IC-N ' ' Y LIBRARY OF THE UNIVERSITY OF CALIFORNIA. Class LIGHTING BY ACETYLENE / GENERATORS, BURNERS AND ELECTRIC FURNACES BY WILLIAM E. GIBBS, M.E. SECOND EDITION, REVISED AND ENLARGED DIVERSITY J OF / NEW YORK D. VAN NOSTRAN 7 D COMPANY LONDON CROSBY LOCKWOOD AND SON 1899 COPYRIGHT, 1899, BY D. VAN NOSTRAND COMPANY TROW DIRECTORY PRINTING AND BOOKBINDING COMPANY NEW YORK v* V TABLE OF CONTENTS INTRODUCTION TO SECOND EDITION, . . \ * ACETYLENE (INTRODUCTION), .... i ACETYLENE (HISTORY), 4 DANGERS OF ACETYLENE, g EXPLOSIVENESS, g ACETYLIDE OF COPPER, n Toxic PROPERTIES, IJ EFFECTS UPON THE EYES, ^ ELECTRIC FURNACES, ....... 15 A CONTINUOUS ELECTRIC FURNACE,. ... 26 GENERATION OF ACETYLENE, 35 THE DRY PROCESS GENERATOR, 4I THE WET PROCESS GENERATOR, 49 THE PLUNGER, ? . . 55 IMPURITIES OF CARBIDE AND ACETYLENE, . . 63 GENERATORS, 69 FIRST CLASS, . ... . . . . 70 SECOND CLASS, . ... . . . . . 95 THIRD CLASS, . . ' . . . * . . . . 99 ACETYLENE LAMPS, . . . m 50(>26 iv CONTENTS PAGE ACETYLENE BURNERS 119 AUTHOR'S EXPERIMENTS, 129 CONCLUSION, . .147 FIRE REGULATIONS, , . 151 LIST OF UNITED STATES PATENTS, . , . .155 INTRODUCTION TO SECOND EDITION WHEN the first edition of this treatise was written, in the months of January and February, 1898, a host of acetylene generators was appearing. New types and modifications of older forms were being put upon the market, while hundreds were rushing into the new field opened by the production of calcium carbide. The apparent simplicity of fhe gas-making process from this new substance was sufficiently at- tractive to excite the interest of inventors generally, and to develop a large number of worthless gener- ators, constructed by those having little mechanical knowledge and no ability to solve the difficulties encountered. The early machines were of the type originally known as " briquet hydrogen " now known as the plunger or dip generators. The next to appear were the dry generators, so-called, in which water was sprinkled or dripped upon the carbide some- times now called drip machines. These were an enormous step in advance of the plunging machine, but with the overcoming of the earlier objections other corresponding difficulties were encountered ; and later, when the wet process or chute generator was introduced, it was thought that a great step in advance had been made. This opinion was in the main correct, as has been shown by the investiga- VI INTRODUCTION TO SECOND EDITION tions of those who have seriously and understand- ingly studied the problem ; but the same thing happened in this case that occurred when the dry machine was substituted for the plunger. Where certain objections were overcome, others were en- countered ; and while all types of machines, and especially the latter two, were excellent gas pro- ducers, they were difficult of management, and some of them were dangerous. The gradual addition of parts for protection against each element of danger or inconvenience has made the machines safer, more efficient, and durable. At the same time, it has made them more likely to become disarranged. The complications which have grown out of the older and simpler forms of generators have not, however, rendered possible the charging of the dry machine with carbide, without the introduction of air or the opening of the reservoir containing an explosive mixture of air and acetylene. This, with such machines, is the greatest fault, and is the one which has been most difficult to overcome. With the wet machine, the loss of gas during the passage of the carbide down the chute, even if the same be filled with oil, is very considerable when using finely powdered carbide ; and this has not been overcome. The waste of gas is perhaps not of great importance; but the possibilities which exist for its admixture in explosive quantities with air in the room containing the generator, and the odor which it is sure to cause, make the generators of either type most unpleasant companions in the house. INTRODUCTION TO SECOND EDITION Vll The solution of this problem of getting the car- bide into the generator without the admission of air or the emission of gas is of the first importance. An almost equally difficult problem, but one of less moment, is the removal of the residuum from the machine. The paste or semi-liquid substance which must be removed from the dry machine, and the thin, creamy sludge from the wet machine, are both difficult of management. It has been proposed to wash the residuum into the sewer; but, on the other hand, it has been suggested that the lime would make an insoluble soap with the grease al- ways present in the drains, which would eventually clog them. In country districts, the use of a small cesspool built especially for the purpose of contain, ing the sludge seems a suitable expedient. Indeed, in communities where cesspools are used for the disposal of sewage, there should be no objection to draining directly into them. The lime is an excel- lent disinfectant, and similar properties are claimed for the acetylene which the water holds in solution. The author, in the first edition of this book, advo- cated strongly the use of an out-door generator built within a cistern. Those which he constructed upon this plan for his own use and for experimental work have given no trouble, and have been extremely sat- isfactory. The same, or even larger, losses of gas while the carbide passes down the chute are present in this machine, which must have a water-seal of considerable length ; but being remote from the place where the lights are used, it causes no inconven- Vlll INTRODUCTION TO SECOND EDITION ience. The expense of the installation, however, is many times that of the portable machine. There seems no reason why a small frost-proof building should not be substituted for the underground con- struction. It has often been proposed to fill the gas- holder with oil, and to protect the generator by means of non-conducting material. In that case the heat set free by the reaction between the carbide and the water can be prevented from escaping, and would maintain a sufficiently high temperature to prevent the freezing of the generator in cold weather. The author has been unable to verify this condition, for lack of sufficiently cold climate. In this latter form of out-door generator, it would be necessary, in the event of using a dry machine, to employ a saturated solution of brine for the exciting fluid. The abandonment of some of the earlier types of machines, and the dissatisfaction which even the best of the more modern ones have given from these causes, makes it imperative that some radical changes be made before the generator can be de- clared a complete success. Means must be provided whereby carbide, coarse or fine, or in any condition in which it usually comes from the works, can be put into the generator abso- lutely without the loss of gas or admission of air. Means must also be provided for removing the residuum under the same conditions, and, in the case of the wet machine, without breaking the seal through which the carbide enters the chute. Diffi- INTRODUCTION TO SECOND EDITION ix cult as these problems seem, they are both possible of solution ; and upon them the most strenuous ef- forts of the inventor should be expended. Their solution will at once make the use of the genera- tors within houses as safe as the use of kerosene lamps, and will entirely remove the disagreeable elements of odor and lime-stains. Until this is ac- complished, the user of acetylene must tolerate its inconveniences for the sake of its incomparable light. LIGHTING BY ACETYLENE INTRODUCTION IN an attempt to set forth the facts concerning the development of the kindred industries of calcic carbide production and the generation of acetylene therefrom, it must be borne in mind that both proc- esses, so far as their industrial application is in- volved, are of very recent date. Whatever is written about either must be con- sidered as an exposition of the art so far only as it is known at the moment of writing. Revision or even radical change of ideas may be expected from time to time as continued experiment brings to light new facts about these hardly known sub- stances. A recent serious explosion of liquefied acetylene prompts the writing of what follows, since it would seem that ignorance or neglect of the admonitions of earlier experimenters was to blame for an ac- cident which cannot but prejudice many against the use of a valuable and safe ilium inant. Since the French have been unusually keen in the pursuit of information concerning calcium car- 2 LIGHTING BY ACETYLENE bide and acetylene, and have not only devised many machines for generating the gas, and furnaces for producing the carbide, but have made public the results obtained, their books and pamphlets on the subject have been freely drawn upon for details of foreign practice. As for the American gas generators, a description of types of those which the author has been able to discover from an examination of the United States Patent Office records, direct interviews with the manufacturers or inquiry among the carbide dealers is included ; but, since hundreds are experimenting in this field, and since two or three new generators are patented in this country each week, it is quite impossible to include the most recent ones. Suffice it to say that, in the very nature of the problem involved, generators may all be divided into three classes, and that any new machine can differ from the existing forms only in matters of detail. For the production of acetylene it is necessary to bring calcic carbide into contact with water in some kind of vessel from which the resulting gas may be conveyed for use. Whether the carbide is thrown into water, or the water is poured upon the carbide, is in general terms a matter of indifference, the result being practically the same. When, however, the renewal of the carbide be- comes necessary in order to keep up a continuous supply of gas, complications immediately enter the INTRODUCTION 3 problem, which becomes still further involved when the removal of the lime resulting from the'reaction is attempted. The generation of a quantity of acetylene is a very simple matter. The devising of means for delivering a constant supply of gas, supplying calcic carbide to the generator and removing the lime therefrom has taxed the ingenuity of some of our ablest inventors. The ideal machine has certainly not yet been in- vented, but existing forms are being constantly im- proved, and at the present writing, the safe, efficient and cheap lighting of houses by acetylene is an ac- complished fact. HISTORY ALTHOUGH only recently become of commercial importance, acetylene has been known chemically since 1836, when the chemist Edmond Davy an- nounced the discovery of " a new gaseous bicar- buret of hydrogen and of a particular compound of carbon and potassium, or carburet of potassium," in the British Association Reports, 1836, pt. 2, p. 62. In 1861, the German chemist Wohler prepared calcium carbide by heating a mixture of lime and carbon in the presence of zinc. Berthelot,in his classic synthesis of a hydrocarbon, passed