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THE
LIGNITE UTILIZATION BOARD
OF CANADA
Created in 1918 by Order-in-Council of the
Dominion Government.
Qa
FIRST
GENERAL REPORT
OF THE
LIGNITE UTILIZATION BOARD
OF CANADA
Covering Operations
OCim | Seelgois:
TO
JAN. Ist, 1924.
Submitted to
THE HON. CHARLES STEWART
Minister of Mines
OTTAWA
Se T>° 5 a2 2 SA 2 TY
aVvERS ry 3 ts 7 eae EL oe E
Eo Re eGee & Qh : : BHOs Be CAPAE PARE §
AjBBG © RaSEWRE F
MAR 3:19 ~~
PRIG Eto
after free circulation is exhausted.
Published, March 15, 1924,
by
THE LIGNITE UTILIZATION BOARD OF CANADA,
288 St. James Street, Montreal
PERSONNEL OF
THE LIGNITE UTILIZATION BOARD
R. A ROSS, E:E.,-D-Sc., M.E:1-C.;
MONTREAL — CHAIRMAN.
J. M. LEAMY, M.E.I.C.,
WINNIPEG, MAN.
HON. J. A. SHEPPARD,
MOOSE JAW, SASK.
LESSLIE R. THOMSON, M.E.1.C.
SECRETARY.
Ane!
SEP 1 9'24
er
3{ MARSA o,
(1)
(2)
(3)
(4)
(9)
(6)
(7)
(8)
ARRANGEMENT OF REPORT
Note: The within report is divided into
the following divisions:— PAGE
Pre meR TEC ATISIIMOSLONY tee coto, BN Gretere eect ote Arciol « «/ KM cobs oe co ear ey 4
Report of the Lignite Utilization Board to the Hon. Charles Stewart...... 5
RreReraincecu(yaex iD te A nit su. o ls Gs ea ies lee ate aaa a ee eR 13
Report to the Lignite Utilization Board by the Secretary, with accompanying
BU Cen Oe Pee, ey San A Nm LATS Seer ean, o cisid dda E . his ek ae ee 15
Orc. oe lOssaT won technical CErms <3. Fa acacte ce cctpeteh se oa gels Ge bate eRe ths 101
PERCE EC MMATIPICTICICUS SAP a y's t's Ge ct ae ae WS Ree Ne NE cade ents) aaa oe 103
Cee ROVLAL en Nomis ch oi goa A Rak a eee ine Sete ha Coe Mie sc ee 104
PEE ie LIOte stom einen tt te Leute ci so oe eno ie Be oc wee, oc alae 105
LETTER OF TRANSMISSION
MONTREAL, February 8, 1924.
Hon. CHARLES STEWART,
Minister of Mines,
Department of Mines,
Ottawa, Ont.
Dear Mr. Stewart:—
As requested I am forwarding under this cover two (2) signed type-
written copies of the first general report of the Lignite Utilization
Board, dated January 26th, 1924, covering the period of its operation
from October Ist, 1918, to January lst, 1924.
In order not to delay the dispatch of this document, and in view
of the lack of any request from you for the Board’s recommendations
on future action, the report confines itself exclusively to a record of the
activities of the Board during the past five years. No mention is
made of the financial aspects of those plant revisions deemed necessary
to attain the original objective of a commercial demonstration. In
order, however, that you may have this information when desired, we
propose to forward to you shortly a special memorandum on this
specific question.
On behalf of the Board, I remain,
Very truly yours,
(Szgned) R.A. ROSS,
Chairman.
FIRST GENERAL REPORT
o1
FIRST GENERAL REPORT
OF THE
LIGNITE UTILIZATION BOARD OF CANADA
TO
THE HONORABLE CHARLES STEWART
Minister of Mines
OTTAWA
MONTREAL, January 26, 1924.
The HON. CHARLES STEWART,
Minister of Mines,
Ottawa, Ont.
Sirs
The following first general report of the Lignite Board is submitted
in response to your request of Sept. 25th, 1923, and covers the period
from the start of the Board’s work, October lst. 1918, to December
eistr.1923.
The fuel stringency in Canada due to the war began to be acute in
1916. At the beginning of 1917 the Research Council appointed a
Fuel Committee to study the Western lignite problem. This Com-
mittee called into immediate consultation representatives of those
Dominion Government departments especially connected with fuels —
namely, the Department of Mines, and the Commission of Conserva-
tion. Asa result of these consultations the Department of Mines and
the Commission of Conservation made certain investigations and
special reports touching upon the question of the utilization of lignite
for domestic use by carbonizing and briquetting. Agreeing with these
_ reports, and focusing the opinion held by all parties to the preliminary
review, the Fuel Committee recommended to the Research Council
that a commercial demonstration of this process be made. In turn
the Research Council recommended appropriate action to the Govern-
ment — contemplating that its execution would rest with the Federal
Department of Mines. Owing however to reasons outlined in Exhibit
A, it was decided to create a special Board to undertake the work.
The authority for the creation of the Lignite Utilization Board, its
status, the relationships between the supporting Governments, and the
personnel of the Board itself, are found in Dominion Order-in-Council
No. P. C. 643 dated March 20th 1918, in Dominion Order-in-Council —
No. P. C. 2064 dated August 22nd 1918, and in a tripartite agreement
dated July 20th 1918, signed by representatives of the Dominion
Government, the Manitoba Government and the Saskatchewan
Government.
With the above described status the Board began its work on October
Ist, 1918, with the objective (laid down by Order-in-Council) of
543552
6 LIGNITE UTILIZATION BOARD
demonstrating the commercial feasibility of producing a carbonized
lignite briquette for domestic consumption.
When the work was started it was believed that the technical process
had been developed beyond the laboratory stage. Upon personal
investigation undertaken by the Board of all processes and plants in
America, (Europe was closed at that time), it became very apparent
that no commercial process for the treatment of lignites was available.
It therefore became necessary for the Board to develop the technique
of a process before any hope could be entertained of giving a com-
mercial demonstration of the project.
The fundamental research necessary to produce such a process
occupied the Board from February, 1919, until the spring of 1920.
This entirely unexpected delay not only kept back the attainment of
the objective by an equivalent amount of time, but also precipitated
the construction of the plant into the most expensive building period
ever experienced, a time quite unprecedented as far as prices and
deliveries were concerned.
During the prosecution of the research just mentioned a process
gradually began to develop. On account of previous work done in
Ottawa by the Department of Mines, the Board’s engineers felt that
the development of apparatus suitable for the commercial carbonization
of lignite was a more difficult problem than the development of a pro-
cess of briquetting. Attention therefore was concentrated on the car-
bonizing from February 1919 to October 1919, by which time it was
felt that the principle and operation of a new type of by-product retort
had been developed to a sufficient degree to permit the Board to move
forward to the construction of its main plant. In other words, as the
objective of the Board lay in a commercial demonstration, the inevitable
risks always incident to full scale development of new processes had
to be taken boldly and at once, as no laboratory experiment can ever
give a satisfactory commercial demonstration. The commercialization
of a process involves inevitably the operation of full scale commercial
units.
With this view clearly held, construction of the Bienfait plant was
started in June 1920, and the plant was finished in August, 1921.
The autumn of 1921 was thereupon given up to attempts to get the
plant into operation. After these trial runs, all parts of the plant
appeared reasonably satisfactory, with the exception of the carbonizing
ovens and certain mechanical features of the briquetting layout. Of
these two departments the carbonizing presented the graver and more
ominous difficulties. After thorough investigation it was decided to
rebuild three of the carbonizers in order to incorporate such changes
as the preceding few months trials had indicated as essential. These
changes were completed by August 3lst, 1922, and trial runs were
again instituted with a great reduction in the operating difficulties
encountered. Successive attempts were made to operate the car-
bonizers, but by the beginning of January 1923, it became evident that
hope would have to be abandoned of making these by-product car-
bonizers commercial. During this time a large number of further
runs had been made in the briquetting building, which indicated that
FIRST GENERAL REPORT 7
the layout and sequence of the machinery was far from right. The
difficulties encountered lay in mechanical troubles’ with machinery
rather in any mystery surrounding the process. In other words, it
was a matter of accommodating large scale machinery to the execution
of a process the details of which in small apparatus had been mastered
in Ottawa.
The situation then in the beginning of 1923 was as follows: The
Board’s own carbonizers were proved non-commercial. The full scale
briquetting layout had proved not to be as suitable as it ought for the
carrying out of the process developed in Ottawa. Therefore it was
apparent that the real gap in the process was in carbonizing though the
attainment of a complete process was an absolute prerequisite to any
commercial demonstration of the project. In this contingency the
Board turned to the investigation of a new type of shaft carbonizing
oven developed within the preceding few months by the combined
efforts of the American Bureau of Mines and Dean Babcock of the
University of North Dakota. Through the courteous co-operation of
Messrs. Hood and Odell of the American Bureau, and of Dean Bab-
cock, the Board made a test of Souris lignites at Grand Forks in the
one example of this oven then existing. The results of this run were
sufficiently encouraging to warrant the Board in erecting at Bienfait
one large size oven of this type with the idea of giving the principle and
construction details a very thorough test. The retort was completed
on June 23rd, and from the beginning of July to the end of December,
1923, was operated practically continuously with proper gas offtake
connections during which time 3000 tons of lignite were carbonized.
As the result of this run the Board states that within specific limits
covered by the claims for this oven (see appendices) the oven can be
termed a commercial success.
In order to demonstrate that the char produced by this oven is suit-
able for and can be briquetted, the supporting governments instructed
the Board to briquette 150 tons at the briquetting plant of the Univer-
sity of North Dakota at Hebron. Again Dean Babcock courteously
acquiesced, and the briquetting test on this char held in December
1923 gave absolutely successful results.
The Board has now reached the point where it can announce that ”
taking in order the necessary steps to produce a carbonized lignite
briquette for domestic consumption, the technical process has been com-
pletely demonstrated with full scale apparatus suitable for commercial
conditions. It now remains (in order to reach successfully the object-
ives laid down by Dominion Order-in-Council) to give a working com-
mercial demonstration of this process, without which the whole project
will have proved abortive.
The Board therefore submits the following as a brief digest of its
work and results over a period of 5 years.
LIGNITE UTILIZATION BOARD
The Lignite Utilization Board started work October Ist. 1918 and to
date over five years have elapsed.
This time has been spent as follows:
nnn
REMARKS.
To insure that the Board would
have complete information as to
development of the process in
America.
Necessitated by discovery that
no lignite carbonizers were de-
veloped to a commercial degree
in America.
Time in
OCCUP ATION years approx.
Investigation of all previous work. X%
Fundamental research i
Construction and equipping of plant. 1
Trial operations and reconstruction 1-4
Demonstration of process now if
proved.
Investigation and demonstration
Construction very slow owing to
conditions obtaining in 1920-21.
Attempts to operate Board’s
own carbonizers, reconstruction
of same, and renewed efforts —
their final abandonment.
of Hood-Odell oven. Briquet-
ting of char. Completion of
process demonstration.
The following is an approximate statement of receipts and expend-
ture from October Ist, 1918, to January lst, 1924.
RECEIPTS:— Approx.
From; Governuments:7¢ gen 32 eae ieee oe $1,036,300
‘* Misc. Sources (Interest etc.)....... 13,900
‘* House Rentals and special Services a/cs 9,500
$1,059,700
EXPENDITURE :— Approx. % of Total
Receipts
AAministration ts..2 ier ae TAA pe $141,600 13:3%
Travelliriestieiss ice IS. See ee ae 12,800 1.2%
Capital exp. in dwellings and Boarding house.. 117,700 11.1%,
Capital exp. in Plant Bldgs., Equipment,
OVENS, ClO rae Sees he eee Peet ae 604,700 et bP bes
Preliminary Operating, Maintenance and
Repairs sy (770 8 GURU. Rass oe Meee 107,200 10.1%
Whiscellaneous.acs :4 6 ead viene Batok Ses 8,300 0.7%
CSaSh:atl Eland): cases acu et emloghewni rs caterer eh es 67,400 6.5%
100.0% $1,059,700
All above accounts were audited to March 31st., 1923.
Results
Making no allowance for any subsequent development of the work
either by this Board or others, the following constitutes a brief digest
of the actual results obtained :—
>a
FIRST GENERAL REPORT )
1) Immediately upon its inception in 1918, the Board started a
complete investigation of all existing methods of carbonizing
and briquetting of lignite with the discovery that no commercial
processes had been developed.
11) This discovery necessitated the embarking upon an extensive
fundamental research into the chemistry and physics of lignite
carbonization with a view of developing the basic information
that would enable the Board to develop a process. This work
was done with the active co-operation of the Department of
Mines, Ottawa. The information thus gained is available
permanently.
iii) As the work developed, semi-commercial carbonizing and
briquetting plants were erected in Ottawa. The operation of
these plants yielded information of considerable value, also
available permanently.
iv) A very thorough test has been given to a special type of lignite
carbonizer, and it has been proven non-commercial. Therefore
one important ghost has been laid.
v) The Board has erected a large plant of a solid permanent char-
acter at Bienfait, and for the operation thereof, has provided
housing, water supply, power, chemical control laboratories,
and complete mechanical equipment.
vi) The Board has aided materially in the development of a shaft
oven carbonizer designed by the combined efforts of Messrs
O. P. Hood and W. W. Odell of the American Bureau of Mines,
and of Dean Babcock of the University of North Dakota.
This advance has been made possible by the very courteous
co-operation extended by each of these three. During this
work the American Bureau acted as consulting engineers to
the Board.
vil) The Board has solved the technical problems of briquetting
lignite char. All known binders were experimented with in
Ottawa, and the most economic selected for commercial develop-
ment at Bienfait. In addition the Board has demonstrated
under instructions from the three supporting governments,
that the special char from the Hood-Odell oven presents no
peculiar difficulties in briquetting, for 150 tons of this char,
produced at Bienfait, were briquetted at Hebron successfully,
through the co-operation of Dean Babcock, the University of
North Dakota.
viii) From the foregoing it is obvious that a complete process of
making carbonized lignite briquettes has been demonstrated
absolutely successfully, with full scale equipment. Thus the
first half of the original objective laid upon the Board has
been attained.
Still to be Demonstrated.
The second half of the original objective laid down by Order-in-
Council is the commercial demonstration of the process now perfected,
10 LIGNITE UTILIZATION BOARD
including commercial quantity production and sale of product for at
least six months. This demonstration can be made at the Bienfait
plant, (provided certain revisions be incorporated). These changes
include alteration to the briquetting layout, installation of the neces-
sary additional carbonizing ovens, improvement of methods of water
disposal, and of the shipping and switching facilities, and the comple-
tion of those revisions to conveyors and handling equipment, neces-
sitated by change in carbonizing process. The necessity for commer-
cial throughput lies in the fact that only by operation in quantity can
there be determined the commercial cost of, materials, labour, repairs,
replacements and technical supervision and control. If this step be
not taken then the money already invested will have been largely
wasted, for no commercial company will accept a process developed
solely onits technical side. The alternatives are completion of objective
with saving of funds already expended, or failure of project with resulting
loss of capital.
The details of all the above mentioned matters are covered fully in
a report dated Jan. 24th, made to the Board by the Secretary, Lesslie
R. Thomson, the text of which, with its appendices, appears as Exhibit
‘““A”’ of this report of the Lignite Utilization Board.
Respectfully submitted,
LIGNITE UTILIZATION BOARD OF CANADA
(Signed) R. A. Ross,
Chairman.
(Signed) J. A. SHEPPARD,
Member.
(Signed) J. M. LEAmy,
Member.
MONTREAL, January 26th, 1924.
All of the following material constitutes EXHIBIT
“A” of the foregoing report.
Overleaf on p. 13 will be found a general index of
Contents, Appendices, Plates and Figures, while on
bp. 101 will be found a brief glossary of technical terms
PREFACE..... Aba htt DAO AS See SORIA IGOR Bian bad Bh te Re ae i OCS Seo casic
INDEX
INDEX
OF
EPXHIBID*A’*;
BEING A
REPORT TO THE LIGNITE UTILIZATION BOARD
BY THE SECRETARY
LESSLIE R. THOMSON.
LEER TOMECUATIMA SP IOT Meira a he ae ets ota ct ORD tier st LRT ch ce aes: dvielic™ Suetate, song ce vibe sya caen ee
1a
ITI
AN
VI
PERIOD OF
Oct. 1918
to
Feb. 1919.
PERIOD OF
Feb. 1919
to
May, 1920
PERIOD OF
May, 1920
to
Aug. 1921
PERIOD OF
Sept. 1921
to
Dee. 1921
PERIOD OF
Jan. 1922
to
Jan. 1923
Coal Resources of world, of Western Canada, Ratio of lignite to total coal
deposits, Fuel situation brought on by Great War, Fuel problem only one of
many research problems, Creation of Research Council, Appointment of Fuel
Committee, Consultation and co-operation of Department of Mines and of
Commission of Conservation, Report of R. C. Fuel Committee, Action of
Dominion Government, Tripartite agreement, The Lignite Utilization Board
an established entity.
RAAT TMT ONS ee te a ated) ot 2 teh Sas oy oer a Share valsealecdiah ors Seas oda Aes Mhare ral te She eee eee ae
Staff and offices, First two meetings of Board, Tentative policy, Digest of
existing information, Lignite situation as anticipated, Tour of French and
Stansfield, Their report, Real situation, Rumours of burning of raw Souris
lignites in domestic heaters, Special investigation on same, and On increased
use of Western coals, Report on this matter, Digest of position facing Board,
Third meeting of Board and resulting action, Policy on capital expenditure.
UND AWN T ATATLUBSS AR OH spc. tyecuchs, cterey 3 EE ees, steak sya 2 eee OE car eS) Ae mee
Relation of experiments to original objective, Arrangement with Mines Branch,
Ottawa, and Organization set up, Equipment, Laboratory, Progress on car-
bonizers, Special carbonizer report by E. Stansfield, Decision to build large
plant, — Reasons therefor, Western trip and consultations, Fourth meeting
of Board, Delegation of authority to Chairman and Secretary, Site and site
negotiations.
DESIGN AND CONSTRUCTION OF BIENFAIT PLANT............+.+- ees abi ae
Specific objective of plant to give commercial demonstration, Decisions on
quality of plant, on flexibility, on unit or non unit construction, and on housing,
Acknowledgment of errors, Unique nature of plant to be designed, methods of
letting contracts, and of purchasing, Construction undertaken and finished,
Description of plant, Pipe line troubles.
PRELIMINARY OPERATION OF STANSFIELD CARBONIZERS...........++-+eecee
Operation of dryers, conveyors, briquetting press, and mixers, gas handling ap-
paratus and carbonizers, Troubles and difficulties, Staff reports of September
and November changes, Consultation in Montreal between Lignite Utilization
Board and C. V. McIntire.
Final’ OPERATION OF STANSFIELD CARBONIZER...-.....-cc+cecsscicvrecre
General situation in January 1922, Reports of C. V. McIntire, Reconstruction
necessary, Further financial grants needed, Negotiations with three supporting
Governments, Final action by Dominion Government, Reconstruction started
and completed, New trial runs, Exhauster troubles hold up work, Consultations
in West, Tentative policy adopted, Further operation, Conference of Jan. 8,
1923, Final decision to abandon. New control of Board.
13
PAGE
15
18
30
40
45
VII
VIII
IX
LIGNITE UTILIZATION BOARD
Periop or Hoop-ODELL OvEN DEVELOPMENT......... siviale.e s ia\G eteicte (piece ote ara iainielalatetsters
Arrangements for holding Grand Forks test, Runs at Grand Forks, Conference
of March 3rd, 1923, Preparation of design, Arrangement with American Bureau
Jan. 1923 of Mines, Construction of Oven, First run, Small troubles, Second run, Con-
to sultation in Winnipeg of July 30th, 1923, of all parties to project, Action of
Jan.1924 Province of Manitoba, Decision to operate oven to Dec. 31st, 1923, Decision to
have 150 tons of char briquetted at Hebron.
BRIQUHTTING vcsess ccc eins Settee sintalae'e 6 ee sie ciere te Siete eels ‘ eee ete sie ofa é igvarn phos etterere
Preliminary work of Mines Branch, Experimental Prouearnene decided at third
meeting, Ottawa laboratory, Work in Ottawa 1919-20, Nukol and A. B. C.
Plant, Toronto, Design and Equipment of briquetting section of Bienfait plant,
Work in Bienfait, Desirability of revision to briquetting layout, Decision to
undertake tests at Hebron and Grand Forks, Results, and Report by R. A
Strong, Outside work and correspondence, Consumers’ tests on briquettes.
IN ANGE OS AES Howie alo ook Ohl ie Beale. See aCe aren sta GL otencTe lev ORT OnaRS ere IE TUTOR ICRC Teen Lm a Trane
Original estimate of cost, Revised estimate, Special grant of 1920, Special grant
of 1921, Special grant of 1922. Analysis of total expenditure, Analysis of
Plant Costs, Methods of bookkeeping, Ledger accounts, Methods of keeping
Auditor-General in touch. Commercial feasibility of whole project.
MIISCELIANEOUSS So: ¢ hicks 's o\s boo Ge ole elonenanedtne alte stie joke Pate rare telat Tela site inte eeeraincet les tuRCeNe keites eite teeing a meee
Relation of and financial scale of L. U. B. effort compared to other similar efforts
(Carbocoal, etc). List of principal low temperature processes, Foundation
Oven Corporation proposal, Fusion Process, Coalite Process, Executive Cir-
culars, Progress Reports, Relationship with Governments, Work done else-
where for us by other investigators, Data Sheets, High temperature metals,
Staff, Summary of Project.
GLOSSARY OF TECHNICAL “CERMS.). «olsen creas ole aa soit ak un Biterene resorts sieee a ciie aie ee
Paq@E
60
68
82
92
101
103
104
105
PREFACE 15
REPORT
TO THE
LIGNITE UTILIZATION BOARD
BY
LESSLIE R. THOMSON
Secretary.
PREFACE
_ The history of the Lignite Utilization Board divides itself naturally
into a number of successive chronological periods, each quite distinct
from the other as regards its special objectives and accomplishments.
In casting about for a logical method of presenting a lucid and
precise record, the Board gradually came to the opinion that, as car-
bonizing had been, since the inception of the project, its most important
division, and as carbonizing moreover had been the source of all the
major troubles, it would be best to build up the body of the narrative
report about that theme, and relegate all other matters to auxiliary
special sections.
Consequently the following report traces chronologically the history
of the Board from the point of view of its complete dependence on the
technical and commercial results of the long struggle to solve the prob-
lem of carbonizing. With commercial failure here, success in other
fields is valueless to this work. The Board must stand or fall on the
result of its efforts to carbonize commercially, — and success there,
makes possible success all along the line.
During the course of its work the Board naturally had to make
extensive researches into the field of briquetting, and the results of
its efforts in that department are presented in section VIII.
_ Other sections are added on finance and on miscellaneous matters,
including — investigations, processes, staff, construction proposals
made by others to the Board, etc.
From the inception it has been felt that the work could only be com-
pleted if pushed to a commercial demonstration. This has not yet
been done, and it is therefore necessary to present a record of an
undertaking still quite inconclusive as to its commercial aspects, and
hence not a real fulfilment of the objectives laid down originally by
Order-in-Council of the Dominion Government. While noting this
fact attention may be called however, to the large amount of knowledge
gained by the research and investigation of the Board, which knowl-
edge is now available permanently.
During the progress of the work a considerable amount of investig-
ation on lignite was undertaken very courteously by other individuals
16 LIGNITE UTILIZATION BOARD
and corporations. The Board wishes, therefore, to record very grate-
fully the co-operation and assistance rendered by :
American: Cyanamid) Companys ates sees New York, N. Y.
Professor Bone, ace a ee ee London, Eng.
J. A. Davis, Supt. Alaska Station, Bureau of Mines,. . Pittsburgh, Pa.
Fusion Corporation Limited, . < .. Middlewich, Eng.
General Briquetting Company,. IRE RR ace Re New York, N. Y.
International Coal Products Corporation,..........Irvington, N. J.
Dr. Klein, Municipal Laboratories, . ads ns DA NO WERYCOL Rann eat
Low Temperature Carbonization Limited,. Panel Sada’ .London, Eng.
Mr. F. E. Lucas, Dominion Iron & Steel COR Sydney, N. S.
Professor Layng, University ol Uilinoicwes sas lea Urbana, IIl.
GiMertz {ER sqne Je slain JADIAICa, oN ae
Theodore Nagel, Cyanamid Company,.. Nacscopeieis lake de se Weak OL Ky tl amet
Professor Parr, University of Illinois,. ees Awa bartnad iP
Peatral Syndicate Liimited).->} 2 se setae eae London, Eng.
Drakouses i Rouse & Campion), 2... csen eee ec ee
(2s otis SC... atbocodl vet pna2 2. sae New York, N. Y.
Professor E. Schoch, .. Austin, Texas
Mr. A. L. Stillman, Vice President, Gen. Bria. ‘Con .New York, N. Y.
Messrs. Wheeler é Woodruff! 2.2525 yee New York, N. Y.
The Board is indeed very grateful for the investigatory work kindly
undertaken by each of the foregoing. Some of it is referred to in the
text of the following report.
There are also other acknowledgements the Board wishes to make
specifically at this time.
Since the inception in 1918 of this special lignite work under a
separate commission, the Canadian Department of Mines has extended
every courtesy and facility to the Board. ‘This was especially valuable
during the conduct of the fundamental research at Ottawa in 1919 and
1920, during which time a laboratory was maintained in Ottawa. In
connection with the Department of Mines must be mentioned grate-
fully the names of Dr. Charles Camsell, Deputy Minister, of Mr. John
McLeish, Director Mines Branch (who has courteously given permis-
sion to publish certain results that were to appear as a Mines Branch
Bulletin), of Mr. B. F. Haanel, Chief Engineer, Division of Fuels, and
of Mr. Ross Gilmore, all of whom have aided this work in many ways.
The next acknowledgment is to the American Bureau of Mines,
Washington, and with the Bureau can be coupled the names of Mr.
Foster Bain, Director, — Mr. O. P. Hood, Chief Mechanical Engineer,
—and Mr. W. W. Odell, Fuel Engineer.
At a time when the Board was compelled to abandon completely
its own carbonizers on account of inability to render them commercial,
the American Bureau very kindly consented to act as the Board’s
consulting engineers in the exploration and further development of the
Hood-Odell oven which had been devised by Messrs. Hood and Odell
and by Dean Babcock a short time previously. During the year that
has elapsed since that time, the relationship between the Bureau and
the Board has been of the most friendly and helpful nature; and the
PREFACE 17
tecord of the work done in Canada by the Board, in the further develop-
ment of the Hood-Odell retort, would not be complete without a cordial
expression of the Board’s deep obligation to the American Bureau and
to the three officials named.
Among the first authorities consulted by the Board upon its con-
stitution in 1918, was Dean E. J. Babcock, College of Engineering
University of North Dakota. From that time onward Dean Babcock has
shown himself uniformly helpful and willing at all times to co-operate
both by advice and by courteously giving the Board permission to
make trial briquetting runs at Grand Forks and at Hebron. Of this
obligation to Dean Babcock, the Board is conscious and desires to
record its very sincere thanks and appreciation.
In order to make the perusal somewhat easier for the non-technical
reader, a very brief glossary of some terms frequently used in this ,
report, appears on page 101.
4
18 LIGNITE UTILIZATION BoarD
SECTION LE
HISTORICAL ASPECT
CONTENTS
Coal Resources of world, of Western Canada, Ratio of lignite to total
coal deposits, Huei situation brought on by Great War, Fuel problem only
one of many research problems, Creation ot Research Council, Appointment
of Fuel Committee, Consultation and co-operation of Department of Mines
and of Commission of Conservation, Report of R.C. Fuel Committee,
Action of Dominion Government, Tripartite agreement, The Lignite
Utilization Board an established entity.
The fundamental reason for the creation and subsequent work of
the Lignite Utilization Board les in the nature and relation of the
coal reserves of Canada to the national requirements.
An inspection of Fig. 1, reveals the fact that the lignite reserves
constitute the major part of Canada’s coal measures, indicates also
the amounts of all classes of Canadian coals, and compares them with
the reserves of the United States and of the whole world.
CoAL RESERVES
RESERVES IN MILLIONS OF SHORT TONS (2000LBS.)
UNITED STATES|WHOLE WORLD
SPECIAL ANALYSIS OF
CANADIAN RESERVES
Comeau Lard Gee Pee
ANTHRACITE Sie ee
OR ALLIED COALS 2 380 24 692 547524} Tora. | [2.380] 2 380)
Recon [ eam) oes|
[Prosns.e| 8 466| 271993] |
CLASSES B&aC™
BITUMINOUS
COALS 312 593 2154984 4 201 044
CLiass D
Sus- BITUMINOUS
COALS & LIGNITE 1043 192 2 053 524 3 pee §35
| Tota. | 10277 501 716] 312 593]
1358 165 4230 200] go05sz103{, = si 888 NGS
UNITED STATES POSSESSES SZ‘). OF WORLD Biches
ACTUAL ae 234
PROBABLE 28] 620 930
TOTAL 28 TS
CANADA " 16%
OF CANADAS RESOURCES 77% ARE IN Dror OF - SUB- BITUMINOUS AND LIGNITE COALS CLASS'O|
Note:- These figures are taken from Coal Reserves of World
By McInnes . Dowling & Leach
FIGURE 1
In their natural raw state most of the low grade lignitic fuels are
unsuitable for widespread domestic use, because, for one reason, the
moisture content of the average freshly mined sample from the Souris
field is about 35%. If shipped immediately, freight charges must be
paid therefore on thirty-five tons of water for every one hundred tons
of coal loaded in cars. In addition, when dried, lignite will disintegrate
and slack off to a mixture of small lumps and dust, making it next to
impossible to use in domestic heaters. It is therefore seen that raw -
lignite cannot be shipped economically, —it is quite difficult to use
in domestic furnaces unless very fresh, —it cannot be stored for a
long period, — and it possesses other objectional qualities. As shown
in the figure about 77% however of Canada’s coal resources are in
the form of lignitic and sub-bituminous coals. It is inconceivable
that such a vast natural resource should be allowed to remain per-
HISTORICAL ASPECT 19
manently only partially developed. This national economic problem
must, therefore, be solved somehow, sometime, by some agency.
In the pre war years there was perhaps an academic realization
of the situation, but no action was planned on a large scale, and any
semi-commercial ventures, conspicuous for their stock selling ability,
had been marked by utter failure on the technical sides. With the
war and rise in fuel prices, a new situation arose in which actual national
need for fuel became for the first time a powerful stimulus. One of
the results of this situation was the creation of the Lignite Utilization
Board of which this report traces the origin, development, and
accomplishments.
By the close of 1915 all responsible leaders of civil opinion had
come to the conclusion, long held by the military, that the allied
cause would only be successful by the acceptation of a very long
and bitter war. The earlier hopes of a short decisive conflict had
given place to the sober determination that, be the cost what it might,
victory was essential if our civilization as we knew it was to survive.
The Governments of the allied powers were at that time not slow
to recognize the decisive aid that science could contribute to the
solution of their economic problems. During the year and a half
that the war had run, both military and civil leaders had learned to
depend in an increasing degree on the extraordinary assistance that
science had contributed to the invention, development, and perfecting
of the implements of war, and it did not require very much stretch
of the imagination to convince those same leaders that only in science
could the no less pressing problems of the economic stability of their
peoples be solved. It was thus to scientific men’that the civil leaders
of all the governments of the world, during the years of 1915 and 1916,
turned for aid in the development, to the greatest degree, of natural
resources in order that the industrial and economic structures of their
respective countries could withstand the shock incident to the termina-
tion of the war, and to provide those sources of wealth by which the
governments could pay for the conflict. The British, French, American,
and Japanese governments appointed during this time scientific bodies
under various names, and the Canadian Government in November
1916 created by Order-in-Council, an Honorary Advisory Council for
Scientific and Industrial Research. *
Among the objgctives of the Research Council entrusted to them
by specific direction of the Chairman of the Research Committee of
the Privy Council of Canada was the following :—
“To make a scientific study of our common unused resources,
“the waste and by-products of our farms, forests, fisheries
“and industries, with a view to their utilization in new or
“subsidiary processes of manufacture and thus contributing
“to the wealth and employment of our people.”
As it is obvious that, among the great ‘unused resources’ fuel for
‘ both domestic heating and power is of the very highest importance,
*For a description of the founding and early work of the Research Council see Ist annual
report of its Chairman,
20 LIGNITE UTILIZATION BOARD
the Research Council upon its constitution in November 1916,
appointed a fuel Committee composed of the following:—
R. A. Ross, E.E., D.Sc., M.E.1I.C., Consulting Engineer,
Montreal, Convenor.
Fs, DADAMS, ‘Sc: D7," EE.D) FIRS. Deane et acu eso,
Applied Science, McGill University.
W. C. Murray, M.A., LL.D., F.R.S.C., President,
University of Saskatchewan.
ASSAMAGKENZIE:-Pha):, (DiC La Leb shee
President, Dalhousie University.
Both the Council as a whole and the Fuel Committee realized that
the general fuel problem of Canada was too large an undertaking
to be attacked by a body with such limited powers and resources as
the Research Council, but felt at the same time that the solution of
the domestic* fuel problem of the Canadian West might be brought
appreciably nearer if attention were concentrated upon it.
From a glance at the figures in Figure 1, P. 18, it is seen that
Canada is the second greatest coal nation in the world from the point
of view of reserves; and yet for years Canada had been a coal importing
country — roughly half of her requirements having been imported
from the United States. The economic loss to Canada of such a
situation was of course obvious.
Another glance at Figure 1. will show that, while Canada is wealthy
almost beyond belief in her coal reserves, yet about 77% of these
reserves are in the forms of sub-bituminous and lignitic coals. This
made it clear to the members of the Fuel Committee that if these
reserves were to be of actual economic value to Canada, in the near
future, some method for their utilization would have to be developed.
In other words, these immense reserves of potential wealth only
become of benefit to the country when they can be marketed and
used profitably.
In order to understand clearly the development of this work, it is
also necessary to glance for a moment at the attitude of the general
public at that time toward the use of these low grade bituminous
and lignitic coals. For domestic heating the public in two Prairie
Provinces had become accustomed to American agthracite, the price
of which reached a peak in Eastern Saskatchewan, where however
there are almost unlimited quantities of lignite. For power purposes
the demand had been for high grade Alberta or American bituminous
coals. Lignite in its raw state was not considered acceptable under
any circumstances for domestic heating with the possible exception
of a few cases in close proximity to the mine mouth. Under these
circumstances this general fuel area was considered to be a logical
point of attack.
This very brief outline of the salient features surrounding the
problem, will convey an idea of the situation which the Fuel Com-
*The term ‘‘domestic’’ as used in this report in reference to fuel means ‘for domiciliary use’ and
not ‘Canadian’ unless the context clearly demands the latter meaning.
HISTORICAL ASPECT 21
mittee found, upon the inception of their work. After making a
number of preliminary studies they decided that the work could be
advanced most quickly and surely by a pooling of the ideas, views
and suggestions of those Government bodies most intimately con-
cerned with the fuel problem of the Dominion. To that end the
Chairman of the Committee called a meeting of representatives of
the Research Council, the Department of Mines, and the Commission
of Conservation. ‘This conference was held on Feb. 13th, 1917, and
may be looked upon as the seed from which has sprung the subsequent
national work on lignites and their utilization.
At the meeting the bearing and relationships of the various factors
affecting a development of the western lignites were thoroughly
canvassed, and a unanimous decision was reached to pursue imme-
diately three separate lines of enquiry:
(a) To investigate immediately the chemical and physical properties
of the Souris lignites, and of their possible by-products.
(b) To investigate the mining and economic conditions of Southern
Saskatchewan.
(c) To investigate the commercial practice and commercial develop-
ment of lignites and briquetting to date.
The results of these three separate investigations must now be
recorded in a few short notes.
(a) At the conference of Feb. 13, 1917, the officials of the Mines
Branch agreed to undertake this investigation in their own
laboratories at Ottawa, but before actually initiating the
research, the officials had to adopt oue of two contrasting
policies:
(i) To undertake a research on as large a scale as possible,
and to study the products and by-products.
(ii) To undertake a research on a very small scale in order to
make absolutely certain that all the variable factors
connected with carbonizing could be placed under complete
and measurable control.
Note. — With the adoption of either of the above policies, research work
on briquetting was to be undertaken subsequent to the work on carbonizing.
In favour of plan (i) it was urged that, — the results obtained
would be more likely to be in line with subsequent commercial
development, the large scale run would give more accurate figures
on by-products, and the whole experiment would serve as a very
useful preliminary operating test on whatever type of retort might
be used in the research. Against this, however, the officials were
faced with the problem that, irrespective of the retort adopted,
the control would not be sufficiently accurate scientifically to fix
beyond peradventure the influence on the product and on the
by-products of all possible variables. ae
Moreover it would only have been feasible to experiment with
one, or possibly two, carbonizers. The results would have been
results with these carbonizers, not results of carbonization; and if
the choice of carbonizer proved unlucky (as it easily might have
22 LIGNITE UTILIZATION BOARD
done at that time when so little was known on the subject) the
value of the results would not have been commensurate with the
considerable cost of the work. Under these circumstances it was
decided to initiate the work on a very small scale, fix the
optimum conditions for production of fuel and of certain by-
products, and then gradually enlarge the scale of the work under
the determined conditions for maximum results. The research
was then prosecuted vigourously and a preliminary report
appeared in May 1917, as a communication to the Royal Society
of Canada* from Messrs. Stansfield and Gilmore.
(b) The research into the mining conditions of Southern Saskat-
chewan was undertaken by Mr. W. J. Dick, the Mining Engineer
of the Commission of Conservation, who made a thorough study
of the field, and his results appeared in October 1917 as a report
of the Commission of Conservation under the title of ‘“Carboniz-
ing and Briquetting of Lignite — Economic Possibilities’.
(c) The investigation into the commercial practice and commercial
development of lignites was undertaken by Mr. B. F. Haanel,
Chief Engineer of the Fuels and Fuel Testing Division of the
Department of Mines. Mr. Haanel made a tour of the im-
portant American and Canadian points connected with the
briquetting and carbonizing industries, and presented a report
on same with recommendations. This report, dated Ottawa,
April 25th, 1917, appears as appendix No. 15, and on perusal
it will be noted that Mr. Haanel recommended that the best
solution for the problem was to choose some qualified com-
mercial firm, and entrust them entirely with the carrying out
of the work. In the subsequent work of the Board every
endeavour was made to get all such firms to quote on the
several contracts for the Board’s requirements.
The Fuel Committee of the Research Council drew up a preliminary
Progress Report, and presented the same to Council on February 17th,
1917.
