowors, 1 having & axpucity of 10C00
cue £t. and one hi:ving a Gupacity of 27500 cue ft. per min.
at 11/4 oz. pressure ceche

2~rinary and seocndary air oleut lines.
Le 4" putentec Denged hendeoperated coul switching
valves for disutriouting the powdered con] from the transport
line to bins. Levers and mind cn-ing for oporating these velves

will ve furnished.

18. Gird type oli.st getes will be furnisho:.
4 hedders to give eccoss tc tos of bing.
5. Sots of bolts and weshors,

eeee- ce ceOQOccccssavce
31

DIGPRIGULING ald BURG a CLP

 

Te Steel woppersu, 4 having w agayuoity of 5 tons
each and 3 mying ac:upzcity of 4 10ons esche A manhole frame
of specisl design will oo attached to the steel cover cf each
hopper. Hoppers will ve provicei with stsvel covers and will oe
made dust-tight.

7» Swek tester gueges wlli oe Supplied for determine

ing the amount of cosl in olins et any tine.

7. Vent pipes for ettuchment to toy plutes of Loppers.
Ze 4"'2" dia. cyclone colleotors c? special construction

will of supplied for use in connect:oh with tho compressed air

trenuport syatom, toether with exit etacks und distributing

chutes.
7. ptructural steel supports for cyclones collectors.
5e 4" putontod flanged hund-o poreted coal switching

vulves for dietrinuting the powdered cotl frenm the truonsport
line to oins. Lovers end hend crmins for operating theso w:lves

will be furnishod.

100. Syphon t:pe Peecers will ve turnished.
100. S@ts of Conl End alr pipods to burners.
Ze Leocondar y ulr vlowers, 1 h.vin a capacity ot 2000

Cue {[t. Gnd 1 h:ving & cepucity of 7600 cuseite ,wr nine ut
11/4 os. pressure euch.
le -rimaery air blast line.

Le Seoond ry air pléact lines.
100.

7.

le

ubryer fireoox setting.

- 50
- 10
- 30
- 10
-100
5

5

15

3

20

mh.
oe”

“HIS

Hewve mOvor,

23233233223

=
= 2

ef
w
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tt
yt
"f
ba |
tt
er

t

wrid type blest gates will be furnivhed.

Ladders to z,ive accecs to top of bins.

anchor polts and weshers vill ve furnished,

CoececccccnececeellOvnec cvennseccece

DIZOL.
~ My abdages

te
b+

“f tty

om

7?
¥

to o9 furnished oy

RHO 2any

AE

grt
am barista &

2 2 fic Que Le uae ah

 

LEO Ve
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Crusher & Kotor Su pportue

Hiring.

Compressed air piping.

noe
4

Qo. a= ON _
pO SE Of i
we 4 8 he teh KN. seni.

an _o on

eV

3g

i ,~* . . rts
Aa -3 U Wierda dead £48

24 ren
aw dots at an

O ph. 00 Cys to drive Crubpher,

f

Kxoavat ion and fandtion.

Kreotion.

Buildi ng.

a]
st
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ee

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9
$7?

et
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"y
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et

ft

Crushed cool elewiios
bryer,
vYigd ¢co.2 elevator
Julveriszsors,
CCHErCr1l sli «
oY tour y Ady Blower,
’

HeconGur 7 Alp "

? |

| + a | |

660 ft. transport line, soavenging pipo, fittings, eto.

“ ¢

PET ys
cand wm db bd ahd a saad

COT C2

eal

ca. OV eveeess (o9, 008 200
(OS

Equipment furnished oy wuigley Furnace.
Specialties Co., in sasordance with
the foregoing quotation Coes oever seoes @260 ~O00 .00

goa Lkaat io TOLTLL COLT enecee 199,006 200

eoccemoenessce res OO00e @eeeeenu ge bees @
wJTGLOL PU ase CML ALT. CCMBPAIY «

The materials, which we are to furnish, in
connection with this ;ro0posal cover the ontire mechanicsel
equipment from the track hop cer to the burners with the
exoe ption of the air comprosyor and uir roceivers, which
we understand ure already installed.

On the lust puysxe of the proposal, you will note
& liot ie mdo of vurious itoms, which the Reo Kotors Com.any
would hive to furnish in conneotion vith this layout. These
items include 61) which are normally oncountered with the
exception of furnace changes.

On some of the small heating furnsces the powdered
coal will ,wobudly oe fired on ono sdde of the hearth and the
secondary air would ce admittod cireoctly opposite, thus
preventing the flame from impinging on the urick work.