hydrogen through a receiver in which an electric arc was maintained between carbon elec- trodes. The hydrogen combined with the vaporized carbon to form acetylene (C 2 H 2 ), which was passed through an ammoniacal solution of copper, where acetylide of copper (C 2 H 2 Cu 9 O) was precipitated. Berthelot, in 1866, obtained carbide of sodium by gently heating metallic sodium in an atmosphere of acetylene. The acetylene, being absorbed, produced C 3 H 2 Na, and, upon being raised to a red heat, the hydrogen was driven off, leaving sodium carbide (C 2 Na) as a heavy, dark, stone-like mass, which gave off acetylene when thrown into water. Others since then have formed various carbides, 4 HISTORY 5 which have been used in the laboratory as a conven- ient means of producing acetylene. In a note to the Academic des Sciences, presented on December 12, 1892, Moissan, who had been ex- perimenting with the electric furnace, made the statement that " If the temperature of the electric furnace reaches 3,000 the material of the furnace itself, the quick-lime, melts and runs like water. At this temperature the carbon rapidly reduces the oxide of calcium and the metal is set free in abun- dance. It combines easily with the carbon of the electrodes to form carbide of calcium, fluid at this heat, which is easily recovered." In March, 1894, Moissan presented to the Aca- demic a sample of pure crystalline calcium carbide which he had obtained by submitting a mixture of powdered lime and carbon to the action of the electric furnace. Prior to this time, in America experiments had been conducted with the electric furnace on a very extensive scale. The Cowles furnace was being used for the production of aluminum, and carborun- dum produced in the electric furnace had become an article of commerce. Mr. Thos. L. Willson had built a plant containing an electric furnace, with which he was experimenting upon further improve- ments in the production of metals and alloys. According to the most authentic reports, the dis- covery by him of calcium carbide was an incident in his search for a flux which should prevent the spattering of the molten alloys in the furnace from O LIGHTING BY ACETYLENE interfering with and short-circuiting the arc. The use of lime and carbon for this purpose naturally re- sulted in the production of calcium carbide. While others, no doubt, produced unwittingly the same substance, none had noticed its character or taken advantage of the future which it promised until Mr. Willson was impressed by its possible commercial value. The French unanimously accord the discovery of the crystalline carbide to the chemist Henri Mois- san, and urge most ably the validity of his claims to the discovery of the substance. The whole matter has been taken up by the Progressive Age, of New York, in a series of articles published during the summer of 1898, in which the claims of both Moissan and Willson are very fairly set forth. The bulk of the testimony would seem to show that Moissan had produced the carbide in small quantities in a laboratory furnace prior to its discovery by Willson ; but had it not been for Amer- ican foresight and enterprise, the commercial im- portance of calcium carbide as a factor in lighting would probably for a long time have remained hid- den in the foreign laboratories. There is no doubt that to Willson belongs the credit of the discovery of calcium carbide in its commercial form, and for the industrial purposes of gas-making. It is not to be wondered, when we consider the possibilities opened up by the electric furnace, that many experimenters hit upon the same facts and were experimenting along the same lines ; and it is HISTORY 7 if only charitable to believe that the claims of each in- ventor are based upon his honest belief. Since the first edition of this book was written, many other experimenters have been discovered who, between the years 1836 and 1894, made some contribution to Science concerning the properties of acetylene. None, however, conceived the possi- bility of using the gas industrially until the electric furnace had become a factor of modern manufactur- ing arts ; and while such honor is due them as the chemist usually receives for his discoveries, their work, viewed from an industrial stand-point, is of little importance. The investigator who wishes to decide for himself the relative merits of the claims for priority of in- vention of calcium carbide is referred to Perrodil's text-book on acetylene and calcium carbide, a trans- lation of which was published in Progressive Age, and the numbers of Progressive Age in which the claims of Willson are set forth. DANGERS OF ACETYLENE Two or three years ago, when the commercial production of acetylene was first attracting general attention, the most diverse and exaggerated ac- counts of its dangerous properties were published. By some it was declared to be intensely poisonous, by others frightfully explosive, while a third faction announced that it readily formed explosive com- pounds with the metals of the pipes and gasometers necessary for its use. Since the truth concerning this gas is now well known, it seems needless to enter upon a detailed description of the dangers then predicted, and it will be sufficient excuse for the misinformation so generally disseminated to say that much of the early carbide was very impure. No doubt the gas resulting from its decomposi- tion contained all kinds of undesirable substances, some explosive, some toxic, and some tending to favor the formation of the detonating acetylides of metals. Now, however, that we may be sure of the purity of our carbide, the dangers attending the use of acetylene have been exactly determined. Without going into the details of the experiments conducted by the ablest chemists of the time, or re- 8 DANGERS OF ACETYLENE 9 lating the experiences of those who have labored to bring into vogue the practical and industrial appli- cation of acetylene, it will suffice to present a synopsis of the dangers attending the use of this gas and the means for obviating them : EXPLOSIVENESS. Acetylene, as alarmists are so fond of stating, is an endothermic substance, which means that in its production a certain quantity of heat is absorbed and disappears. This heat, or its equivalent in some other form of energy, exists in the substance, tend- ing and striving to reassert itself upon provocation. For this reason the gas, under certain conditions, is an unstable body. It tends to resolve itself into its component elements, carbon and hydrogen, and when such dissociation is by any means brought about without the presence of other substances, the result is a certain quantity of hydrogen and a mass of finely divided carbon. This dissociation can be effected in a body of acetylene gas at atmospheric pressure by the detonation therein of a small quantity of fulminate of mercury or other violent explosive, AND BY NO OTHER MEANS. Heat, flame, the electric spark or the electric arc itself will not, according to the most careful ex- periments, produce an explosion under these con- ditions. When the gas is condensed, however, it becomes, IO LIGHTING BY ACETYLENE with each increment of pressure, more and more unstable, and, in consequence, more easily exploded until the point of liquefaction is reached, when it be- comes as dangerous as the high explosives. The disastrous results which have invariably followed the attempts to liquefy acetylene should be sufficient warning against this procedure. The only place where there is any excuse for compressing acetylene is in the chemical labora- tory, where its properties are being studied by those skilled in dealing with unstable compounds, and where explosions are expected and provided for as a matter of course. Taking it for granted that, until the dangers at- tending the use of liquid acetylene have been over- come, the gas under a pressure only slightly above that of the atmosphere will be used in machines for industrial lighting, we may state that, so long as acetylene is unmixed with any other substance, it cannot be exploded by the means usually at com- mand. An admixture of air with acetylene at once alters the case, for then we have the same conditions which determine the explosion of a mixture of the ordinary illuminating gas with air. The two gases then behave in nearly the same manner, becoming more and more inflammable as the proportion of air increases until the mixture contains about one part of gas to four of air, when it becomes explosive. The mixture remains explosive until the proper- DANGERS OF ACETYLENE II tions are one of gas to twenty of air, after which the dilution is too great for the propagation of flame. In each stage the acetylene mixture is somewhat more dangerous than the house-gas mixture, simply because its explosion in each case is rather more violent. With a properly constructed generator, however, there should be no chance for the ad- mixture of air with the gas in any proportion, no matter how small and apparently harmless ; and, since many generators obviate entirely the admis- sion of air to the system at the same time that they fulfil all the other requirements of successful gas- production, there can be no excuse for taking the slightest risk on this point. ACETYLIDE OF COPPER. The presence of ammonia in the gas favors the formation in the gas fixtures of this explosive salt. Well-washed gas should not combine with the small proportion of copper found in the ordinary fixtures. The substance is not easy to make, even in the lab- oratory, and the amount which could by any chance form in the fixtures is very small. The use of copper should, of course, be debarred for any part of the system, and especially for the generator or gasometer. TOXIC PROPERTIES. A most elaborate series of experiments conducted in France upon men and various lower animals has shown conclusively that acetylene is slightly less 12 LIGHTING BY ACETYLENE poisonous than the ordinary coal-gas in general use. In experimenting upon dogs, it was found that, when the animals were removed from the influence of acetylene before they had been fatally poisoned, recovery was more rapid than when they were sub- jected to the effects of ordinary illuminating gas un- der the same conditions. An examination of blood samples taken every few moments showed that acet- ylene was rapidly eliminated from the system. It was also found that fatal results were not pro- duced by the prolonged inhalation of acetylene and air mixtures unless the gas existed in the propor- tion of more than twenty per cent. The author may say that, while he is unusually susceptible to the effects generally produced by in- haling noxious gases, he has experienced no incon- venience whatsoever from breathing day after day an atmosphere rich in acetylene. The danger to be apprehended from leaving the tap of a burner carelessly turned on is too remote to require serious consideration, since the leakage of half a foot of acetylene an hour would require, in an air-tight room eight feet square by eight feet high, fifty hours to produce a mixture of only five per cent, of gas. The odor of acetylene is