A second report which subsequently proved to be nearly in its final
form was prepared after an intensive survey had been made of the
conditions disclosed by the special investigations mentioned in the
previous paragraphs. This report was tabled on June 8th, 1917, and
was adopted by the Council. The matter and recommendations in
the report can be judged by their subsequent publication as ‘‘The
Briquetting of Lignites’” by R. A. Ross+ — being report No. 1 of the
Research Council, Ottawa. It is thus seen that the course of action
recommended by the Fuel Committee of the Research Council was
prepared, recommended, and adopted only after obtaining the concensus
of opinion of all the interested Government departments. The original
recommendations did not go into matters of detail as to how the plant
should be erected or what special researches should be made, but
*See ‘The Carbonization of Lignites’’ by E. Stansfield and R. Gilmore, Part 1, Transactions Royal
Society of Canada, 1917.
tThis report was not issued to the public until the summer of 1918. Just before its publication, Messrs
Stanstield and Gilmore had presented to the R.S.C, a further report on_ the investigatory work originally
agreed upon. See Stansfield and Gilmore — “‘Carbonization of Lignites’’ Part II, Trans. Royal
Society of Canada, 1918.
HISTORICAL ASPECT vA
were limited to the broad principle accepted by all that the carbonizing
and briquetting process appeared well worthy of a commercial demon-
stration.
The question next arose as to the best method of carrying into
effect the recommendations of the report. Neither then nor at any
other time did the Research Council contemplate carrying out the
project under its own aegis. It was their feeling that the work should
be developed by the Department of Mines, and informal discussions
were held from time to time with the officials of that department
who expressed their sympathy with the idea. When, however, the
Federal Government was approached, they took the stand that as the
matter was one which concerned the West intimately, it would be
desirable for the Western Governments to contribute some share of
the expense involved. The Research Council felt that this point was
not unreasonable, and therefore representatives of the Council visited
Winnipeg and Regina in the summer of 1917 with a view to interesting
the respective Provincial Governments, and if possible getting them
committed to some participation in the venture. This mission was
successful, but each of the Western Provinces was strongly of the
opinion that it would be inadvisable to contribute money to be spent
by a Federal Department. They, therefore, suggested that the
simplest plan would be to create an independent commission or board
composed of direct representatives of the participating Governments
which board would have charge of the whole matter. The Research
Council were agreeable to this, and upon the return of the Council’s
representatives, conversations were again opened with the Federal
Government looking to the formation and financing of such a com-
mission.
The Federal Government finally took definite action upon these
proposals by passing an Order-in-Council No. 643, dated March
20th, 1918. By the terms of this Order-in-Council, appearing as
appendix No. 1, the Privy Council recommended that the Minister
of Mines negotiate an agreement with the two Provinces to implement
the understanding reached by the representatives of the three Govern-
ments. By the terms of this agreement dated July 20th 1918, the
text of which appears as appendix No. 2, the Federal Government,
the Saskatchewan Government and the Manitoba Government under-
took to provide the sum of $400,000. apportioned between them in
the ratio of one-half, one-quarter, and one-quarter respectively. The
agreement also provided for the method of obtaining money, the
location of the plant, responsibility and creation of the Lignite Utiliza-
tion Board, the fact that no member of the Board was to be paid,
method of filling vacancies in the Board, minimum number for a
quorum, auditing, and method of holding trust property. By the
conclusion of this agreement the Federal Government paved the way
for the formal creation of a Lignite Utilization Board, and on the
22nd of August, 1918, the Privy Council by Order-in-Council P.C.
2064, — copy of which appears as appendix No. 3 — actually appointed
the members of the said Board as follows:
R. A. Ross, Esq., Montreal, Chairman.
J. M. Leamy, Esq., Winnipeg.
Hon. J. A. SHEPPARD, Moose Jaw.
24 LIGNITE UTILIZATION BOARD
The appointments of Messrs. Leamy and Sheppard were made by the
Federal Government upon the nominations of the Governments of
the Provinces of Manitoba and Saskatchewan respectively.
The Lignite Board was thus constituted under Dominion Order-in-
Council, incorporated with practically the same powers as a limited
company. They could sue and be sued, they could hold property in
their own name in trust for the Crown, and they were to have their
own resources in the bank. Their legal status is outlined clearly in
an opinion from A. Chase Casgrain, K.C., dated September 17, 1918,
appearing as appendix No. 4.
With the creation of the Lignite Board as a separate unit or corpor-
ation, this section closes. But such a separate status clearly implies
the corollary of special responsibilities. After October Ist, 1918, the
Research Council withdraw from any participation whatever in the
control of the work. Their function of promoting the project had
been completely discharged, and from that date onward the whole
responsibility for the conduct of the enterprise rested solely upon the
shoulders of the Lignite Utilization Board. This condition obtained
until January 1923, when a new order was inaugurated to which
reference is made in Section VI.
~
‘TRANSITION PERIOD 25
SECTION II.
PERIOD OF TRANSITION
Oct. 1918 to Feb. 1919
CONTENTS
Staff and offices, First two meetings of Board, Tentative policy, Digest of
existing information, Lignite situation as anticipated, Tour of French and
Stansfield, Their report, Real situation, Rumours of burning of raw Souris
lignites in domestic heaters, Special investigation on same, and On increased
use of Western coals, Report on these matters, Digest of position facing Board,
Third meeting of Board and resulting action, Policy on capital expenditure.
On September 20, 1918, Lesslie R. Thomson, previously Secretary
of the Research Council, was appointed Secretary, and early in October,
R. DeL. French was appointed Mechanical Engineer. Within a few
days the Chairman had concluded with the Deputy Minister, Depart-
ment of Mines, an arrangement for the transfer to the staff of the
Lignite Utilization Board of Edgar Stansfield as Chemical Engineer.
Mr. Stansfield had been, as mentioned in Section 1, the Mines Branch
Official in direct charge of the research work on lignite. The profes-
sional records of each of these three engineers together with those of
other members of the staff are submitted in appendix No. 34 of this
report.
The Board opened its office in Montreal on October Ist, 1918, and
immediately issued a small circular in order to inform the public of
its business status and commercial objectives. This circular appears
as appendix No. 35.
The first two meetings of the Board were held in Montreal on Sep-
tember 16th and September 20th, 1918, at which general plans for
carrying on the investigation were discussed. As the war was still
raging, any actual investigation by the Board’s representatives of
European practice was out of the question. Under such circumstances
the problem had to be solved by the processes, methods, and
apparatus, developed on this continent. At the second meeting,
therefore, a programme was adopted as follows:
Programme Time Allotted
(a) To digest and index as quickly as possible all
the information, suggestions, requests for as-
sistance, inventors’ statements, and patent For (a) and (b)
claims in connection with lignite and its utiliz- 6 months
ation, that had been gradually accumulating
in the files of the Research Council.
(b) To make a personal investigation of all lignite
carbonizing and briquetting plants in the
U. S. and Canada, to examine all those coal
treating and briquetting plants in the U. S.
and Canada from which valuable information
might reasonably be expected.
26 LIGNITE UTILIZATION BOARD
(c) Asaresult of the information gained in (a) and
(b) to either buy, or design and construct, a 12 months
carbonizing and briquetting plant at some
point in the general Souris field.
(d) To operate the plant for a period of 6 months
during which time operating difficulties could
be smoothed out, accurate operating control For (d) and (e)
could be established, and reliable costs ob- 6 months.
tained.
(e) To then report to the supporting governments
on all of the foregoing with the hope of inducing In all 2 years.
large private capital to embark on the matter
as a commercial venture.
The months of October and November were given up to preparing
a digest of the written material already referred to. It was divided
first into 3 groups: — good, uncertain, and useless. Into the first
group were placed all those matters that seemed sound and undoub-
tedly worthy of future study. Into the second were placed those of
which the Board was less hopeful, but which could not be neglected.
Into the last group were placed those suggestions and processes that
were evidently valueless. Correspondence was opened up with
all those represented in groups one and two, and (where possible)
interviews were arranged to take place during the investiga-
tory trip.
Concurrently with the study of the above mentioned matters, plans
were made for the investigatory trip mentioned in (b). Permission
had to be secured from responsible officers of the plants of which the
Board desired to make inspections. Letters of introduction for the
Board’s representatives were obtained to many leading American
officials. Schedules were prepared — all in order that time might be
saved during the actual trip.
The outstanding fact at that time was that the Board expected con-
fidently, as a result of much of the current printed information and
reports, that lignite carbonizing apparatus had definitely passed the
experimental stage, and was all but commercialized. The idea was
further supported (inferentially of course) by the well-known fact that
European practice on brown coals was thoroughly commercial. In
other words, in the light of German and Bohemian success, the degree
of development claimed or supported by writers and talkers on this
side of the Atlantic seemed not unreasonable.
It is seen therefore that the Board then hoped that, as soon as the
investigatory trip was concluded, its duty would be discharged by re-
commending for adoption the best oven from a field of perhaps three
or four suitable ones, or that such and such a process would be suitable
commercially provided certain changes were made in order to allow
it to conform to the peculiar characteristics of lignite. In this hope
they were to be profoundly disappointed.
PERIOD OF TRANSITION ot
On November 11th, 1918, Messrs. French and Stansfield left Montreal
for the investigatory tour, during which they visited the following
cities, —in most of which investigations were made.
New York, N. Y. Pittsburgh, Pa.
Trenton, N. J. Vancouver, B. C.
Newark, N. J. Toco; “BAG;
Philadelphia, Pa. Port Mann, B. C.
Lansford, Pa. Bankhead, Alta.
Wilkes-Barre, Pa. Medicine Hat, Alta,
Scranton, Pa. Regina, Sask.
Dickson City, Pa. Saskatoon, Sask.
Harrisburg, Pa. Moose Jaw, Sask.
Washington, D. C. Estevan, Sask.
Norfolk, Va. Bienfait, Sask.
Parrott, Va. Winnipeg, Man.
Louisville, Ky. Grand Forks, N. D.
Champaign, Ill. Duluth, Minn.
Chicago, IIl. Superior, Wis.
Milwaukee, Wis. Sault Ste. Marie, Ont.
Kansas City, Mo. Sarnia, Ont.
Denver, Colo. Detroit, Mich.
Seattle, Wash. London, Ont.
Renton, Wash. Toronto, Ont.
It will be noted that no visit was made to Hebron where the Uni-
versity of North Dakota maintained a briquette plant for the treat-
ment of lignites. As the plant was being completely revised at that
time, Dean Babcock suggested that nothing could be gained by visiting
it. For this reason the inspection of that plant was omitted.
The Board’s representatives returned to Montreal on Jan. 11th,
1919, and immediately set about the preparation of their report.
While this was being written, a verbal statement was submitted to the
Chairman outlining their proposed findings and also giving details of
the fuel situation in the Canadian West. Among other matters dis-
closed by the investigation was the apparent marked decrease in the
consumption in the West of imported American anthracite, — the
increase in the consumption of Alberta coals, — and the alleged use
of raw Souris lignites in certain furnaces and self-feeders originally
designed to burn anthracite. If the last mentioned point were true,
then it was obvious that the Board’s work would be unnecessary. If
owing to war pressure, methods had been devised successfully to burn
these low grade fuels, with all their disadvantages, in a manner satis-
factory to the householder, then why spend money on the development
of an expensive process? It was felt that the quickest way to get the
real facts of the case was to send French to the West immediately to
look into and report upon that one specific question.
This was done, and French returned to Montreal about the beginning
of February. He prepared at once a report on these matters, which
appears as appendix No. 36. It can be summarized briefly as follows:
1. The large increase in the use of Alberta coals had been brought
about by a campaign organized by’ the provincial fuel adminis-
trators during the preceding summer.
28 LIGNITE UTILIZATION BOARD
2. It was highly probable that the Alberta operators would retain
a considerable proportion of the market they had gained.
3. No reliable information could be obtained whatever on the
alleged successful use of the very low grade lignites in their
raw state in domestic heaters.
The next step obviously was to lay the whole situation before the
meeting of the Board. The third meeting of the Board was held on
February 10th, 1919, and was attended by all three members.
The two most important matters presented to the meeting were:
the verbal report by Messrs. French and Stansfield on their long tour,
and the final report of French on his investigation regarding the uses
of Western coals, and on the development, if any, of the use in their
raw state of Souris lignites. Reference to each of these reports has
just been made.
As a result of French’s report the Board decided to continue its work.
The text of the report of the long tour, dated Feb. 15th, 1919 appears
as appendix No. 16, and it is only necessary in this brief review to call
attention to its salient features. The condensed statements and re-
commendations were that:—
i) The present state of the art of carbonizing lignite did not war-
rant the Lignite Board in erecting a plant in the immediate
future.
ii) The present state of the art of briquetting lignite did not war-
rant the Board in erecting immediately the proposed demon-
stration plant.
iii) That a large programme of experimentation be embarked upon
immediately.
It now remains to present clearly the specific matters of research
recommended by Messrs. French and Stansfield and accepted by the
Board as an immediate programme in order to carry into effect the
terms of the report. These points covered the following:—
Storage: Under this head investigations were recommended regarding
weathering and natural dehydration.
Carbonization: Under this head the heat of carbonization, the rate
of carbonization and the atmosphere during carbonization, and the
initiation of research on a new retort of which the principle had been
devised during the preceding few weeks.
Briquetting: Under this head the suitability of different chars was
to be investigated, differentiated both as to degree of carbonization and
screen analysis; availability of certain binders; quantity of same neces-
sary; and the utility of different types of mixers; heat treatment of
briquettes, and a testing of same.
A fuller digest of these tests, and a memo on each of the expected
results appears as appendix No. 37. Alsoin Fig. 2 is shown a graphical
presentation of the then known conditions in regard to the general
process of making a carbonized lignite briquette. To illustrate this,
three elementary flow sheets are presented, in each of which is shown
PERIOD OF TRANSITION 29
clearly what steps of the process were presently commercial, and those
which needed considerable research.
Before closing this section it is interesting to note that at this time
also the Board laid down a simple formula not only as a guide to its
own staff when dealing with matters coming before them, but also to
serve as an indication to the public of the attitude the Board were
adopting toward the general question of full scale construction and
operation. This formula was “‘Not one dollar for capital equipment
until small scale tests proved practicability”. The Board adopted
this conservative attitude in spite of strong public pressure, and has
never had occasion to regret its decision in this regard.
The next section will describe the conduct of these researches.
30 . LIGNITE UTILIZATION BOARD
SEC TION#1IT
PERIOD OF FUNDAMENTAL RESEARCH
Feb. 1919 to May 1920
CoNntTENTS
Relation of experiments to original objective, Arrangement with Mines Branch,
Ottawa, and Organization set up, Equipment, Laboratory, Progress on car-
bonizers, Special carbonizer report by E. Stansfield, Decision to build large
plant, Reasons therefor, Western trip and consultations, Fourth meeting of
Board, Delegation of authority to Chairman and Secretary, Site and site
negotiations.
At the meeting referred to above, the Board had committed itself
to fundamental investigation only after a very careful weighing of
the whole technical and commercial situation and the general atmos-
phere surrounding such a public project. On the one hand there was
the public pressure then beginning to be noticeable and quite articulate
in such newspaper captions as “Build at Once’, “Show Results’,
“Get Action’? and other similar remarks, while on the other hand
there was that academic tendency, so often present in scientific research,
to accept willingly enough the proposition that as the work was, in
its last analysis, purely experimental, speed was unimportant and per-
haps prejudicial to results. These two views may be regarded as the
Scylla and Charybdis between which the Board has ever since attempt-
ed to steer, and in doing so has noted quite clearly that not only have
the lateral limits of the route been very dangerous, but the length of
the channel itself has been far greater than anticipated. The Board
wishes therefore to record the fact that the large experimental program-
me to be described in this section was undertaken with a clear and
steady view of its relation to the final objective originally adopted —
the commercial demonstration of the carbonizing and briquetting
process.
As a result of the decision made at the meeting on February 10th,
1919, it became necessary to set up at some point a complete exper-
imental plant along approved lines. Two locations were considered
for this laboratory, Montreal and Ottawa. In favour of the former
was the fact that the laboratory would be in close proximity to the
Head Office in Montreal, and thus allow the research staff and the
other engineers to be in more intimate contact than would be possible
if the laboratory were elsewhere. Against the erection of the labo-
ratory in Montreal could be urged the great expense entailed for
buildings and equipment, some of which would be a complete loss
upon the conclusion of the Board’s work in Bienfait. On the other
hand, the equipping of a laboratory in Ottawa, though naturally in-
volving increased difficulty of communication due to the separation
of the staffs in the two places, would mean a comparatively small
capital expenditure (due to cooperation of Department of Mines),
and also that any equipment not required by the Board at the conclu-
sion of its labours, would be usefully located and available for the use
of the Mines Branch. In many other ways, too, the desirability of the
Ottawa location became evident. For example, technical supervision
would be easier, for not a few chemists, already somewhat familiar with
PERIOD OF FUNDAMENTAL RESEARCH 31
carbonization investigations, were available for consultation. The
decision, therefore, was reached to establish the necessary laboratory
in Ottawa. During the few weeks preceding the meeting, this action
had been anticipated, and informal discussions had been taking place
between Edgar Stansfield and the other officers of the Mines Branch
as to the way in which the relationships between the two bodies and
their respective staffs could be organized and recorded in the event of
such a plant being located in Ottawa. To that end a written under-
standing was prepared under date of January 18th, 1919, which re-
ceived the approval of both the Board and the officers of the Mines
Branch, the text of which appears as appendix No. 5ofthis report. It
is sufficient to note here that Stansfield was to retain general super-
vision of the fuel testing work of the Mines Branch, as heretofore, and
at the same time have charge of the work for the L. U. B.
The Board thereupon immediately set to work to purchase equip-
ment to carry on the tests. It will not be necessary to note in this
report the detailed purchases but specific mention should be made of
one practically new Mashek Y-1 briquetting roll press (the smallest of
the commercial sized presses) valued at $1,450.00 for the sum of $310
cash. A small steam jacketed mixer also was purchased. A large
mixing plate was manufactured by the Board, and the usual auxiliary
apparatus was acquired. The total capital cost of the laboratory
and equipment was $4,963.75, and the layout of the laboratory is shown
in Fig.3 As soonas completed it was insured by the Board for the sum
of $3,300 for the year 1919-1920, and for $4,000 for the year 1920-1921.
The summer and early autumn of the year 1919 were given up en-
tirely to experimental work in Ottawa, and to the preparation of
tentative layouts and designs in Montreal. It seems desirable to note
briefly the result of the work in the body of this report, and insert in
the appendices the mass of detail which is of permanent value from
a scientific point of view.
It has been noted that the two main researches were conducted on
carbonizing and briquetting. Those on carbonizing were concluded
about November 1920, with subsidiary research going on until. 1921,
while the briquetting researches were continued well into 1921.
The progress made in carbonizing by the Lignite Utilization Board
during 1919 and afterwards, cannot be dissociated from the immense
amount of work done by ‘the Department of Mines, both previously
and subsequently to the creation of the Board. In particular Stans-
field, Gilmore, Strong, and toa less degree, Nicholls, were for some time
making extensive researches into the quality and characteristics of
Canadian lignites. These researches were embodied in communica-
tions presented to the Royal Society of Canada (cit. loc. q. v.) the
general drift of which was that the by-products either estimated or
apparently obtained by other investigators could not be realized by
the Canadian Department officers. This was one of the deciding
factors that had led French and Stansfield to bring in reports at the
conclusion of their investigatory trip which cast doubt upon a great
deal of the published information. It is obvious, for example, that
by manipulation, the gas yield of any particular lignite can be increased
very markedly, but only at the expense of the residue or of the tar.
32 LIGNITE UTILIZATION BOARD
But as the L. U. B. has always been and is now concerned primarily
with the preparation of a fuel, the quantity and quality of the solid
residue per unit cost were of primary importance. Coupled with this
fact is the other that by-products are only of economic value when they
can be marketed profitably. The Board, therefore, came to the
conclusion, in order to lay down a policy and to estimate the commercial
feasibility of any proposed process, that no allowance whatever should be
made for the possible sale of by-products. But from the point of view
of the future prospects of the industry, the Board felt that a carbonizer
should be obtained or developed which would be capable of producing
by-products if and when it became desirable to do so, or feasible to
market them. Although, for a considerable period no hope could be
placed in the production or marketing of by-products, the Board
would be remiss in its duty if it developed a carbonizer that was in-
capable of producing them.
With the idea in mind of a by-product retort, the first thought
was given to a rotary cylindrical oven. The features that commended
themselves were obviously the complete separation of the gas, the sim-
plicity of operation (no pushers or mechanical devices for discharging
were required) the comparatively easy control of the heat, ability to
carbonize any size of lignite — even dust—, and also that, in view of
the constant agitation of the lignite in passing through the retort, it
would be reasonable to expect a large output, comparable to the
increased output per sq. ft. of heating surface always registered by the
retort with agitation, over those with no agitation.* Against the
cylindrical retort, it ultimately came to be seen that the temperature
at which it would be required to run, in order to duplicate the optimum
conditions for lignite char, would probably preclude the use of ordinary
metals, while high temperature metals had not in 1919 reached the
technical position they now possess. In any case the cost even at the
present time would have been prohibitive. Also the capital costs per
ton of output of those retorts concerning which the Board could get
authoritative information appeared high. The last few remarks
anticipate in time the decision of the Board in regard to a rotary
cylindrical retort but it seems best to record the decision in this place.
Some years later the Board reopened the question of rotary cylindrical
retorts, and the reader is referred to Section X for a very brief des-
cription of the result.
During the latter part of their investigatory trip Stansfield and
French had become seized of the idea that the processes they were
observing, were designed specifically for coking coals and that when
handling non-coking, non-sticky coal such as lignite, the apparatus
and devices available and necessary in treating the more difficult coals
would be unnecessarily costly if used for the lignites. This seemed
to indicate the possibility of a marked decrease in capital charges of
all kinds for a retort developed for lignite treatment only. Some time
before the date of the 3rd meeting of the Board the germ of the design
of a lignite carbonizer had taken root, and when the principle was
brought forward at that meeting it was considered and approved. The
design of the apparatus was thereupon set about with a certain amount
*In this connection see appendix No. 17, with table of approx., capacities per sq. ft. of heating surface.
PERIOD OF FUNDAMENTAL RESEARCH 33
of enthusiasm owing to the novelty and apparent simplicity of the
principles involved. The essential principle of the new carbonizer
was that of a thin steam of lignite moving comparatively rapidly over
very hot inclined surfaces, the thickness of the stream to be controlled
by a series of vertical baffles, the heat to be applied on the under side
of the inclined surface, while the volatile matter was to be withdrawn
from above. In their withdrawal, the gases would come in contact
with medium temperature surfaces only, by which arrangement it
was hoped to avoid on the one hand tar deposition, and on the other
cracking. In order to test thoroughly the retort, two examples of
it were built, one named the semi-commercial and the other the labor-
atory or baby. The former was made with commercial building
materials such as brick, fire brick, steel, cement, etc., and possessed a
capacity of about 200 lbs. of raw lignite per hour. The latter was
built in the usual laboratory materials of glass, platinum, cork, etc. etc.
Each of these models contributed a great deal to the knowledge of the
principle and of the operation of the carbonizer. During this time
successive changes were made in each until by the close of the season
more or less completely successful operation had been achieved; and
it was only after successful operation had been obtained with the
larger retort that the Board made its decision to proceed with the
western plant.
It is important to note at this point that in the very nature of the
case no method existed by which gas handling or tar extraction appa-
ratus could be tested on a small scale. In other words, while informa-
tion of very great value could be obtained by building and testing
models of carbonizing apparatus, models of gas handling or tar extrac-
tion devices would be almost useless. Therefore during the season of
1919 the gas from the semi-commercial retort was simply bled into the air
and burned, while the gas handling equipment of the baby carbonizer
was constructed of condensers and bottles in the ordinary methods of
a laboratory. The Board therefore at this time took the attitude that
the handling of the gas, and the tar extraction, must await the erection
of full scale apparatus in Bienfait.
Stansfield in appendix No. 18 describes minutely the development
of his retort, and goes thoroughly into the question of heat required
for carbonization.
By October, 1919, enough success had been attained apparently
with the Ottawa experiments to warrant the Board in announcing
publicly its intention to proceed at the earliest date with the erection
of the main plant. The reasons for this are elaborated more fully
in the appendices, but should be recorded here in a word or two. The
new carbonizer on which the hopes of the Board were centred had
proved to be on the whole successful, that is to say, the principle had
apparently proven sound (this remark for reasons mentioned above
on this same page does not apply to gas handling apparatus).
The output capacity per square foot of heating surface, and
the output per hundred dollars of estimated capital cost, were
both very much higher than in any retorts of which the Board had
knowledge. In other words, one essential of the problem, — economy
—had apparently been achieved. Without apparent large economy
34 LIGNITE UTILIZATION BOARD
it would have been folly to move forward, but the comparative results
seemed to indicate that the Board had brought the carbonizer deve-
lopment to a successful conclusion so far as experiments on that
scale could prove anything. They felt justified therefore in proceeding
with the erection of the full scale ovens at Bienfait.
Another reason that led the Board to feel justified in its decision to
proceed with the erection of the main plant was the indication of
success in the briquetting results, which however are touched upon
in Section VIII. In other words, in the two main problems facing
the Board, namely carbonizing and briquetting, the experimental
research both on a semi-commercial scale, and on a minute laboratory
scale, had indicated to all those intimately in touch with the situation
the high degree of probability of success. It was only when this point
had been reached that the Board made any public announcement of
its decision to proceed with the construction of a full scale plant.
Having reached this point, the next obvious step was to consult the
mining men in the field, and others practically interested in the de-
velopment and marketing of the lignites. The purpose of this consulta-
tion was to inform them of the tentative plans which had then been
made by the Board, to ask for their criticisms of these plans, to
request the benefit of their advice on many local conditions in regard
to mining, housing of employees, etc., and to receive any suggestions
whatever germane to the problem. As this meeting would involve
the Board appearing in the West it was decided to hold also a public
meeting in Winnipeg, where the interest in the project had been
extraordinarily keen. The purpose of this public meeting was to in-
form any and all interested as to the work done to date, and to make a
statement as to the future intentions of the Board. The Winnipeg
public meeting was held therefore on October 6th, 1919, in the Legis-
lative Chamber of the Parliament Buildings of Manitoba. At this
meeting about fifty people were present including a number of members
of the Government of Manitoba; and a great many questions were
asked of the Chairman, and to these questions full replies were given.
On Wednesday, October 8th, 1919, a consultation was arranged
with the mine managers and operators of the Estevan-Bienfait area.
For the list of those present, and a digest of what took place the reader
is referred to the minutes of this consultation appearing in appendix
No. 39. Information of great value was obtained, and very careful
weight was given to all the opinions expressed, owing to the feeling
that existed in the minds of the Board that men so intimately connected
with the field as were these managers and operators should be in a
position to speak with authority.
Upon the conclusion of the consultation above referred to, and after
absorbing the information obtained, the 4th meeting of the Lignite
Utilization Board was held on Thursday, October 9th, 1919. At this
meeting decisions of great importance were made. These decisions
covered among other things the following topics; right of the Board’s
employees in patents; letting of contracts; site and site negotiations.
The question of patents which might be obtained by the Board’s
employees had been discussed at some length informally on previous
PERIOD OF FUNDAMENTAL RESEARCH 35
occasions, and as it became apparent that the Board as such was not
able under Canadian law to take out patents in its own name, it was
necessary to have such patents as might be sought, taken out in the
name of some one specific person. Under these circumstances the
Board decided that every patent applied for should be taken out in
the name of one member of the staff, and that an agreement be entered
into immediately with each one of them in order to arrange before-
hand as to the rights of the respective parties to any of the benefits
that might enure.
A copy of this standard agreement, which was signed by each member
of the staff, appears as appendix No.6. These agreements provided :—
a) That all interest in any Canadian Patent should be assigned to
the Board.
b) The Board shall pay all expenses 1n connection with those Can-
adian patents, application of which they approve.
c) That the return to the inventor should be at least half of the
net profit accruing on Canadian patents.
d) On foreign patents the Board pays expenses of those they desire
to control, and net benefits accrue to inventor, — while all
expense and gross benefits revert to inventor of those patents
which the Board does not care to control.
At this meeting also it was decided to patent as quickly as possible
the principle of the new carbonizer developed by Stansfield.
The next question discussed was one which affected the conduct of
the Board’s affairs to a very marked degree. The Chairman asked
specifically whether the two Western members desired to have all con-
tracts and business matters submitted to them for their consideration
before any action could be taken by the Board. Upon discussion it
became apparent that if such a course of procedure were adopted the
resulting delays would increase to no small amount the time taken by
the Board in each of its decisions on the various matters coming before
it. Under these circumstances it was moved at the 4th meeting by
Mr. J. M. Leamy and seconded by the Hon. J. A. Sheppard and
* Resolved:
‘That the Board do hereby empower R. A. Ross, Chairman,
and Lesslie R. Thomson, Secretary, to sign all agree-
ments, awards, contracts, and any other documents what-
soever, on behalf of the Lignite Utilization Board, and
to do any or all other things necessary for the complete
design, building, erection, and equipment of the Board’s
plant.”
As a result of the adoption of the foregoing resolution it became
inevitable that the real responsibility during the active conduct of
the business of the Board rested more heavily upon the Eastern sec-
tion of the organization than upon the Western. During the progress
of the work the Western members were kept informed as fully and as
quickly as possible, but the actual decision on each matter was taken
*Minute No. 6 of the 4th meeting of the Board, Oct. 8th, 1919.
36 LIGNITE UTILIZATION BOARD
in Montreal. As a result of the information circulated regularly to
the Western members, and in accordance with their own personal
observations and inquiries, it is interesting to note that at the 5th meet-
ing of the Board held in Winnipeg, October 19th, 1921, subsequent to
the completion of the plant, the following resolution was adopted,
unanimously, — which indicates that the efforts of the Montreal
office were, however, not unacceptable to the Western members of
the Board.
*“The Board made a general review of all its operations ©
from the time of its establishment, and of all contracts
made, expenditures authorized or incurred, work done,
and payments made by and on behalf of the Board, and
particularly of all contracts entered into, awards given,
work done, expenditures incurred, and payments made
in connection with the briquetting plant now established
at Bienfait, Saskatchewan, including those relating to the
plant and buildings, houses, boilers, machinery,. engines,
conveyors, and conveying systems, electric motors, pul-
verizers, briquetting equipment, dryers, water tank, fans
and blowers, pumps, power installations, switchboard,
gas purifying apparatus, water supply and sewage disposal,
valves and piping, laboratory supplies and apparatus. It
was therefore moved by the Hon. J. A. Sheppard — se-
-conded by Mr. J. M. Leamy and
“Resolved
“That the Board place on record its ratification and approval
of all the foregoing items and of all actions by it or on its
behalf done in connection therewith.”
Upon the conclusion of the 4th meeting which as already noted was
held in the West, the Board set itself to a discussion and a settlement
of the question of site. It is interesting to note here that one of
its first researches was directed entirely to a critical examination
of the physical aspects of the general Souris area — particularly in and
about Estevan. One of the early conceptions of the Board was that
the plant should be located over a reasonable seam of coal in order to
guarantee to itself the supply of the most essential of the raw materials
in the event of the coal operators ever attempting to shut off supplies
of raw lignite by charging too high a price, or by any other common
action inimical to the Board’s welfare. If such a seam were ever to
be of value for such a purpose, its quality must necessarily be acceptable
for carbonizing and briquetting purposes. It has already been pointed
out frequently that it takes a little over two tons of raw lignite to
supply the char for one ton of briquettes. This indicates at least a
doubling of the ask content of the original lignite in the resulting
briquette. Hence if the Board were to place its plant over a suitable
coal seam it became necessary to know the ask content of all the lignite
produced in the Souris region.
Of the men available for such sampling and investigation, there was
one who by previous personal experience of the field was best qualified
*Minute No. 4 of the 5th meeting of the Board, Oct. 19, 1921.
PERIOD OF FUNDAMENTAL RESEARCH 37
to undertake it — Mr. Alexander MacLean of the Geological Survey
and also of the geological staff of the University of Toronto. Through
the courteous co-operation of the President, Sir Robert Falconer,
Mr. McLean was given leave of absence for a couple of weeks in the
autumn of 1918 to proceed to Estevan for the purpose of sampling
each of the mines, and also to take any notes that might still be neces-
sary in order to prepare a brief report on the geology of the region.
This report, and the result of the sampling appear in appendices No. 20
and No. 19 respectively.
During the preceding summer the staff of the Board had been en-
gaged in debating confidentially this whole question of the site, and
had come to a unanimous conclusion as to the ideal location of the
plant. The information requisite to reach such a decision had been
furnished by the available reports on the district, by special reports
kindly furnished by the M. L. & Y. Branch, Department of Interior,
by information obtained from Mr. Alex. MacLean (see appendices 19
& 20) and from personal observations made by French and Stansfield
upon their tour. Upon digesting all this information a conclusion had
been reached which was conveyed confidentially to the Board in the
report dated Oct. Ist, 1919, signed by French, Stansfield and Thomson,
which report appears as appendix No. 21. This report recommended
that the plant be situated half way between the two largest mining
companies of the region, namely the Manitoba and Saskatchewan
Coal Company and the Western Dominion Collieries. This recom-
mended site is shown on Fig. 4. In making this recommendation the
staff felt that the obvious dangers and disadvantages of the location
could be safeguarded completely by a properly drawn agreement.
This report was presented confidentially to the Board for their con-
sideration, but no decision was reached until after the meeting held
with the operators and after the general inspection of the field. The
actual decision was reached at the 4th meeting of the Board held on
October 9th, 1919, when it was decided that the report should be
accepted, and that the referred to site should be obtained provided the
Board’s interests could be maintained in reference to the four following
points:
(a) Freight service on existing spurs.
(b) Supply of water from existing pipeline.
(c) Special sidings to be built by each of the companies to the
Board’s site.
(d) The sale in fee simple to the Board of the requisite amount of
land together with a guarantee against any damages due to
subsidence.
Having reached such a decision the Board opened up negotiations
with Mr. Hugh Sutherland, President of the Western Dominion Col-
lieries, the owners of the site preferred, and with Sir Daniel McMillan
and Senator Robert Watson representing the Manitoba & Saskatche-
wan Coal Company — which company owned the pumping station
and pipeline to the Souris River.
The preliminary discussion brought out the following facts:
38 LIGNITE. UTILIZATION BOARD
(i) The Western Dominion Collieries would not consent to sell
but would be willing to lease under certain conditions.
(ii) The bond holders of the Western Dominion Collieries would
have to be consulted.
(iii) That if a lease were drawn, then all the four organizations
interested, (L. U. B., W. D. C., M. & S., & Trustees Corp.,
London) would have to be parties to the agreement.
Upon consideration of the foregoing the Board came to the con-
clusion that, if the site suggested were to be adopted, it would be ne-
cessary to have the lease agreement cover a very wide field of common
or engaging interests. The Board therefore had to decide whether
to forego their hope of what they regarded as the most favourable
location, all things considered, to accept another site with a clear title
in fee simple, or to adhere to their own selection involving as it did
the acceptance of a rather complicated agreement. It was finally
decided that the latter alternative was the better, especially in view
of the power that could probably be wielded by a body of the nature
of the Lignite Utilization Board with its governmental connection and
engaged in the development of a public need. The Board believed
that it would be possible to obtain the site, obtain the necessary ser-
vices of coal, water, etc., and at the same time safeguard itself from the
charge of being in complete control of the two largest companies of the
district. In addition to safeguarding the Board’s direct interests, it
was felt very keenly that the value of its own equity could only be main-
tained by a perfectly free right to sell, sublet, or assign in any way
whatsoever without let or hindrance on the part of either the neigh-
bouring Company, (the Manitoba & Saskatchewan Company) or of
the lessor, (the Western Dominion Collieries). In other words, if the
Board did not or could not posses this free right of disposal, it was
patent that any value created by its efforts in or on the demised pre-
mises was not a marketable asset. Hence on one or two occasions
during the long, tedious, and occasionally acrimonious discussions, the
negotiations were nearly broken off by the Board standing firm for the
eg of the clause that appears in the final agreement as clause
Oval:
During the discussion with Mr. Hugh Sutherland and Senator Wat-
son, already mentioned, the preliminary broad outlines of an agreement
were reached; but the detailed negotiations covering these points ex-
tended all through that winter. In addition the Bond holders of the
Western Dominion Collieries, the Trustees Corporation, Limited,
London, had to be not only consulted but included as a party to the
lease agreement. This document was finally concluded upon May Ist,
1920 when the lawyers representing respectively the various parties
exchanged undertakings on behalf of their respective clients for the
signatures, if and when the necessary surveys could be completed. A
copy of this lease agreement, appears as appendix No. 7 to this report.
Ane pols in the agreement to which attention should be called are
as follows:
(a) That the period of the lease is 21 years and renewable for a
further 20 years. |
(b)
(c)
(d)
()
(f)
(g)
PERIOD OF FUNDAMENTAL RESEARCH 39
Terminable at the Board’s option upon a year’s notice.
The Board agrees to operate a plant continuously between Ist
April and September 30th, which undertaking is subject, how-
ever, to delays or stoppages beyond the control of the Board.
Each of the mining companies is under obligations to do switch-
ing for the Board under a reasonable remuneration.
An ample supply of coal is assured at prices to be determined
in open competition.
The M. & S. agrees to deliver an ample amount of water for
the Board’s purposes with a minimum daily guarantee.
Each of the companies agrees to build a railway spur at their
own expense to connect the Board’s plant with their own mines.
This section has traced the work of the Board from the inception of
its experimental programme to a point where it had apparently been
successful in prosecution of the research, and has related also how the
site of the future plant was determined. The next section will deal
with the questions of design and construction.
40 LIGNITE UTILIZATION BOARD
SECTION IV.
PERIOD OF DESIGN AND CONSTRUCTION OF
BIENFAIT PLANT
May 1920 to Aug. 1921
CoNTENTS
Specific objective of plant to give commercial demonstration, Decisions on
quality of plant, on flexibility, on unit or non unit construction, and on housing,
Acknowledgment of errors, Unique nature of plant to be designed, Methods of
letting contracts, and of purchasing, Construction undertaken and finished,
Description of plant, Pipe line troubles.
The last section has shown that the Ottawa experiments on car-
bonizers had given promise of success, —- in fact they had been pushed
to the utmost. No further laboratory demonstration would have been
adequate for the project, or consonant with the Board’s original order
in Council, which required a commercial demonstration. Hence full
scale apparatus had to be used finally to prove or disprove the whole
conception, and no alternative of such conditions could ever be accepted
as a final demonstration. Therefore the risks always incident to such
construction ultimately had to be taken resolutely.
Before describing the design of the plant in detail, some preliminary
decisions must now be recorded. These decisions included answers to
the following questions: What quality of plant should be built ? —
Should it be flexible, — should it be built at once to full capacity or
gradually as experience of parts proved correctness of design, — and
finally what class of housing should be provided ?