On some of the larger hesting furnaces it would
probeoly ve necessary to build a smell comuustion ch:moer,
eufficient in sise so that the coal would be antirely consumed
before reaching the hearth.

You have not mentionod in your écte whether or
not these furnaces vere equipped with stacks or exhiust systems.

It i6 saseumes thet some cf the larger iurnaces have
stacks. If not they will promoly be necessary,

fhe smll furnaces would give vetter operation with
35

less duet in the workroom if a small exhtust system was in-
etalled to carry off the products of comoustion. This wuld
also carry away a large percentage of theash and therefore
requires less labor to clean the furnaces.
You will probably ve interested concerning the
cost of palverisation and the power reqired for preparing,
distriouting and burning the coal. *
Concerning the cout, we find from our reccrds

thet with present doy orices of lsvor and tupplies and
ullowing 3% cent per E.iti. hour for eneri:zy that the cout per
ton prepared, distributed und burned in uw 10 ton per hor
plant, would bo from $1.55 to 1.65 varging according to
local conditions.

‘The plunt, which we hive recommended, Would oe
operated about 20 hours »wr duy, propuply two shifte with
10 hours each. It is erfficiont to swepnre, aistribute end
burn 10 tons of Indiana or Tllinois betuminous coal per heur,
provided the moisture in the coal received does not run over 10,

Concerning the power requirei, we ocelieve that 20 i.n.
hours per ton of co4ul in a 10 ton per hour plent, would be
sufficient. ‘this includes a1) power from the time the coal is
received until it is vurned.

All our equipment, such &8 Ghutes, elevators, conveyors
und air transport systems are dust-tight in operation, ving

been designed especially for this purpose end te bi:ve many
36

milling plants which are models of cleanliness.

Our air transport system consists of blow teak into
whieh the pulverised coal is fei from the mills. «hen s certain
emoant is deposited in the tank, the inlet is closed and air
pressure applied on top of the coal. This pressure varies from
20 to 654 for lines 200 to 2800 ft. long and forees the coal thro: <:
e 4" standard pipe to cyclone collectors located over the various
coins.

The coal requires about .& cue ft. of air per pound
of coal transported. It will therefore be seen that coal is in
@® solid mes and there is absolutely no danger cf fire or explosion.

Any one of the olow tunks is capable of delivering
2 to 21/2 full charges per hour. i.e. a 5 ton tank, Guoh as
we have stipulated for your plunt, would ve fully capanle of
delivering 10 tons of coal per hour to the furnaces.

This ca ranility cf the blow tank is not limited by
the time it tsikes to disch:-rze the tank vat by the time it takes
to ehurge the tenk from the pulverizing mills. Five tons of coal
can be discharged from the tank in ct liasst five minutes, the
ech] flowing ot the rate of over a ton per minute and at a
velocity exceeding cne mile a minute.

Conoer ning the feeders and burners, you wild note that
we have specified our standard sorew feeders for use in the
boiler room. These feeders are run by a constant speed motor

ond the amount fed is controlleé »b, means of shutters, which
o7

are opened or closed around the shaft of an interrupted sorew.
The opening or clcaing of these shutters is acecmpliahedaé oy
means of a hand wheel or hand chsin wheel on the outside of the
controller. By this means of revulation cot] can be varied
from sero to the thll capacity of the feeder, which with the
type recomended is 1225.’ per hour without changing the speed of
the motor or using a v‘iriable speed mechunien. This mans
that A.C. motors Gan be used throughout the plant.
Yar the heating furnaces we have specified our

ey phon feeder which operates by means of compreased air at
pressure of 2 to 70) ser sq. inch and extracts the ooo] from
the bins and feeds it through 6 amall diameter pipe to the
vurner. This eyphon feeder has been in successful operation

in plants in this country for several years ind is capable

of wide adjustments, thus mkine it possinle to control the

tem perature of the furnace 25 easily 65 with ofl or gas.
08

On the following pages is given in detail the
repert and estimates from the sonnet Co.,
This company, a8 will be noted in their report, does not
consider the proposition feasivle vecsuse of the low ccat
of fuel of] and the price paid for coal. iio offer this
criticism 68 their report: In their computations of the
saving by use of pulverised coal they take the cost of pulveris-
ing as 765 cents perton. This does not inolude the cost of
ianver. Further, they figure cost of power used in pulveris-
ing as iz cents per K.if. instesd of 21/2 cents per K.ii. a8 is
paid by the Reo Conpny. Ordinarily the cost of pulverizing
ranges from $1.25 to 31.65 per ton. “This increased cost in
pulverising would practically eliminste all savings in the
use of pulverized coal in the heat treat department. He
believe the estimate of savin in the boiler room is faifly
accurate,

The following is the sunvstance of the report of
from the Honnet Companys-
39

The present poller HP. is 2700 -.2., using 80
tons cof ooal per 24 hours, which gives us approxim:tely an
averege of 2 1/2; of coal por heur per He2. ‘he new 870
H.Y. Springfield voller that ia now veing installed inoresses
the boiler H.P. toa total of 32570 H.>. This gives us 3750 #£.°.
“ 8 1/2# per hour, or 107 tons per dny of 24 hours.