so peculiar that a very small leak is quickly noticeable. The odor, which is quite indescribable, is decidedly unpleasant, re- minding one somewhat of garlic, or onions. The products of the perfect combustion of acety- DANGERS OF ACETYLENE 13 lene consist solely of vapor, of water, and carbonic acid. ' In the case of incomplete combustion, in addition to these products, carbon monoxide, car- bon, and hydrogen are produced. The latter statement is equally true of any of the combustible illuminants, but the amount of carbon monoxide given off from the acetylene flame of the standard burner will be only one-tenth part of that from ordinary gas. Experiments similar to those mentioned above have shown that animals are affected in about the same degree by inhaling the products from the com- bustion of equal quantities of acetylene and illumi- nating gas. In the case of neither gas need any fear be enter- tained of the effects of inhaling the products of combustion of burners used for lighting. Cases of injury from this cause have happened, indeed, with illuminating gas, but only when used in large quan- tities, for heating, in a gas stove without proper provision for ventilation. EFFECTS UPON THE EYES. When the incandescent electric lamp came into use there was a general complaint that it "hurt the eyes." Later, the Welsbach mantle suffered under the same imputation. One rarely hears either blamed for eye injuries at the present day, The intensely bright light of acetylene will cer- 14 LIGHTING BY ACETYLENE tainly be more than either of the others the object of a similar complaint. A careful observation of the advent of all these lights has led the author to believe that, so long as a light is a novelty, and so long as individuals, prompted by curiosity, continue to look directly at the flame or other source of light, they will quite naturally be temporarily dazzled and partially blinded. As soon as the novelty wears off and they are content to look at the objects illuminated, the com- plaint ceases to be heard. Man for some thousands of years has had for his type of light the sun, and it is without doubt true that the sunlight is yellow. He takes most kindly to a yellow light, which is the reason the electric arc is so unpleasant, with its bluish tint and moonlight effect, and also the reason that the Wellsbach seems green to most of us. As a matter of fact, the acety- lene flame is very like sunlight, and its effect on the eyes cannot but be beneficial, on account of its perfect steadiness. The only disagreeable feature is, that from its small size, it casts a rather sharp shadow, which makes it unpleasant when burned without a diffusing globe or shade. ELECTRIC FURNACES EVER since the beginnings of chemistry, the fol. lowers of that science have sought means for pro- ducing intense heat. A charcoal fire urged by bellows or an alcohol flame intensified by the blowpipe, was used for this purpose by the early experimenters. Then came, with the advent of illuminating gas, the Bunsen burner and the blast lamp in various forms as an important step in advance, and finally the oxy-hydrogen jet with which platinum and irid- ium could be fused. Each improvement led to increased knowledge of the more refractory substances, but investigators still longed for a source of heat, which not only would be more intense, but which should be free from the disadvantages of a highly oxygenated flame. The extreme temperature of the electric arc had long been known and had been utilized in a small way in researches upon refractory materials in con- junction with spectroscopic analysis. During the past few years, however, the production of electric currents of immense quantity has become an estab- lished industry, and it has been possible to so mag- nify the small arcs of a decade ago, that an entirely new and most important piece of apparatus has been 15 10 LIGHTING BY ACETYLENE developed. The result is seen in the electric fur- nace, which may vary in size from a small crucible, in which is maintained the arc of an ordinary street light, to those huge creations of the carbide works, where a thousand horse power of energy is con- verted into the sun-like radiance which fills the space between the carbons. The electric furnace consists, in its simplest form, of a crucible of refractory material, within which an electric arc may be maintained between the ends of two carbon electrodes, which enter the crucible for that purpose. FIG. i. Siemens Furnace. FIG. 2. Moissan Furnace. The substance to be treated, generally in the form of grains, or in powder, is placed in the crucible in such position that it may be traversed by the elec- tric arc, to whose intense heat it is subjected. The electrodes are sometimes placed in a horizontal posi- tion, sometimes vertically, and, again, inclined. When horizontal, they may enter the crucible ELECTRIC FURNACES I/ through holes in its wall, or the crucible may be so shallow that they pass over its upper edge. When vertical, the lower electrode may enter the bottom of the crucible through a hole, or may con- sist simply of a block of carbon laid on the bottom, or the bottom of the crucible, or the crucible may itself be the electrode, provided it is a conduct- or of the current, while the other electrode de- FIG. 3. Moissan Furnace. scends through a hole in the cover when a closed crucible is used, or is guided centrally of the cru- cible by external mechanism in the case of an open furnace. The Siemens furnace, Fig. i, has a graphite crucible embedded in a mass of refractory material intended to prevent radiation. The crucible forms the lower electrode. There is a vent for the gases. 18 LIGHTING BY ACETYLENE The upper electrode is operated by a magnified arc- lamp mechanism. FlG. 4. Willson's Furnace. The first Moissan furnace. Fig. 2, has horizon- tal electrodes manoeuvred by hand. The crucible is so shallow that the electrodes pass over its upper edge. ELECTRIC FURNACES The second form of Moissan furnance, Fig 3, is like the first except that a hole is cut at right angles to the electrodes entirely through the fur- nace, near the bottom of the crucible. By inclining FIG. 5. King Furnace. the furnace, it may be made continuous in action. The charge is fed in at the upper end of the cross- hole, and, after passing through the crucible, the product issues at the other side. Willson's furnance, Fig. 4, has an outer casing 20 LIGHTING BY ACETYLENE of brick (A), a crucible of carbon (B), a lower elec- trode of broken carbon, an upper electrode (C), with a wheel and screw h, g, for moving it, a tap-hole (D), and an iron base-plate, to which one pole of the generator is connected. The King furnace, used at the carbide works at Niagara, N. Y., is on a more elaborate plan, although the additions to its mechanism are of importance only in giving ease of charging and removing the product. The crucible is contained in a small iron car, which may be run out on a track when desired and another substituted for it without loss of time. Suitable chutes allow the lime and coke mixture used for making the calcic carbide to be delivered to the furnace ; flues carry off the gases of combus- tion. The car carrying the crucible is given a backward and forward motion during the action of the current, in order to distribute the contents and to make the action of the arc uniform. The upper electrode is formed of a number of carbons clamped into a massive connector. King & Wyatt have patented a process for form- ing calcium carbide, in which, in lieu of an electric furnace, the mixture of lime and coke is placed in a heap on an iron plate which rests on the ground and forms the lower electrode. The upper electrode is supported on a light crane and is lowered down through the centre of the pile. The carbide forms as a nugget in the centre of the mixture, from which it is removed by means of a pair of tongs. ELECTRIC FURNACES 21 Some furnaces are provided with movable bot- toms for dumping the charge. Others have a tap- FIG. 6. Bullier Furnace. hole for drawing off the molten carbide, but the best practice seems to consist in starting the furnace with the arc at the bottom, raising the electrode 22 LIGHTING BY ACETYLENE from time to time, and allowing the carbide to build up in the shape of a block until a considerable thickness is obtained. The current is then shut off, the upper electrode drawn out of the furnace, and Furnace used at Spray. the crucible removed for cooling, while a fresh one is put in place and the electrode lowered. The Bulller furnace. Fig. 6, is one having a dumping bottom. The sides are vertical, of fire- clay. The iron bottom serves as the lower electrode. The upper electrode is, as usual, of carbon, which ELECTRIC FURNACES FIG. 8. Pictet Furnace. penetrates the centre of the mass of lime and carbon contained in the furnace. As it is raised, there is formed about its end a cavity, into which the con- tents of the furnace fall, little by little. The block 24 LIGHTING BY ACETYLENE of carbide, which occupies the centre of the mass at the end of the reaction, is dropped into a car by opening the bottom of the furnace. The furnaces used in the carbide works at SPRAY, Fig. 7, are of the Willson type, but are double, and are covered by an arched flue, through which the gases escape. The carbons are composed of six blocks, each four inches square and a yard long, held in a clamping head and bound together by an iron sheath. In this arrangement, each furnace must be allowed to cool before the calcium carbide is removed. M. Raoul Pictet has proposed a furnace, Fig. 8, in which the mixture of lime and coke is acted on, first, by a current of heated air at D, then by an oxy-hydrogen flame, G, as it reaches a lower level, and finally by the electrodes I, I, which melt the carbide. A hole in the bottom of the furnace allows the product to drop through into a receptacle, L. This is, apparently, an unsatisfactory method, be- cause the coke must be in excess in order to com- pensate for that burned out of the mixture, and the ash which results from the combustion materially interferes with the proper formation of the carbide. Several attempts have been made to produce a continuous furnace, but, as yet, with unpromising results. The continuous process would certainly be a gain in the economical production of carbide, if it could be made to work successfully. A small portion only of the coke and lime would ELECTRIC FURNACES 2$ be under action at a time, which, as soon as con- verted, would be automatically removed from the furnace ; the necessity of maintaining the mass of carbide at a high temperature until all was con- verted would be obviated, and the loss of time in re- charging furnaces and waiting for the carbide to cool would be avoided. A CONTINUOUS ELECTRIC FURNACE SINCE the foregoing chapter was written. Mr. C. S. Bradley, of New York, has patented a continu- ously-acting electric furnace, which seems to satisfy perfectly the conditions of uninterrupted carbide production. The description of this furnace (Figs. 9 and 10), and its operation is taken from the patent specifica- tion at considerable length, because, in a