These questions will now be touched upon consecutively. The
proposed capacity had already been determined by Governmental
agreement — 100 tons per day of briquettes which appeared to be the
smallest plant suitable for commercial demonstration. This indicated
a fair sized plant, and as it was expected that the ultimate destiny of
the plant would be that of a Governmental testing station for briquet-
ting western coals, it was decided to build in a solid and permanent
style. The decision was reinforced, too, by the fact that the fire
hazard existing in any processing of lignite would be far higher than
in an ordinary coal treating plant. The soundness of this decision is
indicated by two facts. First, in spite of two or three serious fires in
the early stages, no general conflagration resulted. Second, the
original insurance rate was $1.25. Asa result of stability of construc-
tion and of pressure exercised by the Board the rate has been reduced
to 69 cents during the period of. partial shut down.
A highly flexible plant with absolutely complete provision for by-
passing each and every unit with provision also for complete reversal
of routing would have been out of the question for financial reasons.
As indicated in Section VIII, the briquetting room is partially flexible,
and the installation and excess capacity of the dryers are further evid-
ence of flexibility. This arrangement was due to the belief in 1919-20
that it might be possible to develop a market for dried lignite.
It is obvious that in the divisions of raw lignite handling, conveyors,
bins, mixing, briquetting, gas handling, tar extraction, power house,
sewage disposal, water supply and housing, — gradual construction
PERIOD OF DESIGN AND CONSTRUCTION OF BIENFAIT PLANT 4]
in small units would be out of the question. This leaves only two de-
partments, drying and carbonizing, where it might have been possible
to install commercially (from point of view of capital investment) one
or more units, test them, and then install others gradually. In regard
to dryers, scientific requirements* made it necessary to install dryers
of the largest size possible if waste heat from carbonizers were to be
utilized economically. Therefore 2 units of 150 tons each were provid-
ed. Coming next to the carbonizers, they were installed in three paris
of two each — providing six carbonizers in all. It would certainly
have been possible to install one pair, but it must be recalled the public
pressure that was upon the Board to get the plant operating to its
capacity; the honest conviction possessed at that time of the ability
of the carbonizers to function; that it was obvious that only by con-
structing all the carbonizers could a considerable throughout be
obtained and the process be demonstrated commercially; and that the
disorganized industrial conditions of the time made deliveries most
extraordinarily slow.+ If then a unit construction had been adopted the
Board would have to look forward to similar delays in the construction
of the subsequent units if and when decided upon. Also the cost of
such delays would be far more than the amount involved in the capital
construction of a portion of the carbonizers, which was the real amount
of money risked when taking the decision. In addition the gas hand-
ling equipment (necessary to operate even one full scale retort) could
not have been tested adequately except with all retorts in operation.
For these weighty reasons it was decided to take boldly the risks
inevitable with such a decision, and to install the full carbonizing units
in order to provide the product that was being demanded so persistently.
The completion and successful operation of the plant, would require
a staff of from thirty-five to forty-five men. Inno way could the Board
see any suitable accommodation for the type of workmen desired.
While t is true that for some of the rougher work about the yard, etc.
only unskilled labour would be required, it was obvious that for the
successful handling of the carbonizers, dryers, mixers, and the bri-
quetting press, labour of a singularly intelligent character would be
needed. It was difficult to suppose that such men would be content
permanently with the very rough accommodation that apparently
is satisfactory for the workmen in the neighbouring properties. The
men on the staff of the Board would be of a superior type, and coming
from other places would naturally compare the accommodation to
which they had been accustomed with what they would be receiving
at the L. U. B. plant unless suitable provision were made. Under these
circumstances eight workmen’s cottages, four cottages of a slightly
larger size, two houses for manager, chemist, etc., and one boarding
house for the unmarried men were erected as part of a general housing
scheme. The provision of running water and simple sanitary conve-
*In connection with heat economy it must be remembered that the Board knew from the very inception
of the work that for heating the carbonizers no extravagant hopes need be entertained regarding any excess
of available gas. They realized from the beginning that any exteriorly heated retort for lignite would
«
barely provide enough lignite gas for carrying on the project.
tAs an example of these deliveries it is to be noted that the carbofrax slabs for the floor of the car-
bonizers were ordered in April 1920 with promised delivery in July of the same year. Though every
means was taken by the Board to hasten production, these slabs faithfully promised for July delivery were
not delivered until March 1921.
42 LIGNITE UTILIZATION BOARD
niences in these houses has apparently raised a considerable protest,
and the usual charges of extravagance, mismanagement, etc. have been
levelled in a most irresponsible manner. But it is perhaps not too
much to say that the success or failure of the plant might very easily
have been determined by the morale of the staff. It therefore be-
hooved the Board to make every reasonable provision for this need.
It is perhaps interesting to speculate also as to the charges that would
have been made against the Board had the plant proved a complete
success from its inception and had no provision whatever been made to
house the staff. Upon completion rentals were charged for all houses,
which have produced at the rate of 2.2% per annum of the capital
invested. The boarding house has of course been operated on business
lines usually found in industrial plants.
In recording the foregoing decisions, and some subsequent construc-
tional features of the plant, certain undoubted mistakes and errors
are reported, and no attempt is made to hide or gloss them over. The
responsibility for them is accepted fully. . In doing so, however, the
Board only ventures to point out one fact which, in the review of any
situation is so often overlooked — that the critical analysis of all the
factors of a problem that has worked itself to a conclusion by the
effluxion of time seems so extraordinarily simple that even the least
learned are surprised and pained that it was not obvious to those who
had the responsibility of attacking it before the recorded events took
place. Colloquial English has described such a situation by stating that
hindsight is easier than foresight.
These then were the preliminary decisions and points that had to
be weighed, discussed and decided within a comparatively short time.
It is now proposed to discuss the design and construction of the plant.
Attention cannot be called too emphatically to the fact that the
design of this plant was a matter of investigation and experimental
research. The problem before the Board’s engineers was not the
building of a factory to turn out a standard commercial product by
means of a well known and thoroughly developed process, but it was
rather to design an experimental plant that would be devoted to the
commercial demonstration of a chemical and heat controlled process
never achieved successfully elsewhere on a commercial scale. In this
way it was of necessity a new venture into an unexplored region. To
have attained a sweeping success on the first attempt would have been
just as unlikely as to have expected that the first commercial cement
plant or coke oven would have been perfect on the first full scale effort
in those respective industries. This point of view gives the perspective
or scale by which the subsequent work described in this chapter should
be viewed.
In Oct. 1919 was made the decision to undertake the main plant
construction. From that time onward the Board set itself to the
problem of the design of the plant buildings, the design of such appa-
ratus as was not standardized and commercial, and to the preparation
and awarding of contracts for all the main and auxiliary machinery.
*The methods utilized for buying were as follows :—
All the more important purchases were covered by special specific-
ations and contract forms. These were then advertised for tender ata
PERIOD OF DESIGN AND CONSTRUCTION OF BIENFAIT PLANT 43
certain date. The less important ones were covered by specifications
and contract forms and were mailed for tender to all the leading firms
dealing in that special product. Minor purchases were undertaken
by inviting prices by personal letters to those firms of which the Board
had any knowledge.
By far the largest single deal undertaken was that for the construc-
tion of the plant buildings and houses, and as this contract was typical
of the handling of all the more important contracts, the Board submits
in appendix No. 8 copy of the actual contract, the form of which was
issued to all those who tendered in response to the advertisements.
In addition in Fig. 5 will be found a digest of all the bids received, and
the reason for awarding the contract to Messrs. Smith Bros. & Wilson,
Limited, Regina, is quite apparent.
Some question might be raised at this point as to why such a special
type of contract was entered into for the construction of the plant
buildings and houses. In this connection it will be recalled that during
1920 it was impossible to get any contractor to work on any contract
on a-lump sum basis. Under such circumstances the alternative of
a cost plus contract became inevitable, but the Board viewed with
considerable apprehension such a type of contract due to the rapidly
advancing market both in material and labour. Under the pressure
of these conditions very close attention and thought were given to the
contract, and the form already referred to and illustrated in appendix
No. 8 was finally adopted.
The preparation of the specifications, form of tender for the supply
of boilers, steam engines, electric generators, conveyors, motors, etc.,
calls for no other special comment, and in appendix No. 40 will be
found a digest of the contracts entered into by the Board together
with time started and time finished. It is to be noted that large sums
were saved by purchasing second hand, parts of the power equipment
railway cars, briquette press, etc.
The contract for the construction of the buildings was signed on
April 30th 1920, and completion was expected before winter set in.
Owing to the extraordinary delays in the delivery of materials of all
kinds, it was not until the month of August, 1921, that the Board could
announce the completion of construction.
Appendix No. 22 prepared by I. F. Roche and R. A. Strong, gives in
detail a complete description of the plant by departments including gas
handling equipment, in order that the reader may be familiar with
the whole installation.
During the construction of the plant one of the serious difficulties
encountered was that of the interruption of the supply of water due
to the bad state of repair in which the pipeline was found to be. It
will be recalled that by the terms of the lease agreement the Manitoba
& Saskatchewan Coal Company were under obligation to furnish the
Board with water and that a minimum of one hundred thousand
gallons per day was guaranteed. Owing to the constant breaks in
the line the Manitoba & Saskatchewan Coal Company was never able
to live up to this guarantee, and as the period for preliminary operation
drew near the Board’s Resident Engineer, I. F. Roche, grew so anxious
44 LIGNITE UTILIZATION BOARD
about the matter of water supply that the Secretary was sent to the
West especially to look into that question and to arrange if possible
for the immediate amelioration of very unsatisfactory conditions. At
the resulting conference in Winnipeg on July 18th, 1921, the Manitoba
& Saskatchewan Coal Company took the attitude that the line was
beyond repair; expecially was this true for that portion below the brow
of the hill. They also stated that they absolutely refused to build a
new line on account of their own financial condition, unless the Lignite
Utilization Board undertook some share of the cost. In rebuttal to
the above the Lignite Utilization Board took the attitude that the
line was not beyond repair, but agreed as a matter of grace to absorb
their share of any annual charges pro rata that might be incurred by
the Manitoba & Saskatchewan Coal Company in major repairs, but
stated further that, until such time as the plant was operating, the
Board could not and would not entertain any question of assuming
capital charges that properly belonged to the Manitoba & Saskatche-
wan Coal Company. The Conference was adjourned till Tuesday,
the 19th, when after long discussion no agreement was reached, and
a further adjournment was made until Wednesday, July 20th, 1921.
At this Wednesday meeting after prolonged discussion the Board com-
promised the matter by agreeing to a joint capital expenditure (sub-
ject to certain safeguards as to ownership) to put in a new portion of
a cast iron pipeline below the hill, and to this the other parties agreed.
The Secretary left Winnipeg with specific verbal assurance from the
Manitoba & Saskatchewan Coal Company that the matter would be
put in hand at once on the basis agreed upon. One excuse after an-
other was however discovered by this Company for deferring action,
until finally the Chairman decided to call a meeting of the Board in
Winnipeg in October, 1921, and either get the signatures, or enter
suit. Asa result of these energetic measures the Manitoba & Saskat-
chewan Company signed the supplementary agreement, and construc-
tion work on the pipe line was started shortly after and completed in
November 1921. Asa result of this replacement of a new section of
the pipe line along the road allowance, the plant has never actually
been short of water, although the condition has been anything but
satisfactory. Indeed it is doubtful if the line could supply the contract
quantity regularly.
PERIOD OF PRELIMINARY OPERATION OF STANSFIELD CARBONIZER 45
SECTION V.
PERIOD OF PRELIMINARY OPERATION OF
STANSFIELD CARBONIZER
Sept. 1921 to Dec. 1921
CoNTENTS
Operation of dryers, conveyors, briquetting press, and mixers, gas handling
apparatus and carbonizers, Troubles and difficulties, Staff reports of September
and November changes, Consultation in Montreal between Lignite Utilization
Board and C. V. MclIntire.
By the beginning of September, 1921, the construction of the plant
was completed. The point toward which the Board’s energies for a
period of three years had been directed, was finally reached, and the
period of preliminary operation, the culmination of thirty-six months
of thought, planning and labour, was entered.
In putting any new plant into operation, and especially one demand-
ing a number of separate departments or processes functioning like
a chain of separate links, each dependent on the other, it is necessary
to initiate operation by departments ‘successively. During each of
these separate trials the minor defects and troubles that are inevitable
with new or untried machinery must be overcome, and the causes there-
for removed. Thus one by one the several departments are placed
gradually in smooth operating condition, and only when this point
has been reached, do the engineers feel justified in attempting to link
up the operation of one department or process with its neighbour, in
order that there shall be absolute continuity to the movement of the
commodity under production from the beginning to the end.
During the whole of the autumn of 1921, attempts to operate the
carbonizers were the outstanding features of the Board’s work, and as it
was this process that failed so signally to meet expected results, the
discussion on carbonizing will be deferred for a little in order to record
the operation of other parts of the plant linked with the carbonizing.
It will be recalled that the drying equipment consisted of 2-55’
cylindrical rotary dryers built by the C. O. Bartlett & Snow Co., Cle-
veland, Ohio. The first attempt to operate these was made on Aug 22,
1921, with a twofold object, namely: to smooth out the incipient trou-
bles which were sure to be encountered, and at the same time to furnish
dried lignite which could be fed to the carbonizers when the latter
were started. The normal method of operating these dryers was
to be by the waste heat from the battery of carbonizers, but as the
‘carbonizers were not running the auxiliary method of heating — by
coal fire — was of necessity utilized. Owing to the financial strin-
gency at that time it was not possible to purchase certain indicating
instruments and thermal controls which would have to be supplied
ultimately, if satisfactory continuous operation were to be attained.
The first run was a failure owing to the fact that the coal in the dryers
caught fire, and there was considerable trouble extinguishing it. This
was a difficulty that had been apprehended from the beginning by the
Board’s engineers, owing to the low ignition point of lignite as compared
with anthracite coal. Certain changes* were made in the direction
*For details see appendix No. 23 prepared by R, A. Strong.
46 LIGNITE UTILIZATION BOARD
of flow of heating gases, and further trials instituted which indicate
that these dryers can be used for drying lignite coal, without undue risk
of firing the coal which is being processed. It should be noted at this
point that owing to the Board’s preoccupation with carbonizer troubles
no long continuous runs have been made as_ yet on these dryers to
determine absolute efficiencies.
The power plant proved on the whole to be satisfactory. Certain
minor defects developed which were corrected, but since the commence-
ment of operation reasonable satisfaction with the powerhouse and power
equipment can be reported. The only troubles that have developed have
been those due to worn parts, for example: steam valves on the 100
KVA unit, piston rods on the same unit, and one or two of the valves
on the 400 KVA unit, such replacements being almost inevitable when
secondhand machinery is purchased in order to save money, and to
expedite delivery. No success has been attained as yet in operating
the two alternators in parallel. It was hoped to be able to do this,
but experience to date seems to indicate that the governor on the 400
KVA unit is not sufficiently delicate for the purpose. ‘This is, how-
ever, not a serious defect as the 400 KVA unit was designed to carry
the day load alone, and the 100 KVA unit the togsed operating night
loa
The sewage disposal plant was placed in operation immediately
upon its completion. In view of prairie conditions with lack of drain-
age, the system was designed to allow the effluent to run from the col-
lecting basin by gravity into a large number of farm tile drain pipes
in order that the soil might gradually absorb the water. So far this
has only been partially successful, and a considerable amount of
excess water finds its way to the surface of the prairie, to be carried
off by natural evaporation. The net result has been to make the land
to the west of the sewage disposal plant much wetter than before the
plant was located there.
The tests on conveyors, machine shop, briquette cooling, storage,
do not call for any special comment in this report; but incidental
reference can be found to them in various appendices.
It seems logical to record the operation of the balance of the plant —
during the autumn of 1921, under the heads of: carbonizers, gas hand-
ling equipment, and briquetting equipment.
As the carbonizers and the gas handling equipment are so intimately
connected it is difficult to separate completely the reports on these.
Carbonizers :
This section will record the tests, difficulties found, and the final
failure of the Board’s retorts in as simple language as possible, and
leave to the various appendices, the details that are at once of interest
and importance to those who will have to do with the designs of future
carbonizing and briquetting plants.
The Board now had six carbonizers ready for test — Nos. 1, 3, and
o facing the east side of the building and Nos. 2, 4, and 6, the west side.
In all respects these carbonizers were identical in design, and every
constructional detail embodied in them was the result of experience
PERIOD OF PRELIMINARY OPERATION OF STANSFIELD CARBONIZER 47
gained on the semi-commercial carbonizer erected and operated in
Ottawa during 1919. It is to be borne in mind also that owing to
severe financial straits in which the Board found themselves at this
time, it had not been possible to purchase the pyrometers and
similar auxiliary recording and measuring devices that should have
been on hand for these tests. During a greater part of the time when
Stansfield, Strong, and Roche were giving of their very best to the
solution of the operating troubles, they were badly handicapped owing
to the absence of these instruments.
A gentle slow heating fire was lit in carbonizer No. 5 on September
2nd 1921, in order to heat up the carbonizer, and on Sept. 8th,
the fuel oil fire was lit in the combustion chamber. At the start the
upper hopper was filled with crushed coke, and as mechanical operation
under these conditions was achieved, attempts were made to feed dry
coal through the apparatus. The net result was failure, and the details
are described in appendices Nos. 23 and 24 to which the reader is
referred. The basic reasons for the troubles were not at first realized
and to certain secondary causes were attributed the blame for the
results. Among these causes were the Isbell-Porter regulator (which
was the device supplied under the gas handling contract to regulate
pressure in the gas offtake of the carbonizer) the discharge mechanism
of the carbonizers themselves, the cooling devices, and the baffles.
These troubles are described in the appendices mentioned and itis only
necessary at this point to state that while the various troubles were
important and undoubtedly contributed to the result, the causes of final
failure were to be found in constructional and operating difficulties
that were practically inherent in the design as developed at that date.
This observation does not necessarily apply to similar designs that
have been developed since 1922.
In October, changes were made in the pressure regulator, in the dis-
charge mechanism, and in the cooling mechanism. The final payment
by the Government of the extra appropriation (see section on Finance)
enabled the Board to purchase pyrometers, fire fighting apparatus, etc.,
all of which were on hand for the next test. These various changes
were made following a report dated Sept. 12th, 1921, presented by
Edgar Stansfield and the resident staff, R. A. Strong and I. F. Roche.
All the recommendations of this report were put into effect, and on
November lst, the second trial operations were undertaken. Un-
fortunately the gas pressure regulator as revised was but little improved,
and a system of control by hand had to be inaugurated which proved
fairly satisfactory. In later tests this difficulty of gas pressure regula-
tion became so acute that the gas was bled into the atmosphere in order
to simplify the problem. While many difficulties were experienced
during this series of runs it was possible to determine more or less exactly
the cause of each. The main troubles can be listed under the heads,
gas control, floor and wall leakage, and the interruption of the flow of
lignite, caused by the presence of fine lignite dust in the coal as charged.
The presence of this dust made a considerable departure from the
screen analysis that was used in Ottawa. This last specific trouble,
which might be expected to be encountered when using any lignite
that had been stored for some time, led to the development of a new type
48 LIGNITE. UTILIZATION BoarRD
of baffle, somewhat superior to the old ones, and in that way it became
perhaps an advantage though quite thoroughly disguised. At the
close of the November runs Stansfield, Strong and Roche prepared a
report dated November 19th,* outlining the difficulties that had been
encountered, and giving suggestions for remedial action, together with
a further suggestion that after some more runs with the new baffles
(then in course of fabrication) a round table conference be held in
Montreal in order to determine future action. The report recom-
mended that for this conference an expert in retort design be engaged
to pass judgment on some of the suggestions and changes proposed.
The Board agreed with all of these points, and arranged that a con-
ference should take place in Montreal shortly before Christmas, 1921,
with the stipulation that the runs suggested in the report of November
19th should be held without fail in order to determine the efficacy of
the new baffles. These runs were held as agreed upon, and on the
whole the results were looked upon at the time as most encouraging.
Gas Handling Apparatus.
The gas handling apparatus described in detail elsewhere cannot
be said to have been given any thorough trial whatever during the
autumn of 1921 owing to troubles with the regulator — which was not
sufficiently sensitive for the requirements of the plant. The decision
was soon reached to obviate all the troubles incident to the use of the
whole gas handling apparatus, by bleeding the gas direct from the
retort to the atmosphere and thus concentrate all attention solely on
the carbonizers. Owing to this decision, it was impossible to make
any real test on the various parts of the whole gas handling system, —
and it was not until the test runs of the autumn of 1922 that the weak-
ness of the exhauster, and some other difficulties, were disclosed.
These will be mentioned again in greater detail.
Briqueiting.
The first tests on the briquetting machinery were made without
any load whatever merely to prove the mechanical operation of the
various machines and conveyors. It appeared from these tests that
the machinery was in good condition, the power adequate, and the
layout fair. It remained for later tests when carbonized lignite was
going through and being mixed with binder, to disclose those faults of
layout which the Board soon recognized.
The first briquetting operations were made in November of 1921,
using carbonized lignite from the trial runs previously described. The
briquettes made on this run were of very poor quality particularly in
regard to the large amount of binder found necessary to make a bri-
quette that would hold together. Subsequent work has shown, how-
ever, that this was due to causes inherent in the initiation of any new
process. The operators were not familiar with each machine; the
temperature controls were inacurate, etc. etc. The net result of the
runs up to that time might be summarized by saying that briquettes
were made, the machinery was adequate and no reason existed for
apprehending any permanent difficulty in producing briquettes when
*The general sense of this report of November 19th and the exact details of the runs of December,
1921, are covered in appendix No. 23.
PertoD OF PRELIMINARY OPERATION OF STANSFIELD CARBONIZER 49
conditions become stabilized and continuous. Subsequent runs with
the briquetting plant were much more illuminating and much more
successful, but in keeping with the desire of the Board to make a very
sharp distinction between the period closing in December 1921, and
that starting in January 1922, the Board will present the subsequent
briquetting results in chapter VIII of this report.
Acting upon the report submitted to the Board by Stansfield, Strong
and Roche, the Board called a meeting on December 21st, 1921 of
the following :—
R. A. Ross.
R. DeL. French.
I. F. Roche.
R. A. Strong.
C. V. McIntire, New York, Consulting Engineer.
Lesslie R. Thomson.
At this meeting the whole technical situation was canvassed very
thoroughly, each of the difficulties encountered (both operating and
structural) was discussed in minute detail, and the suggested remedies
for same were criticized freely. During the discussion there gradually
emerged a group of remedies and changes which seemed in the opinion
of all present, to combine practicability and a likelihood of achieving
commercial success. Briefly these changes were:
1. The reconstruction of the floors and carbonizing chambers of
three only of the carbonizers in order to test out the proposed
changes thoroughly before rebuilding the remaining three retorts.
To give an idea of relative suitability, three different floors systems
were decided upon:—
(a) Floor in flat tiles of carbofrax in two layers.
(b) Floor in hollow carbofrax tile.
(c) Floor in D-shaped fire clay.
2. The installation of very sensitive gas pressure controllers.
3. The installation of a 5,000 cu. ft. gas holder to act as a balance
wheel in the gas system.
Mr. McIntire was then requested to submit at the earliest moment
in writing his reports embodying the agreement reached for the better-
ment of conditions. These very important reports of Mr. McIntire
appear as appendix No. 24 and the Board attached then, and still
attaches great importance to them.
This brings to a close the history of the preliminary operation of the
Stansfield carbonizer, and Section VI will relate the story of the final
attempts to operate it.
50 LIGNITE UTILIZATION BoaRD
SECTION VI
PERIOD OF FINAL OPERATION OF STANSFIELD
CARBONIZER
Jan. 1922 to Jan. 1923
CONTENTS
General situation in January 1922, Reports of C. V. McIntire Reconstruction
necessary, Further financial grants needed, Negotiations with three supporting
Governments, Final action by Dominion Government, Reconstruction started
and completed, New trial runs, Exhauster troubles hold up work, Consultations
in West, Tentative policy adopted, Further operation, Conference of Jan. 8,
1923, Final decision to abandon, New control of Board.
No narrative of the work of the Lignite Utilization Board would be
thorough or lucid without pausing at this point to call attention to its
financial and technical situation, as existing in the beginning of 1922.
During November, 1921, it had been foreseen clearly that a crisis
was approaching in the finances of the Board. It then became apparent
that the amount of money on hand would not be sufficient to carry to
a conclusion the carbonizer runs then underway, and in addition to
meet the remaining payments on capital expenditure on plant con-
struction. This financial stringency was due to the capital expenditure
exceeding estimate (plant was constructed at period of maximum cost
and minimum labour efficiency) and also to the fact that as the car-
bonizers did not function as predicted, the plant could not be put in
operating condition.
The technical situation in regard to the carbonizers could be summed
up in a word or two’ The Board believed that their mechanical
operation had been proved (certain of the November and December
runs were smooth mechanically). The Board believed that the prin-
ciple had been proved (witness the comparatively good results attained
once or twice when controls had been accurately established and ob-
vious causes of trouble avoided), though the Board also believed that
many of the constructional details were wrong and faulty. It was,
therefore, felt that with improved methods in construction and control,
success ought reasonably to be anticipated. This belief was confirmed
generally by the painstaking reports already referred to, of C. V.
McIntire of New York, with the one exception of Mr. MclIntire’s
statement on capacity. If his prediction in this regard were true,
then the carbonizers were condemned completely. The great claim
for the Stansfield retorts was their apparent large capacity, because
the capacity actually attained in Ottawa per square foot of heating
surface had led to the belief that if the same unit capacity* were
realized in Bienfait, the economy of the retort was beyond dispute.
Consequently the Board believed that on this head Mr. McIntire was
taking perhaps a pessimistic view. Speaking broadly of the other
technical aspects of the plant the Board felt that everything was
reasonably sound, and that the future hinged practically completely
on the question of carbonizing.
*It is an interesting study as to why the unit capacity at Bienfait was so much lower than that attained
at Ottawa. See appendix No. 17.
PERIOD OF FINAL OPERATION OF STANSFIELD CARBONIZER 51
Under all these circumstances, it was decided that the original
objective could be attained most quickly by the reconstruction of three
of the carbonizers, and by the installation of certain gas handling
machinery. To effect these changes, and to make provision also for
working capital, (to purchase coal, binder, pay wages etc.) it was
estimated that a sum of $250,000 would be required. It was next
decided to bring the situation to the attention of the interested govern-
ments and ask for an appropriation in that amount — one-half of
which would be requested for immediate payment, and one-half
subsequently as the need might develop. It was expected also that the
charges for working capital might be reduced when the time came, by
the sale of briquettes made during the period of adjustment.
During November of 1921, however, the Dominion elections were
imminent and nothing could be done until the political atmosphere had
been cleared. On December 8th, 1921, the elections were held, but
it was not until January of 1922 that the new Dominion Government
was constituted and accessible for discussions of the lignite question.
Early in January 1922, the Board opened negotiations with Dr.
Camsell, Deputy Minister of Mines, and submitted the whole matter
to him informally with the request that he arrange an appointment
at the earliest date with the Minister, the Hon. Charles Stewart. This
was done and on January 19th., the Chairman and the Secretary met
the Hon. Mr. Bostock (acting minister) and Dr. Charles Camsell when
the whole matter was discussed thoroughly. Subsequently at the
request of the Hon. Mr. Stewart a report was submitted outlining briefly
the situation. This report, dated January 20th, 1922, appears as
appendix No. 9.
The recommendations touched upon the required reconstruction,
and asked for further financial assistance in the amount of $250,000 —
one half to be paid immediately for reconstruction and testing, and the
other half at a later date for working capital. Another interview was
held a little later at which the Board was told that while the Dominion
Government was not unsympathetic to further financial subvention
of the Board’s efforts, they did not feel justified in proceeding in the
matter on their own initiative. The Federal Government suggested
the Board should approach each of the two Provincial Governments
interested with a view of obtaining their consent to the payment of
their share (one quarter each) of the new amounts. ‘The Board decided
upon sending a representative to interview each of the two Western
Governments and their Legislatures then in session. Owing to the
fact that the Chairman had other committments which rendered it
impossible for him to go, the Secretary wassent. On February 6th 1922,
the Saskatchewan member, the Hon J. A. Sheppard, and the Secretary
interviewed the Premier, (The Hon. Wm. Martin) the Provincial Trea-
surer, (Hon. Charles Dunning), and the other members of the Provin-
cial Cabinet, and in the afternoon of February 6th 1922, the two
Board representatives addressed the members of the Saskatchewan
Legislature on the crisis then reached in the Board’s affairs. This
meeting took the nature of a thorough review of the work of the Board
followed by questions and answers regarding the difficulties encountered
and the criticisms that are inevitable in any public work. On the next
52 LIGNITE UTILIZATION BOARD
day, February 7th 1922 the Saskatchewan Government announced
their decision to undertake their share in the further amounts, with
the proviso that the Manitoba and the Dominion Governments did
likewise. The Secretary then proceeded to Winnipeg, and in com-
pany with J. M. Leamy, the Manitoba member, interviewed the Hon.
T. C. Norris, Premier, and the other members of the Manitoba Govern-
ment. Over a week was spent in Winnipeg during which time the
Secretary addressed a general meeting of the members of the Legis-
lature, and also separately the various constitutent groups into which
the Legislature was then broken up. On February 16th 1922, the
Manitoba Government finally consented to undertake their share of
this new grant, and the Secretary returned to Montreal. Negotiations
were then opened immediately with the Dominion Government. The
situation was recorded in a written report dated February 22, 1922,
a copy of which appears in Appendix No. 10, but resulting negotiations
proved to be very much longer than could have been reasonably ex-
pected. During all this time the actual financial affairs of the Board
were in an extremely perilous condition — the mechanicians and other
workmen on the Board’s staff at Bienfait becoming more and more
discouraged at the lack of employment.* The failure to announce any
decision made many of them apprehensive, and not a few resigned.
The same factors also affected the technical staff. It soon became a
matter of acute anxiety as to how the Board could meet even its small
payroll and salary list. Finally on March 3rd 1922, the Chairman
went to Ottawa determined to obtain a decision but the results were
quite inconclusive as regards money.
Never was the Board in a more critical state —its funds were ex-
hausted — the men were discouraged with delays — and the staff
anxious and disquieted.
The absolute immediate need of the Board was either cash or credit
to enable its payrolls to be met and thus keep together the technical
organization that had been gathered together slowly and which in the
intervening months had learned to depend on one another. The
Research Council of Canada, the godfather of the Lignite Utilization
Board, suggested at this very opportune moment to the Governments
on Friday, March 17th, that they would be willing to make a loan of
$20,000 in order to assist the Board on the condition that the Board
returned the money immediately its own funds were made available
by the Government. The Hon. Mr. Robb kindly gave his O. K. to
this suggestion, subject to the approval of the Hon. Mr. Stewart. At
the same time the Secretary had arranged finally with the Depart-
ment of Mines to give the Board an official letter stating that the
grant of $125,000.00 was being included in the main estimates. With
this letter he was able to negotiate a credit with the Bank of Montreal
in the sum of $25,000.00 and thus the very serious financial crisis of
the Board was tided over at least temporarily. By April Ist, 1922
all the outstanding liabilities of the Board had been liquidated with
the exception of one or two that needed adjusting.
As soon as this temporary financial settlement had been reached, the
Board placed its orders immediately for the material necessary to re-
ay *All che stair but the watchman and fireman had been laid off on Dec. 17th, 1921.
PERIOD OF FINAL OPERATION OF STANSFIELD CARBONIZER 53
construct three of the carbonizers according to the suggestions contained
in the reports and as suggested verbally by Mr. McIntire. Specifically
the hollow Carbofrax tile, and the special fire clay shapes with the
accompanying refractory cements, were the materials most urgently
desired. As soon as these orders were filed with the manufacturers,
the orders for the pressure regulators, meters, the gas holder, and extra
piping were prepared and given to their respective vendors.
The months of May to September 1922 were given up to the recon-
struction of the three carbonizers —one with the hollow carbofrax tile
floor — one with the double thickness of flat carbofrax slabs — and one
with special D-shaped fire clay slabs. Reconstruction of these car-
bonizers was completed on September 5th, and on September 6th, a
slow fire was started in No. 1 carbonizer to heat it slowly in preparation
for the first test run. For this run Edgar Stansfield had come down
from Edmonton to be present in a consulting capacity. By September
8th, the carbonizer was ready for its first run, and runs were made on
the 8th, 9th, and closing at about 5 P. M. on the 10th inst., due to heavy
gas leakage in the expansion joints with resulting bad effects on the
men. ‘These runs are referred to in the reports as “D-1’’; while
further trial runs were made during the latter part of the month under
the index Nos. of “‘D-2’’, “‘D-3’’, “D-4” and “D-5’’, the details of all
of these runs being covered in appendix No. 26.
As will be noted in previous appendices, very serious trouble had
arisen with the exhauster used to pull the gas from the carbonizer
chamber of the retorts. The original specifications laid down by the
Lignite Utilization Board and accepted by the contractor (The Amer-
ican Chemical & Sugar Machinery Company) were for a positive
exhauster to work at back pressure of 1-lb. which would correspond
to about 27” of water gauge. For some extraordinary reason the
American Chemical & Sugar Machinery Company in reissuing the
specifications to the manufacturers from whom they decided to pur-
chase the exhauster required only 7” of back pressure and in addition
consented to accept a blower. This then was the total back pressure
of which the blower was capable, and no thorough test had been pos-
sible until the time now under review, for in the runs of 1921 there
was no gas holder and very much less regulation on the line. Under
these circumstances the inability of the blower to fulfil the original
specifications was not disclosed until it was tried to operate with a
gas holder (designed for 6’’ water gauge pressure) in series in the
line. As it was useless to make further trial runs until this very
important weakness had been corrected, the carbonizers were shut
down until such time as the exhauster failure had been rectified. It
is to be noted also that as the runs ““D-1” to “D-5” inclusive were made
on carbonizer No. 1 —the carbonizer that had been rebuilt in hollow
carbofrax tile —- the inopportune failure of the exhauster made it
impossible to run comparative trials on carbonizers Nos. 3 & 5. The
complete responsibility for this very serious error was accepted by the
American Chemical & Sugar Machinery Company in a signed state-
ment, and at the same time they took résponsibility for righting the
matter at the earliest moment. Copy of this acceptance of respon-
sibility appears as appendix No. 11. Within a comparatively short
54 LIGNITE UTILIZATION BOARD
time of receipt of this written acceptance, and certainly before ship-
ment of the apparatus which they had promised to furnish could be
effected the American Chemical & Sugar Machinery Company went
into temporary liquidation. The Board immediately placed its claim
in the hands of the Company’s Receiver but to date of writing this
claim has not received any adjustment, owing to the apparent fact
that the assets of the Company will not even pay the expenses of
liquidating. As the delay would have proved extremely serious, the Board
placed orders on their own responsibility and on their own guarantees
for some of the material that should have been shipped by the American
Chemical & Sugar Machinery Company, in order to have the plant
operating at the earliest moment.
These various negotiations with the American Chemical & Sugar
Machinery Company were made by the Secretary during October,
1922, and while passing through New York, the Board’s Consulting
Engineer, Mr. C. V. McIntire, mentioned to him that Mr. O. P. Hood,
Chief Mechanical Engineer of the United States Bureau of Mines, had
just returned from an investigatory trip to Germany where he had
observed the latest practice in regard to the treatment of German
brown coals. Mr. McIntire suggested that it would be well worth
while to send a representative to Washington to interview Mr. Hood
in order to hear the latest developments along these lines. To this
suggestion the Board agreed, and on Nov. 8, 1922, Mr. McIntire and the
Secretary went to Washington to interview Mr. Hood. As the results
of this conference were of far-reaching consequence to the Board, the
journal of the visit is included in this report as appendix No. 41. It
is sufficient to note here that the Secretary returned to Montreal
very much impressed with the economy and simplicity of the Hood-
Odell oven, which had been developed within the previous few weeks
at Grand Forks, N. D., through the cooperation of the American
Bureau of Mines and the University of North Dakota — Dean Bab-
cock.
In order to enable the Chairman to get a more intimate knowledge
of the progress of affairs at Bienfait he instructed the Secretary to go
to the West on November 14th, see conditions at the plant, see Stans-
field, interview the two Premiers, and if possible effect a statement of
immediate policy for the future. On November 14th, therefore, the
Secretary left for the West and as a result of his visit, discussions,
interviews, etc., the Board recorded its decision and position as at
- December 8th in the following language.*
“By the completion of the 5th run practically perfect
operation of the carbonizer had been obtained. Lignite
was carbonized regularly and every interruption en-
countered could be accounted for clearly without any
doubt existing as to its cause. Except for exhauster
troubles, no outstanding difficulty was met with to prevent
the Board from carbonizing lignite continuously in this
apparatus, with, however, the possible exception of cracks,
which have developed in the floor material. It will be
*Extract from Progress Report dated Dec. 8th, 1922,
PERIOD OF FINAL OPERATION OF STANSFIELD CARBONIZER 55
recalled that in the trial runs of 1921 this was one of the
fundamental difficulties encountered, but the manufacturers
were insistent that a large improvement had been made in
the quality of their product. It is too soon yet to report
that the new carbofrax material is a failure. On the other
hand, we are disapointed and somewhat anxious that
cracks should be developing so soon. It is probable that
future cracking may be prevented when operating the
carbonizers continuously in the near future, and it is quite
possible that the cracks may be due to the very hard treat-
ment that necessarily was present when testing No. 1
retort. In other words, the constant heating and cooling
might easily be more than any fire brick construction could
withstand.”
“The difficulties encountered in operation were in the main
chargeable to the exhauster. When any attempt was
made to bring the combustion chamber up to high working
temperature the amount of gas produced became too great
for the exhauster to pull away. This condition was very
baffling until it was discovered that the apparatus furnished
to the Board was not in conformity with the specifications
for same originally approved by the Lignite Board. This
discrepancy could only be made evident upon operation —
and when so disclosed, steps were taken to hold the vendors
responsible. A written admission of this responsibility
together with a written agreement for replacement of
apparatus was thereupon obtained. Before the vendors
could complete this order, and effect shipment they went
into temporary liquidation, and the matter is being hand-
led now by the Board’s lawyers. In the meantime, in
order not to hold up the work, the Board has placed orders
for changes and revisions, assuming responsibility of
payment themselves. The new rotor for exhauster and
small steam turbine for driving the machine are now on
the way to Bienfait, and will be installed within a short
time.”’
“To sum up, the Board states that :—
(a) It does not regard the work done to date on No. 1
retort as having proved complete success. On the
other hand it is a long way from failure. A retort may
be looked at from three points of view: Does it oper-
ate ? Is the design as nearly correct as present knowl-
edge enables it to be? and thirdly —is the capacity
commercial ? It is self evident that failure from the
first mentioned point of view would spell complete
disaster for any retort. From this point of view it
can be stated that our No. 1 retort is a success. In
other words, it operated for a long period with no
serious interruptions to flow of coal, etc. The only
qualification of this general statement lies in the
possible break-down of the carbrofrax floor material
56 LicNiTE UTILizaATION Boarp
to which reference has been made already. This
achievement is a distinct advance gained over last
year’s work. From the point of view of design, we
feel that the amount of research work done by Mr.