If the boilers are changed from stoker fires to
palverised coal, we Gan reasonaoly caint on a saving of 15% oF

16 tons of coal per daye

107 tons of coal «ut 7.10 delivered 759.270
91 ”" “ “ “ 7.210 “ RUS 75 [or
We 714.05

va5e.0 ,8f day X 20 dys - gltccd5.CO usnved per year.
There is a possibility that it would not ve advis-
aple to change some of the small furnaces in the hont treat-
ing Jepartment frou 011 *o pulverized coal on account of the
seamlh amount of of] use: and the expense necestary to fit up
the furnaces with hoods and stacks to carry off the guses.
For sake of argument lets assume that «11 furnaces
in the he:t treating and frorze demrtment can ce arranged
to use pulverize: coal. At present “900 gsllons of fuel oil
ia being used in these two departments por day. It t:kes one
ton of coal to replace 200 ghllons of fuel ofl which means that
approximately; 20 tons of coal will ne re wire’ yer duy to re-
place the 3900 gallons of oi] now used.
3900 Gallcns of of] et 4 1/28 - - - -$175.50

20 Tons of ooal at 7.1" |
75gufor pulverizing 157.00

savings per duy ~- 18.50
16.50 per day x 300 dys equals 76660.00 savings per year.

Savings on ooilers per year ~13G05
Saving on forge and hest treating
furnaces 5550
Total ~ - = = .

The power required to convey the coal from the
track hopper to the pulverizser, pulvorised and distribute
the coal to boilers and furnaces is 30 Keife hours per ton.
fhe power at 1 3/4¢ per Kei. emals 52 1/2¢ and we have
figured 20¢ a ton for repairs and uvkeep which mkes 72 1/2¢
per ton, ami in the forging calcul::tions we i::ve figured this
at 75¢ per ton. If the cost of power is different you can
change your cslculations accordingly.

The ‘iaber item we huva not considcred for 4t should
not take any more labor to operate the coal plisnt and boilers
than it now takes to operste the stokers.

For the pulverized coal installation we wuld advise
the following ecuipment in connection with the present coal
han@ling machinery. (Cn the under side of the »resent coal
bunker that is locate: in front cf the bofler, place cast iron
gates to deliver the coal to a 24" belt conveyor. i'.znetio
separator to be pimced over belt convevor to extract the
magnetic material from the cosl. 6& He. Jpur Gear Re.mwoer to
drive belt conveyor.

Steel Hoover Belt Convevor to Dryer.
41

One 5° - 0" dia. x 50° ~ 0" Jong Fotury Coal Oryer.

Cne 15 Heve client chein Driver to drive Dryer.

Cne 6" Dust “emovel screw Conveyor to convey the
coal dust thit my accumul:te in stack end of dryer to screw
conveyor leadin:; to sulvorizer.

One 4stometic Peodrding Thermometer to record the
temperature of the co#l a5 it loaves the dryer.

One 12" Screw Conveyor Uryer to dryec coal odin.
Cne 3 Here Jour Gear Poducer to drive sorew conve vor.
One § ton Dryed Coil Zine
Two 5 ton per hour ‘onnot -ulverisers.
Two 75 Hece Silent Chain Drivers to drive the pulverize
T¥o 60" Bonnot cxhausters with the neceesury piping
and collectors to convey the pulverizec coal from the pulveriser
to the pulvorizei coal storme nin.

One 50 Ton Cupteltz eulvorised Coal Storage 3in vi th the
necessur:; feed screws.

Automatic Nezulator, vent piping, collectors, blowera,
distriouting oije end burners for supplgng the dooilers vith
pulverized col.

the forge end hest tresting depsrtments will recuire
in addition to the ubove, one additional 5) ton pulverized coal
storage bin with the nocesesnr,; feed screws, automatic regulators,
vent piping, collectcrs, lowers, distributing  »iping and burners

for conveying the pulverized cok] to the furnsoces.
42

T fhe cost of our equipment to serve the boilers
would be $6,000.00 with $15,000.00 additional for the equipment
for forging and heat treating furnaces,

fhe pulverized coal machinery will require a pvuild-
ing 40" - Oo" x 80' - 0" x 46" - 0" high to the eaves.