general way, it is an excellent account of the manner in which carbide is produced : " The object of the invention is to permit a con- tinuous and uninterrupted operation of the furnace, and withdrawal of the product, and to protect said product from the action of the air when at a high temperature. " The furnace is especially designed for employ- ment in the manufacture of metallic carbides. It comprises a receptacle for the charge to be oper- ated upon, in which it inserts an electrode, means being provided for continuously moving the recep- tacle with relation to the electrode so as to bring fresh portions of material under the action of the electric current. The construction which it is pre- 26 A CONTINUOUS ELECTRIC FURNACE 2? ferred to employ comprises a rotary wheel or annu- lus, into which projects at one side an electrode, and provided with means for preventing the ma- terial from spilling, and means for supplying fresh material to be acted upon by the current, and facil- ities for removing the product, the whole being so arranged that the operation may be carried on in an uninterrupted manner, the furnace constantly form- ing fresh additions to the product and permitting the latter to be removed as frequently as may be necessary. The wheel is preferably turned by power-driven machinery, and is provided with a hollow periphery, to which are attached over an arc covering the lower part of the wheel buckets form- ing throughout said arc a closed receptacle for the material to be operated upon. Said buckets are ar- ranged to be withdrawn or opened when they reach the discharge-end of the wheel-arc. The material, in the form of powder or granules, is supplied to the side of the wheel which contains the electrode or electrodes. The electric arc, or the limits of the space within which the electric action on the ma- terial takes place, are wholly within the mass of pulverized material, so that a wall of unchanged or unconverted material will surround the product of the furnace, and the motion of the wheel in such direction as to surround the converted material by a body of unconverted material, and thus exclude air until the converted mass has become sufficiently cool to permit its removal and further treatment for packing for shipment or storage. In the formation 28 LIGHTING BY ACETYLENE FIG. 9. A CONTINUOUS ELECTRIC FURNACE FIG. 10. 30 LIGHTING BY ACETYLENE of a carbide ot calcium, for example, an intimate mixture of ground lime and ground carbon is sup- plied to that side of the wheel-arc into which the current is introduced, and is fused, permitting the carbon and calcium to combine, and forming a pool of liquid carbide of calcium within the wheel-rim, which pool is surrounded by a mass of uncombined mixed carbon and lime, which acts as an efficient heat-insulator, keeping the walls of the receptacle comparatively cool. As the wheel turns, the pool is withdrawn from the neighborhood of the electric arc, or region of electrical activity, and the liquid carbide cools and solidifies under a superincumbent and surrounding mass of material, which prevents access of air and thus prevents wasteful consump- tion of carbon by combustion. Thus a core of solid carbide of calcium is formed within a granular or pulverized mass of material, said core growing in length as the receptacle recedes from the electrode until it emerges from the other end of the wheel- arc, when the removable sections of the wheel-rim may be taken off one at a time, permitting the pul- verized material to fall away from the solid core of carbide, which may be broken off or otherwise re- moved periodically. Thus the formation of carbide goes on continuously without necessary interruption for recharging or removal of the product. " Fig. 9 is a sectional view on a plane at right angles to the wheel-axis. Fig. 10 is a sectional view on a plane parallel to the wheel-axis. " I represents a wheel formed in sections and A CONTINUOUS ELECTRIC FURNACE 3 1 bolted together, and having a horizontal axis mounted in boxes at or near the floor-level. The rim of the wheel is concave in cross-section, and is provided at intervals with pivoted latches (3, 3 a ) to engage studs (4, 4 a ) on semi-cylindrical sections of plate-iron (5) to support them on the wheel. Auxili- ary plates of thin sheet-iron may be bent around the joint between the sections on the inside of the wheel-rim, to prevent the pulverized material from sifting through the cracks at the joints. The wheel may with advantage be made about fifteen feet in diameter, and the rim and plate-iron sections of such proportions as to form a circular receptacle of thirty-six inches in diameter. The inner wall of the wheel-rim is provided with holes at intervals to receive copper plugs (6) connecting with the several plates of a commutator (7) by conductors (6 a ), on which bears a brush (8) connecting with one pole of an electric generator (9). The other pole of the generator connects with a carbon electrode (10) about four inches in diameter mounted in a sleeve (11) provided with a screw-thread on the outside, which engages an internally threaded sleeve (12) secured to a bevel-gear (13) meshing with a gear (14), on the axis of which is a crank (15) for adjust- ing the electrode. The electrode and its regular ing mechanism are mounted on a framework ad- jacent to the wheel-pit, so that the electrode may be fed into the receptacle formed by the wheel-rim and the rim sections when partly consumed. " 16 is a feed-hopper provided with a spout (17) 32 LIGHTING BY ACETYLENE projecting into the wheel-rim, and a gate (18) for regulating the supply of mixed material to be acted upon. "The wheel-pit is preferably provided with sloping sides, so that any powdered material which drops from the wheel, at its discharging end or elsewhere, may slide by gravity to a conveyer (19), the buckets of which return it to the feed-hopper, to again pass through the furnace. " The wheel is preferably connected with an elec- tric motor by speed-reducing gearing. Said motor is shown diagrammatically at 20. The motor- shaft carries a worm (21) acting on a spur-gear (22), on the shaft of which is secured a worm (23) mesh- ing with another gear (24), on the shaft of which is a third worm (25) meshing with a gear on the wheel- shaft. By this mechanism, a very slow speed of the wheel may be maintained, a complete revolution being made once in five days. In using the appa- ratus, the rim-sections are latched over the wheel-rim over an arc covering the lower part of the wheel, and the gate of the feed-hopper is opened. A charge of intimately mixed pulverized carbon and lime, in proper proportions to form carbide of calcium, falls into the receptacle around the wheel-rim and accu- mulates until the top of the electrode is immersed therein. The circuit of the dynamo-electric ma- chine may then be closed and the electric motor thrown into operation. As the charge is moved away from the electrode, intense heat is created and the refractory material fuses, forming a pool of A CONTINUOUS ELECTRIC FURNACE 33 liquid carbide of calcium, or other compound, de- pending on the nature of the furnace-charge. As the wheel turns, the pool gradually recedes from the electrode and slowly cools while inclosed within walls of refractory, uncombined material on all sides, the cool product forming a bottom for the liquid compound. Thus a continuous core of the product is formed, new rim-sections being added by a work- man at intervals of a few hours. The electrode, at starting, should project well into the receptacle, and, as the wheel turns, the electrode rises relatively to the charge, and, when it reaches a point near the top of the rim-section, a new rim-section is hung on the wheel by means of the next set of supports, and a strip of sheet-iron is bent around the joint between the rim-sections. The gate of the hopper is then opened and the rim filled, or partially filled, with material. As this material in its powdered state is a very poor conductor of electricity as well as of heat, the immersion of the electrode does not inter- fere with the heating action. When a new rim-sec- tion is added on the electrode side of the wheel, one is removed at the other side. Thus the process continues until the solid core of the furnace product appears at the discharge-end 'of the wheel, when a rim-section is taken off and the powdered material falls into the pit, leaving a pillar of solid product projecting vertically, which may be broken off or otherwise removed. Solid carbide of calcium is a conductor of electricity, and the copper plugs make a good contact with the same, thereby constituting 34 LIGHTING BY ACETYLENE the carbide itself one of the electrodes. The action of the commutator leads the current to a point of the carbide core close to the electrode, and thereby prevents unnecessary resistance, which would inter- vene if the plugs were more widely spaced. The conducting plugs (6), which are remote from the arc, help to carry the current, and thus heating of any one contact with the carbide core is reduced.' GENERATION OF ACETYLENE THE calcium carbide of commerce comes to us in air-tight cans of various sizes. The usual pack- age holds either fifty or one hundred pounds. Upon opening the can, we find a heavy, dark-colored, stone-like substance in lumps of various sizes. The largest pieces are the size of one's fist, while the smallest are in the form of grains broken from the larger pieces in shipment and travel. The specific gravity of calcic carbide is 2.22. Its fracture presents a crystalline surface like that of broken cast-iron, but almost immediately loses its lustre when exposed to the air, becoming covered with a film of lime. Upon dropping into a tumbler of water a piece of the carbide as large as a hickory-nut, a surprisingly violent reaction takes place. Acetylene is rapidly generated at the surface of the carbide, and, rising in the form of bubbles, throws the water into violent ebullition. A considerable amount of heat is lib- erated at the surface of reaction, which may boil the water in the tumbler if the piece of carbide is large. The whole mass of liquid, which is rapidly whitened by the lime set free, is in such violent commotion and is sosoujft/bythe issuing gas that many bubbles carry away sufficient heat to break as 35 36 LIGHTING BY ACETYLENE little puffs of steam before the water has reached the boiling-point. The issuance of steam must not, how- ever, be confounded with the appearance of the first bubbles which arise, and which being charged with finely divided lime give off a white dust which looks much like condensed steam. If this experiment is repeated upon a larger scale, with several pounds of carbide and a pailful of water, the phenomena are more striking. In this case the nature of the vapor, which rises soon after the reaction begins, may be discovered by noting that it does not disappear like steam, and it will be found, upon putting the hand into the bubbling water, that the liquid which seems to be boiling is quite cold. The violence of the reaction is surprising, even after seeing it many times. The water during the reduction