Stansfield and others, since the construction of this
retort, would enable us to prepare today a superior
design, both as regards economy of heat and trans-
ference of same to lignite coal in passages. Under the
remaining head of capacity, the Board is disappointed
with the showing made to date, which is briefly that
the discharge is only about 50 to 60% of what it was
calculated to be. In addition auxiliary fuel was
necessary owing to the large amount of heat that is
diverted to the rotary dryers. The figures on capacity
are subject to some improvement, and perhaps to a
very marked improvement, when our exhauster
troubles are solved, and when three or more carboniz-
ers are in operation in parallel. Condensing the
Board’s opinion on the question of carbonizing, we
would say that we have not yet achieved success, but
we are a long way from failure. In other words,
enough success has been achieved to warrant us in
recommending the prosecution of the programme
hereinafter referred to.”
“(b) In the departments of raw lignite handling, drying,
briquette cooling, briquette storage, power plant,
water supply, housing and sewage disposal, the
Board would report that everything is in reasonable
condition though as yet it has been impossible to
undertake full duty trials.”
“(c) In the department of briquetting the Board is not at
all satisfied with the layout which it possesses at
Bienfait, but is of the opinion that successful bri-
quetting can be accomplished there, and that major:
revisions should only be undertaken when the fuller
knowledge that hard continuous operation will pro-
duce, becomes available.”
It is to be borne in mind in connection with the foregoing statement
that only one carbonizer had been tested, and that test had been held
under very discouraging circumstances as regards gas pressure control
due to the failure of the exhauster. In order that the Board could
reach what they regarded as a sound opinion as to the strict actualities
of the situation, they had had to make an endeavour to read between
the lines of the evidence available, to make certain suppositions, — to
weigh as carefully as might be the balance between the contrasting
inferences of observed phenoma, —to make what allowance they
could, not only for known troubles, but for unsuspected difficulties.
While in the West the Secretary confirmed also arrangements for
a round table conference with the Governments concerned. The
situation was that long delays had taken place in the work from the
time originally specified. Success seemed to be somewhat distant
PERIOD OF FINAL OPERATION OF STANSFIELD CARBONIZER 57
and there was in the minds of the three supporting Governments a not
unnatural feeling that they were not sufficiently in touch with the
venture in order to commend it vigorously to their respective legis-
lative bodies. Under these circumstances the Hon. Mr. Dunning sug-
gested a round table conference of all interested parties to be held
toward the end of December, 1922, and it was agreed to hold the con-
ference either in Winnipeg or in Ottawa at the earliest date.
While at the plant the Secretary met the two Western Members of
the Board and discussed thoroughly with them and Roche and
Strong a tentative policy for a period of 4 to 6 months. As the
attitude of the Board at that time in regard to policy cannot be set out
more clearly than by Thomson’s memos and minutes, it is worth while
to refer the reader at this point to his report of pros and cons of the
various alternatives that then presented themselves. This analysis
and digest appears as appendix No. 42. It is to be borne in mind that
the policy recommended was based on the experience available at the
time, as modified naturally enough by personal estimates of the degree
of amelioration that a proper exhauster and the operation of three
carbonizers in parallel would have made in the actual performance ot.
one carbonizer. From the close of the conference in Bienfait until the
end of December nothing transpired to change the opinion of the Board,
and early in January, a draft report was prepared in Montreal along
these lines with the idea of submitting the same to the round table
conference due to be held in Winnipeg on January 8th, 1923.
During the month of December 1922, a new rotor for the exhauster
was delivered, and on Jan. 2, 1923 the steam turbine for operating
same; and by Jan. 8th these new units were installed. In conformity
with the policy agreed upon at the November conference in Bienfait,
the Winnipeg conference was held on Jan. 8th, 1923, when it was
decided to close down the plant for a time. It is seen, therefore, that
no actual operation with the new exhauster rotor was ever held. Car-
bonizer runs using bleeders had been carried forward with vigor, and
it was arranged that either Roche or Strong would meet the Chairman
and Secretary in Winnipeg upon the occasion of the round table con-
ference with the idea of bringing a verbal report with them as to the
degree of success that had been attained on these new trials. These
then were the arrangements conceived in conformity with a policy
~upon which no little amount of thought had been given. It was a
policy that was only embarked upon with a determination to drive the
plant to its capacity in order to elicit those results of great importance
that such a trial alone could give, — and to disclose further weaknesses
and faults that became apparent only under periods of severe mechan-
ical strain.
On arriving in Winnipeg, the Chairman and Secretary met Roche,
and received verbally a most discouraging report of new weaknesses
and breakages that were formerly unsuspected, — of operating dif-
ficulties not before encountered, — of old difficulties largely increased,
—of grave risks in operating the gas system due to leakages at the
retorts, and of gallant effort on the part of the staff in battling against
very severe odds, dogged by a succession of reverses. The burden of
the report was that the carbonizers were not and could not be made
58 LIGNITE UTILIZATION BOARD
commercial. While it was possible that the carbonizers might even
yet be made to operate, the delicacy of their controls, their sensitivity
to small variations of external conditions, their want of elasticity in
accommodating themselves to changes in atmosphere, feeding con-
ditions, discharge conditions, etc., all combined to demonstrate to the
minds of the resident staff at Bienfait, that they did not and could
never discharge their expected and predicted functions. But as the
Board’s objective from the beginning had been to commercialize a
process, to demonstrate that this method of treating a low grade
lignite to produce a high grade domestic fuel could be made commercial,
then insofar the word “‘failure’’ was writ large and clear upon the
Board’s carbonizing endeavours.
The problem now before the Chairman was to decide almost in-
stantly as to where the balance of the probability in the future lay.
Had the resident staff at Bienfait taken a perhaps too gloomy view
owing to their gallant struggle alone against heavy odds ? Should the
tenor of the Board’s report to the round table conference be, — ‘Things
have gone wrong temporarily but our proposition still is sound,’ or
should the report be, — “These carbonizers are a failure from a com-
mercial point of view.’ If the latter were the proper course then the
work of years would have to be cast aside and the future faced clearly,
and full responsibility accepted. Then would the Board be accused
of capriciousness in deciding and announcing one policy in December,
and an entirely opposite policy in January. These and kindred prob-
lems had to be met squarely, decided soberly, and decision announced
with no timidity. But new experience and fresh evidence must, in
the minds of reasonable people, always constitute an imperative reason
why a previous decision should be reviewed and if necessary altered.
The record of the runs of December 27th to January 5th was unques-
tionably far more discouraging and the troubles encountered far more
grave than anything yet disclosed. Under these circumstances the
Chairman announced to the meeting that the Board would abandon
immediately any further development of their own carbonizers. For
the minutes of the salient feature of this meeting the reader is referred
to appendix No. 12.
The Board at the close of the meeting found itself in a peculiar
position. After all their hopes in their own carbonizers, and the con-
fident expectations of success in their performance, they had now to
state that they were’ a failure from a commercial point of view, nor
could they guarantee any other carbonizer that would operate success-
fully. The only light they would cast on a rather obscure and sombre
situation was that afforded by the reported performance of the Hood-
Odell oven during the preceding summer to which reference has al-
ready been made in this chapter in connection with the Secretary’s
visit to Washington. This report was confirmed by some interesting
tests made during the preceding few weeks by R. A. Strong on a model
made in Bienfait of the Hood-Odell oven. The Board took the atti-
tude that it was, as far as they could judge, the only apparent avenue of
escape from the present dilemma, and recommended that a large sample
shipment be sent from Bienfait to the oven at Grand Forks provided
arrangements could be made through the courtesy of the American
PERIOD OF FINAL OPERATION OF STANSFIELD CARBONIZER 59
Bureau and Dean Babcock. The Dominion Government’s technical
representatives also recommended the same course of action. After
considerable discussion the three participating Governments accepted
these unanimous recommendations and the Board was instructed to
undertake the arrangements.
It now remains to record a very striking change, which took place
at this meeting, in the relationship between the Lignite Utilization
Board and the three supporting Governments. To this date the
Board had pursued its work in an atmosphere singularly free from
outside influence. With one or two slight exceptions no attempt had
been made whatever, to influence, to change, to alter, to lead, or to
suggest any decision, policy or action of the L. U. B., and the Board
would be distinctly remiss if it failed to record at this point its very
heartfelt appreciation of the freedom which it had enjoyed from its
foundation to January 1923. This freedom of course was distinctly
envisaged and bargained for by the Chairman on accepting office, and
in preparing this report he wishes to avail himself of this chance of
recording his personal appreciation of the fairness and the loyalty with
which the three Governments up to January, 1923, observed the un-
derstanding. Now, however, a subtle change came over the situation.
Not unnaturally the Governments were very far from satisfied with the
results to date. Their dissatisfaction was justifiable from certain
points of view, or at any rate understandable. Whereas formerly the
decisions and policies of the Board had been under the Board’s own
control, from now onward the real control passes from the Board to a
committee whose membership while not defined was very real, and the
management of the enterprise reverts to “‘conferences”’ held periodically
of all the interested Governments with the Board.
The alteration in the status of the Board is recorded here as a plain
record of a change in the conduct of the enterprise. From January
1923, to the date of this report, the Board therefor has been sometimes
in a position of being asked specifically to execute work that in certain
cases did not commend itself to its judgment as being either essential
to the conduct of the work, or, though perhaps desirable, as likely to
yield results commensurate with the cost.
Immediately after the Winnipeg meeting, and in accordance with
the decisions reached, the Board closed down the plant to the utmost
degree, in fact to a point where there were but two or three men on the
payroll other than the salaried officers, and concentrated all their
attention on preparations for the test on the Hood-Odell oven at
Grand Forks.
This section closes the history of the final period of the Stansfield
carbonizer, and Section VII will discuss the Hood-Odell development.
60 LIGNITE UTILIZATION BOARD
SECTION VII
PERIOD OF HOOD-ODELL DEVELOPMENT
Jan. 1923 to Jan. 1924
ContTENTS
Arrangements for holding Grand Forks test, Runs at Grand Forks, Conference
of March 3rd, 1923, Preparation of design, Arrangement with American Bureau
of Mines, Construction of Oven, First run, Small troubles, Second run, Con-
sultation in Winnipeg of July 30th, 1923, of all parties to project, Action of
Province of Manitoba, Decision to operate oven to Dec. 31st, 1923, Decision to
have 150 tons of char briquetted at Hebron.
To obtain permission for the holding of the test on the Hood-Odell
oven at Grand Forks, negotiations were immediately opened with the
American Bureau of Mines and with the University of North Dakota,
Dean Babcock. One hundred tons of screened lignite were prepared for
shipment to Grand Forks, but owing to the lack of facilities for screening
this coal rapidly the operation took considerable time. The screened
sizes used were those recommended by Mr. W. W. Odell, of the Amer-
ican Bureau of Mines, who with Mr. Hood, Chief Mechanical Engineer,
and Dean Babcock, had developed the oven. The tests were held
at Grand Forks between February 7th and February 16th, 1923, in
the presence of the following representatives of the interested parties :—
bet! vt Ve ( J. M. Leamy,
Representing the Lignite Utilization Board ; I. F. Roche,
| R. Av wStrong:
Representing the Dominion Government: Ross Gilmore.
Representing the American Bureau: W. W. Odell. .
During the test the most extraordinary weather prevailed — bliz-
zards and storms, —and low temperatures were practically con-
tinuous. This factor would not have to be mentioned were it not that
the oven was outside of any shelter, exposed to the rigors of winter
conditions on the prairie.
The original intention when building this experimental oven had been
to confine the tests to summer operation only. This permitted the
main walls of the oven to be quite thin and made housing protection
unnecessary. Under these circumstances it is apparent that the
temperatures and operating conditions in the interior of the retort
would be affected to no small degree by the exterior conditions of wind
and temperature. In fact it proved to be impossible to run the whole
100 tons through the retort as, owing to adverse weather conditions,
the requisite temperatures inside the oven could not be maintained.
Sufficient work was done, however, to obtain general data sufficient
for the Board to present a Progress Report in the beginning of March.
In conformity then with the decision reached on January 8th, another
meeting was called, to be held in Winnipeg on March 3rd, in order
that the results of the tests in Grand Forks in February might be com-
municated to the three supporting Governments. At this meeting
the following were the official representatives:
PERIOD oF Hoop-OpELL OVEN DEVELOPMENT 61
Representing the Dominion Government:
Dr. Chas. Camsell,
B. F. Haanel.
Representing the Government of Saskatchewan:
Hon. Mr. Gardiner,
T. M. Molloy.
Representing the Government of Manitoba:
Hon. Mr. Bracken,
Hon. Mr. Craig,
Hon. Mr. Black,
Hon. Mr. Clubb,
Hon. Mr. Cameron,
Mr. D. L. McLean,
Provincial Deputy Minister of Public Works.
Representing the Lignite Utilization Board:
J. M. Leamy,
Lesslie R. Thomson,
I. F. Roche,
R. A. Strong.
The general tenor of the report of the Lignite Utilization Board can
be summed up as follows:
ies
ior:
The Hood-Odell retort as at present developed, is not absolutely
out of the experimental state, in other words it is not developed
to the point that the Board had hoped and apparently had been
led to believe.
The amount of success, however, certainly warrants the erection
at Bienfait of one or two of these retorts and that they should
be tried out over a period of at least six months.
In view of the shortness of time between the close of the exper-
iments at Grand Forks, and the present meeting, that actual
details of these retorts be left over for the decision of the Board’s
engineers.
That in addition to the amount of money authorized for the
construction and operation of the Hood-Odell retorts, the
Board also be authorized to proceed with the changes in the
present briquetting layout. In this connection the Board
would be glad to have any financial restrictions placed on the
expenditure of this money that the Governments may care to
lay down.
Camsell on behalf of the other technical representatives of the
Dominion Government, and Mr. Ross Gilmore presented a report which
could be summed up as follows:
(i)
(il)
The Department of Mines, Ottawa, does not believe that the
Hood-Odell retort is out of the experimental stage of develop-
ment. ,
Enough success was achieved, however, to warrant the con-
struction of one or two of these ovens at Bienfait.
62 LIGNITE UTILIZATION BoaRD
The whole situation was then thoroughly discussed and the difficulties
in the way of the two Western Governments in regard to further
financing were pointed out. On behalf of the Board the Secretary sub-
mitted a rough memorandum of the cost of building one of these retorts
and operating it for a period of six months — namely $40,000. He
also stated that the Board had on hand approximately $24,000 (This
turned out subsequently to be in the neighbourhood of $23,400).
After a thorough discussion of the whole question the following action
was agreed upon unanimously:
1. That the Lignite Utilization Board be authorized to utilize the
$24,000 at present standing to their credit, to construct and
operate a Hood-Odell Retort as a unit of the Government’s
plant at Bienfait.
2. Following this experimental work the Lignite Utilization Board
will report to a Conference of the Governments interested.
3. In order to make available if required the $125,000 voted by the
Dominion Government last year, the Governments interested
agree to sign a new agreement, so that this amount may be used
for further experimental work, provided however, that the
Lignite Board reports favorably on the Hood-Odell Carbonizer,
and the unanimous consent by the three Governments interested
is secured for any further expenditure.
On reference to the foregoing three decisions it will be noted that the
Board was instructed to build one Hood-Odell oven, and to operate the
same until the capital charges and operating charges had used up the
quoted sum of $24,000.
To implement this decision the Board immediately get in touch with
Mr. O. P. Hood, Chief Mechanical Engineer of the Bureau with the
idea of concluding arrangements for them to act as the Board’s Con-
sulting Engineers in this specific matter. This very courteous offer
had been made by the Bureau some little time previously, and the very
sincere thanks and deep appreciation of the Board are here recorded.
After the necessary arrangements were completed the Bureau was
requested to prepare immediately the necessary construction drawings
for a new oven so designed as to incorporate all those improvements,
suggested as a result of experience gained by operation, both of the
original runs at Grand Forks during the summer of 1922 and of the
special winter run of February 1923. In order that this might be
achieved Mr. Odell proceeded to Bienfait so that there might be a
complete pooling of the ideas of himself, Strong and Roche. On April
20th the Board received from the Bureau the detail and construction
drawings, and the necessary orders for new material were placed imme-
diately. Arrangements had also to be made with the Saskatchewan
Government for the loan of a roll crusher (through the courtesy of
R. N. Blackburn) used to prepare the raw lignite to conform to the
desirable screen analysis. The insurance companies had also to be
consulted, and a decision had to be made as to the best position on
which to erect the oven in order to utilize to the greatest degree possible
the existing coal handling and conveying machinery. Its final location
is shown on general plot plan, — Fig. No. 20. Construction work on
PERIOD OF HooD-ODELL OVEN DEVELOPMENT 63
the oven was started on May 2nd, and completed on June 21st. During
the time of construction, arrangements were made for the supply of
the requisite amount of raw lignite, and negotiations carried out for
the lowering of the insurance rates due to the reduction in hazard
occasioned by the fact that the bigger carbonizers and dryers were
shut down. During this time also paper studies were made in con-
nection with the improving of the briquetting building. Operations
on the oven were started at 9 a. m. on June 25th, as Mr. Odell had
arrived at Bienfait on June 23rd with the object of being present for
the first runs, of which the character will be recorded a little later in
this report. It is sufficient to state here that the first run was from
June 25th until July 3rd, when it was suspected that some of the cast
iron baffles had been burnt out. The oven was thereupon stopped,
emptied and cooled, new baffles were inserted and some minor changes
made. On July 13th, the oven was again started and was operated
continuously until August 21st.
Between these two dates, however, important decisions affecting
the future of the Board were made and it will be necessary to introduce
these now into the narrative and to defer for a short time the general
description of the work on the Hood-Odell oven.
It will be recalled that the Lignite Utilization Board was authorized
on March 3rd, 1922, to build one of these Hood-Odell ovens and
operate the same until such time as the sum of $24,000 would have
been expended. It became apparent early in July, 1923, that this
point would have been reached by the end of that month. The
Deputy Minister of Mines, Dr. Camsell, who had some time previously
been requested by the Province of Manitoba to act as their technical
representative in connection with this matter, was therefore notified
of this fact; and the suggestion was made to him that the agreed upon
meeting be held about the end of July in order that the supporting
Governments might determine their future policy. A meeting was
therefore called to be held in Winnipeg on July 30th, 1923. Among
those present were the following:
The Hon. John Bracken — Premier, Province of Manitoba.
The Hon. W. R. Clubb — Manitoba.
D. L. McLean — Deputy Minister of Pub. Wks. Man.
The Hon. Jas. G. Gardiner— Regina, Sask.
The Hon. Mr. Cross — Regina, Sask.
Dr. Chas. Camsell — Ottawa, Ont.
Ross Gilmore — Ottawa, Ont.
J. M. Leamy — Winnipeg, Man.
Lesslie R. Thomson — Montreal.
I. F. Roche — Bienfait, Sask.
To this meeting the Lignite Utilization Board presented an important
report dated July 27th, copy of which appears as appendix No. 13.
The Winnipeg Meeting divided itself roughly into two parts, a
morning session held in the office of the Premier, and an afternoon ses-
sion held in the Hon. Mr. Clubb’s office. At the morning session, a
general discussion took place on the recommendations of the Board,
64 LIGNITE UTILIZATION BOARD
on the report on the experiment by Mr. Gilmore, the Dominion Gov-
ernment’s representative at the test, and other related matters. It
will be noted that the Board’s recommendation at this meeting was
for a distinct forward movement in order to produce results, to save
the necessary overhead, and in other ways effect the truest economy in
the development of the general project.
The afternoon session was held in the office of the Hon. Mr. Clubb,
Minister of Public Works, with Mr. Clubb in the chair. Mr. Clubb
stated that there had been a meeting of the Manitoba Cabinet since
the morning session, and that Manitoba in view of the wording of their
vote could not consent to any expenditure of her share of the money
for further experimental work — it having been voted ostensibly for
commercializing the project. It was therefore beyond their power,
without further legislation, and under the circumstances, they had
decided to withdraw from the project entirely. On behalf of the
Board the Secretary ventured to submit two questions:—
(a) Inthe event of the remaining two partners meeting the present
experimental expenses, would Manitoba be willing to contribute
her share ($31,250) for working capital at a later date. To
this question Mr. Clubb replied that he could not commit him-
self, but it was possible.
(b) As all parties to the undertaking were now represented did
they desire to reach any decision respecting the plant. In
other words, did they wish to close it down, disband the staff,
or did they want the work carried on for a time.
This extraordinary and entirely unexpected decision of Manitoba
taken at a time when both the Board and Dominion Government had
submitted the most favourable technical reports that had been tabled
since the original carbonizer difficulties had occurred, made it necessary
for the various representatives to refer the whole question of policy
back to their respective Governments. This becomes a fitting example
of the inability of mixed committees to handle expeditiously a technical
problem of this kind. It is only fair, however, to state in this connec-
tion that the action of Manitoba was quite understandable, and their
situation must be visualized for a moment. The Provincial Govern-
ment had found themselves since their election in very straitened
financial circumstances. The strictest economy obviously was neces-
sary in every particular.
To the remaining two Governments, however, the decision seemed
so unfortunate that considerable hope was expressed that it might be
possible for Manitoba to reverse her decision upon further consideration.
To that end negotiations were undertaken between Ottawa, Regina and
Winnipeg, but it was not until the middle of September, 1922, that
Manitoba finally confirmed its decision to have no further participation
in the finances of the Lignite Utilization Board. In these negotiations
looking to a continuance of support of Manitoba the Lignite Utiliza-
tion Board had no part whatever.
The position of the Board must now be reviewed for a moment in
order to make the subsequent decisions clearer. As already_men-
PERIOD OF HooD-ODELL OVEN DEVELOPMENT 65
tioned the Board prepared and submitted an important report to the
meeting held in Winnipeg on July 30th. See appendix No. 13. This
report was not acted upon or accepted at the time. Manitoba threw a
virtual bombshell into the meeting by announcing its decision to with-
draw. Upon agreement with Dr. Camsell and the Hon. Mr. Gardiner,
the Board continued the operation of the Hood-Odell oven and the
conduct of minimum services at Bienfait. From July 30th until Sep-
tember 14th, the Governments were negotiating as to the possible con-
tinuance of Manitoba’s support, but on the latter date the Hon. Chas.
Stewart announced to the Board the final decision of Manitoba to
withdraw and it then became necessary for the two remaining part-
ners to determine their policy. On reference to the Board’s report of
July 27th, 1923, it will be noted that the recommendations made were
based on the assumption that the financial resources of the Board would
be in the heighbourhood of $125,000. The withdrawal of Manitoba
produced an entirely different situation because with only two part-
ners remaining, it became apparent that as at October Ist, 1923 the
Board’s liquid assets would only be about $75,000. This reduction
would be caused by the repayment to Manitoba of her unexpended
share ($31,250) and the absorption of operating charges and current
liabilities if the Board were to be closed down as at the latter date.
The question of further financial subvention by the two remaining
Governments was considered to be quite hopeless unless distinct and
favourable advances could be recorded in the fields of carbonizing and
briquetting. To that end the Hon. Chas. Stewart requested the Board
to submit a written recommendation for immediate policy, governed,
of course, by the financial limitations just mentioned. In other
words, the Board was requested on September 14th, to submit imme-
diately a written recommendation for the quickest way to get the
greatest results with the least expenditure. This request was made
verbally by the Hon. Mr. Stewart to the Chairman and the Secretary
when the latter were in Ottawa at his request. In the limited amount
of time available (about an hour and a half or two hours) the Board
considered the matter and submitted that afternoon such a memoran-
dum to the Hon. Mr. Stewart, and a copy of this dated September 14th
appears as appendix No. 14 of this report. This written recommenda-
tion was given to the two supporting Governments to consider and to
take such action upon as they might see fit. Again it will be noted that
the decisions on policy were not with the Board. When presenting this
report to the Government’s representatives, the Secretary again urged
them to feel quite free to suggest or make any changes in the method
of carrying out the whole project; in the composition of the Board; in
the disbanding of the Board if desired; to transfer the work to a Govern-
ment Department; or to take any such other action as might lead to
a quick realization of the common objective so ardently desired, namely
the production of briquettes in commercial quantities.
The interested reader might ask at this point why did the Board
submit to any interference of this kind when the whole matter could
have been settled by handing in their resignation. It will be recalled
that no member of the Board was under salary or emolument whatever.
The work was entirely honorary. It would therefore have been
very easy to have adopted an air of injured dignity and resign; and the
66 LIGNITE UTILIZATION BOARD
Board wishes at this point to record the fact that at the January
meeting by the Chairman, and at the March and July meetings by the
Secretary, both official and informal assurances were given that if they
(the Governments) desired the resignations of any or all of the Board,
the Board would only be too happy to submit the same. The Board
assured the Governments at each of these meetings and also the Hon.
Mr. Stewart and Dr. Camsell on September 14th that the work was
of far greater importance than the feelings or personalities of those
connected with it. The best evidence of the Board’s willingness and
anxiety to see this national work pushed to successful conclusion can
be found in their oft repeated assertion that if by resigning they could
advance the work, they would be glad to do so, or if by remaining at
their posts they could advance the work, this likewise they would be
glad to do. In other words, personalities or personal desires, connec-
tions, or feelings, were of infinitely less importance than the competent
prosecution of the work to a successful conclusion. If, therefore, the
Board had been mistaken in putting up with this situation it has been
due to an honest desire to discharge its plain and simple duty.
As above mentioned the memorandum of September 14th, 1923,
was left with the two Governments as represented by the Hon. Mr.
Stewart and Hon. Mr. Jas. Gardiner. Upon receipt of this memo. the
two supporting Governments sent out investigators of their own to
satisfy themselves as to the wisdom or otherwise of the recommend-
ations. On September 25th, they had received reports of their own
representatives and requested the attendance of the Lignite Utilization
Board. The Secretary was sent to Ottawa to interview them and on
that afternoon received their decision as follows:—
(a) The Lignite Board will continue the operation of the present
Hood-Odell oven until the end of December, 1923.
(b) The Lignite Board will ship at the earliest moment 150 tons of
lignite char from the Hood-Odell oven, of which 125 tons will
be of low volatile content and 25 tons of high volatile content.
The Lignite Board will also make arrangements with the au-
thorities at Hebron to run this char through their briquetting
plant with observers present representing the Board and the
Governments interested. The Board will also have the
resulting briquettes shipped to such points as directed by the
Governments.
(c) The Lignite Board will present an interim report on this
briquetting run at the earliest moment thereafter.
(d) The Lignite Board will prepare their final report for submission
about the end of December, which report will contain, of
course, the substance of the interim briquetting report.
It will be noted that this agrees with half of the recommendation
made by the Board itself on September 14th, but defers action on the
remaining half, substituting therefor a trial briquetting run at the
Hebron plant. The representatives of the Government had returned
with the assurance that the authorities at Hebron would be able to
make an immediate test, but unfortunately this information proved to
PERIOD OF Hoop-ODELL OVEN DEVELOPMENT 67
be erroneous, and it was not until December 8th that the test was
commenced, with the last run on December 20th. As a preliminary
measure the Board shipped a small amount of lignite char of different
kinds to Grand Forks, North Dakota, to be briquetted at the exper-
imental plant at the University, which run had been arranged through
the courtesy of Dean Babcock. This run was undertaken to de-
termine action on briquettes of such variables as, percentage of volatile
matter in char; use of lignitic pitch, etc.
The foregoing instructions on policy divide themselves into two parts
— those having to do with the Hood-Odell oven, and those having to
do with briquetting. The latter parts are dealt with in Section VIII,
and it only remains now to sketch the work on the Hood-Odell oven
until the close of December 1923.
During the operation of the oven after its first and second shut
downs, it became apparent that the life of the cast iron baffles was not
indefinite, and thought was given to the substitution of baffles of some
of the modern high temperature metals. It was found that if the whole
baffle were made as originally designed, in one or two of the high grade
metals, the cost would be prohibitive. Two solutions were suggested,
one with tips only in the high temperature metal, and the other with
a much lighter baffle. Owing to one of the manufacturers’ failure to
live up to promises it was only possible to test out two kinds of baffles,
and then for a period of one month only, whereas the life of a cast iron
baffle appears to be at least two months. The report on these matters
will be found in appendix No. 27, by R.A. Strong, which presents
a complete record of the Hood-Odell oven operation.
In accordance with the Government’s instructions the Hood-Odell
oven was shut down on Dec. 31st, 1923, and immediately afterwards,
the work of closing down the plant was undertaken. At date of
writing, the plant is completely shut down, and all workmen are dis-
charged with the exception of watchmen and fireman. The latter are
necessary to maintain fire protection services.
68 LIGNITE UTILIZATION BOARD
SECTION VIII
BRIQUETTING
CoNTENTS
Preliminary work of Mines Branch, Experimental Programme decided at third
meeting, Ottawa laboratory, Work in Ottawa 1919-20, Nukol and A. B. C.
Plant, Toronto, Design and Equipment of briquetting section of Bienfait plant,
Work in Bienfait, Desirability of revision to briquetting layout, Decision to
undertake tests at Hebron and Grand Forks, Results, and Report by R. A.
Strong, Outside work and correspondence, Consumers’ tests on briquettes.
Previous to the creation of the Lignite Utilization Board in 1918, the
Department of Mines, Ottawa, had done valuable work on the briquet-
ting of lignite chars. This work had been undertaken by Messrs.
Stansfield and Gilmore, using a small hand plunger press. The
briquettes produced were fabricated, therefore, one at a time, and thus
possessed only an experimental or scientific value. By 1919 enough
work had been done by the Department to bring forcibly to their
attention the capacity as binder agents, of hard wood tar pitches, coal
tar pitches, and sulphite liquor pitches.
As a result of the 3rd meeting of the Board, held Feb. 10,1919—See
Section 11 — the Ottawa staff had been launched upon an investigation
of both carbonizing and briquetting. It therefore became necessary to
decide at once on the type of press to use in the investigations.
Figure 7 referred to in the report appearing as appendix No. 16 of
Stansfield and French gives a digest of the briquetting plants in North
America in operation during the early part of 1919, and Plate No. 1, a
photo of their respective products. It is interesting to note that three
types of presses were used, roll presses, Rutledge presses, and Komarek
presses. See Plates 2 and 3. The last named is a modified roll press,
while the Rutledge is an American plunger press turning out briquettes
of from 10 to 16 ounces in weight. It will be observed that of 13
briquette plants listed (one of which had two installations), eight (8)
use the simple roll press producing small briquettes, and two use the
Komarek roll press producing small briquettes, and four use the
Rutledge plunger press, producing large briquettes. Thus 10 of the
total 13 plants were producing a small briquette. Of the others the
output of one of the Rutledge presses was destined practically entirely
for export to South America. It is not within the purview of this
section to discuss the relative merits of roll or plunger presses, but
suffice it to say that British, French and German practice has been in
the main to produce a large briquette of from 12 ounces to two or more
pounds in weight, with however a good proportion of the output of
the British plants destined for export, because the large briquettes are
usually superior in their shipping qualities.
As the objective of the Board was to prepare a fuel for Western
Canadian consumption and not for export, it was decided that a small
briquette either pillow shaped or ovoid of about 2 ounces would be
more suitable for the domestic furnaces in the West, which, without
exception, were designed to burn American Anthracite. Having
reached a decision upon this point, it was then concluded that a roll
BRIQUETTING 69
press would be cheaper in first cost, simpler in handling, and more
economical in maintenance. Therefore all research work was limited
to briquetting with a roll press, the acquisition of which has already
been touched upon. Appendix No. 37 lists the specific briquetting
objectives laid down for prosecution at Ottawa. For convenience these
objectives are here repeated.
i) Investigations into the relative suitability for briquetting of
lignites carbonized at different temperatures.
ii) Investigations to determine best fineness of material to be briquetted.
iii) Investigations into available binders as to amount, and propor-
tions for mixing.
iv) Investigations as to type of mixers, in other words would paddle
mixers or grinders prove the more effective.
v) Speed of operation of rolls.
vi) Secondary heat treatment of briquettes to render them smokeless.
vii) Briquette testing methods, etc.
Section III has mentioned the research laboratory set up in Ottawa,
of which the briquetting equipment was as follows:
(a) One roll crusher for pulverizing coal.
(b) One small ball mill.
(c) One small steam jacketed mixer.*
(d) One large horizontal paddle mixer.
(e) One drying plate.
(f) One rotary dryer.
(h) Such auxiliary equipment as scales, blower, meters, etc., etc.
(g) One Mashek type Y-1 three pocket roll press as illustrated on
Page 70 of the No. 4 Catalogue of the Mashek Engineering Co.,
New York. This press was selected owing to the fact that
though quite small it was a commercial unit. The results
obtained from its use would be applicable to commercial con-
ditions with large apparatus.
Fig. 3 illustrates the layout of all this equipment.
It remains now to discuss the results of the investigations above
listed. It will be simpler to discuss them under the headings (1) to
(vii) as above mentioned.
(i) Effect on Briquetting Results of Varying Carbonizing Temperatures.
The investigations into the relative suitability of lignite carbonized
at different temperatures was not prosecuted completely owing to
other factors in the situation. It is to be noted that, as the final
objective of the Board was to commercialize a fuel process, it was
essential that the greatest possible number of B. T. U’s. be left in the
lignite residue after carbonization. As a result of the researches on
Carbonization (See “‘Carbonization of Canadian Lignite’’ by Stansfield
— Journal Industrial and Engr. Chemistry. Jan. 1921) it developed
that carbonization at approximately 600° C., yielded a residue having
*This mixer is small and used commercially as a bread kneader being manufactured for bakers’ pur-
poses. It was not suitable for mixing large quantities of lignite, but with smail batches, made a most
satisfactory machine.
70 LIGNITE UTILIZATION BOARD
the highest B. T. U. content. Such a residue was therefore laid down
as the desired objective, and no peculiar difficulty was anticipated or
discovered in briquetting char carbonized at that temperature as dis-
tinct from char carbonized at other temperatures. In fact standard
briquettes had been made with residues carbonized at widely different
temperature. (In this connection see results of work at Hebron and
Grand Forks in December 1923, appendices 30 and 31.)
The following are the typical chemical analyses of the carbonized
residues as discharged at varying intervals from the semi-commercial
carbonizer in Ottawa. (for description of this, see Section III p. 33, and
appendix No. 18.)
2 min. 2-% min. 3 min. 4 min.
MOsturé ok, eae 0.0 0.0 0.0 0.0
ASHti oy. wate ete ee 19.6 19.6 AG? DA
Vole Viattera meno 18.6 17.8 ib RE 6.5
Hixed:@arbon—..: . ok 61.8 62.6 Ofna, 70.8
Ba AS ee dass? ao 11,140 11080 11180:-)) PbO
(ii) Fineness.
The investigations to determine the best conditions for briquetting
as judged by screen analyses, were not pushed to a final conclusion
owing to the fact that fineness is not an independent variable, but is
intimately connected with binder discussed under — 1il.
It has already been noted that a roll crusher for pulverizing lignite
had been installed in the Ottawa laboratory. In addition there was
a small coffee mill, which was found extremely useful, because as a
matter of repeated observation it was discovered that the coffee mill
gave a sized product that appeared to make an excellent briquette.
Consequently this product was adopted more or less as a standard, and
was often referred to as “‘coffee mill size’’.
The following is a screen analysis of some lignite analysized after
passing through the coffee mill, and carbonized at 600° C in the
cruciform retort.
Screen Size % Cumulative %
— 10+ 20 60.1 60.1
— 20-2 740 21.8 81.9
— 40+ 60 8.0 89.9
— 60+ 80 3.3 93.2
— 80+ 100 yaa 95.8
— 100 + loss 4.5 99.8
0.2 100.0
It will be noted that there are no lumps over an eighth of an inch in
size. Figure 8-a represents an average screen analysis of fourteen sam-
ples of carbonized residue. The curve shows that on the whole the
material is of fairly uniform consistency. The figures Nos. 9 and 10
give a tabulated digest of several screen analyses of a number of
briquetted coals as compared to the carbonized residue used by the
L. U. B., and of the effect of carbonization on the residue. The phrase
“rolls 1”’ and “‘rolls 2” refers to the roll crusher mentioned previously.
BRIQUETTING 71
(iii) Binder Investigations.
Bulletin No. 24 of the Bureau of Mines, Washington, and the previous
work of E. Stansfield and R. E. Gilmore of the Department of Mines,
Ottawa, constituted the starting point for the L. U. B.’s further resear-
ches in briquetting.
The following is a list of the binders investigated either specifically
by the Board, or indirectly by reference to the work by other experi-
menters :—
Single Binder: High, medium, or low melting point coal tar pitch, oil
pitch, asphalt, lignite pitch, and hardwood pitch: also sulphite liquor,
sulphite pitch, etc.
Treated binders: chlorinated or sulphonated tars, oxidized asphalts,
treated sulphite pitch (with alkali, or with salts to render insoluble),
ele;
Combinations of binders: Combinations of above alone or singly, or
in mixtures with the addition of coal tar, lignite tar, hardwood tar,
soft asphalts, flour, starch, clay, water glass, cement, straw, etc., with
or without the addition of water. Also tests with mixtures of coking
coals.
The limits of this report do not permit a discussion of various theories
of binder action, voids, moisture action, pressure, etc. It seems better
to state as succinctly as possible the general conclusion reached, and
give the final results so far as any tabulation can make them of service.
It must be remembered that success in briquetting depends ona knowl-
edge of a technique, and this knowledge is practically impossible to
tabulate, though general limits and operating data can be so recorded
with value to subsequent investigations.
At this point it might be well to note that the Board has in most
cases discarded the phrase “‘percent of binder’”’ owing to its ambiguity,—
and has substituted therefore, the phrase “‘mixing ratio”. The mixing
ratio is the number of parts by weight of binder added to 100 parts
By. weight of the carbonized residue. A briquette might be made up
of :—
100 parts by weight of carbonized residue.
8 parts by weight of coal tar pitch.
4 parts by weight of sulphite liquor solids.
The Board’s method of describing the above binder would be:—
M. R.
C. T. P.— 8
Ss. L.— 4. (Solids)
Figure 11 shows graphically the relation between the two systems
of recording amount of binder. Figures 12, 13, and 14 constitute a
tabulation of the greater part of the Board’s early work on briquetting.