The total cost of a pulverized coal installation —
to serve the pnoilers and furnaces would oe as follows:

Pulver ized coal machinery $75,000.00 Electric
Motors, Secondary Air Blowers and piping for same, changing
of furnaces, vents for stacks for carrying off the gases, erection
of machinery and building $50,000.00 making a total of $125,000.00
for the plant complete ready to operate.

AS long &s coal &nd oil remain =. the present prices,
the saving of $19155 per year en an investmnt of this kind is
considered low. However, if the price of oil should advance and
coal come down in price, the proposition to install pulverized
coal equipment would become very attractive. We are enclosing three
cats of the Burhham Plan which will give you some idea of the
machinery required for an installation of this kind.

The track hopper and elevator are already in place so
that the 24" belt wamild receive the coal from the present bunker

and deliver it to the chute leading to dryer.
43

fhe following report from the C omoustion
Sconomy Corporation seems to os a very preliminary report.
and really does not give a cor yreixmnaive solution of the
problem. It appears, in oanmrison with the .uigisy
report, to be s ver, genoral estirute and on the face of
{t, shows very little work cn the part of tha @ompany. In

sunstance the report ig s-
COMBUSTICH 200 Mi. COs.

4 - 400 HP. Joilers, - 5 » 760 Ibs. mer hour.
2 - 550 Herve " 950
a - B90 Wale " =. a 2.600 " we

Totul - - Jf,720 ~~ =~"

n@ note that your total tonne now is about 60 tons
per day, indicating thut the noilersg are not fired at 100;;
Bating 2% hours oer dey. “6 would therefors suggest that you
figure on a saving of 204 in fuel costs fired st the doiler.
You would need s pproxinitaly 20 tons ocr coal par dsy7 on the aiff-
erent furnaces, which would make a maxinum of 100 tone per day
fow firing a pulvecising plint with a capnoity of 7-tons per hour.

Phe aporoximite cost of the complete installation would
be as follows:

Pulverising 2quipment - - - «- = = = - [653,000.00

Buildin; for culveriaing lant 41, 500 .00

Conveying System, somplete, for hunde
ling the coal to the different furnaces

and pokilerse. = e2 © © ee ee em ew ow 5,675.00
Firing s;nipment for iJcllers «6,500 .00
“ " “ Furnaces 38 .450 00 |

 

Approx. Total Cost of Compkete
Instell:.tion « « - £149 ,525.00
45

The combustion seoncmy Corporation report

seemea to cover, ina highly thereotic:1] way, a suving thet
might reanlt from a chuinge in the Loilor room from stokers
to pulverized coal. It will b2? noted thet this company allows
only 1.5 ¢ per eis be. fcr powsr, while tne Reo Cos, pays
2.5f per KeW. hre Tiis wuld oxe tha powar iten:77.95 instead
of $88.77 as c~iven in their report.

Ha are sorry to a7 trat the Reo vover Jlant does
not have a daily loz sheet, nor heve they any data avallanle
as to the efficiency of the mllers. This is & great hundicip
in mking out 4 problem of this cort. Therefor we dunsider that
this company is given ua we fr as it is possible, as good
& report on the saving to ce ootuines.

It Will] be notec thet this con sny does not selieve
that it would ne eccnomicesel to change frem o11 tc pulverise: coal
in the heat tre:it furneces.

The report is es rollowsa:
46

Pas . UNG Fy f.7t ot _¥ , . 's * . om 2
CO 23 OU LEGS bested. cee oh iW ow da

assuming an efficieng,s of 65, und using © eoul

consum.tion cf sG tuaa yer duyus civen, the present stean

load Would ve &loroxi sy tely 40,CCO deilere ATHe ,Wr diye

Cost ut® Srenoit

fon

 

 

yuel see tons ~ 4 7 el u ton eesceee:, 005 200
Libor eesti NTBe H0¢ eeoneeracve-s ole

+ 099 20
akinzg & ocot pear selle’. he OF eOlLd

It m.y pe th. on dcoking over the plsnt you Gun

decide that tha afficiency «8 ussumed is not corract, end in

thet event you caa ch ne the snove figures to suit.