of the carbide is in a state of the most vio- lent commotion. Bubbles rise in great masses to the surface of the liquid, but there instead of burst- ing, as one might expect, they roll over and over among themselves, and seem to the eye to go down again into the places whence they came. As the carbide is exhausted there is a gradually lessening disturbance of the water until the end of the reac- tion, when a thin stream of individual bubbles rises to the surface where each may be seen to break in the way one might expect. The water, after the reaction has ceased, is left white and thick with lime, which gradually settles to the bottom of the containing vessel. If the water is then decanted the lime remains in the form of a GENERATION OF ACETYLENE 37 semi-fluid paste, which flows easily. A few pieces of impure carbide, together with an occasional nod- ule of glistening carbides and silicides of various metals may be found at the bottom of the fluid. The latter are formed in the electric furnace from the various impurities contained in the lime and coke. When calcium carbide and water are brought to- gether, a very simple mutual disintegration takes place. The reaction results in two new substances, namely hydrated lime and acetylene. Chemically expressed the formula is: CaC 2 + 2H 2 O = CaOH a O + C 2 H 2 Calcium carbide 2 molecules of water Hydrated lime Acetylene Considering the molecular weights : CaC 2 + 2(H 2 0) = CaOH 2 + C 2 H 3 40+24 2(2 + 16) 40+16+2+16 24+2 and reducing these to decimal relation we find CaC, + 2H 2 = CaOH 2 + C 2 H 2 62.5 + 37-5 56.25 = 115.625 + 40.625 100 pounds + 56.25 115.625 + 5.81 cu. ft. calcic carbide water slaked lime acetylene A certain quantity of heat is set free during the generation of acetylene, which in the method de- scribed is manifested by a rise in the temperature of the water into which the carbide is dropped. A more striking way in which to show the libera- tion of heat that attends the decomposition of cal- cium carbide, is to dip a small piece, held between the thumb and finger, into water and then to quickly withdraw it therefrom. As the moisture reduces 38 LIGHTING BY ACETYLENE the carbide, the temperature rises to such a degree that the piece must soon be dropped. When water is supplied to a considerable portion of calcic car- bide, drop by drop, or in such small quantity that the carbide is not wholly submerged, the temperature of the inner portions of the mass may rise several hundred degrees, even reaching a red heat. If a wooden pail is filled with carbide and a small quan- tity of water poured on the mass, the pail may take fire after an hour or more. Under these conditions the acetylene is given off with clouds of steam and vapor, the gas has a strong odor of ammonia, and the reaction seems more vio- lent than in the case where the water was in excess. The total amount of heat liberated is of course the same in each case, provided equal weights of carbide are used ; but in the first instance the water which surrounds the carbide is put into violent mo- tion by the rising gas, so that every ounce of it is successively brought into contact alternately with the carbide and with the walls of the containing ves- sel, where its heat may be conducted away. Besides this, the specific heat of water is so great, that its temperature is raised less than that of other bodies by the same cause. So long as the carbide is surrounded by freely moving water, it is doubtful if its temperature could rise to a point at which the gas would be decom- posed, for water at the boiling-point has remarkable heat-absorbing capacity, provided its circulation is maintained. GENERATION OF ACETYLENE 39 When the carbide is in excess, however, the water which is supplied forms a paste with the reduced lime, and surrounds the carbide with a non-conduct- ing coating. The issuing gas affords the only exit for the heat, and not only comes off at a high tern- perature, but is often partly decomposed while the unreduced carbide increases constantly in tempera- ture. Moissan has shown that when the liberation of acetylene is attended by a considerable rise of tern- perature the gas is partly decomposed into sub- stances having a similar structure, known as poly- mers, such as benzine, styrolene, anthracene, tar and naphthalene. Acetylene is then said to polymerize, and the gas is partly changed into benzine vapor. If the tern- perature rises still further the elements of the gas are separated ; hydrogen is given off, and carbon, in a state of fine powder, is set free. The simplicity of the process of making acetylene from carbide would lead one to suppose that the construction of a generator for supplying the gas in the quantities required for lighting buildings would be an easy matter. Such, however, is not the case, and indeed so great are the difficulties encountered in producing a generator which may be depended upon for an unfailing and uniform supply of pure gas, that although hundreds, nay thousands, have labored upon the problem, it is safe to say that to- day not a single generator can be purchased which may be called a perfect apparatus. 4O LIGHTING BY ACETYLENE The conditions to be satisfied in an ideal generator are as follows : First Safety : A From explosion of confined gas due to pres- ence within a closed generator. B From fire risks. Second Economy : A In the yield of gas, whereby the maximum output of acetylene is obtained from each pound of carbide, and where all waste in using or recharging the generator is avoided. B In the production of a pure gas free from poly- mers or other products of decomposition, which lower the candle-power per cubic foot. Third Ease of management: simplicity. Fourth Non-liability of the apparatus to get out of order when put in the care of unskilled per- sons. The construction of a generator possessing in full all these requirements is a difficult matter. So far as is known it has not been done. It is proposed to discuss the problem point by point, but it will first be necessary to describe the lines along which ex- periments have progressed and upon which existing generators have been built. Acetylene has hitherto been made by either the " dry process " or the " wet process." THE DRY PROCESS GENERATOR In the "dry process" generators a large quantity of calcium carbide is placed within a gas-tight reser- voir where it is automatically sprinkled with small successive charges of water, the intention being that the addition of water shall be proportional to the yield of gas. Generators built upon this plan consist usually of a separate generator and gas-holder, so arranged that at each downward movement of the gas-hold- ing bell a small quantity of water will be admitted to the generators in which it will fall in small streams upon the carbide contained therein. A typical generator of this class is shown on the page following. The generator proper, A, is an iron box closed by a gas-tight door. Within it is a pan for holding the carbide, B, and a sprinkler, C, fed with water through the pipe, D, and cock, I, from the tank, J. The generator is surrounded by a bath of cold water, E, which contains a coil of pipe for cooling the gas on its way to the gas-holder, L. A safety-pipe, T, leads to a water-seal, G, which relieves any accidental rise of pressure of gas in the generator, and also serves as an escape for the water which is condensed upon the cool walls of the generator. The gas, after passing through the cooling-coil, is 41 LIGHTING BY ACETYLENE washed by bubbling up through the water in the washer, S, and thence flows down to the three-way- cock, H, where any moisture it contains is drained off to the safety-seal, G, by the pipe, V. This pipe acts in emergencies as a safety vent as well as a draining pipe, and should be of ample size. From the cock, H, the gas passes to the bell, L, of the gas-holder. Thence, it is taken to the burners by way of delivery-pipe, M, past the drainage-tube, U, through the dryer and filter. The cock, I, is normally held shut by a spring, but is opened by the pressure of a finger, W, pro- jecting from the bell when the latter sinks to a predetermined point. THE DRY PROCESS GENERATOR 43 In some dry generators, such as that of Dicker- son (Fig. 21), there is an arrangement whereby the quantity of water entering the generator is definitely measured at each descent of the gas-holder bell. In the " Niagara" generator, a " tip-tank" is used. This fills with water from a constant source, and at each descent of the bell is emptied into the gene- rator. The gas-holder should be provided with separate inlet and outlet pipes. Moisture is carried into the house-piping when one pipe is made to answer both functions. Either pipe may be made, however, to act as a guide to the bell, or the safety-pipe may be used for this purpose. Some prefer to have an in- dependent guide consisting of a central rod or of a pair of rods one at each side of the bell, as in Figs. 38 and 26. The gas-holder should be provided with a safety pipe, which telescopes into a larger tube carried by the bell. When the bell is so full of gas that the orifices near the lower end of the outer tube have risen to the surface of the water contained in the gas-holder, any further supply enters these holes and is carried to the seal G and thence to the outer air, where it is discharged. The gas on its way to the burners should pass through a dryer, in order that moisture may not be carried into the filter nor into the house-pipes, where it may condense and give trouble by cutting off the supply of acetylene, or may freeze and burst the pipes. A filter is shown at Q, consisting of a cylinder of 44 LIGHTING BY ACETYLENE loosely woven but thick fabric, through which the gas passes. This is a really necessary attachment, although rarely used. Without it the finely divided lime, which always comes into the gas-holder with the acetylene, gives trouble by entering the house-mains and eventually clogging the burners. Indeed this is the principal cause of burner stoppages, and for this reason it is also advisable to insert into the base of each jet a small pledget of cotton as an additional filter. In a plant installed by the author, ten per cent, of the hundred burners used needed cleaning daily, until these filters were used, since which time none has shown signs of clogging. In order to make clear the other difficulties which may arise with this class of generator, even the ideal one figured herewith, they will be described in detail. Beginning at the reservoir, J, the water-supply may fail. This may be avoided by connection through a ball-valve with the town supply, whereby the level is kept constant. The cock, I, which is held shut by a spring, may fail to close or may leak, causing a waste of gas. The remedy for this is to use a " tip-tank " or a measuring cock as in Fig. n. The cooling coil may clog with lime or the prod- ucts of polymerization. In that case gas wastes through the safety-seal, G. The cure is a large coil easy of access for cleaning. Means for flushing the coil with water might be devised. THE DRY PROCESS GENERATOR 45 The three-way cock may leak or