These figures will give a general indication of the breadth of the
Board’s researches. In addition, certain briquetting experiments were
made on behalf of the Board by outside companies using carbonized
lignite supplied by the Board. The quality of their briquettes was
decidedly inferior to that obtained in Ottawa, and yielded no information
72 LIGNITE UTILIZATION BOARD
of great importance. After a con-
stant prosecution of the experiments,
and following a thorough exploration
of the markets, all but a few bind-
LIGNITE UTILIZATION Bo. or CANADA
Diagram Showing Relation of
Mixing Raho to Percent Binder.
ers were next dropped from further 4A
consideration. The bindersretained | A Since
for further study were coal tar Se
pitch, petroleum pitches, sulphite ATT
liquor pitches, starches, glutens and PAWADIBIRIES 3 kp
straw jelly. The last three were con- 444
sidered only as auxiliary binders to Att |
be used in conjunction with one ae eae |
or more of the standard pitches. ttt as
By a process of elimination, due BBGReBSLUBEG |
to prohibitive cost, petroleum pit- [| ty
70)
5 10 5
ches and sulphite pitches were next § ° a ae |
dropped, at least temporarily, until
their price at Bienfait could be BSR TR
reduced, and all attention was con-
centrated on coal tar pitch, or on combinations of C. T. P. with waste
flour screenings. The result was as follows:—
The minimum amount of coal tar pitch necessary when used alone
to make a first class commercial briquette as standardized by the
Board is M. R. 13. Within certain rather narrow limits, 1 part of
weed seed (Waste flour screenings) will replace 2 parts of C. T. P.
Thus a very good briquette was produced with
M. R.
Gn ieee: | 9
W. S. 2
It is interesting to know that carbonized lignite requires almost
double the quantity of binder necessary to produce a briquette phy-
sically comparable to one composed of Anthracite fines. This fact
alone vitiates many of the conclusions reached by certain writers on
the subject who venture to transfer results obtained from anthracite
briquetting into the field of lignite briquetting.
During this time also some attempts were made to incorporate as —
a part binder the pitches that might be obtained during the regular
processing of the lignite. This obvious suggestion of so utilizing these
pitches was strengthened markedly by the very high cost of C. T. P.
binder at Bienfait. Unfortunately the intimate emulsion formed by
the lignite tars with water, seemed to render the distillation of the pitch
so uncertain that the quality was never uniform. Whatever the cause,
the tests on such pitches gave very inconclusive results, and it was
decided to give up any hope of using these pitches in the immediate
future, with the expectation of attacking the problem later.*
*This was done at the Hebron and Grand Forks tests of Dec. 1923 through the courteous cooperation
of Dean Babcock. The matter is referred to later in this chapter and also in appendices 30 & 31.
BriQUETTING 73
As the result of these investigations, the Board decided to initiate
its work at Bienfait with a straight coal tar pitch briquette.—M. R. 13.
Moisture.... 4.3
The proximate analysis of the straight C. T. P. ee ees we
briquette made at Ottawa is ile OS id bavi ee OOS
(iv) Muxers. Bebe Liou
From time to time great claims have been made for the efficacy of
paddle mixers and of masticators (sometimes termed edge runners or
Chilean mills). Edge runners are installed in a number of plants, and
certain of the operators felt that they were indispensible. On the
other hand certain other operators reached the conclusion that intimate
mixing by paddle mixers was perfectly feasible. Owing to the large
cost of these various mixers, it was decided to defer experimenting with
them until the main plant was constructed. Examples of each were
installed at Bienfait.
v) Speed of Rolls.
The rolls of the Board’s small press are 2’—014” in diameter and were
operated at 10-11 R. P. M. making a tangential speed of about 70 feet
per minute. These speeds are capable of reasonable variation without
impairing the quality of the resulting briquettes.*
vi) Secondary Heat Treatment.
The question of secondary heat treatment is one mainly of cost
owing to the difficulty of constructing a furnace or a retort in commer-
cial sizes in which the process can be made continuous. The extra
handling and capital charges all add naturally to the cost of the finished
product, and the question arises, —is the resulting smokelessnes
worth the cost ? ;
_ So far laboratory methods go the Board has accomplished the car-
bonizing by special heat treatment, of several types of briquettes. One
of the most interesting examples is a test on a batch of standard coal
tar pitch briquettes, M. R. 13. The carbonization of this briquette
was made in a large metal retort, immersed in a bath of molten lead.
The temperature of the bath was about 500°C. About 514 pounds of
briquettes were used producing a hard briquette, possessing a smooth
surface somewhat difficult to distinguish from the untreated briquette.
In: this particular experiment the temperature was not quite high
enough, and the resulting product showed a slight trace of smoke, but
it was very very slight. The treatment of this briquette resulted in a
10% loss in weight.
After being allowed to stand for two days, the treated briquettes
were analyzed with the following result :—
%
MOISTOret. SA. vie eee ee 2.9
Volatile Matter: 22a 8.3
HaxeciGarbonsak sea eee (pA
A Shara chs ch ino! ect eee ee ee 16.5
Bw lous per. lb:.tewstt: tease. 11760
*It is interesting to note that the relation between diameter of rolls, size of pocket and tangential
mpect vary very markedly depending on the material that is being briquetted. For example, conditions
that would be correct for coal briquetting are quite inapplicable and unsuitable for the briquetting of
flue dust. A considerable field of research is here open.
74 LIGNITE UTILizATION Board
After considerable time had been spent in weighing the advantages,
cost, etc., of smokeless briquettes, it was decided to postpone further
investigations until such time as the main plant would be in operation,
and a commercial briquette was actually on the market.
vil) Briquette Testing.
The various tables on briquetting previously mentioned in this sec-
tion have summarized the results of many of the tests conducted.
There were however, certain other tests which may be of interest.
In order to ascertain the probable behaviour of briquettes in the
extremely cold western weather, certain typical examples were sub-
jected to freezing and thawing tests. These were conducted in the
sharp freezer of the Wm. Davies Co., Limited, Montreal, through the
courtesy of the officials of that company. ‘Tests were run as follows:
The briquettes were first immersed for 24 hours in water and then
placed in the sharp freezer for 24 hours. The temperature of this was
from 0°F to minus 12°F. After 24 hours in the freezer the briquettes
were removed and thawed out for 24 hoursin water. This alternating
treatment was continued for four complete cycles, and a close examin-
ation was made of the briquettes. On the briquettes that the Board
classified as good and water proof, no signs of deterioration were
visible whatever. It will be admitted that this test is a very much
more severe one than any natural freezing or thawing could be.
The foregoing is a brief summary of the briquetting results achieved
in the Ottawa laboratory.
———____— §—_—__—_—_
During the conduct of the above mentioned researches in Ottawa
during 1919-20, the Montreal office was busy preparing the designs of
the main plant. Necessary approximate sizes of apparatus, ap-
proximate dimensions, and the general space requirements for the
dryer building, the carbonizer building, power house, and in fact for
all buildings, with the exception of the briquette building, were obtained
and were available for use during the design of the plant. But inform-
ation necessary to design the briquette building intelligently and econ-
omically was practically impossible to obtain so quickly. It therefore
became necessary to make a very rough approximation of the space
required for briquette machinery etc., in order to allow the contract to
be prepared and awarded in the spring of 1920, and then ata later date
the detailed layout of briquetting machinery could be made. In other
words to save a delay of perhaps 12 months, it became necessary to
fit briquetting machinery into an existing building design, rather than
to enclose a machinery layout with building walls. This is one of the
reasons for the subsequent difficulties with layouts, because the resulting
crowded condition of the machines gave rise to some bad drives and
sequences.
In the report of Stansfield and French mention is made of the courteous
co-operation offered by the General Briquetting Co., New York. One
of the plants designed by this company was that of the Nukol Fuel Co.,
Toronto. After correspondence, permission was kindly given for a
comprehensive inspection and test of this plant — provided no inter-
BRIQUETTING 75
ruptions were made to the throughout or general operation. This
permission was accepted, and in April 19, 1920, R. A. Strong and
Hammond Johnson, members of the Board’s engineering staff, reported
in Toronto, and spent over a week at this plant.
Upon the conclusion of the test at the Nukol Plant, a brief inspection
of the Anthracite Briquette Co’s plant, Toronto, was made. No tests
were possible at the plant, and the information recorded was gained
by the inspection only.
The conclusions of the Nukol plant test may be summarized as
follows: |
(i) Washing of this particular coal at point of origin might easily
pay for itself by reduction of ash content — a worse then use-
less ingredient.
(ii) Alleged efficiency of edge runner not proven conclusively.
(iii) A probable relation exists between briquetting temperature
and density of briquette.
The full details of this test and inspection are covered by a report of
Strong and Johnson appearing as appendix No. 28.
As a result of the accumulated information then in hand in regard to
briquetting, it became necessary :—
(a) To decide on number and sequence of briquetting units.
(b) To design binder feed equipment and layout.
(c) To prepare the layout of machinery.
After considerable thought, it was decided that the briquetting
machinery would consist of the units below mentioned. The inclusion
of them all in one plant was not due to any strong conviction as to the
outstanding merit of any one of them, but rather the feeling that the
Board would be negligent if it omitted to give full scale tests of each
of the types in view of the large claims made by various operators. It
was felt also that if any one unit proved a failure or too expensive in
operation, it would be a comparatively simple and not a costly change
to by-pass it in the process.
The binder system was laid out as described below, and reports on
it appear later in this section.
The layout of the various units now definitely accepted for inclusion
in the process, brought in its train intricate problems, to aid in the
solution of which the Board retained as Consulting Engineers, the
General Briquetting Co., New York, the leading authorities on this
continent. It was arranged with this company to second to the
service of the Board, for as long as necessary, one of their briquetting
engineers selected by themselves especially for this work. This was
done and in due course a layout was prepared and submitted. Upon
close examination by the staff, several improvements in it were sug-
gested, and it was decided to have the Board’s staff prepare an alter-
native revision. This revision was completed in the Spring of 1921,
and the two layouts were very carefully compared from every point
of view. It was then decided by all parties to adopt the revised
layout, which appears in figures Nos. 18 and 19,
76 LIGNITE UTILIZATION BOARD
The following is a detailed description of the Bienfait briquetting
plant and binder system, as originally erected in 1921. — Subsequent
changes are referred to in appendices.
The mixing and briquetting equipment consisted of:—
2— Type M-1 ten ton horizontal steam jacketed mixers, man-
ufactured by the Mashek Engineering Company, New York.
One of these is used as a tempering mixer.
1 — Vertical fluxer 42 inches by 8 feet, manufactured by the Traylor
Engineering Company.
1 — 15 ton 8 foot diameter masticator manufactured for the General
Briquetting Company, New York.
1 — 15 ton Belgian roll press — rolls 261% inches in diameter by
111% inches face containing 6 rows of ovoid moulds with 36
moulds to one circumference. The weight of the briquette
produced is approximately 2 ounces. The press was man-
ufactured by the Gilley Machinery Company, Gilley, Belgium.
The routing of the material may be traced by referring to plan view
of briquette building shown in Fig. 19, and to section DD, appearing
j Litto d RS
The carbonized residue is taken from the base of a large steel pyramid-
al bottom bin, and passes directly through a short conveyor (No. 20)
to the first horizontal paddle mixer (No. 21) into which the coal tar
pitch binder is run. The control of the binder will be described in a
succeeding paragraph.
Passing through mixer No. 21, the mixture is fed to a vertical fluxer
(No. 22) which discharges directly into the edge runner (No. 23)
(chilean mill).. From the edge runner (No. 23) it passes through a
short conveyor (No. 24) to the tempering mixer (No. 25), whichis steam
jacketed and capable of controlling the temperature of the whole mass.
From there it is hoisted by a vertical conveyor (No. 26) and discharged
into the main press (No. 27). After being formed the briquettes pass
over a shaking screen (No. 28) which removes all fines and broken
parts, and returns them by means of a special inclined chute to the
tempering mixers (No. 25). The good briquettes are passed over the
screen (No. 28) and slide down a series of inclined chutes to a cooling
conveyor where they are cooled under air draft. This long conveyor
(No. 29) operates through an underground tunnel connecting the
briquetting building with the storage bin. This tunnel is cooled by
forced draft operated by a 714 H. P. motor connected to a fan discharg-
ing 20,000 cubic feet of air per minute, and which was arranged so
that every briquette will be on the belt for at least 4 minutes subject to
high velocity air cooling. The two mixers and the fluxer are thoroughly
provided with ventilating ducts, shown clearly in section DD, which
permit ample ventilation for excess steam, or any gas, etc.
The binder is delivered to the plant in tank cars which are emptied
by gravity into an underground concrete storage reservoir. The
pitch used has a melting point of 140°F. usually determined by
the cube method. The storage tank possesses steam coils at its
bottom in order to keep pitch fluid, The binder is pumped to a small
BRIQUETTING ri §
overhead control tank, made from sec-
tion of 15’’ black C. I pipe — 6’-0”
high. This tank is fed by a 2’ feed
pipe, opening into the tank at a point
about 24” from the bottom. The dis-
charge pipe is also 2”’ in diameter, and
leads from the bottom of the tank.
In order that the control of quantity
of binder should be as simple as possible
it was decided to limit it to one valve,
and in order to insure a constant dis-
charge, arrangements were made so
2 Intake that that the pitch would be kept at a
Slam jackeled constant temperature (giving constant
viscosity) and operate at a constant
head (giving constant pressure). Uni-
form temperature was to be obtained
by having all binder piping steam
jacketed. A uniform head is obtained
ss by providing the control tank witha
weer bell mouthed 3” overflow pipe, the
dATP AES lip of which is 48’’ above the bottom.
FIGURE 63 By this means a head of 48” will
always be operating in the discharge
pipe. The details are shown in Figure 63.
The control valve in the discharge pipe was to be calibrated empiri-
cally after plant had been in actual operation.
The foregoing constitutes a description of the briquetting plant as
designed, and the construction of it was completed in August 1921.
a Qe
The trial runs of this equipment during 1921 and 1922 are recorded
by R. A. Strong in appendix No. 23.
As disclosed therein the layout of the machinery is faulty, and parts
of the binder circulatory system unsatisfactory.
The faults and difficulties may be recorded as follows:
Summary of mechanical disadvantages of present briquetting
layout, from point of view of briquetting lignite char.
(1) The arrangements for feeding char to lst mixer are not capable
of sufficiently accurate adjustment.
(2) There are not sufficient means for controlling temperature of
char before coming in contact with the binder.
(3) There is no provision for crushing the char before mixing with
the binder. This point has been due to recent decision to omit
edge runner.
(4) Thefvertical fluxer has been proved to be not suited for
mixing lignite char,
78 LIGNITE UTILIZATION BOARD
(5) The edge runner has proven not entirely satisfactory for such
soft materials as lignite char, and should be omitted in subse-
quent development.
(6) Any system involving a lifting of the mix from the last mixer
to the press is not entirely satisfactory, and should be avoided.
(7) The shaker screen with drop to cooling table, constitutes too
severe a method of handling fresh briquettes.
(8) Gravity flow of pitch to mixer is not satisfactory, as quantity
is not subject to accurate control.
As a result of these apparent weaknesses, the Board recommended
in March 1923 to the supporting governments, that the briquetting
layouts be amended, that certain changes be effected in the binder
system, and that-in general, the briquetting plant be placed at.the
earliest date in an operating condition, in order that when the car-
bonizer difficulties had been solved* the whole plant would be ready
to operate without further delay and thus eliminate carrying charges
on a shut down plant. But by the terms of the understanding reached
at Winnipeg March 3, 1923, the Board was precluded specifically from
making any expenditures on, or alterations to an equipment with
the layout of which they were by then quite dissatisfied. This recom-
mendation regarding revisions to briquetting layout was urged again
on the governments at the July 30 meeting in Winnipeg,! and again in
the memo of September 14,2 deposited in Ottawa. In each case how-
ever a negative decision was given by the governments.
Acting on the express instructions of the governments the Board next
made arrangements with Dean Babcock, University of North Dakota,
for two briquetting tests on carbonized lignite produced at the Bienfait
plant by means of the Hood-Odell oven. It was felt by the govern-
ments that it would be desirable to test the applicability to briquetting
of the char from the new oven. It was therefore arranged by the
Board with Dean Babcock to undertake at the earliest date two tests:—
: f 125 tons of standard vol. char.
i) At Hebron plant N. D. \ "95 “hich vol Char.
Small one ton tests to explore
variables such as low volatile
char, use of lignite pitch produced
| by distilling tar from Hood
Odell oven.
The layout of the plant at Hebron? is covered by a special report
of R. A. Strong which appears as appendix No. 29, and the result of
the tests at Hebron are covered by another report of Strong’s appearing
as appendix No. 30. These tests may be summarized as follows :
ii) At Grand Forks N. D.
*As then seemed imminent and as subsequent events proved to be true.
1 See appendix No. 13.
2 See appendix No. 14.
3 Further information on the Hebron plant and its very important work can be found in Bulletin No.
221 of the United States Bureau of Mines entitled ‘‘Production and Briquetting of Carbonized Lignite”’ by
E. J. Babcock and W, W. Odell.
BRIQUETTING 79
OBJECTIVES. RESULTS.
(a) To determine whether the (a) No serious mechanical dif-
char as produced from the ficulties were encountered
vertical shaft oven erected at during the test and a satis-
the Bienfait plant would pre- factory grade of briquette
sent any peculiar difficulty in was produ ed.
briquetting.
(b) To determine whether a satis- (b) No mechanical difficulties
factory briquette could be were encountered in prod-
produced from a char con- ucing a high volatile bri-
taining a somewhat higher quette although these bri-
volatile content than that quettes did not appear to be
ordinarily produced. as good physically as those
with a low volatile content.
(c) To determine whether lignite (c) Lignite pitch was incorporat-
pitch as made from the lignite ed with the coal tar pitchina
tar recovered in the operation ratio of 20% of lignite pitch,
of the Hood-Odell oven at and the briquettes produced
Bienfait could be utilized as were equally as good as
a binder. those made with coal _tar
pitch alone. This is an im-
portant result.
(d) To obtain all information (d) Accurate records were kept
possible in regard to plant of all possible variables in
operation. the plant such as speeds and
temperatures.
(e) Make all necessary tests to (e) The test on briquettes in-
determine the quality of the cluded, — analysis of raw
briquettes produced. material, — analysis of final
product, — drop tests, —
and stove tests. In connec-
tion with this last mentioned
test, comparison is made
between the lignite briquet-
tes and Anthracite coal on a
basis of degrees hours. This
somewhat new but. import-
ant method of comparing
fuels affords very interesting
results.
The record of the tests at Grand Forks is covered by a special
report prepared by R. A. Strong — appearing as appendix No. 31,
and may be summarized as follows:
(1) A two ounce briquette is superior to a 4 ounce briquette as a
greater pressure is obtainable with the smaller size. (This
applies to the product of roll presses only).
80) Licnite UritizaTioN Boarp
(2) Two sets of rolls are preferable in crushing as a more uniforni
screen analysis is obtainable and this results in a better bri-
muette;
(3) Binder requirements are dependent on volatile content of char.
The higher the volatile the more binder required.
(4) High volatile briquettes are not as strong in the fire as those
made from low volatile char.
(5) Lignite pitch can be mixed with coal tar pitch and thus utilized
as a binder.
(6) Briquettes made with lignite pitch alone are not as strong as
those made with the mixture of coal tar pitch and lignite pitch.
(7) The use of lignite pitch tends to eliminate dust in handhng
briquettes also decreases tendency for the mix to stick in the
press rolls.
(8) The char as produced in the vertical retort installed at Bienfait
does not offer any new problems in briquetting.
~ The report of the Hebron and Grand Forks tests must not be closed
without recording an especial word of appreciation of Dean Bab-
cock’s unfailing courtesy and co-operation, for which the Board is
more than grateful.
In any work of this character, it is inevitable that a great many
attempts would be made to persuade a semi-public commission to adopt
this or that “‘process’’. Some of the processes or methods thus suggest-
ed are good and extremely useful, — others less so. The experience
of the Lignite Board does not provide any exception to the situation
and no record of the briquetting work would be complete without
stating that the following briquetting processes have been investig-
ated, either slightly (due to small amount of time at disposal, or to
reluctance of owners to place their cards on the table,) or more com-
pletely in other cases. Some of the ideas and methods presented have
great merit.
General Briquetting Co. New York.
Sheehan Process. Seattle, Wash.
Fournier Process. France.
Treadwell Process. New York.
Laing Process. New York, Winnipeg, and other
cities. Called to our attention
by a number of different repre-
sentatives at various times.
Oliver Process. Edmonton.
In connection with all these matters, the Board would observe that
it has already developed successfully a technique of carbonized lignite
briquetting, but wishes to record its appreciation of the co-operation
so often extended by other investigators above noted. The General
Briquetting Co., (Mr. A. L. Stillman, Vice President) New York should
be noted especially. During the time of the Ottawa work, Mr. Stillman
and his company made a number of extensive briquetting investigations
on carbonized lignite, which proved of real value to the Board.
BRIQUETTING . 81
It has already been noted that 150 tons of lignite briquettes were
made at the Hebron. plant of the University of N. Dakota. Of these
briquettes, one carload lot was forwarded to each of the supporting
governments in order that they might be tested by a large number of
individual non-technical consumers, whose opinion of their marketable
qualities would be of great value. 100 lb. samples were distributed
by the Saskatchewan government immediately upon receipt of the car,
to members of the government, members of the legislature, members
of the press, and other leading citizens. At date of writing this report
it has only been possible to obtain opinions from a few recipients of
these samples, but through the courtesy of Mr. T. M. Molloy, the
Board has received copies of their written views. These make intensely
interesting reading, and may with fairness be digested as follows:
For use in cook stoves and open All unanimously of opinion that
grates. : carbonized lignite briquettes are
a wonderful fuel.
For use in furnaces. Great majority are enthusiastic
but some find excess of ash or
clinker, but all admit sample was
not large enough for a thorough
test.”
*The scientifically managed stove tests referred to by R. A. Strong in appendices 30 and 31 are however
of even greater value in reaching an estimate of the ultimate suitability of these briquettes for domestic
consumption.
82 LicNITE UTILIZATION Boarb
SECTION IX
FINANCE
CoNTENTS
Original estimate of cost, Revised estimate, Special grant of 1920, Special
grant of 1921, Special grant of 1922, Analysis of total expenditure, Analysis
of Plant Costs, Methods of bookkeeping, Ledger aceounts, Methods of keeping
Auditor-General in touch, Commercial feasibility of whole project.
It is proposed in this Section to treat the following subjects:
(a) The relation of the ultimate total expenditure to the original
estimates, and reasons for the large increase thereof.
(b) An analysis of the total expenditure of the Board.
(c) An analysis of the cost of the plant.
(d) Methods of bookkeeping, accounting, and reporting to Govern-
ments.
(e) Estimate of commercial feasibility of the whole project from
financial point of view.
DISCUSSION ON (a) — The relation of the ultimate total expenditure
to the original estimates, and reasons for the large increase thereof.
Upon starting operations the Board had financial resources in the
sum of $400,000 half of which was supplied by the Dominion and one-
quarter by each of the two Provincial Governments of Manitoba and
Saskatchewan. From 1919 onward additional grants have been made:—
YEAR AMOUNT
Original:prant. 2s, See ee 1918 $400,000
$400,000
Special additional appropriation.......... 1920 $280,000
Special additional appropriation (net)..... 1921 137,500 (approx.)
Special additional appropriation (net)..... 1922 218,800 (approx.)
$636,300
Grand Totalaica.se $1,036,300
In all these payments, with the exception of the last named, the three
supporting Governments maintained the original ratio of distribution
— one half by the Dominion and one quarter each by the two Provinces.
It now remains to enquire why this startling increase — an additional
sum of nearly 1-14 times the original amount ? Was it a case of bad
estimating or inefficient administration? These questions can be
answered completely by a detailed consideration of the additional
estimates; and for convenience they will be named and referred to by
the year in which they were granted.
FINANCE 83
The 1920 and the 1921 additional estimates were made necessary
by the following causes:—
i) The original estimate of $400,000 was made by the Fuel Commit-
tee of the Research Council (see Fig. No 15) in 1917. Board
was founded in 1918. Fundamental research delayed Board
about a year. Thus construction was prosecuted from 1920-
1921 at the very peak of material and labour prices, a time un-
precedented in construction difficulties and costs.
ii) In the original estimate no provision whatever was made for
importing civilization to plant, as location was quite impossible
to determine at that time. Ultimately the sum of approximately
$118,000 was spent on housing, and the sum of about $36,000 on
sewage and water supply plants.
The 1922 appropriation was occasioned by the fact that it was neces-
sary to make an extensive reconstruction of the carbonizing and gas
handling equipment* and to supply working capital for purchase of
coal, binder and: wages, etc. The combined requirements amounted
to $250,000, one-half of which $125,000, was granted in 1922, and the
remaining half in 1923. Of this latter amount, however, one-quarter
($31,250) was returned by the Lignite Utilization Board to the Receiver
General owing to the fact that Manitoba in September, 1923, with-
drew her support from the project. (See Section VII).
It now remains to discuss consecutively and in some detail the rea-
sons which made it necessary for the Board to ask for these appropria-
tions. ?
1920 Appropriation of $280,000.
The principal reason for the increases necessary was, as already
mentioned, the increase in the cost of material and labour between the
years 1917 and 1920-1921. This advance was simply unprecedented,
and the years 1920-21 marked the most difficult and expensive period
for construction ever experienced. To illustrate this increase the
original estimate of cost as presented by the Research Council in 1917
and the estimate as prepared by the Board in May 1920 are shown
respectively in columns 1 and 2 of figure 15. It will be noted that in
the Research Council estimate, there is no provision whatever for
bringing civilization to the plant (houses, sewers, water supply, etc. as
it was contemplated that plant would be in some town). Column No 3
of the same figure shows the estimate of prices prepared by the Board
in May 1920 to cover cost of purchase of exactly the same plant, had
construction been undertaken during the first quarter of 1917. A
perusal of this figure will show clearly that the plant as designed in
1919-1920 was not out of scale with or more elaborate than the plant
cee contemplated by the Fuel Committee of the Research
ouncil.
The total of column No. 2 figure 15 is $675,000. This figure included
a provision of a sum of $75,000 for housing (which afterward proved to
be very much less than was required) and a very small amount for
working capital. The excess of this total figure $675,000 over the
*For necessity of this step see Sections V and VI Pp 47-51,
84 LIGNITE UTILIZATION BOARD
original appropriation was approximately $280,000, and the request
for this additional increased amount of money was laid before the Hon.
Arthur Meighen, the then Minister of Mines, in a special report dated
May 25th, 1920. The three participating Governments agreed to
pay their respective shares of this amount by a tripartite agreement
dated Nov. 12, 1920 and upon the signing of the agreement, the Dom-
inion Government released its share of the appropriation by forwarding
the sum of $140,000 on January 21st, 1921. The other amounts were
paid subsequently by the two Provincial Governments.
1921 Appropriation of $137,000. (Approx)
By May, 1921, the completion of the plant construction was well
within view, and it was naturally expected that operation would be
started without any undue technical difficulties other than the usual
incipient troubles always disclosed when placing in operation a plant
composed of many departments or processes. It became apparent in
April that the amount of money available from the original grant of
$400,000 plus the 1920 grant of $280,000, would not be sufficient to
complete the capital construction, and in addition no adequate provi-
sion had been made in either of the original appropriations for working
capital. Owing to the fact that the Board expected at least a period
of three months with no reasonable return from sale of briquettes, and
owing to its desire to have an ample reserve of working capital, a
request was submitted to the Dominion Government on May 23rd,
1921, for a further appropriation in the amount of $140,000. The
negotiations following this request were long and arduous. As before,
the Dominion Government took the position that each of the support-
ing provincial Governments must become a party to a new agreement,
(which would embody their respective responsibilities), before any ques-
tion could be entertained of releasing the money. In addition the Minister
of Mines took the precaution of ordering a special investigation into
the commercial aspects of the venture by Walter E. Segsworth, Esq.,
M.E. This report was presented to the Minister sometime in August,
1921, though the contents of it were carefully withheld from the
Board for a period of over two years. During these long drawn out
negotiations the cash resources of the Board were getting lower and
lower. Owing to the uncertainty of the situation it was not felt pos-
sible to assume the most ordinary obligations, and by the beginning of
September the position was indeed precarious. Carbonizer operation
had started, but the Board had not sufficient money to purchase in-
surance against fire or explosion, nor had it enough to buy fire hose
or nozzles, pyrometers, or other scientific instruments necessary for
the proper control of the tests. The increasing gravity of the situation
was realized finally by the Government, and on September 28th, their
cheque was received for the sum of $137,542.96. This appropriation
was earmarked for expenditure by the Board roughly as follows:—
$100,000 for working capital and operating expenses, and $35,000 for
capital charges necessary to complete plant construction.
1522 ApDpropriation of $250,000.
By the late autumn of 1921, it became apparent that the financial
resources of the Board would be barely sufficient to bring to a close the
FINANCE 85
carbonizer runs then being held.* The foregoing paragraph has indi-
cated that the 1921 grant of $137,000 was earmarked to be expended as
follows:
Operating and working capital....... $102,000
Gaia area. Sed AO ra ne 35,000
Toward the close of the year 1921 it was seen that this $137,000
would have to be expended as follows:
(Operating texpelises... 16 eee... 42,000
Capital pecans, feo ol, 94,000
This made an overrun on capital expenditure of about $55,000
beyond the estimate of 1921. This large difference was due to an error
in estimating total capital requirements on plant buildings, housing
and equipment. This serious error is deeply regretted, even though it
amounts to only 7.8% of total cost of plant, housing and machinery.
As a result then of the extra capital requirements, and as a result of
the increased time taken in attempting to get the plant in an operating
condition, the Board found its finances practically exhausted at the
end of 1921. This coincided with the technical crisis in the carbonizers,
and it therefore became necessary to prepare a thorough estimate of
cost of reconstruction, cost of operating, and amount of working capital
required. These matters were gone into in considerable detail, and an
amount of $250,000 determined upon. After a number of informal
discussions with the Dominion Government, a formal report on the
matter was submitted to the Minister of Mines on January 20th, 1922.
The matter was next discussed with the two provinces and their con-
sent obtained.° The Dominion Government was then approached
again, and a report} was submitted dated February 22nd, 1922. On
April 15th, 1922, the Federal Government had concluded a new agree-
ment and paid over to the Board the half amount $125,000 asked for
immediately.
This half appropriation met all the expenses of the Board during
the next 11 months (April Ist, 1922 — March lst, 1923) for all pur-
poses, carbonizer and gas system reconstruction, normal operating
expense, and cost of all trial runs during autumn of 1922, and finally
the cost of the special Hood-Odell oven test at Grand Forks, N. D.
during February, 1923. At the close of this eleven month period there
remained a sum of approximately $23,000 and the Board was instructed
to expend this amount in building and operating one of these Hood-
Odell ovens at Bienfait. At the same time the signing of a fifth agree-
ment{ between the three supporting Governments made possible the
payment of the remaining half appropriation ($125,000) to the Board
on April 30th, 1923. This total of $148,000 has enabled the Board to
build one Hood-Odell oven at Bienfait during May and June, 1923,
operate it for a period of 6 months, conduct special briquette runs at
Hebron, N. D. during December, 1923, return $31,250 to the Manitoba
*The general situation is described in Section VI pp. 50 and 51.
"See Section VI pp. 51 and 52.
{See appendix No. 10.
tDated March 10, 1923,
86 LIGNITE UTILIZATION BOARD
Government, pay all operating charges, and still hold a balance of
about $58, 000 at Jan. Ist, 1924 exclusive of those monies accruing to
the Board from house rentals and Special services.
b) Analysis of Total Expenditure.
It is proposed in this section to present a bird’s eye view of the total
expenditure of the Board from a number of angles.
The receipts of the Board have been:
RECEIPTS Oct. 1st 1918 — Dec. 31st. 1923
Approx
From Governments>) eee eee ee $1,036,300
Misc, Sources -cbbps ent 0. ee ce eo 13,9
House Rentals and Special Services a/cs 9,500
$1,059,700
The expenditure is first presented under the same heads as were used
to keep the Government officials in touch with the financial aspects of
the work. These are:—
EXPENDITURE :— Approx. %of Total
Receipts.
Engineering and Administration.............. $141,600 13.3
‘Travelling 24 ee $452 Riva eeRe Meas a Rey, ee
peasant LURE AN tel. oe oe iy
Mee eT iH osin ace ieee 117,700 111
Operating Expenditure and Maintenance and
epairs:.. 0. ot ule aetae sae eee eee 107,200 10.1
Miscellaticous, -280s", 00a ene, Se 8,300 0.7
$992,300 93.5%
ONOUVFMAMIJIJASONDJEFM JJASONDIF MAM J a0 WO EMA ST Ou ESE MAMIDA SOND
CurRVE OF MONTHLY
Salaries per Month =====
ee iy Nolese ed
de oak lasfa Pres
ECE EE EEE EEE
in thousands
70 >=
n” 3 il
60 a=
a
50 S&S
wo
40 =
teed to a aa) al galt pa
SSSS87 000) \0G Se Seen
ACCC ECCS
Vi
YAS er A dS
920 1
DONDE mams JA WAMIIAS MIJAS OPOAF MAaMILA SONS
$
FIGURE 16
FINANCE 87
The relation of this expenditure to time and date is shown by graph
in Fig. 16.
A glance at the foregoing figures will make evident the absurdity of
the million dollar plant rumour so frequently heard during the discus-
sion of this project. The total capital amount invested in the plant
itself amounts to only $604,700 including the Hood-Odell oven and
accessories. The remaining portion of capital appears under housing,
etc. Coming now to an analysis of these various general heads the
poe +e engineering administration is $141,600. This is broken up
as follows:
Office supplies, Stationery, Printing Blue
Prints, Tracing Cloth, Routine Eas
Miscellaneous Office Expenses. . ORE PT SH RATL
Rent, Light, Taxes, and Insurance. . Rr Re Hd ACEO
NAC ASI Coen on A Sn A 1,292.00
Ui nin Ge oe Ween a her ile aot ad Ma ee ee aie oe 113, 435.00
Reports, Investigations, Legal Fees and Bond-
NON ASOSES Mites remn trace win hy. Lt ee 13,450.00
$141,600.00
In connection with salaries in the foregoing list, it is to be noted that
not one cent of salary has been paid to any member of the Board.
Their services have been entirely honorary from the beginning to the
end of the whole project. It is to be noted also that total administrat-
ive expense including engineering on whole programme, (much of
which was experimental and some of which was occupied by marking
time) is only 13.4% of total receipts.
The total travelling expenses need no comment.
Plant capital expenditure is approximately $604,700, and this amount
is analyzed completely in the next section of this chapter.
Capital expenditure in Housing can be divided as follows:
Boarding, Houses). 2. SP AYA OO: $31,400.00
TLOUSES. <2 .. Dene a tarts eee... et an 86,300.00
$117,700.00
Operating expenditure totals $107,200 and can be divided as follows:
Olea dy Genres ss, AL eee ee a eee $ 5,500
lnsirance andy] axesue i at..< ) Corrugated steel: ae eee 23,000 sq. ft. ail 8,510.00
12.,, Tar and gravel roofing... 2s 2 pase ae He 95 squares 15.00 1,425.00
13. Lathing and plastering..:....4..1-:..... 1,050 sq. yds. 1.10 1,155.00
14, ‘Composition floorssce. ccc see eee 65 sq. yds. 3.70 243.75
1627 Windows ny..ot so) fie ee te eee 4,600 sq. ft. 1.50 6,900.00
IBN SDOOLB. «oases so eee pore 1,700 sq. ft. 25 2,125.00
17. Painting and tinting, not including ‘
structural steel. .'«..4): seieiien epee ne 9,100 sq. yds. .50 4,550.00
18. Finishing concrete floors................. 1,800 sq. yds. 1.08 1,944.00
19. Prim ‘and ‘mill york itetn soe ee eee Lump sum 1,775.00
20) "Hardware. 2...) 9) 5 See ae ee Lump sum 1,730.00
elt) Hiectric lighting.:; Sys iiewn se cen eee Lump sum 2,243.00
pay Heating, y .:.'. 6% (sae, taicaen © Srna Lump sum 3,136.00
2a. 552 WIM ping Sos conde See eee Lump sum 2,914.00
24. Sheet metal work.................-.-... LUmMp sum 682.00
$150,243.25
The foregoing unit costs are subject to variation according as there may be any increase or decrease
in freight rates from the rates in effect on the date of the signing of this agreement; such variations
shall be effective when determined in writing by the parties hereto.
(6) Upon the termination of the work, the final estimated cost to be used as a basis for the determination
of the contractor’s fee shall be made up as follows, to wit: — the actual quantities entering into
the work and as set forth in clause 2 (a) hereof shall be taken and to them shall be applied the
same unit costs as have been used in computing the estimated tender cost referred to above.
(c)
APPENDIX No. 8 119
For the purposes of explaining the working out of the foregoing arrangement, the parties set forth
the following example: — Assuming that the original Bill of Quantities comprises the following:
QUANTITY Unit PRICE DETERMINED ESTIMATED
BY CONTRACTOR TENDER Cost
10,000 cu. yds. of concrete. ............ $10. $100,000.
200,000 feet board measure lumber...... : $35 per M. ’ :
LOOOOOubsksteelen seu ot ces toe ee 8c. erected 8,000.
i , $115,000.
Plumbing lamprsuni prices cic S85 ie e2oe esd.
Lares ests Anke ee gals.| O.1 A at 5A ae: 5:0 530) 4.0
Ammonium Sulphate........ Ibs.| 0.5 VA a4 1002 118 Ao aloe
Gasok TATA: Ce c.f.} -590 | 1,190.|'2,020.) 3,130 | 3,810 | 4,900 | 5,530
Gas measured moist at 60°F. and under a pressure of 30 ins. of mercury.
LABEL SIV.
BALANCE SHEETS, LIGNITE CARBONIZATION.
1,38C-
Temperature of Carbonization..°F.| 660] 750} 885 | 1,030 | 1,120 | 1,275 | 1,475
Weight Balance Sheet — \
dry coal basis:
Carbonized Residue.......... Ty Bl Co TOS a7 Bra 66-37, 6453 4 OL OURS
Vers che ae te eas ee OAV tL O82 (Oe are tas r Gee Boe 8 eel Pa ear
Gai) es SGU, stein ha Sa | SPV elec SLALOT EL OA alee 2 ak Lee
Water of Decomposition...... Teh 6 9NS 9585 Sere eS Al ee see
Unaccountediiom ecviee eee On =Oad OFT 0.2 0.5 ae | 0.0 O«3
Thermal Balance Sheet —
Heat value of products as per-
centages of heat value of original
- charge.
Carbonized Residue.......... Fa) 92524) 8893. (ASle7 78 . W748 OPO oe.
Tar woh. Scat cree ea ee ae CHa eG AT, Sr? 6.0 6.5 5.9 4.6
Gas... .<.. Sons ee eee A ie. & ding ips $:3.| LOL6n eee 7
Lossvc2: 22 ae we eee Se nS) is 6.6 126 8.1 Geotiad 2 62
Note: — The lost heat in the thermal balance sheet is probably largely or entirely
accounted for by the well-known exothermic reactions that take place when coal
is heated. These are especially large in the case of lignites and other high-oxygen
coals.
Tables II to V show some of the results obtained in the carbonization of Shand
lignite, based on a series of experiments in which the products of carbonization (carbon-
ized residue, tar, gas, ammonia, and water) were collected, measured, and analyzed.