“ne cost with pulverized fuel base: on the same Jord

as sbove Eni Saoumine cond of LE,COO Wa vould oout, pulv. rized

to the alant, .7.10 per ton, and ausuming an opera. ing

efficiency of 75. vhich is easily ontuinslle with pubnerized

fuel, we arrive 4ttim followin, fisures “whtah are approximatel,

correat:

FUG] ceeccasesdS tons — . 7e1C & TON ceoeeeee 468.50
2ower for prepurution of the coul 6nd

-iringe

oo tons 20 ge Tate por ton ateOid5d ver im hr. 22.77
Liscr coveria,; tha followin: men:

1 - ffremmn - 24 hrs 60d - 14.40

L- 4snmen - 12 mrs 50g = 6.CO

1 = pulve. attnt. 16 75d - 7.50

le-uaryer " 1O- v0g = 6260

l - conveyor sattnt. - 16 56g 6.00

 

78.50
47

Coal for dryer eee 12 ton ” a? elO poeeetedO
Repairs & LuoricuntsS ease 15¢ per ton

hiundled eoneccesncncccnanne- DAK |
(17.00

The cost of tha preparntion 6nd firing enuipment
would oe approximitely £110,000.

Ausuming interest ~ 64, taxes ~ 2,5 and denreciétion
° 84, the total eunnunal charve for the ancve would de

817,600 or on a SOO day basis “53.65 per duye

qirty tts -~,-
ba ~ «
a dé ae and £

Mua] ceossnccnccccesccccnasenseoes 04050060

rower SBS RHRSCAERSSCHEESHSLHOSSESES ES @ 22077
Lo por SOSSRSSROHBSCLASHSSSESSS FEF 23 290

Coal for dryer, reporirs &
LuoricantsS eesceee 17 200
Interesat, deaorecistion & taxes 68.205

7, Otal @eagmse@eeneeoeeseeeca ene tcaeaaeneeceoa Geen dade @ Be 0 H5e98

605.92 ejuals .0151 por Boiler horsepower hour.
40, OOO

®
33868 on 80,000 3eHere por day, the followin;
charges would ve approxinitely correct:

FUCl eoeolSd tons © <7 10 per ton eoney 955260
2ower for preperation ana firinjz: -
ae kt per ton ~ .015 D8F Lil eaonenconanse 42.92
Labor consisting of the follcwinz:

1 fireman 20254 bra ~ WOg secacenes: 14 240
1 ash mn ..]2 hia - 50g eoecaeeecseoe 6 OO
21 oulv.e “titinde lu 75g eetasecere 2 e00
iL dryer " eel | 50g @eececeaces 8 200
50 200
Coal for dryer .efel tons © G.10 14.91
Re xirs and Luoricents Loy _ 20.40

~ on
-_ >
©5edl
48

s uel wc cocecenccccccncccccase 5, 155260
<Coa#er @®eeesn H@eoeooeseesaeaennesenevenves 6s 46292
Li DOT cosas scvccesccaccccesns 5O CO
Coal for drver, rexwirs and
Luorie:.nts Cuaveovvneneon eek
£277 cherse for int. deprecin-g
tion and Luxedeccecaacccs £4205
otal @e@eeenaeuaueeeeweesoeaeeseeeaeseaeweveeencnewseene eae 8 1156.48

ZA50 248 eyuals .0144 nor 3ciler “arse 2ower Houre
8

 

It must 08 noted, hovever, that in the stoker
analyais no chrrzse hive oeen rede for power, coal hundle
ing lavor, mintenince or caureciation.e Ycu noo dly
ein secure these figures from tr lant records and re ke
dane all<cwanoe for ine sume.

Shere sr@oa mumper ci edventsces thst might pe
mentiones in fsvcr of the pulverised fuel, two of which : re
continucas 0 erating &t high ratings with hivh efficiencies, end
saving over the stokers during ounking porfiods.

sith reference to tho forgings «nd hest treating
furnace, we would not recommend the ch.ncing from oil to
pulverized fuel on these furnuces for the following ret.sons;

Yirst: A Zerze numoer of the gurnsces could not oe
arranged to burn pulverize: fuel.

second: <All of the furnsuces :re amall] snd coel

cqild not oe burned ss efficiently <8 oil in eny of them.
Chird 3; Céepitul expenditure charzes would
more than offset any savin; in fuel tht could pe mide.
Fourth; ror this clsus sot «ork of2 £8 much