become clogged. If, however, the seal, S, is so arranged that it cannot become dry, the cock may be discarded. The seal, however, introduces another difficulty. When the gas bubbles violently through the seal a rhythmic disturbance is set up in the gas-holder which makes the lights near the generator flicker, and sometimes is violent enough to extinguish them. If the seal is abandoned the three-way cock, or its equivalent, must be retained, and vice versa. The retort cannot be entirely filled with carbide. Consequently at each charging a quantity of gas es- capes when its door is opened and an equal quantity of air is shut up in the generator each time the door is closed. The issuance of gas is an element of danger, al- though not a great one when the generator is intel- ligently managed. The entrance of air, however, lowers the candle-power of the gas, and may be suf- ficient in quantity to produce an explosive mixture in the bell. It certainly does produce an explosive compound in the generator, but the fear that the heating of the carbide, which attends the production of gas in this type of machine, may ignite the mixture, is probably groundless. The yield of gas from freshly introduced carbide is so rapid, that the air is swept out of the retort before the temperature of the carbide has reached a dangerous point. The air space is none the less an objectionable 4 LIGHTING BY ACETYLENE feature in any generator, and should be cut down to the least proportions possible. No way has as yet been discovered for avoiding- it in the " dry ma- chines." The trap, G, may clog with lime to such a degree as to become inoperative as a means for relieving excessive pressure. It may, however, be flushed out occasionally by pouring water into the retort. There is no danger of its getting dry, for all the moisture in the system should drain to it. The door of the retort may leak, in which event a dangerous quantity of acetylene may escape. A vertical retort closed by a cover having a water-seal prevents this trouble, provided the seal is maintained at a constant level by a float-valve or by constant vigilance. Gas continues to be generated after the water- supply ceases, in an amount too large for the bell to contain, and is wasted. When a machine of this character is started with a fresh charge of carbide, little difficulty is met in regulating the water-supply automatically to flow to the carbide, and generate gas in proportion to the amount used. After being in action a short time, however, the lime disengaged forms a protective and absorbent coating over the blocks of carbide, which takes up the water as fast as delivered until it becomes satu- rated. It is then only that the water gets free ac- cess to the carbide. Consequently the machine responds slowly to the THE DRY PROCESS GENERATOR 47 addition of separate increments of water. On the other hand, when the supply of water is shut off, the carbide, being hygroscopic, continues to absorb moisture from the wet lime, causing the evolution of gas to continue for a longer time than was in- tended. This action causes irregularity in the working of the machine, and when coupled with the fact that the hot lime absorbs a larger quantity of water than it can hold when it has cooled, makes machines operated on this principle unsatisfactory. The polymerization of acetylene by the rise of temperature in a machine of this class is probably its worst feature. When a large quantity of carbide is charged into the retort, and is then acted on by successive small additions of water, the tempera- ture may rise to the point at which the acetylene is changed as generated into other substances such as benzine or may even reach a red heat, at which the gas is split up into carbon and hydrogen. In the latter case both phenomena are present as a rule. Lampblack collects in the water-seal, and benzine may be detected in the gas-holder. The loss of illuminating power is not the only re- sult of these changes. Certain oily or tar like prod- ucts are condensed in the pipes, and are carried by the benzine vapors to the burners, where they soak into the lava tips, there to carbonize and eventually stop up the jets. Much of the trouble given by the clogging of the burners is due to this cause. An index of the amount of decomposition taking 48 LIGHTING BY ACETYLENE place in the generator is the discoloration of the lime residuum. If it is nearly white or of a bluish tint all is probably going well, but the appearance of red or yellow spots and patches of discoloration indicates that the temperature has been too high. It is a matter of some doubt, however, at just what temperature acetylene begins to decompose. The makers of dry machines invariably affirm that the importance of the matter is much exaggerated, while the manufacturers of wet generators aver that it is the most important fault corrected by their plan of operation. The water-jacket has been abandoned in many dry generators, as being nearly useless in keeping the carbide cool. The carbide is generally placed in a pan which is then slipped into the generator. The water-jacket is, in this case, too remote from the carbide to absorb much of the heat which is set free locally at the point of reaction only. When a water-jacket is not used, the cooling coil through which the gas passes is sometimes placed directly within the gas-holder. The dryer through which the acetylene passes on its way to the filter is preferably filled with calcium carbide, which, in addition to absorbing the mois- ture from the gas, gives up more gas in so doing. THE WET PROCESS GENERATOR This is shown diagramatically above, in connec- tion with a gas-holder. The generator consists of a cylindrical can, closed by a top which is pierced with two holes one for the exit of gas into delivery pipe, B, and the other for the entrance of a chute which depends through the top of the generator to a point considerably below the surface of the water, and is of such shape that a piece of carbide dropped into its upper end will be delivered into the gener- ator at a point where the rising bubbles of gas can- not re-enter the chute nor escape, except by the gas- pipe, B. 49 SO LIGHTING BY ACETYLENE While in the dry machine a measured, small quan- tity of water is periodically delivered to a large mass of carbide, the action in the wet generator is exactly the reverse. The carbide is dropped in small, measured quantities into an excess of water. The generator may be of the very simple type shown in Figs. 36 and 37, in which case the carbide is dropped down the chute whenever the bell has nearly reached the lower limit of its travel. The bell, however, may be made to automatically per- form this operation in a number of different ways. In the diagramatic figure, the descent of the bell turns a ratchet-wheel which moves the circle of small car- bide cans (M) one by one, over the top of the chute (F), at which point a latch is tripped and the con- tents of each can is delivered successively down the chute into the generator. The gas which bubbles up rapidly through the water contained in generator, A, passes by way of the pipe, B, to the Tee at C, where any water or moisture which is carried over with the gas drains into the trap, D ; the gas then rises through the three-way cock and enters the gas- holder. The arrangement of the safety and delivery pipes is the same as described in the dry machine, both being drained into trap D. The safety-pipe (E) is carried out of doors, prefer, ably to top of building. The top of the chute is extended laterally to ac- commodate vent pipe, G, which should also be car- ried to the highest convenient point outside of the building. A sharp upward draft will normally exist THE WET PROCESS GENERATOR 51 in this pipe, and will carry away any gas which .rises through the chute during the fall of the car- bide into the generator. A filling box is built upon the side of the gener- ator, with which it communicates by a short up- turned pipe (I). Water is added from time to time through this box, which also allows the water-level to be seen. A water-glass in this situation soon be- comes so coated with lime, that it is useless. A baffle plate (J) surrounds the entrance of the delivery pipe (B), in order to prevent the entrance of water thereto. This plate is funnel-shaped, hav- ing a hole in its centre below the water-line. Water or lime, which enters the side holes in the baffle plate, drains away by the central hole. At the bottom of the generator is a valve through which the reduced lime in the form of thick cream may be drawn out, and at L is a grating which pre- vents the unreduced pieces of carbide and other im- purities from falling through into the lime-chamber. These are occasionally removed through the hand hole, K. There are certain drawbacks to the generation of acetylene by this type of machine, and certain acci- dents which may happen. The gas in the holder is kept from returning and passing out through the chute (F) entirely by the fact that the chute forms, with the water in the generator, a water-seal. If, through carelessness in allowing the water in the generator to get low, or by reason of a leak in 52 LIGHTING BY ACETYLENE the generator, the seal at the bottom of the chute is broken, the gas in the holder immediately escapes into the chute, and is thence carried out and wasted through the vent pipe (G). This trouble may be ob- viated by connecting the filling tank (H) with a con- stant water-supply, and maintaining its level by means of a float valve, but in that case it seems sim- ply to be adding another element of complication, which in its turn may get out of order. A leakage in the draw-off cock or hand-hole re- sults in the soiling of floors with the milk of lime which is formed in the generator. When carbide is dropped into this type of ma- chine the evolution of gas is very rapid, and the surface of the water in the generator is so disturbed by the issuing bubbles that if the water-level is too high, a very considerable quantity of water and lime is carried bodily into the pipe, B, and forced by the rush of gas in some cases as far as the bell of the gas-holder. It is for this reason that a separate de- livery pipe is quite necessary, as the moisture or free water will settle in the gas-holder before reach- ing the delivery pipe. Ordinarily the trap (D) takes care of the water which is thrown into pipe B, pro- viding the latter is of ample area. Of course, the trap may clog, but by completely filling the generator with water, the pipe and trap may be flushed and the lime driven out. The three-way cock may leak, but the safety-pipe, which is connected with it, prevents the gas from entering the house. Fortunately, in this class of THE WET PROCESS GENERATOR 53 generators there is almost no rise in the tempera- ture of the carbide, and the gas is very thoroughly washed by bubbling up through the water in the generator. In case any part of the mechanism which delivers carbide to the generator fails to work, the machine is rendered inoperative and the supply of carbide ceases. This is a good feature in a machine which is somewhat more complicated