The way in which the yields and properties of these products vary with the change
in the temperature of carbonization is interesting; but of greatest importance to the
Board was the conclusive evidence given by these figures that both the extent and
value of the by-products to be obtained from carbonizing lignite had been very com-
monly overestimated. This will be further considered later.
Tables VI and VII give results from a series of similar tests on coals from five of
the mines in the Estevan district. Table VI shows that there were marked differences
between the results obtained with the different coals. A study of Table VII, however,
where the results are computed to the results that would have been given if the coal
charged in each case had contained 33% of water and 7% of ash, shows that the differ-
ences noted in Table 6 are almost entirely due to the accidental variations in the ash
and moisture content of the coal sample tested. Or, as stated above, with the exception
of variations in ash and moisture, the coal is very much the same throughout the area.
APPENDIX No. 18 157
TABLE V.
YIELDS AND ANALYSES OF PRODUCTS OF LIGNITE CARBONIZATION.
1,380-
Temperature of Carbonization..°F.} 660} 750} 8851} 1,030 | 1,120 | 1,275 | 1,475
Water:
Wiloisture 1). Coal. as Charged... i o2u0 |. 31-9 | 316.1131 .82) 31-2, 6310 +3347
Water of decomposition.......%| 4.7] 6.7 | 8.1 8.0 | Qeeeiit) Bs 4k Bed
‘ROR WALEED a ad). opt he To) ot. Os1 30.0) (F39°7 1739.8) 1° 40.4 ea Ae G
Carbonized Residue:
Yield; from coalas charged... .%| 59..2c1.53.8 1 48:8 | 45.5 | 44,21b 41 8 lAg 2
Ashreontent % ates tokc Oy aea: Oo Looe io. 0) ibe 9: 216 901-17 GaleeO lec
Calorific value...... B.t.u. per Ib.} 11,150} 11,815) 12,110) 12,390] 12,320} 12,110] 12,270
Tar:
Density, crude tar. ee O98)='0°99)) 1.00} .1.00l6 1.00 SOT
Yield, dry tar per 2 000 Ibs. ‘dry
Bod be Were tcark Ce these Pais. fares 6.0 7.9 Ad 8.1 Go 2.8
Galorificivalue, dry tar +72. We...
Lo bt ee ee B.t.u. per lb.} .... | 17,260} 17,250] 17,040} 17,030] 16,970] 17,100
Distilled at 590°F.: ;
Wictitinte deren ed. es. ae Ole e009 55. 6: +64 27 S38 a8 12.6072 4206
Betciimestatiews oes fo ices Oe e. Bet OG Le M409 LSA ah) Shed! eS Webs]
Pitch, as percentage of carbonized
residue oS ae Me o/r8 ieee ae A ae U4 ASS Eo nead 20 2:7
Gas.
Yield per 2,000 lbs.—
of coal as charged......... ek 590} 1,190} 2,080} 3,050} 3,810} 4,900} 5,540
GMGneu COdine ies staid: c.f.) * 870) 1,740) 3,010) 4,510) -5,536},\7;320h8, 840
of carbonized residue....... c.f.| 1,000} 2,200} 4,300} 6,700} 8,600] 11,900} 13,800
Analysis —
Carhomidionce ey): fe. 2.1 GV .6053° 05:0) 144.9) 4 be a6 ales sul Zoe
Btirylenexett tue han... s! CLL Osten tel StOe iy EeOs he 2 | 1.97 (eee0
Qryceil fete tee: cise. sie A SS Liat Vid (Ol Aibon0as We O45 jones
Carbon monoxide......:... Fl hil © Gioe Sed [51925 \ 10. Selec del
[Veit 3406 1) tm eta er a a (al cast a fim al Wd fe 2A Soaks el ey ead Gad A wd oh wars og opi PAL ja
TAVOTOCen aah. tee ee Tob OA ee Sal Ota LG Atte 2 Ot le 22 abort
ON TET ODEN ae Se sped Yc ete v 7 a8 BAAR) 97 SYR Bs Re a aad Os OY SO ES Aoi SSS
Calorific value, gross. .B. t.u. per c. f jet 0 Wem MA iste) Ps tated ir ha fasnyiiad ies (he well ove Ene ts ec)
net T1702 | 195-5 320 8oh 340 ge OUD hud (Deal wnst)
Hae aan ae oy haetting halt eh ak Ren eee Ale 1,22 1.24 {0-96 1.0.94 1°0°86,150.79..), 0769
*Cut at 620°F. instead of 590°F.
Gas yields and calorific values are in terms of cubic feet of moist gas, measured at
60°F. and under a pressure of 30-in. of mercury.
The calorific values and densities are calculated from the analysis. Densities are for
dry gas compared with dry air at the same temperature and pressure.
When the Lignite Utilization Board staff commenced work in 1918, one of their first
tasks was to study all the information available from the Ottawa researches, as well
as that collected by the Research Council’s committee. In November, 1918, the
above work was sufficiently advanced to enable French and Stansfield to make an
investigatory tour through the United States and Canada, with the assurance that
they had the names and addresses of all the most important firms and persons who
could give information, and that they themselves were sufficiently acquainted with
the whole field to know what information should be sought and to profit by it when
obtained. This journey took exactly two months, during which forty-one cities were
visited, nine low temperature carbonization processes were investigated, and also
thirteen briquetting plants and five plants burning powdered coal. In addition, a
very large number of firms and persons were interviewed. The investigation was
not extended to England or the continent of Europe on account of the extremely un-
settled conditions there at the close of the war.
158 APPENDIX No. 18
TABLE VI.
COMPARISON OF ANALYSES OF CHARGE AND RESIDUE, ESTEVAN AREA LIGNITES,
CARBONIZATION TESTS AT 1,070-1,110°F.
W. D. M. &S. Bienfait Shand Estevan
Sourcesot- Sample ..7 4. os Mine, Mine, Mine, Mine, Bagel a8 5 Se
Taylorton | Bienfait | Bienfait Shand Estevan
Analysis of Charge:
Moistures:j <. fee % 34.1 3E2 LOW 34.4 34.7
ASR AG) i.) 2 ee % 6.6 8.4 fps T5 9.3
Volatile Matter....... o 28.2 28.0 35.8 26.0 26.3
Fixed (Carbon>47,4-3:. % oh 314 3823 28 .1 29°77.
Calorific Valued se se.
CA ER 8 B.t.u. per lb. 7,270 7,180 8,540 6,470 6,640
Analysis of Dry Coal (calc.):
Calorific Valuemire ee |.
va Me (2): B.t.u. per lb.| 11,030 10,420 10,500 9,870 10,170
Yield of Carbonized Residue:
basis of coal charged. .% 42.8 » 45.0 apse 45.3 A356
basis of dry coal...... q 65 .0 65 .4 64.1 69.1 66.8
Analysis of Residue:
Ashi se .cbiee eee 14.3 16.7 i: 2A 202
Volatile Matter... b..- 7, 9.1 9.9 9.7 Ger ON
Pixed: Carbon tees i 76.6 fee! 78.0 67 .0 70.5
Calorifie Values ee:
dee i ie B.t.u. per lb.} 12,820 12,190 13,050 11,360 11,990
Gain in Calorific Value on
carbonization:
from coal as charged. .% 1Oae 69 .6 52.6 TD=2 80.4
from dry coal. oa q 16.2 16.9 24.3 1B. 17.9
It had been thought that as a result of this investigation it would be possible to
recommend specific processes and equipment to the Board for adoption in the com-
mercial plant they proposed to erect in southern Saskatchewan. The above engineers
reported, however, that in their opinion no suitable carbonizer was available, and that,
although many suitable makes and types of driers and briquetting equipment were
available, little was yet known from practical experience in North America of either
the drying of raw lignite or the briquetting of carbonized lignite. The engineers
therefore recommended to the Board the prosecution of further experimental research
with the special view to the development of a suitable type of carbonizer, this to be
followed by research on the briquetting of lignite in a commercial type of press. This
recommendation with regard to the carbonizer largely depended on a matter of policy
with regard to by-products. Most of the writers on the subject of lignite carbonization
had claimed the production of large yields of such by products as gas, tar and ammonia,
and had stated that in commercial operation the sale of these by-products would pay,
or largely pay, for the operation of the plant. The Ottawa researches, on the contrary,
had clearly proved that the production of gas, tar, and ammonia, had been greatly
overestimated. In this connection it should be explained that the gas yield can be
made considerable, but only at the expense of carbonized lignite, which, for the Lignite
Utilization Board, was the main objective. A very careful study of the whole situation
convinced the Board that the gas normally produced (that is, the gas produced otherwise
than by burning up the carbonized lignite) would scarcely be sufficient in amount to
supply the heat required to dry and carbonize the lignite treated; and that, in the
immediate future, the ammonia would not, and the tar probably would not, pay interest
on the large capital and working charges involved in their recovery and conversion
into marketable by-products. This decision with respect to by-products has been
challenged from time to time, but further developments have all gone to show that a
contrary decision would have been almost certainly fatal to any hope of success. It
APPENDIX No. 18 159
TABLE VII.
COMPARISON OF YIELDS AND ANALYSES OF PRODUCTS, ESTEVAN AREA LIGNITES,
CARBONIZATION TESTS AT 1,070-1,110°F.
Results computed to the common basis, as from coals containing 33% moisture
and 7% ash.
W. D. M. &S. Bienfait Shand Estevan
Mine, Mine, Mine, Mine, Co SeB.!
Taylorton | Bienfait | Bienfait Shand Estevan
Source of Sample.........
Water:
Moisture in coal
gcharpeda ew, . yste2. % 331.0 3320 23.10 SaN0 33.0
Water of decomposi-
tiOh ee ee, % 8.4 8.9 8.7 8.5 8.6
Totarwatert Sia 0 41.4 41.9 41.7 41.5 41.6
Carbonized Residue:
Yield, from coal as
enargens ee re Operas 43 .3 (ake af 43 .9 44.0
Ash’content:.)..5..0..% 14.9 14.6 14.5 14.8 14.7
C@alorine-value;: 222,83
Me BEATE B.t.u. per lb.| 12,800 12,700 12,700 12,750 12,600
Tar:
Yield, dry tar per 2,000
letsesward th) eae e gals. 6.9 6.4 Ae 4.9 Boa)
Pitch, as percentage of
carbonized residue. . % SLO 2.9 Zaee, Fay | Te
Gas:
Yield per 2,000 lbs.—
of coal as charged. .c.f. 3,260 3,340 3,320 3,310 3,210
of dried coal... ..).c-f. 4,870 4,990 4,960 4,940 4,790
of carbonized residue
eee ee eC k 7,500 7,720 7,610 7,540 7,310
Analysis —
Carbon dioxide..... a 40.2 40.0 44.4 39.9 42.7
Ethylene, etc. ... 2): % 2.6 ono 1.9 ane 2.3
(XV OCT Ee daesl dnd % 0.4 0.3 0.3 0.3 0.3
Carbon monoxide... % 9.4 9.4 LOZ 9.2 9.9
Methane wis). ans viv: % 28.9 28 .0 2E 28 .9 26.8
HIVOTOSED famine. chins % 16.3 18.3 14.0 ERS TSEO
INitrOCeTee as. de atic % 2:2 155 6 2h) yt
Calorific value, gross......
ye Pe B.t.u. per c.f. 415 410 380 410 390
Calorific value, net........
Mcgee Soul B.t.u. per c.f. re Vhs 370 345 370 350
DENSILVS TR ote eee 0.93 0.91 0.98 0.92 0.95
Ammonium Sulphate:
Yield, per 2,000 lbs. coal
Te Te ees re Ibs. LL 11.8 Lhal 1220 11.6
160 APPENDIX No. 18
should, however, be pointed out that the development of a by-product industry is an
aim which must not be forgotten, and that in the years to come, when a carbonization
industry is firmly established, the commercial possibilities of the by-products may become
considerable. At the time, however, it would have been very poor policy to invest
capital in a by-product industry in southern Saskatchewan. This point has been
treated at some length, as it is of vital importance, and one on which widely divergent
views have been held.
Almost all the carbonization schemes submitted to the Board claimed as their chiet
advantage the large yields of by-products which they gave. Many of them, moreover,
were designed primarily to handle coking coals, although they could also treat the
non-coking lignites. The complications involved by the desire to increase the yields
of by-products and by the necessity to handle material which becomes sticky when
heated made them appear in every case to be unduly costly. The Board felt that,
to handle with commercial success a low-grade fuel where there would be no profits
accruing from by-products, required a carbonizer of high capacity, low capital cost,
and low operating cost. They decided that none of those considered met these require-
ments, and that, until they could either design one themselves or find one more suitable,
it would be a mistake to proceed with commercial work. Further experimental work
with the above idea in view was therefore to be proceeded with, also further work
on drying and briquetting.
The Board therefore arranged for the continuation of its research programme. The
possibility was considered of carrying this on near the offices of the Board, at McGill
University or elsewhere in Montreal; but it was decided that the only practical scheme
was to continue it in connection with the Fuel Testing Laboratories of the Mines
Branch in Ottawa. A co-operative agreement was therefore entered into by the Board
and the Department of Mines to permit the research work to be continued in Ottawa.
Under this agreement, which was approved on January 20th, 1919, an intensive and
thorough investigation was carried on until the summer of 1921. It is worth noting
at this point that on account of the thoroughness of the earlier investigations further
progress followed rapidly. In January, 1919, therefore, the writer devoted himself
to the question of the best type of carbonizer for lignite to meet the Board’s requirements.
One of the first requisites for any carbonizer design is to get an approximate figure
for the heat necessary to carbonize the lignite. Hollings and Cobb discuss the thermal
phenomenon during carbonization in a paper published in the Transactions of the
Chemical Society, 1915, 107, 1106. They give and discuss some quantitative results
of earlier workers, and also give some painstaking qualitative results of their own.
They quote Mahler as finding that the aggregate heat value of the products of distilla-
tion of Commentry coal were 3.5% less than the heat value of the original coal. They
state that this is usually assumed to be the quantity of heat evolved as a net result
of the chemical! actions taking place during distillation, and is therefore not available
as potential energy in the products. They point out, however, that this assumption
is only correct if the thermal capacity of the coal between ordinary temperatures (at
which the calorific value is determined) and the mean temperature of decomposition
is the same as the thermal capacity of the products between the same temperatures.
Unfortunately no reliable figures are available for the mean specific heats of coal and
some of its products, and they estimate that the difference between the thermal capacities
may be large compared with the above figure of 3.5%.
They quote other authors to show that in twenty-eight European coals the loss in
aggregate calorific value on carbonization varied from 2.1% to 7.2% of the net calorific
value of the coal. The loss tends to increase with the oxygen content of the coal.
These figures are in good accord with those shown in Table IV, where the loss with
lignite, which is a particularly high-oxygen content coal, amounted to 8.1% of the
gross calorific value when carbonized at 1,120°F.
Assuming for the time that this loss does represent the heat evolved during distilla-
tion, the following calculations give an approximate idea of the heat evolved during
carbonization. A number of assumptions will have to be made. Thus: that the
temperature of carbonization is 1,120°F., or 1,060°F. above room temperature; that
the mean temperature of the gaseous products leaving the retort is 700°F., or 640°F.
above room temperature; that the mean specific heat of the carbonized residue up
to 1,120°F. is 0.4, and the mean specific heats of the tar and gas up to 700°F. are 0.6
and 0.3, respectively; also that the heat required to convert water at 60°F. to steam
at 700°F. is 1,350 B.t.u. per pound.
APPENDIX No. 18 161
The gross calorific value of the lignite employed in the tests represented in Table IV
was about 10,500 B.t.u. per pound of the dry coal: that is, the heat evolved in carbon-
ization at 1,120°F. amounts to 8.1% of 10,500, or 850 B.t.u. per pound of dry coal.
The heat required per pound of dry coal to heat the solid and gaseous products up to
1,120°F. and 700°F., respectively, are as follows, for the weights taken from Table IV :—
Coke: 0.643 X 1,060 X 0.4 = 273
ape O42, 5 DAN 0 6 ae 16
Gash Odd § 5 640-%< 0.3 35
Water of
decomposition: 0.134 & 1,350 = 181
iL ta eee. PAE SARs oe 505
Therefore, from these calculations the heat evolved during the carbonization by the
decompositions effected is 850 B.t.u., and the sensible heat of the products is 510 B.t.u.,
leaving a net balance of 340 B.t.u. evolved per pound of dry coal carbonized.
Tests were made to determine this value experimentally. A charge of dry coal was
carbonized in an electrically heated retort. The coal was charged into a cold retort,
and the retort and charge gradually raised to 1,075°F., and held there until the evolu-
tion of gas had practically ceased. Careful record was kept of the temperature of the
retort at regular time intervals throughout the experiment, and also of the quantity
of electricity required. An empty retort was then similarly heated with the current
so regulated that the retort was heated at the same rate as before, and the heat main-
tained at 1,075°F. for the same time. The current consumption was measured as
before. The current consumption in the second experiment gives a measure of the
heat required to raise the temperature of the retort and furnace to the requisite tem-
perature, and to make up for radiation and other losses. The difference between
the current consumption of the first and second experiments gives a measure of the
heat required to carbonize the charge. The experiment is unsatisfactory, as the
quantity required is measured as the difference between two large amounts. A small
percentage error in either of the tests, therefore, causes a large percentage error in the
value required. The mean of two reasonably concordant results showed that 380 B.t.u.
are required per pound of dry lignite charged. In other words, calculations based on
the heat value of the charge and its products show an evolution of 340 B.t.u., whilst
the experiments show an absorption of 380 B.t.u. per pound of dry lignite. This
discrepancy may be due to errors in the experimental determination, or may be due,
as suggested by Hollings and Cobb, to faulty assumptions on which the calculations
are based.
The effect of moisture in the coal is important. If the moisture is driven off in the
retort, escaping with the other gases at 700°F., each pound of water will require approx-
imately 1,350 B.t.u. If, on the other hand, it is driven off in a drier, escaping at, for
example, 212°F., it will only require 1,120 B.t.u. Assuming, then, that carbonization
requires 380 B.t.u. per pound of dry coal, and drying in the retort requires 1,350 B.t.u.
per pound of water, the total heat required per pound of coal charged will decrease
1% of 380 B.t.u. and increase 1% of 1,350 B.t.u. for each 1% of moisture present: that
is, a net increase of 9.7 B.t.u. If the value of —340 were taken instead of +380, the
net increase for each per cent of moisture would be 16.9 B.t.u.
Experimental proof of the conclusion that the doubtful value of the heat for carbon-
ization is small compared with the fairly definite value of 1,350 B.t.u. was given by the
repeated cehservation later in large scale carbonization runs, that a small increase in
the moisture content caused a very marked decrease in the capacity of the retort.
If the drying is carried out partly in a drier and partly in the retort, it may be assumed
that 1,200 B.t.u. are required for each pound of water. If the higher of the two values
arrived at above is assumed for the heat of carbonization, then to dry and carbonize
one pound of coal with 33% of water would require (0.33 X 1,200) + (0.67 X 380)
= 396 + 255 = 650 B.t.u., of which 60% will be required for drying and 40% for
carbonizing.
One pound of this coal with 33% of water might be expected to give off, on carbon-
ization at 1,120°F., 1.85 cu. ft. of gas with a gross calorific value of 405 B.t.u., or a
total available heat of 750 B.t.u. An over-all efficiency of 87% in carbonizer and
drier would therefore be essential if they are to be heated entirely by the burning of the
gas produced. If the tar were also to be burned, some further 450 B.t.u. would be
available, or a total of 1,200. This would only require an over-all efficiency of 54%.
162 APPENDIX No. 18
In the preceding calculations the high value of +380 B.t.u. required for carbon-
ization was taken. The low value of —340 B.t.u. deduced from determinations of
calorific values was entirely ignored. Although this latter value, like the former, is
liable to considerable error, it hardly seems possible that it is 720 B.t.u. too low. If
the mean value is accepted, then the total heat required as above becomes 410 B.t.u.
instead of 650 B.t.u., and the required efficiencies are: 55% for gas alone, and 35%
for gas and tar.
Some values of the heat required for the carbonization of coal and peat are given
below; but several of these, it should be pointed out, are for high temperature carbon-
ization of coking coals. The lower temperatures required for lignite carbonization
should permit of marked reduction of the heat required; also the lignite gives out
more heat in its decomposition. On the contrary, the coal charged would be com-
paratively dry, which would require, other things being equal, less heat than would
be required for the lignite. Furthermore, the fact that in the examples cited the hot
flue gases from the retort escape up the chimney, whilst in treating lignite they might
be used in direct contact with the coal for driving off the more than 30% of moisture
it contains, should permit of a very large increase of over-all efficiency of operation.
On the whole, it seems reasonable to expect that lignite would require very distinctly
less heat per pound for its treatment than the figures cited below for coal.
(1) A seven-day trial in 1910 with a modern horizontal retort setting (Transactions
of the Institute of Gas Engineers, 1910, page 259) showed for 12-hour charges
1.60, and for 8-hour charges 1.65 cwts. of coke per ton of coal charged. The
average retort temperatures were 1,820°F. and 1,810°F., respectively. If the
coke is assumed to have a calorific value of 14,000 B.t.u. per pound, the above
figures average 1,140 B.t.u. required per pound of coal treated.
(2) A test on 140 tons of coal in a Glover-West installation at Manchester (Transac-
tions of the Institute of Gas Engineers, 1911, page 129) showed a consumption
of 9.37 pounds of coke (13,750 B.t.u. per pound) per 100 pounds of coal: that is,
1,290 B.t.u. per pound of coal treated. In this test the aggregate heat value
of the products was 2.65% less than the heat value of the coal charged.
(3) Intests made by the British Fuel Research Board (Report for the years 1920-21 ,
Table 9) in a Glover-West installation, the smallest consumption of heat
(Test B) was 1,510 B.t.u. per pound of coal treated.
(4) In another test made by the same Research Board (Technical Paper 4) in the
same Glover-West installation, 11.01 tons of 20% moisture peat were carbon-
ized in 18 hours at a temperature of 1,832°F. with a consumption of 3,480
cu. ft. of gas per hour. The gas had a calorific value of 325 B.t.u. per cubic
foot. The consumption of heat was therefore 830 B.t.u. per pound of peat
treated. It is suggested in the report that the heat consumption is possibly
low, but that the error is unlikely to exceed 5%. This case more closely
resembles the carbonization of lignite than does the previous ones, but it should
be noted that the temperature of carbonization in this test is about 700° higher
than that desired for the lignite.
(5) In yet another test made by the above Research Board (Technical Paper 7)
in their Glover-West installation, a coking coal was carbonized at about 1,430°F.
a low temperature for the installation, and yet higher than that required for
lignite. The coal charged contained 6.5% moisture. The aggregate loss of
calorific value on carbonization amounted to 3.7%, or 462 B.t.u. per pound
of coal charged (corresponding to 850 B.t.u. per pound of dry lignite at 1,120°F.).
The following table shows the heat consumption per pound of coal fired.
Heat dissipated from Setting. «uae eee .. 693 B.t.u.
Heat dissipated from pre-heater................... 54.5
Heat’ lost in‘flue gasesivi' 5 INN ee sees renee: AVS Gh
Heat piven to coal? :. 2) 5.2) ae eee 20a ial
‘Total. 636.5, ntiapsn on Sinker pate nae eee Be 1,444 B.t.u.
The high value of the total heat is quite natural in view of the fact that low temperature
carbonization was carried out in a retort designed for high temperatures. Comparison
with lignite values is of interest.
APPENDIX No. 18 163
Coking Coal Lignite
at 1,430°F., Ab et 20eb
B.t.u. per Ib. B.t.u. per Ib.
(a) Heat required to decompose coal ?
(from aggregate loss of calorific value
PY CATDONIAAGIORL wie lott a's Suis —462 (determined) —850 (determined)
(b) Heat required to raise temperature
of products of combustion.......... +744 (by difference) | +510 (by calculation)
(c) Net heat required for carbonization.| +282 (determined) —340 (by difference)
This difference between the nature of the coals fully accounts for the difference in
values in line (a). The lower temperature of carbonization of the lignite would explain
the lower value in line (b), so that the value of —340 B.t.u. in line (c) would appear
to be reasonable. The error could hardly be greater than that allowed for in taking
the mean between —340 and +380.
(6) In an unpublished test made in June, 1922, with an electrically heated lignite
carbonizer of a type to be described later it was found that when the lignite
charged contained 13.8% of moisture and the carbonization was carried to a
degree giving a discharge with 13.8% of volatile matter, the electrical energy
supplied amounted to approximately 1,000 B.t.u. per pound of charge. This
was in a very small retort with a capacity of approximately 12 pounds per
hour, so that the radiation losses might be expected to be very high as compared
with large scale operation.
A number of the cases cited are of later date than the period at which the Lignite
Board was making a decision with regard to a design for a carbonizer. They are,
however, quoted here as giving more reliable information than those studied at the
time; yet they but serve to confirm the opinion then formed.
In conclusion, therefore, there appeared to be justification for assuming that the gas
evolved during lignite carbonization should be ample to provide all the heat required
for carbonization if a reasonably efficient retort were designed. It also appeared to be
just possible that this heat would also dry the lignite, but this point was so doubtful
that it was evidently advisable to be prepared to supply supplementary heat for this
operation.
A study of Figure 28, based on the Ottawa tests on the carbonization of Shand
lignite, gives an idea of one of the requirements to be considered in the design of a
carbonizer in order to obtain the best possible results. The curves show that the
maximum calorific value of the residue is obtained by carbonization at about 1,050°F.
It also shows that at this temperature we might expect a yield of carbonized material
of 66% of the weight of dry coal taken. This material would have an analysis of:—
Rixedicat bon? £2 ewes pie te ober. (iP s
Mal aLilesmintter aceuwhiicc dies: shavanclte a 114%
PLSIT of haaa doh ate: A dk Belen pth © dea 114%
WAIORINC ValiGatcc: citie nt tes. souk aes 13,560 B.t.u. per Ib.
If, however, instead of being carbonized in a small retort with an exact temperature
control, the coal were carbonized in a commercial-sized retort, it is clear that, whilst
it might be subjected to a temperature which averaged 1,050°F., yet the coal nearest
the walls might be heated to 1,300°F., and the coal in the centre of the retort only
heated to 800°F. The curves show, further, that the yield from the coldest pieces,
under these conditions, would be 77%, and from the hottest, 61%; but the average
yield, as before, would be close to 66%. The fixed carbon would vary from 65% to
82144%, the volatile matter from 25% to 5%, and the ash from 10144% to 124%;
but the average would in each case be reasonably close to the analysis at 1,050°F.
The calorific value, on the other hand, would be about 13,000 B.t.u. for the coldest
pieces, rising to 13,560 B.t.u. for those carbonized at 1, 050 °F., then falling again to
about 13,300 for the hottest pieces The average in this case could not be 13,560 B.t.u.,
but would fall some 200 B.t.u. lower It follows, clearly, that the further apart are
the maximum and minimum temperatures of carbonization, the lower will be the
average B.t.u. of the product; or, the more nearly each particle is carbonized at the
optimum temperature, the higher will be the average B.t.u. of the product.
164 APPENDIX No. 18
This requirement could be met in an ordinary shaft retort by maintaining the heating
flue at the desired temperature and passing the charge so slowly through the retort
that every particle of coal attained to this temperature; or by making the thickness
of the charge so small that all parts were at approximately the same temperature.
It could also be met by keeping the charge thoroughly mixed, as in a rotary retort,
whereby the same result would be attained. Construction difficulties caused a decision
against the third method. The first two were ruled out on account of the consequent
small output per retort.
Another method for achieving the desired ends was then considered: that of subjecting
the coal in a thin layer to a very high temperature, but for such a short time that the
coal could only attain to the desired temperature. In other words, obtain the uniform-
ity of temperature by the thinness of the charge, and the high output by the use of
high temperature and consequent rapid carbonization. Control of degree of carbon-
ization in such a process would be by regulation of the time of carbonization rather
than by regulation of the temperature in the heating flues.
The possibility of this method was tested by the experiment of heating for varying
short times a thin layer of coal in a muffle heated to nearly 400°F. higher than the
desired temperature of carbonization. (See Mines Branch Summary Report for 1919,
page 36.) Tests were made with a half-inch layer and with a one-inch layer of lignite,
and the results are shown graphically in Figure 29. As would be expected from the
above discussion, the residue from the half-inch layer had a higher calorific value
than had that from the one-inch layer. The former value, it might be noted, was
only slightly more than 100 B.t.u. lower than that obtained by complete carbonization
in a retort with careful temperature control. Table VIII gives the results obtained
by complete carbonization of the same lignite at 1,095°F. and at 1,110°F. with the
optimum results for half-inch and one-inch layers carbonized in a muffle at 1,475°F.,
as taken from the rounded curves of Figure 29.
PLA Dletee vel
COMPARISON OF COMPLETE AND RAPID CARBONIZATION.
Method of Carbonization........... In Lead Bath In Muffle
Temperatures: 17) 342s. bola Soe °F.| 1,095 1,110 Az PATS
Thickness‘offLayens ne eee ins. sere alates a i)
Time of carbonization......... minutes} Until Until
completed | completed 5 9
Yield {ish 2 Set ede aera q, 67.5 Giuul 69 .2 67 .0
Ash. 3.5 22h ek eee en GF, 18.9 18.9 18.7 19.4
Volatale Matter 223.3) sia eee oY 8.7 8.4 9.0 7.9
Fixed 'Carbon.22).. 5.. Boe eee ye eee Load T23 Cot
Calorific Value...........B.t.u. per lb.) 12,170 | 125150 12,040 11,860
No great accuracy is claimed for these muffle tests, but they proved the point in
question, and it was not thought worth while to make more careful tests at that time.
In the modern high temperature coke oven, the coking period in recent years has
been reduced to 12 hours, in retorts where the thickness of charge is only 12 inches.
In the tests described above, lignite was carbonized in five minutes by reducing the
thickness of the charge to one-half inch. A design was now required for a furnace
in which this process could be carried out. The first suggestion of importance was
the shaft carbonizer indicated in Figure 30. The main idea of this was, briefly,
that of a series of muffle chambers one above the other. The baffle plates shown
were inclined at an angle (45°) slightly greater than the angle of repose of carbonized
lignite, which was found to be about 37°. In this way the coal would slide down
through the retort from baffle plate to baffle plate. The thickness of coal on any plate
would increase downwards as shown, being controlled by the distance between the
two baffle plates at the top and by the difference between the angle of repose of the
coal and the angle of the baffle plate, in this case 8°. The rate at which the coal flowed
through the retort could be controlled by the rate of rotation of the discharge wheel
at the bottom. In each pocket or muffle chamber the coal would be subjected to
heat radiated from the wall separating the chamber from the heating flue. The gas
evolved would pass into the central offtake flue. In the diagram a pair of such retorts
APPENDIX No. 18 165
are shown. The coal thickness, as shown, would average four to five inches, but in
view of the mixing which would occur at each passage from one chamber to the next
it was thought that uniform carbonization would be effected in spite of the thickness.
In the retort sketched, each baffle plate is approximately three feet by four feet.
If there were fifteen baffles in each retort, the total charge in the double retort would
be about three tons. If a thirty-minute treatment were required, then the capacity
would approximate 100 tons of discharge per day.
This design was tentatively submitted to the Board by the writer, but was abandoned
by him almost immediately. Experiment confirmed the fear that the gases evolved
would become cracked in contact with the hot walls of the retort. The carbon that
would thus be deposited on the walls would impede the heat transfer, and would steadily
reduce the retort capacity until it became necessary to stop operation to burn off the
carbon. Furthermore, some rough calculations indicated that it would be impossible
to pass the heat through the walls at the required rate, even though the heating flues
were maintained at a temperature far above economical suitability, and the walls
were made of only single thickness firebrick construction.
A second design was submitted by the writer a few days later, and on February 10th
1919, it was accepted by the Board as sufficiently hopeful to warrant testing. In this
design, which is shown in Figure 31, the retort was inclined instead of vertical, and
the coal was heated from below instead of by radiation from the walls. The chamber
feature was maintained, and also the feature of a gradually increasing thickness of
charge as the coal passes down through each chamber, this change in thickness, as
before, depending upon the difference between the inclination of the plates over which
the coal flows and the angle of repose of the coal. As before, also, the passage from
one chamber to the next would cause a mixing of the charge. In this design, however,
the coal rests directly upon the heated plate, so that as the plate is cooled by the coal
on its upper surface the temperature gradient through the plate could be far greater
than if it was only cooled by radiation as in the earlier design. Moreover, the plates
over which the coal travels could be made of thinner material than would be possible
for the wall of the shaft type. The gases rising from the heated coal in the inclined
design pass off through the offtakes provided in the chamber covers without coming
in contact with any strongly heated surface. Cracking of the gases is thus reduced
totheminimum. The construction suggested is shown inthe drawing. It was proposed
to divide the retort into two or more parallel channels for the sake of structural strength
and simplicity. The coal would be fed in through a hopper at the top, and pass down
through the retort, over the heated floor plates, and under the baffles. It would leave
the retort through the discharge wheel, anti flow into a cooling chamber. The gas
evolved from the coal would pass off through the different offtake pipes into a common
pipe, then through the purifying system and back to the gas burner. The air for
combustion of the gas would enter through an intake and pass down a pre-heating flue
to the burner. It would become heated whilst passing down the flue, carrying back
i ine combustion or heating flue the heat which had escaped through the floor of
that flue.
Calculations in this case indicated that the design was a possible one, but they made
it clear that it would be advisable that the floor plates should be as thin as possible,
and made of the best conductor of heat that would stand the conditions involved.
Practical tests of this design followed two lines. One was that of small scale models
erected in the laboratory and heated by electricity instead of by gas. The coal channel
in these models was usually only two inches wide, but varied in length from about
three to six feet. It is not proposed to include a description of these retorts in this
report, but the experience gained with them was extremely valuable, and a number
of points brought out will be discussed later. The other method of test consisted
in the erection and operation of a semi-commercial sized retort out of doors on the
grounds of the Fuel Testing Station at Ottawa.
The advantage of small scale electric models was the ease and rapidity with which
they could be constructed, tested, modified, and retested. The first one was not
begun until the plans for the large-scale model were under way, yet the first test was
made with it on April 24th. This model, even after several changes had been tried,
was an unmitigated failure so far as operation was concerned; but the information
gained from it was very useful later. The second electric model was not begun until
July 13th. Experiments with this model were carried on simultaneously with the
large scale tests. The results with it were on the whole so satisfactory as to give
reasonable certainty that the large scale model could be successfully operated, even
when, in the earlier days, the results with that model were discouraging.
166 APPENDIX No. 18
The working drawings of the carbonizer to be erected in Ottawa were prepared
in Montreal by R. deL. French, assisted by H. R. Evans. They were practically
completed by March 21st. Tenders were then called for, and orders placed. Con-
struction was commenced about the middle of April.
Figure 32 gives a longitudinal section of the carbonizer proper, and Figure 33
is a side elevation showing the general arrangement. The sectional drawings in Figure
32 show that in essential features the design closely followed the original suggestion.
There was a heated flue situated under an inclined, stepped, carbonizing floor, down
which the coal flowed by gravity from a feed hopper at the top. The thickness of the
coal on the carbonizing floor was controlled by a series of baffle plates under which
the coal had to flow. The rate of flow of the coal was controlled by a hand-operated
discharge wheel. The treated coal, after passing the discharge wheel, fell into a cooling
hopper from which it was withdrawn from time to time through a spout containing
a number of cooling coils. The baffle plates, with the concrete covers over them,
formed a series of gas chambers through which the gases from the coal passed on their
way to the offtakes shown in the side of the chamber. Observation holes were provided
in the cover. Pyrometer holes were provided close to the bottom of each baffle, also
in the heating flue and in the air preheating flue, as shown. The gas burner for heating
the carbonizer was placed at the bottom of the heating flue as shown. The products
of combustion were caused to follow a staggered path along the heating flue by means
of the baffles shown in the general section and in the section G-H. At the top they
passed out through a short, horizontal pipe to the stack. The air for combustion of
the gas was supplied by a small blower connected to the air intake, and then passed
down the air preheating flue on its way to the burner. It might be noted that there
was only one channel in this carbonizer instead of the two or more parallel channels
proposed in the original design. This channel was about eleven inches wide, as shown
in the section E-F.
The general arrangement is shown in Figure 33. It will be seen that the carbon-
izer proper was carried on a steel girder frame. This was pivoted at the bottom, and
was supported at the top by a pulley block and wire rope from a tall wooden gallows.
The furnace was expected to be operated with an inclination of 45° on the floor plates,
but it was designed as above in order that other inclinations might be tested. Figure
33 also shows a small coal-fired furnace which was used for the preliminary heating
of the carbonizer. This furnace was connected to the bottom of the heating flue by
means of a jacketted flue pipe. It was proposed to use the lignite gas for heating
after the retort was in full operation, but city gas was also provided for use as required.
The gas outlets are shown in this drawing connected to an inclined downtake pipe.
It was proposed to connect this foul gas main to a cooling and purifying system; but
as a matter of fact this was never done, and city gas was used for heating in all the
tests. The stack is shown on its concrete foundation, with the flue pipe from the
carbonizer to the stack.
In the first design for the Ottawa carbonizer it was proposed to use firebrick slabs
12” x 12’ x 12” for the carbonizer floor, as shown at the left of Figure 32 in a double-
scale inset. Later it was decided to use carborundum slabs of only one inch thickness
in order to increase the capacity. This necessitated the use of a small filler in order
to avoid further changes in construction. This arrangement is shown in a second
inset under the above in the same diagram. There was a delay in the delivery of
the carborundum slabs, so that it became necessary to use some substitute. The
retort was therefore built with cast iron floor plates. These were made with small
side plates to support the baffle plate in the desired position. The floor plates are
shown to double scale with side plates complete on the right hand side of the drawing,
but in the general section and in the following Figures 34 and 35, etc., the side
plates are only shown on the lowest floor plate to avoid confusing the drawing. The
original floor and baffle plates were designed to be placed in suitable grooves in the
side walls, as shown in section E-F. When it became necessary to temporarily substi-
tute the cast iron plates, it was arranged that the upper part of the retort should be
the full width of the plates to permit their ready withdrawal and replacement. It
was this change that necessitated a new form of support for the baffles.
It may be noted that an expansion joint was provided in the floor and walls between
the common brick and the fire brick. In the floor and on one side this joint was filled
with sand, and on the other side it was filled with slag wool.
From time to time the construction of the carbonizer was changed. These changes
are shown in Figures 34 to 40, entitled ‘Modified Construction”. The first
of these shows, on the same scale as the others for purposes of comparison, the retort
APPENDIX No. 18 167
as constructed and as operated in the first real run on July 18th, 1919. Subsequent
changes and the reasons for them will be described later
The carbonizer was first heated on July 11th, and first run on July 18th. It was
subsequently run from time to time, with intervals for modification, until November
21st, when winter conditions compelled a shut-down. At that time most of the desired
information had been obtained, and it did not appear advisable to build the necessary
covering building to permit of winter operation. The carbonizer, during the above
period, was operated on forty-eight different days. Details of some of these runs
follow.