Cleaner then coLle

49
fhe suller un:ineering Co., ives a
very general report on the provlem, not going into detail ut
all. ‘They, however, appurently consider that the proposition
would be a fessidle cne and that © saving would be optsined by
the use of pulverizec coal. The estimated cost given, as
will be noted, doses not cover the cost of equipment for the

fur naces. The min idea of the report is as Follows:
PULLE2 ANGLILUIRING O6l0AIf

The fireoox on the 870 2 noiler is epproxi-ately
correct for firing this voiler ut normil rating, out from the
information which we oun gather from your blue prints, we feel
gure that it eill ve necessary, to h.vo suit..ble combustion
che mbers of the dutch over. t7pe installed in connection with
the nbelance of the boiler. even for normal reting. .@ also
have assumed that there «111 be wulfficient roon for the in-
ata llation of the anxilisry equipment Including the pulverized
coul oins, ourners, feeders, eto., ni further tht « powdered
coul plant ouilding and equi, ent ccoula be plsced in fairly
close moxinity to the boiler room.

Cn a deasis of &© tote] d:.fly consumption «f£ 80 net tons
of coil being consumed in 24 hors und astuming & gompined ooiler
and furnace etficienoy of 60.138 the rosent tveraze in your
poiler room there wald be o suving of & pproximutel y 25.4 «hen
using pulverized cou] or 62 net tonse “0 tons eporoximitaly
would be rewired to do the mme upcunt of work in the metullurxical
furnaces operating with of], «hich, added to the ooiler re suiremnts
would mke & tots] of G2 not tons of oulverized col] perd:y of
24 harsa. (n the poiler d.ta sheet you should show thetthe 3.7T.U.
value of the cml varies from 12,000 to 14,COO per lo. or fin
average of 15,000. vitn & fuel ci this value tnd opersting ut

78% combined boiler and furn:ce efficionoy, the evi orution wuld

pe 10.457 of water per Ip. of cosl rired or 22: of coal ver voile
52

HP hour. Onthe avove msis of csiiloulation there would pe
reqiired a pulverizins plant inoluding 2-42" ruller Mills and this
plant would huve to operate 12 to 12 hours in order to take care
of the total requirements. |

de are familiar with the guneral construction of
various types of metallurgical furnaces you refer to und we are
of the opinion that the furnaces, other than the pot type, could
be operated satisfactorily «ith pulverized coal if remodeled.

A pulverized ooul plunt of the mise mentioned above
would h:ve a total maxiom dsily oupracity in 22 hours of 160 net
tone if operated oontinuocusly. The cost of the inutallation

would be us follows:

 

Coul plsnt Building £16,035.00
econ) Lill W.chinery 71,565.00
Soller = juipment for 7 wcilers 57,509.00
“reizht 6 656.00
ong ineering 14,493.00

This does not include anything for the mtsllurgicul furnaces.
Tne report of the smerican Industrial ingineering
Coe, ia given below. This is more or less of a prelininary
report. Thoy base their fuilure to make a more complete and
accurate report wpcn lack cf dsta.

ihnile we are juite well aware that tho data
furnished th:se comoanies was not as ccmoalete as caild oe
@Gesired, it is noticezble that there iu a wide difference in
the reports of the different ccmpoanics.

te have no information on hand re;zurding the
equips nt and methods ueed oy this company, £38 we have never
received any literuture from them. There eure some interest-
ing statements in their report whish ¥111 be given below.

In snalysing your data on the noiler plant we
find thet you consume: 24000 tons of coal for 24-hours, running
20 - a@&s ys per year of normal rating, iat we find in checking
uo this cosl consum,tion, thit the sooilars mst huevo oeen stand-

ing or operating only part of the tine.

ror the 270C-H.-. pliant opersting 24-hours the
(ooal consumption will pe eporoxi:mtely 226500 los. or 1l4-tons.
The additional 870 H.2. ocller will consume in 24-hours
7308O los. or 3G tons, mikin; &¢ totul for the ooiler plant
of 150-tons. ‘The turnaces wald consume 1Se-tons per 24-hours,
basing our célculition on the fuel of] conmmet, mking a crand
total of 168-tons .er 24-hours.

ve do not know the present,efticiency of your voilers,
4

but will say thet we would oe able to ootsin an everage, or at
least 76% 4f fired with pulvorised coal, providing of course,

that the combusiion champars were changed to meet with the vest
operating conditions. Compuring the Reo Zlant witha sinfilar
installut ion, however, we ere quite positive that we shall oe able
to optain at least 10,. better results then you sere now getting
With your present stocker inutullation.

Pulverising lant:
We are figuring on a Lulverizing Pli:at consisting
of the following machinery.