than the dry machine. Of course, no air can by any possibility enter the gas-holder, unless the chute-seal is broken, but there is with each charge of carbide a certain amount of gas lost up the chute during the passage of the car- bide through the water into the generator. Usual- ly this loss of gas is insignificant, but if the carbide is in very small pieces they sink slowly through the chute, and the loss may be as large as half the amount of gas which would be generated from that charge, and in that case the reaction which takes place in the chute is so violent that the water is car- ried up in a great mass of bubbles and foam, which sometimes overflows the top of the chute, spatter- ing lime and water freely about in the vicinity of the machine. The only way which has been discov- ered thus far to prevent this difficulty is to use car- bide broken into lumps of fairly uniform size. When it becomes necessary to use finely broken carbide, the boiling over and loss of gas may be prevented by enclosing this fine carbide in a common paper- bag, which may be dropped either by hand or auto- matically down the chute. In the course of about 54 LIGHTING BY ACETYLENE thirty seconds the paper is sufficiently wet for the evolution of gas to begin; the bag soon bursts open and the gas is given off rapidly. Unfortunately, the manufacturers will not as yet sort the carbide into pieces of uniform size. This is perhaps the only product of a similar character which cannot be so procured. Almost every other material which is broken for ease of shipment or use, such as coal or stone, may be purchased in pieces of nearly any size desired. It is understood that in the new works at Niagara Falls and else- where, the carbide will be put through screens by which it will be separated into different grades. THE PLUNGER There is another class of generators, which, al- though nearly obsolete in this country, was much used in the first days of lighting by acetylene. In these generators the carbide in considerable quantity is suspended over a large body of water within a gas-tight vessel, and is so arranged that it is alternately immersed in and withdrawn from the liquid. In some instances the carbide is suspended from the top of a movable bell, as in Fig. 29, whereby it is lowered and raised in turn from the water. In others, as in Fig. 30, the water rises and falls in re- lation to the carbide. This method of generating acetylene is, perhaps, the worst that could be de- vised, as it has all the faults of the others with no redeeming traits. It is almost impossible to design such a generator which can be recharged without great waste of gas. Then the evolution of gas is extremely uneven, being violent at first and rapidly becoming less as the carbide is exhausted. The carbide is entirely withdrawn from the water after each immersion, so that it is not only removed from its cooling influence, but the moisture taken up with the carbide drains away, leaving it in the best possible condition for generating heat. 55 5^ LIGHTING BY ACETYLENE The tendency for the water to be thrown into the mass of carbide by the violence of the reaction fol- lowing its first immersion, necessitates the use of impervious plates which divide the charge into thin layers. Even then the water is thrown up around the sides of the charge, and more gas is given off than can be used or the holder contain. For experimental use, where a small quantity of acetylene is occasionally required, this generator is convenient. It may be very small, is the simplest of any, and may be considerably improved in the uni- formity \vith which it generates gas by covering the water with a thick layer of oil. Under these con- ditions and where the generator is small, it is very satisfactory for use in the laboratory. Professor Vivian B. Lewes, the leading English authority on acetylene, sums up the generator sit- uation in the following words: "The generators of the third class are undoubted- ly the best, as with the water kept in excess and charged at the rate of eight pints per hour for each pound of carbide decomposed, it is impossible for the temperature to rise above the boiling-point of water. To ensure this, however, there must be a false bottom to the generator, capable of being oc- casionally rocked, about a foot to eighteen inches above the true bottom, the lime sludge being drawn off from the bottom, and water admitted pro rata from above. If there is no false bottom and a big charge of carbide is introduced, it becomes so coated with lime that the melting-point of tin may THE PLUNGER 57 be reached in the interior of the mass, but under all conditions this class of generator yields the purest gas, as the acetylene, having to bubble through the lime-water formed in the generator, is washed free from most of its impurities. " The generators of the first class, in which water is allowed to drip or flow on to the carbide, have several drawbacks. A popular fallacy with the makers of automatic generators of this class is that when the water-supply is cut off the generation of gas ceases, whereas in fact it continues for an hour to an hour and three-quarters longer, although the rate at which the gas is evolved gradually gets slower and slower until it ultimately ceases, this con- tinuation of generation being partly due to conden- sation of water vapor on to the undecomposed car- bide as the generator cools and the decomposition of water mechanically held by the slaked lime, while, if the temperature be very high the slaked lime is itself dehydrated. In this class of generator the temperature frequently rises to a sufficient de- gree to cause the formation of benzine, while in some cases tar is produced. " Overheating, when it reaches this point, is readily detected by the appearance of the lime left in the generator; this should be practically white, but if it is found to be yellow, serious overheating has un- doubtedly taken place, while the appearance* of oil or tar in any part of the apparatus is a still more damning proof of its unfitness. " The worst offenders as regards overheating are 58 LIGHTING BY ACETYLENE to be found in the second group, where the alternate dipping of the carbide into water and its removal as the bell rises allows the action to proceed without any cooling influence being brought to bear upon it, and it frequently happens that under these con- ditions the wuole charge of carbide becomes red hot, tar vapors, hydrogen, various hydro-carbons and benzine vapors are mixed with the acetylene, and its illuminating value drops by leaps and bounds until its light-giving properties are no better than those of a good oil gas, while the burner tips become choked and smoking and general discontent reigns supreme." Returning now to our list of conditions which the ideal generator should fulfil, we shall be able to find what elements are present or lacking in existing machines, and along what lines further development is likely to proceed. In the matter of safety from explosion due to pressure of gas in the generator, it need only be said that at the present day no generators are made in which a dangerous rise of pressure could take place. Danger from explosion of the gas in the generator by coming in contact with fire is, however, a more real hazard. In the dry machines the retort must be opened in order to insert fresh carbide. During this opera- tion the gas within the retort escapes, while air gradually takes its place, making both within the retort and in its immediate neighborhood an explo- sive mixture. In the wet machines the same things DISCUSSION 59 happen when the water is drawn off for recharging. Theoretically, this is unnecessary in the latter class of apparatus ; but in practice it nearly always hap- pens, and considerable skill is required to prevent its occurrence. In both machines gas may leak from the cocks, and in the wet generator some is always lost during the passage of the carbide down the chute. This may be removed by the ventilator ; but, on the other hand, under certain conditions of wind and weather a " back draft " will exist which drives the gas into the room containing the ma- chine. The clogging by frost of the safety-pipe leading from the gas-holder has been suggested as one source of danger. If the safety-pipe is properly drained, however, this cannot happen, and is men- tioned as a caution only against generators which are poorly made. The installation of any generator should include the construction of a specially ventilated room or closet of sufficient size to contain the complete ap- paratus, and a small quantity of carbide for im- mediate use. With this precaution and the living up to the hard and fast rule that the room shall not be entered by artificial light, any modern acetylene generator, be it wet or dry, is, in the opinion of the author, entirely safe as a primary cause of fire. In the matter of economy and maximum yield of gas, both classes of generators are deficient, with a slight advantage in favor of the wet generator. Both waste some gas. The dry machine loses 60 LIGHTING BY ACETYLENE an appreciable quantity at each opening of the re> tort, with the further disadvantage of entrapping a like amount of air. In addition to these channels of waste, there is in the dry generator the ever-pres- ent trouble of over-production and waste through the safety pipe; and in some a considerable degree of polymerization takes place, with its attendant in- conveniences of clogged burners and lowered can- dle-power. In the wet generator there are two causes of loss in economy. The first results from the time which is taken for the carbide to sink through the chute, during which process the acetylene escapes up the vent pipe. When carbide in large pieces is used, or when the carbide is protected by being previously immersed in oil, the loss is small ; but with the fine or dust- like material which constitutes several per cent, of each package of carbide the loss is greater than the available yield. This fine carbide, even when made into a paste with kerosene oil, generates acetylene with almost explosive rapidity. The water is driven up the chute, the seal is often broken ; and not only is the greater part of the intended charge of gas lost, but that in the bell also. In this event the lights go out, and the generator is temporarily disabled. A smaller loss occurs by reason of the solubility of acetylene in the " sludge," which must be often removed from the generator. This is small, however from one-half to one per cent, in usual practice. DISCUSSION 6 1 If the " sludge" is allowed to become too thick with precipitated lime, even the large pieces of carbide sink with difficulty through the chute, and the loss of gas during the charging process is great. In ease of management the dry machine, when it performs its functions properly, has some advan- tage. It is more quickly charged by those accus- tomed to it than is the wet machine. On the other hand, the by-products of the dry machine are intensely disagreeable, as compared with the "sludge " of the wet generator, and ordi- narily require handling more often. The dry machine is