It should be noted at this stage that the carbonizer was designed to operate on dry
lignite, not on lignite as mined. It was also designed to operate on crushed coal. The
equipment available for crushing the coal was a set of rolls belonging to the Mines
Branch, for which the Board provided special fluted rolls. The only equipment avail-
able for drying the coals was a gas-fired, rotary retort belonging to the Mines Branch,
and originally designed by the writer for carbonizing tests. This retort, after modi-
fication of the feeding device, proved quite satisfactory as a dryer, but its capacity
was far below that of the carbonizer, as it only gave an output of about sixty pounds
of dried lignite per hour; so that it was essential to operate the crusher and dryer for long
periods in order to store up raw material for comparatively short runs of the carbonizer.
This necessity materially curtailed the running of the carbonizer.
The usual procedure in a run was somewhat as follows. The carbonizer was gradually
heated by means of the coal-fired furnace, first using natural draft, then, later, forced
draft. The gas burner was then lit, and the carbonizer further heated. Carbonized
or partially carbonized lignite was then charged in to fill the carbonizer and hopper,
and the discharge wheel then started. At first the rate of discharge was kept very
low, but this was increased from time to time as the temperature increased. When
the carbonizer appeared to be suitably heated, and everything working smoothly,
dried lignite was fed into the hopper as required for the remainder of the test instead
of carbonized lignite.
The rate of operation of the carbonizer was controlled by the discharge wheel shown
in the drawings. This was hand-operated by a wheel outside the hopper. The wheel
was marked to show the correct amount to turn from each bucket to the next. When
the furnace was in operation the wheel was given a one-sixth turn, that is, one bucket
was discharged, at regular time intervals. ‘This time interval commonly varied from
one to three minutes, as arranged. The capacity of each bucket was three and one
half pounds, so that to discharge every three minutes corresponded to a discharge of
seventy pounds per hour, every two minutes to one hundred and five pounds, and so on.
Temperatures were recorded by means of indicating pyrometers. These were
commonly located in the following places: in the charge; in the first, fourth, and eighth
compartments, numbered from the bottom; in the top opening into the heating flue;
and in the bottom, or bottom but one, opening into the air preheating flue. °
_In full runs, samples of the charge and of the discharge were taken from time to
time and analyzed, the coal charge was weighed, regular records of the temperatures
were kept, also gas meter records, discharge rate records, and, frequently, flue gas
analyses and screen analyses of the charge and discharge. Also any special features
were recorded.
In the following diary of the operation of the Ottawa carbonizer the periods are
numbered, corresponding to those in Figures 34 to 40, inclusive.
Period 1. — Run 1, on July 18th. — The carbonizer was brought up to heat, and
lignite then fed in. Difficulty was at once encountered, as it was found that coal
would not feed down steadily under the baffles without constant poking. The brick-
work of the carbonizer, also, leaked badly. The sides opened up with the heat, creating
large openings between the sides and the cover plates.
MODIFICATIONS. — The original drawings called for 14-inch clearance past the
baffles, but this had been increased to 3¢-inch during construction. Tests showed
that 14-inch clearance was required around the baffle with the dried coal on hand
for the tests. This coal was slightly coarser than that used in the earlier tests with
the laboratory model, and on which the design of 14-inch had been based. ‘The carbon-
izer was therefore modified to give a clearance of l-inch around the baffles. New
covers were also constructed, 18 inches long, to rest on the side walls, instead of being
only 12 inches long, inserted between them. This change, therefore, allowed movement
of the side walls without the creation of serious leaks. It also had the effect of raising
the covers of the carbonizers about two inches, making a larger gas space above the
168 APPENDIX No. 18
coal. The covers, therefore, no longer rested on the baffles as before. Fillers, however,
were put on two of the baffles to close the space between them and the covers. This
resulted in there being three distinct gas chambers instead of eleven as before.
It might be noted at this point that it was never found possible to keep the brick-
work gas-tight. It was therefore decided not to attempt to collect, measure, and
burn the lignite gas, but to let this escape to the air and to use city gas entirely for the
heating. Trouble, moreover, was experienced in most of the runs with blocks in the
gas offtake pipes. These blocks were due to the dust rising with the gas and depositing
with the tar in the offtakes. This mixture of tar and dust frequently baked to an
extremely hard material that was very difficult to remove. The reduction from eleven
gas chambers to three was an advantage, as it gave alternative outlets for the gas from
every chamber if one or two of the pipes became blocked. Also these offtakes could
be cleaned without interfering with the operation of the retort.
These modifications are indicated in Figure 35. The width of the carbonizer
chamber was eleven inches. Other details not shown were as before.
Period 2. — Run 2, July 29. — This run was stopped very shortly, as a large leak
was found from the heating flue into the carbonizing chamber under the bottom floor
plate. This leak was afterwards stopped.
Run 3, July 30. — Ran about 1,500 pounds of coal through the carbonizer, but had
trouble with the discharge, as coal flowed past this when wheel was at rest.
Run 4, August 1. — Discharge now in order. Had trouble with blocking in one
of the lower compartments. A workman, trying to remedy this by poking, knocked
down a baffle plate and displaced a floor plate, necessitating a shut down of the run,
MODIFICATIONS. — Examination of the cast iron floor plates showed that the lower
ones had suffered from the heat and were seriously burned and buckled. A small
consignment of four carborundum slabs had arrived by this time, so these were put
in to replace the lower four cast iron plates. Incidentally, it became necessary to
find a new method for supporting the baffle plates. Also, in replacing the cover plates,
the two fillers previously referred to were omitted so that the whole gas space constituted
a single chamber. It will be noted in Figure 36, that these carborundum slabs were
laid flat, not stepped, so that the inclination of the floor on these plates was 56° instead
of 45° as on the cast iron floor plates, and as designed.
As rebuilt, the lower three and a half plates were carborundum, the others cast iron.
The width for the upper seven chambers was eleven inches, as before, and in the lower
four chambers, twelve inches. The capacity of the retort between the entrance to the
discharge spout and the rod across the feed hopper, under running conditions, was
104 pounds after this reconstruction.
Period 3. — Run 5, August 6. — A difficulty was experienced in this run before
the furnace had really come up to full heat on account of interruptions and low voltages
in the electric current supply. This interfered with the motor-driven air blower,
and the run was therefore abandoned five hours after the discharge was first started .
Run 6, August 8. — Before commencing this run, cleaned up the gas offtakes which
were choked, also cleaned several baffle openings which had become choked with bits
of rubbish, presumably fed in with the carbonized coal when starting the trials: After
this test a six-inch mesh screen was kept over the feed hopper to eliminate this difficulty
with choking. The test was continued all day without any notable difficulty. During
the afternoon the rate of discharge was 70 pounds per hour. The temperature of the
retort was rising steadily all day. At the end of the run analysis of the carbonized
material showed 8% of volatile matter. The coal charged contained 7.5% moisture ,
Experience gained in the attempted operation of the first electric model had indicated
that it would be necessary to keep a graded heat along the floor of the carbonizer
chamber: very hot towards the bottom end, but cool towards the top end. The reason
for this is as follows. If a layer of cold material entering from the hopper at the top
is fed on to a very hot plate, the tarry gases liberated from the coal touching the plate
are condensed as they pass through the cold upper layers of the coal. This then
becomes sticky, does not flow under the baffle, and prevents steady operation. If such
a block is formed, operation of the discharge removes the coal below it, and the exposed
plates become very hot. After a while the tarry coal causing the block becomes heated,
the tar distills off, the material begins to flow again, and there is a rush of coal from
the hopper to fill the lower part of the carbonizer once more. This green coal, coming
on to the overheated plates, causes a big rush of gas. An episode such as the above
is referred to in the following pages as a slip. When the heat on the floor of the carbon-
APPENDIX No. 18 169
izer 1s suitably graded, the coal does not reach a point where tarry vapours begin to be
given off until all the coal has reached too high a temperature to allow the condensation
of tar. All stickiness is thus avoided.
When trouble was experienced in these earlier runs from slips, the correct remedy
was therefore at once applied: that is, the upper portion of the carbonizer was kept
cooler. The results of the earlier runs fully confirmed the belief that the lignite must
be treated gradually to avoid trouble from it becoming sticky: that is, the temperature
of the upper plates must be graded down. It was also found that the faster the coal
was travelling, the hotter it was possible to maintain the upper plates without causing
slips. In this run there were slips for a while after commencing to charge green coal,
but after the gas supply to the burner had been slightly reduced there was no further
trouble to the end of the run. Note, by green coal in this connection is meant dried
lignite in contradistinction to the carbonized lignite charged at the beginning of the run.
Run 7, August 11. — This was another single day run. After conditions became
regular, the discharge was maintained at 70 pounds per hour. The temperature of
the carbonizer rose steadily throughout the run. For the last two hours the discharge
contained from three to four per cent of volatile matter. Analysis of a composite sample
of the discharge showed 5.4% volatile matter, and 11,720 B.t.u. per pound. Operation
during the run was fairly satisfactory. The gas consumption was 600 cubic feet per
hour at the middle of the run, but this was later reduced somewhat.
Run 8, August 12. — A similar day’s run to the above, but with the discharge speeded
up to 105 pounds per hour. Analyses of the samples taken during the last three hours
run varied from 5.7 to 7.4% volatile matter, and averaged 6.4%. All went fairly well.
Run 9, August 14. — A similar day’s run to the above, but with a discharge of 140
pounds per hour. A small gas explosion during the operation of starting up, a minute
or two after the evolution of gas began, but before all the air had been displaced, moved
some of the covers. These were pushed back into position, the cracks cemented, and
the run continued. The average analysis of discharge during the last two hours run
was 10.3%. The average rate of charge during this period was 215 pounds per hour,
and the discharge 140 pounds. This corresponds to a 65% yield.
Run 10, August 15.— As before, with 140 pounds discharge. This was not as
satisfactory as the previous run. The temperature rose too high at the top of the
retort, causing irregular operation. The coal charged had 8.2% moisture. The
discharge was erratic, varying from 10.0 to 14.4% volatile matter. The city gas
burned was about 540 cubic feet per hour.
Run 11, August 18. — This was a very windy day, and shortly after the first evolu-
tion of gas when the green coal entered the furnace there was an explosion which blew
a number of covers off the carbonizer. During this period, as stated above, the gas
chamber had not been divided at all. The bottom of the carbonizer was prcbably
filled with air, and the top with gas. The leaky condition of the brickwork and the
strong wind resulted in a gas-air mixture reaching some point where the temperature
was high enough to ignite it, with the results cited. It might be noted that the only
time when there appeared to be any danger at all was shortly after the first charging
of green coal. With care this danger could be entirely eliminated.
MODIFICATIONS. — Before repairing the carbonizer, certain changes were made.
The simple gas pipe burner was changed toa bunsen burner, as shown in Fig. 37, in order
to get a more intense heat in the lower part of the carbonizer without unduly heating
the top part. The bottom four firebrick baffles, which were without satisfactory means
of support. were replaced by seven cast iron baffles supported by side plates which
rested on the floor. These baffles had a one-inch clearance underneath, as before;
but, being closer together, gave a thinner layer of coal over the more intensely heated
portion of the floor. The width of the chamber, at the top was eleven inches, and at
the bottom was ten and three-eights inches between the side plates of the baffles.
These changes reduced the normal capacity of the carbonizer from 104 pounds to
69 pounds between the entrance to the discharge and the rod in the hopper.
Period 4. — Run 12, August 25-26. — This was intended to be a 30-hour run, but
the supply of dry coal came to an end after only 20 hours of regular running. An
attempt was made to continue with undried coal, but the carbonizer immediately
choked.
Approximately 114 tons of dried material were carbonized. For the first four hours
after operation became normal the discharge was at the rate of 70 pounds per hour,
and contained 7.9% volatile matter. For the next six hours the rate was 105 pounds,
with an average of 12.0% volatile matter. For the last seven hours, the rate was
170 APPENDIX No. 18
140 pounds, with an average of 11.4% volatile matter. The composite sample of
the charge showed 7.1% moisture. The raw coal which blocked the carbonizer when
charged at the end of the run contained 22.8% moisture. The gas consumption for the
last eight hours averaged 460 cubic feet per hour
Run 13, August 29. — Tried to operate with carbonizer lowered to an inclination
of 4016° on the plates, but could not get material to flow. At 421° still had difficulty.
Found an obstruction in one compartment, but even when this was removed operation
was much inferior to the usual running at 45°; therefore raised carbonizer to original
height. Could not raise to a steeper angle without removing the hopper, and the
regularity of movement at 45° appeared as good as could be expected.
Run 14, September 2. — In this and subsequent runs a small booster was used on
the gas line. This gave a steady supply of gas to the furnace in spite of fluctuations
of pressure in the gas main.
This run was continued for about seven hours: four hours at a 70-pound rate, and
three hours at 105-pound rate of discharge. The discharge towards the end averaged
9.5% volatile matter. The gas consumption was 475 cubic feet per hour.
Some of the discharge samples were cut in half in the riffle; one half was analyzed
as usual, the other half was screened through a 10-mesh screen, and the oversize and
undersize analyzed separately. The results were as follows.
VOLATILE MATTER, %
Sample No. Regular Over 10 mesh Through 10 mesh
1 Tie 9.1 ipsa
ie 10.0 10.7 9.8
%§ Led 15.0 11.1
4 15:5 18.4 15%3
Average Lit Pod 10.8
This shows that the larger pieces are not as well carbonized as the smaller ones, and
suggests the advisability of leaving the material a longer time in the carbonizer in the
hot bottom compartment to allow an equalization of temperature to take place. This
point was considered both in the subsequent modifications of the Ottawa carbonizer
and in the design of the full-sized retorts.
It should also be mentioned that it was found that if a sample of the discharge was
analyzed at once and then re-analyzed next day, the repeat analysis might show as
much as 2% more volatile matter than was found in the first. This presumably is
due to the occlusion of air by the carbonized lignite.
Run 15, September 3.— A similar run to the previous one, with discharge rates
of 70, 105 and 140 pounds per hour. No special new features observed. Had rather
more difficulty than usual.
Run 16, September 4. — Commenced a similar run, but found it even more difficult
than on previous day to maintain steady operation. Difficulty appeared to be located
in the chambers over the lowest iron plates. Shut down the run at noon.
When the carbonizer was examined, it was found that the three lowest cast iron
plates were badly buckled and burned. These warped plates had obstructed the
channe!, and caused the difficulties of the previous runs. It was also realized that the
expansion and contraction of the iron plates in the intermittent running of these tests
was largely responsible for the damage to the brickwork of the retort.
MODIFICATIONS. — The three cast iron plates referred to above, which had side
plates and were stepped as originally installed, were replaced by three flat cast iron
plates with half-cut ends, arranged flat in continuation of the carborundum slabs.
Four new cast iron baffles were used at the bottom of the retort, and these were followed
by five of the old cast iron baffles. The new baffles had one-and-one-half inches
clearance, and were ten inches long from baffle to baffle. This increased the capacity
over the carborundum slabs 65%. The cast iron baffles were covered with firebrick,
arranged loosely to allow the ready escape of the gas. This arrangement reduced
the loss of heat radiated to the top of the carbonizer. It also cut down the gas space,
and thus reduced explosion risk. The capacity of the modified carbonizer from hopper
rod to discharge spout was about 75 pounds, instead of 69 pounds as before. The
increased capacity towards the bottom was nearly counterbalanced by the reduced
ebay aa the middle of the carbonizer. The carbonizer as thus modified is shown
in Figure 38.
APPENDIX No. 18 L7}
Period 5. — Run 17, September 10.— A short day’s run. Discharge alternated
between 70 and 105 pounds per hour. At the faster rate the temperature of the retort
fell too low. Gas consumption was 480 cubic feet per hour.
Run 18, September 11.— A short day run. Discharge rate mainly 70 pounds per
hour. Temperature satisfactory. Gas consumption, 515 cubic feet per hour.
Run 19, Seplember 12. — A short day run.
Run 20, September 15. — A fourteen-hour run. Discharge varied from a 70-pound
to 140-pound rate. Gas rate, 530 cubic feet per hour. This was a very unsatisfactory
run. Afterwards it was found that the gas offtakes were choked, and that one of the
loose firebricks had fallen down off a baffle, almost blocking the channel. Before
the next run, changed the gas offtakes to two-inch pipes, each pipe connected by a cross
to a separate vertical two-and-one-half inch pipe. These vertical pipes were open at
top and bottom, but the bottom end was water-sealed in a vessel which also acted
as a tar collector. There were eleven of these offtake pipes.
Run 21, September 18.— A short day run. Discharge, 70 to 140 pounds per hour,
Gas rate, 540 cubic feet per hour. A very windy day, but carbonizer ran fairly well.
and unusually smoothly.
Run 22, September 19.— A long day run. Discharge rate, 70 pounds per hour.
Gas rate, 540 cubic feet per hour. Analysis of the discharge showed a high volatile
matter content in the earlier part of the run, but this came down somewhat later.
It averaged 13.9% volatile matter.
Run 23, September 23.— A short day run. Discharge rate, 70 pounds per hour.
Gas rate, 580 cubic feet per hour. Got good temperatures in the afternoon, with a
consequent drop to 10% volatile matter. Moisture in coal as charged, 6.8%
In some of the earlier runs (for example, Run 9) the volatile matter was reduced
to 10% with a discharge rate of 140 pounds. In the later runs it appeared hard to
reduce to this volatile matter content with only half the discharge rate. It was thought
possible that this was due to the reduction in the quantity of coal in the carbonizer,
with the consequent reduction of time that any piece .of coal remained in the retort.
MODIFICATIONS. — A new design of cast iron baffle was inserted. This design
rested more firmly on the floor of the retort. Also some cast iron fillers were made
which enabled the distance from baffle to baffle to be varied at will. As thus modified,
there were ten baffles in all, instead of thirteen as before. These are shown in Figure
39. Also, a sheet of wire gauze was inserted on the top of the baffles to prevent
anything falling down which would obstruct the channel. A loose firebrick cover was
put on as before. The capacity, as modified, was 89 pounds from spout to hopper,
an increase of 14 pounds.
Period 6. — Runs 24 to 28, September 29 to October 3. — Five runs were made during
the week, each run from 9 a.m. to 10 or 11 p.m. The operation was fairly smooth,
and no poking was required. Early in the week there were some big slips, but by
Friday these had almost ceased. Some high temperatures were attained, with a white
heat at the bottom of the heating flue. The lignite gas production was distinctly high.
During the first run dry lignite was carbonized, with a discharge rate of 70 pounds.
The volatile matter gradually decreased from 11.6% to 5.5%. With a rate of 105
pounds, the volatile matter averaged 11.8%. The gas consumption averaged 610
cubic feet per hour. The carbonizer was unusually cold at the beginning of this day’s
run.
During the remainder of the week a mixture of dry coal with high-volatile-matter
carbonized coal from previous runs was charged. This was done in order to obtain
a large stock of thoroughly carbonized material for briquetting tests.
The top carborundum plate (a plate broken in half to fit the necessary space) and
the bottom iron plate were in poor condition at the beginning, and in very bad condition
at the end of the week. There was one hole completely through between the plates.
The combustion flue was found to be almost blocked with broken fire-brick baffles,
lignite ash, iron slag, etc. It appears that this must have been responsible for much
loss of heat, the gases escaping wherever possible. The under surface of the carborun-
dum plates was scarred by molten iron slag, but they were otherwise in good condition.
The iron baffles came out in perfect condition. The iron plate referred to above had
buckled to such an extent as to almost block the centre of the carbonizer channel.
oe a discharge thimble at the bottom had buckled and blocked the centre of the
channel.
172 APPENDIX No. 18
MODIFICATIONS. — Two iron floor plates had been sent off in June to be “‘calorized’’,
but these had not yet been returned. On the other hand, a full consignment of carbo-
rundum slabs had been received. These carborundum slabs were known as “‘Carbo-
frax’’, the earlier ones being ‘‘Refrax’’. It was therefore decided to reconstruct the
carbonizer with ‘‘Carbofrax’’ slabs and iron baffles throughout. This meant the
abandonment of the test of calorized iron plates which had been intended. The
arrangement is shown in Figure 40. The baffles were covered with wire screen
and loose firebrick covers as before. There were ten two-inch gas offtakes, and three
gas chambers, as shown. The broken fire-brick baffles in the heating flue were not
replaced. This shortening of the passage for the flue gases may, at least partially,
account for the lower efficiency of the retort during the later runs. The iron plate
forming the bottom of the feed hopper was slightly more inclined, to allow the whole
carbonizer to be dropped to an angle of 51° on the plates, a change made possible by
the absence of any stepped plates. The inclination of the discharge spout, which
could not be readily changed, prevented a drop to 45°. The new capacity was 88
pounds, or slightly less than before. A re-calibration of the discharge wheel with
carbonized lignite showed slightly over 3.8 pounds per turn, so this figure is used in
some of the subsequent runs. *
Period 7. — Runs 29 and 30, October 9 and 10.— Two long day runs, treating a
mixture of dry, partially carbonized, lignite. Operation was very smooth, but tem-
peratures were low, and flame smoky. The gas consumption was high: over 700 cubic
feet per hour. The gas consumption figures about this period, as compared with
earlier figures, threw doubt on the accuracy of the gas meter. It was suspected that
the suction of the gas booster has in some way damaged the meter, but no ready means
was available for testing.
The gas burner was changed after Run 30 to increase the air admitted. Four one-
inch air holes were drilled to supplement the existing four holes of three-quarter inch
size.
Runs 31 to 34, October 14 to 17. — These runs were on successive days from 9 a.m.
to 10 or 11 p.m. Had no notable trouble during the week, but again found it difficult
to get a good hot flame. The first three days, treated a mixture of dry and carbonized
lignite, but the fourth day treated dry lignite only, and took careful records. During
this test, ran one hour at a 23-pound discharge rate, three hours at 46 pounds, five
hours at 76 pounds, and five hours at 114 pounds discharge per hour. Noticed that
the movement in the feed hopper did not regularly follow the movement of the discharge
wheel, but found that the trouble was in the discharge chute, which, owing to the
modifications introduced, was at an inclination of only 38° for part of its length. This
test was noteworthy in that the moisture in the coal charged rose as high as 11 to 12%
yo since trouble. The temperatures in the retort, however, were markedly
epressed.
Runs 35 to 38, October 27 to 30. — Four long day runs on successive days. These
runs were carried out by the laborers almost without supervision. Rate of discharge,
mainly 76 pounds per hour. Operation was very satisfactory, but output low. —
The day following Run 38, the meter was found to be completely out of commission,
and it was replaced by a new one,
Runs 39 to 42, November 3 to 6. — Four long day runs, carried out mainly to increase
stock of carbonized material. Operation satisfactory, but output again low. New
meter would only pass 550 cubic feet per hour. The temperature with 520 cubic feet
per hour appeared higher than with 700 cubic feet with old meter.
Run 43, November 17 to 21.— This was an 88-hour continuous run. Tests were
made at intervals during the run, at four different rates of discharge. These tests
were run in each case only after the carbonizer had become reasonably steady under
the conditions prescribed for the test. The general diary follows.
Continuous Carbonizer Run, Nov. 17 to Nov. 21, 1919.
General Diary
Nov. 17 9.00 A.M. Gas lit.
1.00 P.M. Carbonizer filled.
1.15 P.M. Discharge at 10 minutes commenced.
3.00 P.M. Discharge at 5 minutes commenced.
6.00 P.M. Discharge at 4 minutes commenced.
7.00 P.M. Carbonizer up to approximately full heat.
Temperatures remained fairly steady through the night. -
*N.B.—This value varied with the size of the coal, and also with the direction of rotation of the wheel.
APPENDIX No. 18 173
Nov. 18 Weather cloudy, with occasional rain during the day.
9.18 A.M.
to 4.59 P.M.
Test A run at 4-minute discharge. Charge fed in 100 lbs. at
a time, and discharge taken over same periods.
5.00 P.M. Continued run as during test.
Nov. 19 Weather fairly mild, with snow.
5.00 A.M. Turned gas full on.
6.00 A.M. Changed to 3-minute discharge.
9.05 A.M. Test B run at 3-minute discharge. Charge fed in 130 lbs. at
to 5.01 P.M. a time, and discharge taken over same periods.
5.02 P.M. Continued run as during test.
Nov. 20. Weather clear, cold, and windy.
5.00 A.M. Changed to 2-minute discharge.
8.00 A.M. Changed back to 3-minute discharge whilst making some
to 9.00 A.M. repairs and cleaning gas offtakes.
10.12 A.M. Test C run at 2-minute discharge. Charge fed in 200 lbs. at
to 6.00 P.M. a time, and discharge taken over same periods.
6.00 P.M Changed to 24-minute discharge.
ie 20 7.15P.M. Test D run at 2%-minute discharge. Coal fed in one bag of
to 165 Ibs. at a time, and discharge taken over same periods. No
Now 21 12.28 A.M.
trained observer during this test.
Very little trouble with operation during the week. Stopped only when all dried
lignite was used up.
TABLE IX.
CARBONIZER RUN, Nov. 17 to Nov. 21, 1919.
AVERAGE TEMPERATURES, ETC., OVER THREE-HOuR PERIODS.
Date Cy Ga Cs; F, "As Air Coal | Gas, Dis-
and Temp.,| Temp.,| cub.ft.,| charge
Hour Gg °F od TE one id DP °F. °F. | per hr. | period
Nov. 17
12-3 P.M.| 960 890 830 | 1,330 310 50 150 515 10
3-6 1,470 | 1,050 O07 7 1530 410 48 120 523 10-5 ©
6-9 1,590 870 540 | 1,550 450 45 145 487 4
9-12 1,610 720 460 ! 1.550 * ae 490 4
Nov. 18
12-3 A.M.| 1,600 760 470 | 1,560 ne ee 523 4
3-6 1,600 890 480 | 1,570 Wide a 523 4
6-9 1,650 860 470 | 1,580 540 45 120 537 4
9-12 1,640 800 430 | 1,600 570 42 95 520 4
12-3 P.M.} 1,660 900 470 | 1,620 600 42 85 523 4
3-6 1,580 870 470 1,590 610 4] 90 507 4
6-9 1,540 840 480 | 1,540 580 Ae 497 4
9-12 1,570 990 HILO al 500 Ries BAY 480 4
Nov. 19
12-3 A.M.| 1,570 930 530; 41,530 ae 513 4
3-6 1,570 | 1,020 590 =} 715540 1 506 4
6-9 1,550 990 560 | 1,550 a 26 it. 517 3
9-12 1,420 710 p30 } E550 560 28 115 52% 3
12-3 P.M.| 1,280 750 570 | 1,580 580 29 155 530 7
3-6 1,310 780 550 | 1,620 600 27 150 523 3
6-9 1,330 740 490 | 1,560 590 ee 507 3
9-12 1,310 800 5d" 117,530 os 513 a
Nov. 20
12-3 A.M.| 1,250 670 510 | 1,500 ee 520 3
3-6 1,220 730 SSO ti e510 ae 520 3-2
6-9 1,220 710 480 | 1,510 550 a4. Cy 503 2-3
9-12 1,510 620 380 | 1,480 560 eae 75 507 2
12-3 P.M.} 1,500 530 380 1,450 560 24 60 517 a
3-6 E5401 4/0 380 | 1,440 550 25 60 503 2
6-9 1,600 590 370 | 1,430 530 24 ey 507 2%
9-12 1,580 600 370 © (215440 520 24 510 21%
*New fire end inserted.
174 APPENDIX No. 18
Table IX gives the temperatures, gas consumption, and discharge rates averaged
over three-hour periods throughout the run. The temperatures marked C-1, C-4 and
C-8 are taken with the pyrometer fire ends inserted in the charge at approximately
the bottom of the carbonizer and one-third and two-thirds of the way up, respectively.
Temperatures F-9 were taken at the top of the heating flue, and A-2 at about two-
thirds of the way down the air preheating flue. It should be noted that the tem-
peratures of C-1, C-4 and C-8 vary widely according to the exact position of the fire
end: that is, with its proximity to the strongly heated floor of the retcrt. The coal
temperature is also uncertain.
Table X gives the average results over the test periods run. A sample was taken
from each bag of coal charged, and a corresponding sample of the discharge. These
were analyzed separately for moisture and volatile matter. Composite samples were
also prepared for each test period, and these were more fully analyzed. The analyses
in this table are the averages of the separate samples.
The yields, especially at low rates, are uncertain, due to possible difference in content
of retort and spout at beginning and end of test. The yield for Test B is apparently
too low. There are also marked discrepancies in the analyses for this test. The duty
rates noted are the pounds of coal charged per 24 hours per square foot of effective
floor area. The width of floor between the baffle walls was 1034 inches, and the heated
floor length almost 9 feet, giving an area of approximately 8 square feet.
Table XI gives the analyses of the composite samples of charge and discharge during
the test periods.
TABLE: X,
AVERAGED RESULTS THROUGH TEST PERIODS.
D
Discharve Heriod..Ae.2 ee minutes 4 : 2% 2
Duration oftests = 5, 7 oF ©. fas ieee hours| 7.7 7.9 5:2 7.8
Gds ‘consumption -eue she ee c.f. per hr.| 517 523 508 510
Gas consumption........c.f. per lb. of discharge} 10 7.6 6.0 4.9
Coal charged: aoe
Weight, moist as charged......... Ibs. per hr.| 91 115 11 5"326 154
Weight;tdry-hasis®.. 2.38. 8 Ibs. per hr. 78 108 114 Loy
Duty: rate ae ee, ee a Oe, ee 270 345 aH) 460
Moisture*content) 95. 8. eee ee % 13.8 5.6 9.7 10.7
Carbonized residue:
Weight 225 Oe piten 2) Soe ene Ibs. per hr. 51.8 68.7 84.7 104.8
Weight per 1” width of retort.....lbs. per hr. 4.8 6.4 7.9 9.8
Yield; from coal as'charged 22). 7-0 2 eas % 56.9 59.9 67.2 68.0
Yield, from-dry Coaly peer ee DAs ae % 66.1 63.4 74.3 76.2
Volatile matter content.......... TOME Min eke % 5.1 7.0 16.3 18.1
Temperatures:
Airy.) o#ie) 4. Gad eee ee ee eee os 42 28 24 24
Coal in feed: hopper 3... 5) seen, ue oF 93 140 ag 60
Air preheating flue!) foot oe ee °F.| 590 577 525 Oe ae
Heating flue, at top.ah.4)545.4 cere °F.| 1,605 1,580 1,440 1,450
Coal in retort; at 44downs, 4. es Fa) 455 550 370 385
Coal-in'retort, at: -24dowm). .fi3 een ee °F.| 850 750 595 535
Goal in retort, at bottom’... .\ 2 ee 5 1,630 1,350 1,595 1,520
APPENDIX No. 18 1i¥ §3)
TABLE XI.
ANALYSES OF COMPOSITE SAMPLES OF CHARGE AND DISCHARGE.
P re
Mere CTIONTS G0 ot et ee ee. Oe i. | B
Charge ‘Discharge Charge ‘Discharge
LTE a gS he clon SR 2 AP rag SR % 13:7 aay. By gts
“As ot SERRE EY 9 Rete sh cm ienley ASB a Ee iI i, eek 15:1 4 bee
AMAT Matter 41). c eae bee Ae % 32.4 6.5 38.2 Likk
Prigece CaArDON Sent ee Gee ie at % 40.7 70.8 41.6 67.7
PEEL EAU Seco bsetn Ee Ree re a. be Inzo 10.9 1.25 6.1
SalOrinc. Value. os ..: oa.) .b.t.u- per 1b.) , = 8,930 11,180 8,940 11,140
AN oad na la 7 Ratios ei ee ape NI OR D re
Charge | Discharge} Charge} Discharge
IVICRSLUICCIN ESR a ee ee ss % 9.7 sere 10% aaa
LEN OS at th Soa a ae en % 13:5 19.6 13.6 19.6
MelALIEANALLCT bs wae Ue Colas oa. 17.8 34.0 18.6
PremerCat ONG ss os mw sos k.s « % 42.4 62.6 41.7 61.8
OD A BI ell 9 2 Oe rie eee 1.25 aan 1:25 a
SPAMOLING ValUG ina iS we! B.t.u. per Ib.| 9,390 11,050 9.200 11,100
SUMMARY AND CONCLUSIONS OF TESTS WITH OTTAWA CARBONIZER.
The tests with this carbonizer were taken as proving that the basic design was both
workable and satisfactory; that partially dried lignite could be carbonized to any
desired extent; and that it could be made to flow steadily down through the retort
by means of its own weight, controlled only by the discharge mechanism at the bottom.
The tests, however, also showed that the actual construction of this carbonizer was
Been aclory in many ways, but principally because it could not be maintained
gas-tight.
It was considered probable that an increase in the length of the retort, with a cor-
responding increase in the velocity of the coal, would tend towards smoothness of
operation rather than the reverse. It also seemed certain that a very marked increase
of efficiency could be obtained with a wider retort, where radiation loss would be
relatively small.
It was obvious that this retort could not be operated with the gas produced from
it, even if the brickwork had been tight enough to allow this to be collected; but it
did not seem hopeless to expect that the contrary might be the case in the larger and
better constructed carbonizer, built later at Bienfait. (See Figs. 41 and 42).
Cast iron was shown to be unsatisfactory as a floor material, but carborundum plates
appeared to be suitable. The cast iron baffles, on the contrary, worked well and
stood the heat. The carbonized lignite was sometimes found to have a higher ash and
lower calorific value than might be expected; but with leaky brickwork some com-
bustion of the charge on windy days was almost inevitable.
No information could be obtained either as to the yield or analysis of the gas and
tar produced. For this information the earlier work has to be consulted, or the results
obtained with the laboratory model retorts.
176 APPENDIX No. 19
APPENDIX" 19
The Lignite area of Southern Saskatchewan.
By A. MacLean.
The work begun in this area in August of 1917 was continued during the present season. Owing to
the lack of student assistants it became necessary to ask J. H. Lill, who for the past three years has been
camp assistant, to act as field assistant as well. It is a pleasure to record the high efficiency of Mr. Lill in
this capacity.
The field to be covered by the work extends from the Manitoba — Saskatchewan boundary to Range
21, W. 2nd. Meridian, and from the International boundary on the south, northward to the north side of
the eighth row of townships. Inthe western part of this area the topography is characterized by the hilly
front of the Missouri Couteau and the broken and irregular uplands to the southwest of it. From the foot
of the couteau the country slopes gently to the eastward falling from an elevation of 2339 at Ceylon (twp. 6,
range 20, W. 2nd.) to 2028’ at Webster (twp. 5, R. 16, W. 2nd.) to 1870’ at Estevan, (twp. 2, R. 8, W. 2nd.),
and 1610’ at Gainsborough near the Manitoba boundary. This part is deeply dissected by the valley of
the Souris, and in the region adjacent to it, by the valleys of its tributaries, Long Creek, Short Creek and
Moose Mountain Creek.
The best exposures are in the vicinity of Estevan, and from here down theriver to beyond Roche Percee.
Other exposures are to be found in the neighborhood of Halbrite and in the valleys of the Missouri Couteau
region. For other parts of the field it is necessary to depend on the records of drill holes. For access to
these the writer returns thanks to the well drillers. farmers, and prospectors of the district. It was hoped
to work out a type section in the region of the best exposures (Estevan and Roche Percee) and with the aid
of this section to catalogue the rock of the limited and isolated exposures in other parts of the area. This
seems to be the only plan feasible but it is attended with considerable difficulty. The rocks, sands, clays
and lignites are of shore formation origin, and as is common with this type of deposit the lateral variation
is considerable, so that correlation through the criteria of physical characteristics is open to question.
Fossils are very scarce and even when present it is to be remembered that the present lateral variation in
the rock is but one expression of the original variation in conditions which would have their effect on the
fauna as well as on the disposition of the time. An attempt to compile a composite section (subject to
subsequent revision) of the eastern part of the district gives the following arrangement.
ComPosITE SECTION, SoutH SASKATCHEWAN LIGNITE FIELDS.
ROCK Thickness | Depth IKlevation
1,886
[Aa 4 BT] | Cr eee n Gio tie ODN Peat Bets WA en rene s LEONG ah hes Boek Seared ae 6 6 1,880
B. Dark brownish green colloidal clay with a little silt, weathering to
a coarse nodular mud, showing on exposure surface no sign of
Deane. Cae See ee ee ee eee te eee teen tae eee 10 16 1,870
Cl. Lighter colored colloidal silt, with bedding well marked by reddish
colored laminae or bands. This color is also often expressed in
streaks:and flashes).”: & civ ASE Pi. SP Sees Ss ee Ee eee 6 22 1,864
Lignite seam (2’’)
C2. Griatrn he bis cis be nuts SAR 36.1 6.9 10.8
1438 Same, 1,000’ S. and 900’ W. of tipple........... tay, 730 10.8
1439 Western Dom. Collieries, Ltd., Bienfait-Taylorton
seam, Bienfait, W. entry 750’ W. of mine head... 34.4 6.8 10.4
1440 Same, E. entry, 1,000’ E. of mine head.......... 36.3 6.3 9.9
1441 Sask. Coal Co., Ltd., Roche Percee, upper seam,
Weentry..400' from mine head.../) 12 mess Jaane ape ff 6.3 9.4
1442 Thistle Mine, (J. A. Auld), Roche Percee, upper
seam, entry, 600’ from mine head. Mineclosed | .. 34.2 5.8 8.8
1443 Interprov. Coal Co., Ltd., Roche Percee, 2rd seam :
fromptop, O00. trom@mine head... ... vss «aos 33.1 TOR! iRise a
1444 Same, seam below that now mined, test tunnel,
100°). of mine head; 25’ 1m tunnel)...4¢ ee 31.4 10.4 Loe
180 APPENDIX No. 21
APPENDIX 20 (Continued)
ae MINE pire iee Ash dried at
y 220° F.
1445 Duncan Campbell’s mine, Roche Percee, main
entry, 500" fromumine Neaueemeunom arr cine 34.5 D.3 8.0
1446 Bienfait mine, Bienfait, Bienfait-Taylorton seam,
460! Ni and 850 ava Oletip ples eee aerate 36.3 5D. 2 8.2
1447 Same, 1,500’ S. and 600’ FE. of tipple............. avhads 5.7 9.1
1448 Bienfait Commercial Co., Ltd., Bienfait, Bienfait-
Taylorton seam, 240’ S. and 200’ E.. of mine head OVl ef Be 8.4
1449 Crescent Col. Co., Ltd., Bienfait, Bienfait-Taylor-
ton seam, 180’. and 100’ S. of mine head...... 36.1 5.5 8.6
1450 Excelsior Coal Co., Ltd., Pinto, air shaft entry,
(OF TrOM An Ne; BeEaG seer Erte elena ee Stata He 8.5
1451 Riverside mine, (A. Wilson), Taylorton, Bienfait-
Taylorton seaim, 400’ from face of hill......... 34.7 6.5 10.0
1452 W. Bowman’s mine, Short Creek Roche Percee.. - 34.0 520 7.6
1453 W.R. Armstrong’s property, outcrop, 4’ from sur-
face vertically and 50’ horizontally............ 37.0 as 8.4
1454 Wee McGregor mine, 2nd seam from top, Mine
CLOSER RE ee ee GCs clic tore 23R 16.6 Zone
1455 W. E. Price’s mine, Roche Percee, upper seam,
350 ctromimine ead earn tee eee ane 34.3 Gre 9.9
1461 Slack from Manitoba & Sask. mine, sample taken
Dyrotansheld Sie ewe es eee henna 32.9 12 oN 18.1
APPENDIX No. 21
RECOMMENDATIONS TO THE CHAIRMAN RE SITE OF PROPOSED PLANT
Factors Affecting the Situation.