Building - 32° x 60° x 32' high
i1- uteel oar hoppyor - 12° x 12°
l - Neciprocating Leeder bilow hopper
Lignetic JOpnreator = 14" x Jo"
Crusher ~ £4" x 24" single roll.
aw Ucul e levutor - £565 ton per hour cepacity.
$* center to centar.
gn sorew conveyor ~ SO® lcngze
100 ton capecity raw co.l bin
2ecdi procetin: feeders for dryerse
KOe A@- 4 Xugzles and Coles Dryers.
vry cocl elev.tor, Ji-ton cipsacity 67°
center to center.
12 ton iry Cal oinas.
5 roller High Side Raymond 2ulverizing mills.
onootisg tenk with scales.
250 cuoic feet per minute air compressar with
20 - Here nmotore

~
|

Moto py bbe

bt PY To tS
ete

Motora tor e&vove:

Ll - <4 He2e motor tor crusher

2 - 10 dele moter for raw cox] elevitor and moznetic
iQ Jator .e

~- 20 iie2e motor for dryers.

- 5 Se2.e mota@ fer dry cosl elevator

- 100 Hee itotors for culvorisora.e

fo

2
@

re numning ejuipment trons port system for the

|

Pulverized Joel «ond Circulating system for the emall furnaces,
we have not itemised in this estinate, heitner hive we

attempted to go into detail figuring out the various foundutions
not knowing the confition of your ground, out oelieve tmt the
emount put for same will mst the cx,enses. The total instulle-
tion cost re.dy to run with necessary chanzes to furnaces will

amount to approximately 2155,0C0.C0

Operating Costs:

"he totel operating cost of labor for coal delivered
to furnaces, including cost for hindling the co:-l &nd :vilveris-e
ing wold be 60g per ton.

fhe Orying will require 25-losu. c2 coal per ton,
ary coal.

she totul pewer required for crushing, elevating,
grinding and Dlowing is sutely outst “3 Lew. hours per ton of
coal.

The total maintensace cost, including labor, sare

parts, waste ond luoricunts will not excoed 7g per ton.
vart ve

Conclusionse

Considerins the provlam from the stundsoint of oressnt
prises of coal and of], $7.10 per ton for coul and 4.54 per
gallon for oil, we bdelieve that the instillation of & pulverized
006] aystem would resalt in a large encuch saving in ths boiler
room to warrant its installation, out thet the saving in the heat
treat desurtment would not oe sufficient to mike this chinve
feasible.

In dravinzg our sonclusions, wo h-ve tuken Picures,
which we conider an sversze, from the reports of all the ccm.unies
corresponded with. n@ are handicapoe: oy the fact that the
Reo Motor C:r Comoany ms no deta of ooiler room tests or daily
log sheets; in vhort, they have not datermined the 6 rficiency
of their poillers and stokers. Conse juently, it hs oeen
necessary for us to assume efficiencies es the com anies have
done in their computstions.

The figures on sieving £re ts follows:

fuel ueged, fiscuring from present poiler Here of 2700, using sO

tone of oo.) per 24 hours gives 2.5 # of coal per hour ser voiler

Here with the new voller in use we herve 2750 3.2.2. 88 & total

7 2e5 B per hour gives a totel cf 107 tons per ésy of 24 houre.
susuming & comdinei efficiency of osoiler and furnsce

at 604 with stoker installation, and a comined efficiency of 78: ,

which suthorities clain is ossily ontiinzole with pulverized coal,
@ saving of 16,2 is ovtuined. Therefore with the pulverized
coal installation, 91 tens cof coil per 24 hours will oa
necessary.
. Ho« to obtuin the cost -ulverising, drying, and
delivering to the furnace, thea followin, items wild o@ assumed:
K.iWe hre. rejyuired par ton of pulverized coal prepared and de-
livered to the furmsce - 25.
Cout of pcwer yer ton = 67g
Ceal reqaired for arying - 25: per ton.
Cost of dryer coul p»or ton of »ulverized ool dried - 9d
3. vor hours revuire: per ton = .5
Note: 132 tens is the amount of coal necessary
daily for ooth the voilers end the hest treat furnuces. In 4&8 wuch
as voth ure suy,y2lied from the s:mo plant, the lavcr item must ove
gpresad over the total since Go itvor hours yer dsy are required to
prepare anc coliver the cosl. “he avarugs cost of le. or is 6Cd
per hour. ‘hen the cout of lupor per ton is .5 x 60 =» 3d.
fotal cost of weperation and del ivory per ton eyualy 71.02
Therefore the total cout with pulverized col per au; would be
S710 ~ F102 = S812. GBel2 x 91 = 2728.92 per daye
A cost which can be considered in connection with the
stoker installation is the labor required to operate the plant.
At wesent this amounts to 48 labor hours per day «t 60g per hour
or 728.80. ‘The superintendent of the power plant states that
it would require no more lcbor with the &70 H.». boiler in operatim.
58