certainly simpler in its best form than the wet, but neither is really complicated. All the pipes and connections are permanent fix- tures, and each generator has only one or at most two cocks or valves. To offset the devices whereby water is fed to the dry generator, the wet machine has some simple form of ratchet mechanism for dropping carbide into the water. Either is simple enough to be un- derstood by those to whom the attendance of the apparatus is generally entrusted, and neither is like- ly, except through gross carelessness, to get out of order. Before acetylene as an iiluminant takes the place which it is destined eventually to occupy, material changes must be made in the method of its genera- tion. At the present writing, the problem does not 62 LIGHTING BY ACETYLENE seem an easy one, nor does its solution seem im- mediately probable. The gas-holder, with its inlet and exit pipes, its safety appliances and drainage system, is all that can be desired, and is, withal, extremely simple and dur- able. In the author's opinion, the crux exists in accom- plishing, without undue complication, three things. The first is to introduce the carbide into the gen- erator without loss of gas or admittance of air. The second is to remove the lime under the same -conditions ; and the third is to devise a means in the dry generator for the prevention of over-production and heating. Until these desiderata are accomplished facts, the generation of acetylene will be at best a disagree- able performance, tolerated for the sake of the un- rivalled light to be obtained from the gas. In spite of its difficulties, the problem is not in the least hopeless, neither is there any insurmount- able obstacle in the way of its accomplishment ; and it is to be fully expected that as the interest in acetylene becomes wider, as the demands for per- fection in generators become imperative, more per- manent apparatus will take the place of that which has temporarily served to tide the new illuminant over the period of its infancy. IMPURITIES OF CARBIDE AND ACETY- LENE In the manufacture of calcium carbide, in spite of the most careful effort, it is practically impossible to obtain either lime or coke which is entirely pure. For this reason the carbide, and, consequently, the acetylene generated therefrom, is alway contam- inated with other products. The amount of im- purities in the gas is generally so small as to be neg- ligible. The principal impurities in the carbide are of importance from the fact that they are not acted upon by water, and when the carbide is converted into gas they remain within the generator either in the form of* lumps, like pieces of clinker, or of rounded nodules of various sizes. The nodules are of two kinds, one small and non-magnetic, which upon examination appears to be principally graph- ite, reduced from the coke by the intense heat of the furnace ; the other nodules are hard, white, and glistening on the surface, sometimes showing signs of rust when exposed to dampness, generally possess- ing magnetic properties, and are of a hardness suf- ficient to scratch glass. These nodules contain silicon and iron, with some- times traces of aluminum and magnesia. They are 63 64 LIGHTING BY ACETYLENE somewhat similar to carborundum in their proper- ties. The contamination of acetylene, which results from the use of an impure carbide, was at one time considered a very serious element of danger. The only danger which could result from an admixture of foreign substances with acetylene, would be the possibility of forming in the mixture a self-igniting gas or compound of gases. There are two gases phosphoretted hydrogen and siliciuretted hydrogen which are spontane- ously inflammable upon contact with the air. Either of these may exist in acetylene produced from car- bide which contained calcium phosphide or silicide. The experiments, however, of Professor Vivian Lewes have shown that either of these gases would have to be present in a very large proportion in order to make an explosive mixture with the acety- lene. He examined twelve samples of carbide from different sources in which the percentage of phos- phoretted hydrogen ranged from a trace to nearly two and a half per cent., and found none under the most favorable conditions capable of producing a self-igniting gas. He discovered, also, that an act- ual admixture might be made containing as high as eighty per cent, of phosphoretted hydrogen intro- duced separately into acetylene without producing a self-igniting mixture. It is believed that no authentic instance of acci- dent from the self-ignition of acetylene has been re- corded, and in the American carbide the proportion IMPURITIES OF CARBIDE 65 of calcic phosphide is, by careful selection of the materials, kept down to a minimum. Nearly all acetylene which has not been carefully washed, shows the presence of a small quantity of ammonia together with some sulphuretted hydro- gen. The ammonia is detrimental in that it favors the production of acetylide of copper in the cocks of the burners, making them turn with difficulty after a time ; but it is so easily removed by passing the gas through water, together with the sulphuretted hydrogen which accompanies it, that neither of these impurities need exist in the gas made in a well- managed generator. It is said that much of the European carbide, manufactured upon the Continent, contains suffi- cient phosphoretted hydrogen to produce an irrit- ating vapor of phosphoric acid in the rooms in which the gas is burned. In this country there has been no report of a similar trouble. As a matter of fact, the impurities which have been most often noted in the gas are due to overheating in the gener- ator. When acetylene is subjected to a high tem- perature it splits up, as is well known, into certain polymers, such as benzine, styrolene, naphthalene, anthracene, tar and oily hydrocarbon. The decom- position is more complete as the temperature is> higher, and is nearly in the order of the substances given above. At a red heat carbon is separated in the form of lampblack, and hydrogen is set free. The objection to a gas containing impurities is 66 LIGHTING BY ACETYLENE chiefly that of the money loss, owing to the poor yield per pound of carbide. The benzine vapor, hydrogen and other volatile products, resulting from too high a temperature in the generator, not only do not of themselves give luminous flames when burned in an acetylene jet, but they actually, by dilution, reduce the candle- power of the remaining gas. In addition to these disadvantages, the benzine vapor is the frequent cause of the clogging of burn- ers. It exists in the form of vapor condensed within the pipes, and is carried to the burners by the outrush of acetylene. There it is deposited upon the steatite tip of the jet, and after being absorbed is carbonized and causes a contraction in the jet orifice. Jets which have once become smoky from this cause, rarely recover their original power of illumination, even if carefully cleaned. It is probable that a cer- tain amount of the benzine, and other liquid which has been absorbed by the steatite tip, remains there and is gradually carbonized and driven into the ori- fice by successive heating of the burner. The very general use of bicycle acetylene lamps, which are made entirely of brass, has caused the theory of the formation of acetylide of copper to fall into disrepute. In these lamps, however, brass is always used and not copper ; and the lamps are, as a rule, nickel plated, both inside and out. The charges of carbide are frequently renewed, and the lamp, by constant washing, is kept relatively clean. The experiment of Bullier, who found that a pol- IMPURITIES OF CARBIDE 67 ished copper plate was practically uninfluenced by acetylene for a considerable length of time, has con- tributed to the general feeling that the formation of acetylides is an exploded idea. The author has experimented carefully upon this subject and is entirely satisfied, as a result of his work, that acetylide of copper is formed with great readiness whenever ammonia is present in the gas, in the presence of moisture. He furthermore finds that a polished copper or brass surface is much less affected than is one which has been already cor- roded and covered with oxide. He finds also that a surface fresh from the file or the turning lathe, cov- ered with minute tool-marks, almost immediately shows the red coloration peculiar to acetylide of copper when subjected to the action of nascent acetylene. It is not pretended that any real danger exists from this formation in the gas fixtures and pipes, but the gradual corrosion of the stop-cocks is annoy- ing, and the author is convinced that it is a frequent cause of leakage. It is certainly inadvisable to use either copper or brass in the construction of the generator. Another impurity almost always present in ace- tylene which has been recently produced, is a fine dust thrown off from the lime in the process of de- composition. This cloud of lime-dust is so light and its particles are so fine that it remains suspended in the gas for hours, and unless special care is taken to remove it by filtration through cotton or other 68 LIGHTING BY ACETYLENE fabric, the dust enters the pipes and eventually clogs up the burners, and assists in cutting out the stop- cocks. Another impurity which is of almost universal occurrence is air. In small proportions this has no other ill effect than to lower the candle-power of the gas, but it certainly should be excluded if, for no other reason than the fact that in certain propor- tions it makes an explosive mixture. It will be understood that if the generator con- tains a certain quantity of air, this goes over into the gas-holder with the first gas which is generated, and there will be a time at the beginning of the gas- making when the mixture is explosive. The admis- sion of air to the gas in any quantity is certainly in- advisable, and may be dangerous. GENERATORS IN the earlier stages of experiment with acetylene, before suitable burners were devised, it was consid- ered necessary to mingle a certain proportion of air with the gas, either in the generator or in a special mixer, before it reached the distributing pipes. Since this practice has been entirely given up, on account of its danger, it will be unnecessary to more than mention such apparatus as something to be carefully avoided. The same may be said of such generators as de- liver the gas under considerable pressure, and of the various machines for reducing it to a liquid form. Generators for the production of acetylene gas under the very slight pressure necessary to send it to the burners may be divided broadly into three classes, each of which has many modifications, and in each of which the various operations have been performed in devious ways. Some of the variants scarcely come under the classes into which they have arbitrarily been di- vided, but, as they are not numerous, it seems un- necessary, so long as they retain salient features of any one type, to classify them separately. The three types of generator may be classed as follows : 69 7