Therefore the lavor cost per ton of coal burned with stoker in-
etalletion would be 25g, miking & total cost for the cosl handled
$7.25 per ton. “his amounts to 7.°5 x 107 = [786.45 per duy.
SubSracting the cost per aay with pulverized coal

from that with the stokers (7456.45 = 723.92 3947.53), the suv-
ing of £47.55 por day remlts. Ina yeer of ‘OO working duya
this emounts to a suving cf 214,259.00.

Next in considerinys the cost in connection with the
heat treat department, we cive the rfollowing déeta:-
At requires one ton of coxl to ecusl 200 g2llons of fuel oil,
per dey, it wmld rewire ayproximitely 2 tons cf coal to take
the place of the 5900 gulicny of ofl] now used. Tne cost of the
of] equals 3900 x .045 e (175.50 . je mve aseumed that it
required ten lsvor hours ut 60g per hour to tuke cure of the oil
equipment. This mikes a tots) of ,181.50 per duy for the coat of
the ofl.

taking the figures obtuined from the boiler room
celcule tions, the cost of the pulverize: coal per dey would oe
8.12 x 20 » 9162.40. This amdumats to & saving of £19.10 per
day in the hext trest deprtmnt, or for & yeur of S00 wrking
Gays it amounts to & saving of 2570.00 .

che sivinz shown above for the mat treat dept. is
not large emourh to werrent the hoxvy ex:anditure of esx pital
that womld be necesssry to mike the chungee ‘he following
are some of the rez sons wh; we do not consider it to be feusible

to change to ® pulverized ool systan in the heat treat department;
It would pe necessary to discord or sell most of the present
equipment at a heavy loss; the furnaces would have to be re-
oullt to burn pulverized coal; and an exhaust system would be
necessary in order to remove the products of compustion in the
'farnaces.

ie also refer to the statement of the Combustion
Engineering Cor poration's report in regrds to the fessibility
of the clange. Havever incase fuel o11 aguin rises in price
to that which wau paid during the war, 134 per gallon at one
time, it might pe that the change would be warranted. The
reason for the present slump in prices is tho fsot that many
industrial conce’ ns are shut down and the ofl companies hve
a large supply on hand, probably in tank cars, When the
time comes for narmal output sguin, it is almost certain tha
fuel of] will rise in price aguin,.

The fuller sngineering Co. states that it would not
be necessory to change the fire box construction of the 870
HePe boiler for burning pulverised co#l. However, they are
of the opinion that the other poiler compustion chambers would
have to be changed somewhat, even for normal rating.

It will be noted that nothing has been said thus
far, of depreciation, regairs, insurance, interest and taxes.

We have assumed that these items would balance each other in

both installations. In moking this aseumption, we are using the
paper “Pulverised Coal for Stationary Boilers" by Scheffler and

Harnhurst, as an authority.
———- — — a or . - pe ee eee

Bd suiGunaluy

"Powdered Coal is a ruel" --- a book by Cer’. lerington.

*"Yowdered Coal For Stationary Boilers” = = AeSeiie de Bulletin
prosented by F.A. Soheffeler und YW.uUe. Burnhurst.

Bulletins #10 and #12. - - - .uijley Furnsoce Speciulities Co.

"Qse of 2ulvwerized Coéel Under Central Station Boilers" - - a
bulletin from Combustion sngineering Corporation. New York City.
"Steum From -ulv&rised Coal” - - Bulletin from culvorizsed Fuel
squi parent Corporation, New York City.

“>ulver ized Coal For Steam Goneration" ~- - Bulletin 17 from
Fuller sngineering Co., Allentown, cennaylvania.

"“Pulverised Coal For Roasting and sSmelhting ino Orey" - -

Bulletin oy H. R. Collins of the Fuller sngineering Co., Allentown
P&e

"powdered Coal" - - 3ulletin 2 Combustion iconomy Cor poration
Chicugo, Il.

">ulverised Coal for Boilers” -- 3ulletin # 600 Fuller ing ineering

Co., Allentown, Pa.
ee

tap nak

\ Tae Shan
trary a

 
 
 
iii

175 5675

93 03

|

 

i