The following are the factors affecting the selection of the proposed plant:
I. — Capacity of adjacent mines to supply raw material of proper quality for an extended period.
Il. — Water supply.
III. — Cheapness of raw material.
IV. — Quality of underlying lignite in case Board might find it necessary to develop its own mine.
YV.— Cheapness in shipping product to operating railway.
VI. — Drainage.
VII. — Problems of housing staff.
DISCUSSION :
(I) Capacity of adjacent mines to supply raw material of proper quality’ for an extended period : The
capacity of the principal mines, the product of which is satisfactory to us, is as given in accom-
panying table. Opposite each mine will be found also the percentage moisture content as mined,
and percentage ash content when reduced to a dry basis.
From this table, it will be observed that the two principal mines are the Western Dominion Collieries
and the Manitoba and Saskatchewan Coal Co., either of which is satisfactory from our point of
view. Owing to the size of these mines, it is probable that the Board will not have to undertake
any mining operations on its own account.
(II) Water Supply: From analyses, we know that the water of the Souris River will be satisfactory for
all our purposes; hence, other factors being equal, it is cheapest to obtain water from the river.
The two above-mentioned companies (the M. & S., and the W. D. C.) already have in operation
a pipeline and pumping unit, which are more than sufficient for their needs. We understand also
from Senator Watson, that they will be willing to come to some arrangement to sell us water.
Actual rates could be discussed at a later date.
If the plant were located at any other point than in the immediate vicinity of the pipeline, it would
become necessary to either go to heavy expense to put in a special pipeline, or to use well water
with the prospect of having to drill extra wells. See map Figure 4.. To date, the analyses of
well waters show that these are not so suitable to our needs as the Souris River.
(III) Cheapness of raw material: There are only three methods of getting raw material for our plant:
(a) — Mining ourselves. ;
(b) — Purchasing coal from immediate vicinity with delivery by mine cars or lorries.
(c) — Deliver all material from mines located at a distance, by means of freight shipments.
APPENDIX No. 21 181
(a) The Board should commence mining operations only as a last resort, — in the event of business
conditions arising which compel us to adopt this method.
(b) The purchase of either slack or run-of-mine lignite from existing collieries in the immediate
vicinity will undoubtedly give us the cheapest coal, for the reason that we avoid excess hand-
ling charges and expensive freight shipments (especially i in view of the fact that about 35% of
the charges would be incurred in shipping water).
(ec) While this method is a possibility, it will prove very expensive. For example: To ship lignite
from Bienfait to Estevan would involve an initial charge of 80c a ton (straight freight charges)
which, after allowing for presence of moisture would represent from $1.25 to $1.50 preliminary
fixed charges on the finished briquette. If, in addition to this, the charge for moving lignite
from Taylorton to Bienfait be included, it would make the figures even worse. In view of
the foregoing, it will be seen that it is practically essential, for the success of our project, to
purchase our raw material free of shipping charges.
(IV) Quality of underlying lignite in case Board found it necessary to develop its own mine: The lignite
throughout the Estevan area is too high in ash to be even considered as a source of raw material.
In the Souris region, the only mines that are suitable from this point of view are those already
listed, and it will be noted that these mines all lie at the easterly end of the field, that is to say, in
the region of Bienfait, Shand, Roche Percee, Taylorton and Pinto. The Board feels that the site
should be located in such a manner that, if through business jealousy or for other reasons it became
impossible to get slack at a reasonable ‘figure, they could immediately start to operate their own
mine. In view of the foregoing discussion on shipping, it will be seen that it is not feasible to have
the mine at one spot and the plant at another hence the plant must be located over a seam with
a low ash content, and the location must be so chosen that other benefits, such as water supply,
shipping ete., are all safeguarded.
(V) Cheapness in shipping product to operating Railway: If the plant be located on any of the operating
railways, the only expense will be the overhead, interest etc., on the building of a short siding, plus
switching costs. If, on the other hand, the plant i is not located beside an existing railway, we must
either pay for the erection of a long spur, plus cost of switching by our own locomotives, or pay the
switching charges of the companies who now operate private spurs. We are informed by Mr.
Lanigan, F. T. M. of the C. P. R. that the present charges between the Manitoba and Saskatchewan
Coal Co., and Bienfait, and between the Western Dominion Collieries and Bienfait are about
$2.50 per car. These two private spurs are operated jointly by the two mentioned companies, and
it would be probably possible for the Board to come to an arrangement to have their locomotive
move our cars over these lines, especially in view of the fact that we shall be purchasing material
from them if the Board adopt. the present recommendation re site.
(VI) Drainage: The drainage factor is one that can hardly be discussed indetail until the actual site has
been chosen. A great deal will depend on the elevation of the ground etc. etc. The problem before
us is to dispose of a small quantity of effluent from the toilets in the office building and plant, a
small quantity of liquid discharges from the Pe DOEeT Oey and a much larger quantity of clean water
used for cooling purposes.
(VII) Problems of housing staff: These problems are serious, and in the long run may compel the Board
to spend a considerable amount of money in construction of houses, bungalows, and perhaps a
small club, depending upon the character of the staff. It is to be noted, however, that these
problems would have to be faced at any site, except possibly in Estevan itself, However, Mr.
Lanigan, of the C. P. R. informs us that Estevan itself is not overbuilt and it would only be possible
to obtain houses in Estevan by ousting present tenants.
TABLE 1
List of Mines Producing Lignite of Quality Satisfactory to the Board
Output, add 25%
total merchantable coal
1915 1916 1917 1918
MINE
Bienfait Commercial Co., W.-
J. Hawkinson, manager.....
Bienfait Mine, (Hosmer) rok es
L. Hamilton & R. J. Hassard,
SE Sap pl dig he eT NEE niles
Manitoba & Saskatchewan....
OTA Ott tel fae wanes Meee
Wm. Addie, manager..
Western Dominion Collieries
Ltd., Andrew Millar, mana-
Ses ees Ser Toisk Daath ae tcTees 19,261
41,040 | 57,306] 77,393 65,922
30. L 63,584 71,828 76,259 75,369
(Slack) 32.9
(lun eke 6s Poe et ON aera 3-2-6 34.4 10.4 88,500 | 91,200} 113,214 | 104,834
36.3 9.9
Riverside Mine, A. Wilson,
OWDER. 29 Genet aoe ea 34-1-6 34.7 10.0 2,846 ele *1,389
Excelsior Coal Co., Ltd....... 30-1-5 Boe SED) Lak, Sd Pade cae 434
Souris Valley Colliery E. Sid-
reas OWNCI cre reay ike von 24-1-7 34.5 Go 789 540 945
W.E. Prices, Mine,. ....]| 19-1-6 34.3 9.9 Re crat |nchote eet ae eae
Saskatchewan Colliery Co.;
Jigar TiO? fe eaten t 29-1-6 33.7 9.4 420 2,600
Thistle Mine, J. A. Auld owner,| 2 9-1-7 34.2 8.8 1,242 391
William Bowman,............ 25-1-7 34.0 7.6 ‘ SER, Be SHEE Por
Wak Armstrong;.....20h cs ss cia? 37.0 8.4
Duncan Campbell,........... AaB: 34.5 8.0
Crescent Collieries, Ltd. J. R.
Brodie, manager........... 29-2-6 36.1 8.6 398
Outputs are given in tons of 2,000 lbs.
*This mine has been closed since March, 1918.
182 APPENDIX No. 22
DEFINITE RECOMMENDATIONS:
The staff, after a thorough consideration of the whole problem recommends that the Lignite Utilization
Board, purchase or otherwise acquire a site somewhere in the northern half of section 3, Township 2, Range
6. The size should be at least twenty (20) acres. The advantages of this site are:
(a) —It is over excellent coal.
(b) — It lies half way between the two largest operating companies, and a spur siding could be run to each.
(c) — It is in close proximity to the pipeline now supplying water to the Western Dominion Collieries
and the Manitoba and Saskatchewan Coal Co.
(d) — The only shipping charge to get the product on to the operating railway at Bienfait (the C. N.
or C. P.) is $2.50 per car on either of the privatelines. (Figure supplied by Lanigan from memory).
It is to be noted in this connection that this charge is on an all coal basis, nothing being paid to
ship moisture.
(e) — Drainage in this Section will probably be simple owing to the height that the land lies above the
Souris River.
The disadvantages of the site are:
(a) — The lack of hotel accommodation and other usual troubles occurring in an isolated place.
(b) — No houses are available for the senior members of the operating staff, such as Manager, Superinten-
dent, etc.
(Sgd) R. deL. FRENCH
(Sgd) E. STANSFIELD
MontREAL, Oct. 1st, 1919. (Sgd) Lrsstie R. THomMson
APPENDIX No. 22
Description of the Plant
By R. A. Srrone and I. F. Rocue.
The Order-in-Council creating the Lignite Utilization Board defined as its objective the commercial
demonstration of a process for the carbonization and briquetting of Canadian lignites. Such a demon-
stration naturally involves the construction of a plant sufficiently large to collect accurate data as to costs,
maintenance and repairs on machinery, and such other information necessary for establishing an industry.
With this end in view the Board erected a plant, sufficiently large to turn out 100 tons of briquettes per
day, 3-14 miles from the town of Bienfait, Sask., in the heart of the Souris field. The development of this
district is, as yet, not very extensive, and all the large mines are within a radius of 4 miles of the location
selected by the Board. Fig. 4 shows the location of the plant in respect to all the operating mines, and in
addition gives a great deal of information on water supply, land levels, mining leases, etc., as existing in
1919. As will be noted, the site, which comprises 20 aeres of ground, is midway between the Western
RTE eR and the Manitoba & Saskatchewan Coal Company, the two largest producing mines
in the field.
In order to give railway connection to the plant one of these mines has constructed a spur and the
other is under contract to do so when the plant is on an operating basis. Each of these mines — the M.
& 8. Co. and the W. D. C. —, has a railway spur to Bienfait, and thus by means of the present connection
and the existing railway trackage at Bienfait, the L.U.B. plant has connection will all the other mines in
the district so that coal may be purchased from any or all of them.
The following description of the plant and its operation is made in order to record permanently the facts
regarding the original installation, as designed and erected in 1920— 1921. In other appendices will be
found references to subsequent changes. ‘The description will be given under the following heads:—
(a) General Layout.
(b) Type of Construction.
(c) Raw Lignite Handling Equipment.
(d) Drying Equipment.
(e) Carbonizing and gas purification Equipment
(f) Mixing and Briquetting Equipment.
(g) Storage and Loading.
(h) Power House.
(i) Water Supply.
(j) Sewage Disposal.
(k) Office Building.
(a) GENERAL LAYOUT
The plot of ground on which the plant is built comprises 20 acres, secured by lease from the Western
Dominion Collieries. The reasons for leasing rather than an outright purchase are fully discussed in Sec-
tion IIT of the Secretary's report. A reference to the data map in Fig. 4 shows that the land in this parti-
cular locality is decidedly flat which makes drainage a difficult problem. It is also without protection from
wind and fire, and it was, therefore, necessary for the Board to provide a system for water disposal and
adequate fire protection. To protect the buildings from drifting snow in the winter months a wind break
of trees has been planted on the west side of the stite. i
The plant itself consists of a dryer building, a retort house, and a briquetting room; a ‘power house, a
building for office and laboratories, a briquette storage bin, storage tanks for tar, water supply reservoir
and elevated tank, sewage and water disposal system, a binder unloading shed, and a shed over the track
hopper — together with trackage in the yard for the storage and moving of cars. The general layout is
shewn in I’ig. 20. ; :
APPENDIX No. 22 183
The process consists of crushing and storing the raw lignite, drying it in preparation for the retorts, car-
bonizing and briquetting the char, and the storage and shipping of the briquettes. The general arrange-
ment is shown in the flow sheet which appears as Fig. 6.
The dwellings for the employees consist of a boarding house for single men, and fourteen houses of three
different types, i.e., Class A, Class B, and Class C. There are two Class A houses builtin one block. These
houses are for the use of the Manager, Chemical Engineer and any other resident executives. There are
four Class B. houses built in two blocks of two each, and eight Class C houses built in two blocks of 4 each.
The classification has reference to size only, and in all the houses the maximum of comfort with a minimum
of expenditure has been aimed at. The layout of the houses is shewn in Fig. 20.
(b) TYPE OF CONSTRUCTION
Owing to the uncertainty of the fire hazard in an operation of this nature the policy adopted by the
Board was to construct the plant proper as nearly fireproof as possible. The main buildings were cons-
tructed of brick and steel with galvanized iron for a roofing material. The steel for the columns as well as
the metal bins was fabricated and erected by the Dominion Bridge Company and the brick used in the
walls was supplied by the Estevan Coal and Brick Co. of Estevan, Sask. Plates 4 to 8 show the plant
under construction at different dates and indicate the type of construction used.
The only wooden construction used was the roof for the power house, the binder unloading shed, the shed
over the track hopper, the shed enclosing the tar tanks and the briquette storage bin. The fire hazard in
the sheds and bin is not very great, hence this cheaper type of construction. The houses are of wood but
they are sufficiently far removed from the plant for fire protection. In addition hydrants and hose are
provided for immediate use in close proximity to these dwellings. The location of these hydrants and hose
boxes has been approved by the Western Canada Fire Underwriters Association.
The wisdom of building fire proof buildings was amply demonstrated during the early stages of plant
operation. A slight explosion within the retort resulted in a large amount of incandescent coal being dis-
charged on to the floor of-the retort house which immediately took fire and burned out two window
sashes and the electrical connections. The damage was small but in another type of building this accident
might have resulted more seriously.
(c) RAW LIGNITE HANDLING EQUIPMENT
This equipment includes the machinery for the unloading of the raw lignite as it is delivered from the
mines, and for its crushing and storing preparatory to being processed.
The lignite is delivered in bottom dump steel cars, and is dumped into a large double compartment hopper
through grids capable of passing 10’’ lumps. The coal is discharged from the bottom of these hoppers by
means of two lateral conveyors which discharge to an inclined apron feeder leading to the crusher. The
erusher is a Jeffrey swing hammer pulverizer type B — No. H. 3 — driven by a 75 H. P. Lincoln electric
motor at a speed of 1,000 r. p.m. It was intended to crush the coal below 34’ and in this respect the ins-
tallation proved satisfactory (see Appendix 23).
The entire equipment for the handling and crushing of the raw lignite was supplied and installed by the
Jeffrey Manufacturing Co. and was designed to handle a maximum of 50 tons per hour.
The crusher discharged into a vertical elevator placed between two large cylindrical bins where the
crushed coal was stored. These bins are 39 feet high and 25 feet in diameter and have a capacity of 300
tons each so that a three days’ supply can always be maintained in the event of delaysin delivery. Owing
to the danger of fire due to spontaneous combustion these bins were constructed of reinforced concrete and
steam connections were made so that a jet would be available in case of serious outbreaks of fire. (The
actual results obtained in this connection are described in Appendix 23).
The bins are provided with a conical bottom for discharge, and a belt conveyor is provided which collects
the coal from the two bins and delivers it to an inclined bucket elevator which carries the coal to the dryer
bins. Fig. 21 shows an elevation of these bins together with their discharging device.
(d) DRYING EQUIPMENT
In appendix 18 it has been clearly shown why the decision was made to dry and carbonize in two opera-
tions. The drying apparatus selected were two C. O. Bartlett and Snow rotary dryers. These machines
are of somewhat different construction to the ordinary single shell rotary type, and are known as the
four compartment coal dryers. They consist essentially of revolving steel cylinders 55 feet long and 6
feet in diameter, provided with the necessary fittings for the continuous introduction of wet lignite, for the
discharge of dry lignite, and for the removal of the evaporated moisture. The first 20 feet of each drum
is a straight cylindrical section, and the remainder is of four compartment construction having clear spaces
between the compartments, through which the hot gases will circulate. They are enclosed in a brick
work setting quite similar to the settings of horizontal return tubular boilers.
The wet lignite is introduced into the inside of the cylinder at one end and is divided into four independent
streams when it reaches the four compartment section. It is constantly elevated by a series of lifting
flights properly arranged inside the cylinder, and showered through the hot gases and against the hot
cylinder plates. At the same time it is propelled toward the discharge end, where it is discharged after
the desired amount of moisture has been drawn off.
The hot gases which supply the heat for drying are introduced into the brick setting at the feed end, and
circulate first around the outside of the cylinder and then through the space between the compartments,
thus coming in contact with the heating surface of the cylinder and giving up the greater portion of their
available heat. After the gases have passed around the outside of the cylinder they may be directed by
means of a series of dampers in any of three ways;
1. They may be passed directly into the fan or stack.
2. They may be passed through the inside of the cylinder in the same direction as the lignite and in
direct contact with it, and then into the fan or stack.
3. They may be passed through the cylinder in an opposite direction to the lignite and in direct contact
with it and then into the fan or stack.
Fig. 24 shows a diagram of this damper arrangement and a sectional elevation of the setting, and plates
9 and 10 show the brick work setting and shell during erection. As will be noted a furnace is provided for
supplying heat to the dryer shell. This furnace was in addition to a connection from the carbonizers and
was to be used only in the event the waste gases from the carbonizers proved insufficient for the drying
operation.
184 APPENDIX No. 22
Two dryers were installed which had a guaranteed capacity of 150 tons each. It was considered at the
time of their purchase that a possibility existed of selling dried raw lignite as a separate product, and pro-
vision was made for diverting the output of one dryer if such a market developed but up to the present
there has been no call for such a product.
Steel bins were provided, capable of holding 50 tons of raw crushed lignite, which served for feeding the
dryers. A ratchet device operating a small screw conveyor regulated the amount of coal entering the shell
thus ensuring a constant feed. Plate No. 10 shows this feeding device also the furnace referred to above.
The dried lignite as discharged from the dryer was elevated by a vertical bucket elevator discharging to a
screw conveyor which served for distributing the coal to any section of the dried lignite bin desired. The
sequence of the inclined elevator and dryer feed bins is shown in Fig. 6.
(e) CARBONIZING EQUIPMENT
This equipment includes the retorts, the gas purification system, the handling machinery necessary for
feeding the dried coal to the retorts, and such conveyors and elevators as were required for removing the
carbonized residue and conveying it to the briquetting room. The bin for the storage of dried lignite is
of steel construction, capable of holding 600 tons of dried lignite, with discharge spouts located above the
retort hoppers. Flexible steel chutes are provided so that two carbonizers can be supplied from the one
discharge.
Six carbonizers were installed, and as they have been fully described in Appendix 18 no further descrip-
tion will be included here. The location of the retorts is shown on the plan view of the retort house, Fig. 19,
and a section of the carbonizer and bin for feeding is shown in Fig. 41. As will be noted the retorts are
built back to back so that each bench consisted of three retorts, Nos. 1, 3 and 5 on east side and Nos. 2, 4
and 6 on west side of carbonizer building. The dried lignite is fed in from the top as above described and
passes through the retort by gravity, its rate being controlled by the speed of the discharge paddle at the
bottom. It is carried by screw conveyors to an elevator which discharges in the storage bin above the
briquetting building.
The discharge mechanism of the retorts is probably worthy of mention here as this feature gave consi-
derable trouble until it was redesigned. The original method of removing the carbonized residue was by
means of a gate valve which was set to allow the proper amount of flow through the opening by gravity
while the residue was cooled by means of water sprays. This system of withdrawal and cooling was an
absolute failure, and a new discharge was designed which removed the coal positively by means of a paddle
wheel, the speed of which was adjustable, the.cooling being effected by means of a water jacket. This
system was fairly satisfactory. Fig. 22 shows a sectional perspective view of the carbonizers as originally
designed and installed.
The gas from the retorts is taken off under a slight pressure by means of offtake pipes, and after being
purified is returned to the combustion chamber of the retorts. 'The apparatus for the recovery and puri-
fication of the gas was designed and installed by the American Chemical Machinery Company of Chester,
Pa., the representatives on this continent of Blair, Campbell & McLean — Scotland. The details of th
equipment and its location are shown in Figs. 17a and 19.
This apparatus regulates the flow of gas from the carbonizers; cleans the gas of dust, tar and water
soluble matter, thus making it suitable to be returned to the carbonizers and burned as a fuel; separates
t he tar and solids from the scrubbing water; cools the water for reuse and collects the tar.
The apparatus consists of the following:
(a) Dust Separator.
(b) Centrifugal Scrubber.
(c) Exhauster.
(d) Gas Control Regulator.
(e) Seal Pot.
Observation Box.
Separating Tank.
Interchangeable Type Cooler.
Storage Tanks.
_-~
~
—
OE NO a el el oo ell oan
(9) Pumps. ; : , :
(k) All necessary piping, fittings and valves to make,the installation a complete unit.
The above letters appear as identification marks in Fig. 17a, — showing layout of gas handling
equipment.
Operation
The gas, by virtue of the Exhauster (c) is pulled from the gas outlet of the carbonizers, at a pressure
of from zero to one inch water gauge, through the raw gas line to the dust separator (a). From the dust
separator, the gas passes directly into the bottom of the scrubber (b), where it is intimately brought into
contact with the scrubbing water as described below, which removes all light tar and water soluble cons-
tituents. It then passes through the exhauster (c) as clean gas into the manifolds leading to the carbonizer
burners. Water is drawn from one of the storage tanks through the interchangeable cooler (h) to the
scrubber (b), flows through the scrubber, seal pot (e), observation box (f) and into the second storage tank,
whence the tar and water are finally separated and the process repeated. The storage tanks are connected
4a the ae aly such a manner, that while one tank is being filled with the emulsion, the second tank is
eing emptied,
(a) Dust Separator
The function of the dust separator is to remove all dust and solid matter from the fresh gas as it comes
from the carbonizers and to take out the heavy tars. The separator is constructed entirely of cast iron with
internal baffle and water spray nozzles and set over a sump which forms a water seal and reservoir for the
dirt. One side of the sump is inclined so as to facilitate the removal of the dirt and heavy tars.
(b) Centrifugal Scrubber
The centrifugal scrubber removes from the gas all light tars and water soluble matter. It is constructed
entirely of cast iron with steel shaft supported by radial and thrust bearings. Cast iron buckets are securely
fastened to the shaft, which is made to rotate at a speed of 250 r. p. m. by means of a5 H. P. motor through
a pulley fastened to the shaft. The gas enters the scrubber at the bottom and rises counter flow to the
scrubbing water. The gas, in travelling upward, is made to pass from side to side through each scrubbing
chamber and as the shaft revolves the deflectors act as a scrubbing medium and impart to the gas a centri-
APPENDIX No. 22 185
fugal motion. The washing water is fed at the top of the scrubber and is carried by means of division
plates into the above mentioned buckets, where it is immediately driven by centrifugal force through the
deflectors in the form of a fine spray. It then travels from plate to plate and bucket to bucket. until it
reaches the bottom, whence it is discharged from the scrubber, carrying the tar and impurities with it.
(c) Exhauster
The suction side of the exhauster is connected to the gas outlet of the scrubber, thus pulling the gas
through the entire system and discharges the gas into a manifold which leads back to the burners in the
earbonizers. The exhauster is of Canadian-Buffalo Forge type and is complete with outboard bearings,
and motor mounted, as a complete unit, on the same cast iron base.
(d) Gas Control Regulator
The function of this instrument is to regulate the pressure of from zero to one inch water gauge, at the
gas off-take of the carbonizer and to deliver the gas back to the carbonizer burners at a pressure of about
six inches water gauge. The regulator is of the type manufactured by Isbell-Porter Co. with outside
adjustment to give the exact regulation desired.
(e) Seal Pot
The seal pot prevents any leakage of the gas from the scrubber or of air into the scrubber at the water
discharge connection. _ It is constructed entirely of cast iron with internal baffle and brass air cock on cover
to prevent the formation of an air pocket. ,
(f) | Observation Box
The observation box is connected to the discharge of the seal pot in order to make it possible for the
operator to observe the exact physical nature of the scrubbing water as it leaves the scrubber. The box
is constructed of cast iron with pyrex glass sides held in place by polished brass frames with a brass water
cock on the top to prevent the formation of an air pocket.
(g) Separating Tank
The separating tank is constructed of steel plate with loose cover. The object of this separator is to
separate the tar from the water, keeping the emulsion warm enough so that the tar will float, and draw off
the water from the bottom and the tar from the top. Overflows are provided to facilitate its operation.
(h) Interchangeable Cooler
The interchangeable cooler takes the once-used water after the tar has been separated and cools this
water to be circulated back through the scrubber. It consists of two cast iron headers connected by long
steel tubes expanded into tube plates which are fastened to the headers and each end is covered by a cast
iron cover plate. The baffles in the headers cause the water to flow back and forth in a zig-zag path
through the tubes while water is made to flow over the tubes. On the top of each header are pipe plugs
which can be removed when starting up to prevent the formation of air pockets.
(i) Storage Tanks
Two large, mild steel storage tanks with steam coils and traps are used for collecting the tar and water.
Both tanks and one coil were furnished by the Lignite Board, but the coil for the second tank was designed,
furnished and installed by the American Chemical and Sugar Machinery Company.
(j) Pumps
Three horizontal, direct acting, simplex steam-driven pumps are used in conjunction with this apparatus.
These pumps are all of iron construction and are designed with large valves and of ample size to handle the
emulsion of tar and water used. The first pump is used to draw the water from the separating tank and
pump it into the storage tanks. The second pump is used to withdraw the water from the storage tanks,
pass it through the interchangeable cooler and then into the scrubber. The third pump is used to remove
the tar from the storage tank.
(k) Piping and Fittings
The raw gas piping which connects the gas _ offtake of the carbonizers to the inlet of the dust catcher is
wrought iron pipe with cast iron fittings. These lines are designed to have a slope of approximately one
inch per foot and auxiliary water wash-out lines are connected to each gas offtake to facilitate the removal
of any tar or solid matter which might accumulate in the piping. Each offtake line contains a butterfly
valve to regulate the flow from the carbonizer also a gate valve, which serves as a by-pass so as to allow any
undesirable gas to escape to atmosphere. These lines are fitted with expansion joints between fixed points
in theline. The return piping from the exhauster to the carbonizer burners is wrought iron with cast iron
fittings with valves inserted to regulate the flow of gas to each burner manifold.
The piping leading to and from the gas regulator is designed in such a manner as to connect the inlet and
exhaust side of the blower. The pressure connection on the regulator controls the system by allowing
rene less gas to pass from the outlet to the inlet side of the exhauster by virtue of the pressure in the raw
gas line.
All the tar and water piping is wrought iron with cast iron fittings and this piping is so arranged that
either of the storage tanks can be by-passed.
(f) MIXING AND BRIQUETTING EQUIPMENT
On reference to the flow sheet which appears as Fig. 6, it will be noted that the char after leaving the
carbonizers is stored in the residue bin and from there flows through the various machines to the briquette
press. An apron feeder delivers the char from the bin to a horizontal paddle mixer where it is mixed with
the binder. The discharge is to a vertical fluxer from which the mixed material passes to the edge runner
thence to a second steam jacketted paddle mixer, used as a temperer, and is then elevated to the press. The
186 APPENDIX No. 22
briquettes are discharged on a shaking screen to remove fines and descend by means of a chute to a cooling
table located in an underground tunnel through which air is circulated by means of a fan. The cooled
briquettes are elevated by a continuous bucket elevator to the briquette storage bin and are discharged in
the bin by means of a distributing conveyor. The fines are returned to the last mixer by means of a belt
conveyor. After a few days storage the briquettes are sufficiently hard to stand shipment and are loaded
from the bin into either box cars or gondolas as desired. The briquetting room and layout of the machinery
are shown in plan and elevation in Figs. 18 and 19.
The binder is delivered on the receiving spur in tank cars, It is placed in the binder unloading shed
which is heated by means of steam coils. Steam is also circulated in the pitch car through coils provided
for that purpose. When fluid the pitch flows by gravity to a large underground concrete reservoir capable
of holding 41,900 U. S. gallons, equipped with steam coils for keeping the pitch hot. A Kinney Rotary
plunger pump delivers the pitch from the reservoir to a small supply tank equipped with an overflow pipe
which returns the excess pitch to the reservoir and insures a constant head. (This tank is shown in Fig.
63, P. 77). The flow of pitch from this tank to the mixer is by gravity and the quantity is regulated by
means of a steam jacketted valve.
Description of Apparatus
The mixers used are of three different types which were included, in order that their respective merits
might be thoroughly tested and the best suited ultimately selected.
The horizontal mixers were steam jacketted machines manufactured by the Mashek Engineering Com-
pany being their type M (Catalogue No. 4) and are driven by gear and pinion. On the center shaft of the
mixer there are mounted separate cast steel hubs. To the larger part of these hubs are bolted manganese
steel mixer blades, plain straight blades curved to overcome wear, which are followed by spring loaded
spreader blades, the wearing end of which is manganese steel. On the opposite side of these blades are placed
large scraper blades made of manganese steel bolted to the hubs so as to plow off the squeezed, pugged
material after the spreader blade passes from it. On the end is a special lock hub, on which are mounted
two manganese steel expelling blades. Provision is made in the mixer for the introduction of water or
steam as might be required. wy
The vertical fluxer was supplied by the General Briquetting Company who secured it second hand. It
was originally manufactured by the Traylor Engineering Company and had been in service only a short
while. The machine is 3-14’ in diameter and 8’ high with a central revolving shaft which contains 8 cast
iron blade sockets set at 90° with each other alternately from the bottom to top. Each blade socket is fitted
with two shaft blades making a total of 16. Immediately under each set of shaft blades there are stationary
shell blades fitted to the shell in such a manner that they can be easily removed from the outside. Pro-
vision is made for blowing steam into the mix during its passage through the machine.
The edge runner or masticator was supplied by the General Briquetting Co. The machine is a Chilean
mill, and consists of a heavy cast iron base with pan, frame, overhead driving gear, and two rollers. The
top of the cast iron base forms the floor of the pan proper and has a machined surface covered with hard
cast iron lining plates resting on the floor of the pan. The frame consists of two inverted ‘‘A”’ shaped side
standards set on separate concrete foundations in an inclined position to insure greater rigidity. A pair of
25 pound channels connects these standards and serves as a support for the driving gears, There are two
mixing rollers 48’’ diameter and 30” face, revolved by means of forged steel crank shafts 6’ in diameter
which are fastened into a cast iron hub made in halves, bolted to a vertical shaft, which arrangement
permits the necessary variation in movement of the rollers.
The mixed material is fed in on the outer rim of the pan and is worked towards a central discharge by
means of adjustable blades and scrapers giving a combined crushing and mixing action.
The briquetting press is a Belgian Roll press making a two ounce egg shaped briquette. The rolls are
26-14” in diameter by Il-4”’ face. Each roll has six rows of eggette shaped moulds, 36 moulds to the circle,
or a total of 216 moulds to each roll. The press is provided with a feeder and regulator arrangement
directly above the rolls by which the flow of the material into the rolls can be controlled.
The cooling table is a metal conveyor travelling at a very slow rate, located in an underground tunnel
which has an opening through a stack to the atmosphere. One No. 7 conoidal exhauster is connected to
the opposite end of this tunnel which is used for circulating a current of air over the hot briquettes in order
to hasten cooling. The fan is capable of exhausting 20,000 cu. ft. of air perminute. The metal conveyor
and the continuous bucket elevator, which elevates the cooled briquettes to the briquette storage bin
were supplied and installed by the Jeffrey Manufacturing Company.
(g¢) STORAGE AND LOADING
The cooled briquettes after being discharged from the cooling table are elevated to the top of the
storage bin where they are distributed to any portion of the bin desired, by means of a distributing
belt conveyor.
The bin is a wooden structure 80 feet long by 16 feet wide by 55 feet high and is capable of storing
600 tons of briquettes. The floor of the bin slopes from back to front at an angle of 60° and chutes
are provided at intervals along the length for discharging the briquettes. A track is provided in
front of the bin so that the briquettes fall by gravity through the chutes direct into the cars.
(h) POWER HOUSE
The power plant consists of three 150 H.P. H.R.T. boilers, a 400 K.V.A. unit, a 100 K.V.A. unit, a 30
K.V.A. unit and a 25 H.P. engine connected to a D.C. generator for excitation. A section and plan view
of the power house js shown in Figs. 26 and 25,
The boilers were manufactured by the Vulcan Iron Works, Winnipeg, and guaranteed to meet the
requirements of the Province of Saskatchewan. They are 72’ in diameter and 18 feet long constructed
of 17/32” plate, containing 72 lap welded tubes 4 inches in diameter set in horizontal and vertical rows.
They are suspended from steel beams by means of 1-14” ‘‘U”’ bolts connected to hangers on the boiler,
the beams being supported by steel I beams of sufficient strength to carry the weight.
Each boiler is provided with twin 3” pop safety valves, one 8-14 inch steam gauge, three 34 inch gauge
cocks, one 34 inch water gauge glass, one 18’ water column and one 2” blow off valve of the ‘‘Duro”’ type.
The grates are the diagonal type 6” x 36” having 14 inch openings, forced draft being provided by a Coppus
blower.. Two duplex piston pumps for boiler feed water are provided in conformity with provincial regul-
ations also one Cochrane open type vertical feed water heater with oil separator, filter and float.
APPENDIX No. 23 187
The 400 K.V.A. unit consists of a 400 K.W. 3 phase, 60 cycle, 600 volt Canadian General Electric Co.,
generator, direct connected to a Robb-Armstrong cross compound Corliss engine. This unit was built
in April 1908 for the Lehigh Portland Cement Company, and was in operation at their plant at Belleville,
Ont., for a portion only of the time until 1918 when it was purchased by the United States Government
(Ordnance Dept.) from whom the Board purchased the machine after inspection had revealed it to be in
good condition. When newit had a guaranteed water rate of 19 pounds per H.P. hour at fullload, operating
non-condensing.
The 100 K.V.A. unit was purchased from the MacGovern Company. It consists of a 100 K.W.,
600 volt, 60 cycle, 3 phase, generator direct connected to a Westinghouse single acting compound engine.
The machines had been in service a number of years but thorough inspection revealed them to be in fairly
good condition.
Excitation for the two generators is provided by one exciter unit comprising a 25 K.W. 125 volt Westing-
house generator direct connected to a Westinghouse vertical duplex engine. This engine is also belted to a
small 30 Kilowatt 550 volt 3 phase 60 cycle generator with self-exciting revolving armature, which is
used for light loads during experimental operation.
Two power lines were provided so that either of the two large generators could be used separately, and
provision was made for synchronizing the two units in the event the power requirements made it necessary.
A three panel switchboard, purchased from the Monarch Electric Co., was installed containing all the
necessary instruments for power and lighting control.
(i) WATER SUPPLY
The water supply is obtained from the Souris River, a distance of 1-14 miles from the plant, through
an existing pipe line built to supply the requirements of the two neighbouring mining companies. An
extension of thisline was built and connection made with a large semi submerged, covered concrete reservoir
capable of holding 150,000 Imperial gallons.
In order to provide working pressure an elevated tank was erected which has an additional capacity
of 83,000 Imp. gallons. This tank is supplied by means of a Lea-Courtenay horizontal type double suction
single stage volute pump having a 3” suction inlet and a 3” discharge outlet. The pump delivers 250
U.S. gallons per minute when running at 1,750 r.p.m. and is direct connected to a 20 H.P. Lincoln Electric
motor. In addition an 18” x 10” x 12’ standard make, underwriters’ type fire pump is installed capable
of delivering 1,000 U.S. gallons per minute. This latter pump is only for use in the event of fire and has
been passed by the Western Canada Fire Underwriters Association. _The two pumps described are located
in the power house and are shown in Figs. 25 and 26 while Fig. 20 gives the location of reservoir, overhead
tank, supply and service lines.
: (j) SEWAGE DISPOSAL
Plant and house waste is taken care of by means of a double compartment sedimentation tank. The
water after partial purification is passed from the second compartment by means of a syphon to sand
beds. The sludge is periodically dumped direct on the prairie. The location of the sewage disposal
plant is shown in Fig. 20.
(k) OFFICE BUILDING
The floor plan and cross section of the office and laboratory building is shown in Fig. 23. The building
contains the general offices and an office for the manager, together with laboratories and office for the
chemical staff. The laboratories are equipped for coa Jand gas testing and such other work as enters into
the control of the process.
—— §-—_
APPENDIX 23
Operations during 1921 and 1922.
By R. A. STRONG
The operations during the years 1921 and 1922 included every department of the plant and the results
obtained are discussed under the following heads:-
(a) Raw Material.
(b) Crushing.
(c) Storage.
(d) Drying.
(e) Carbonizing.
(f) Briquetting.
(g) Power House.
(h) Water System.
(j) Sewage System.
It is not the purpose of this report to describe in detail the apparatus used in each department as this
has been fully covered in appendix 22. It is merely a record of the operating results and if these seem
negative in character it should be remembered that the Board were pioneers in large scale work of this
nature and success in every department of an entirely new process could not reasonably be expected.
(a) Raw MATERIALS
It was the original intention of the Lignite Utilization Board to avail themselves of the cheap lignite
in the district which isin the form of slack. There are two distinct disadvantages in connection with
the use of such material:-
T3507. 3 APPENDIX No. 23
(1) Lack of adequate supply.
(2) High ash content of the slack which renders it unsuitable for briquetting.
It is estimated that there are only about 30,000 tons of slack available per annum in what is known as
the Souris field. This is only 50% of the total requirements of the Board’s plant, and the remainder
would have to be made up of mine run coal. A larger demand exists for slack coal now than when the
Board was formed, and it is no longer a problem to dispose of what was formerly a waste product. It
is being burned with success on chain grate stokers, and by reason of its cheapness is in considerable demand.
Several different types of stoves have also appeared in the district which can be operated successfully on
this material.
The slack is obtained by screening the mine run coal, and by cleaning up the mines at intervals. With
this latter method a large percentage of clay is mixed with the coal, which increases its ash content to such
an extent that it is entirely unsuitable for carbonizing and briquetting. In view of the fact that not more
than a 50% yield is obtained in the form of briquettes it is evident that the ash is practically doubled,
and consequently it is essential that the ash in the original material should be kept as low as possible.
In addition the ash has a low fusion point, and when high ash briquettes are burned, clinkering becomes
a nuisance and will cause the consumer to condemn the product.
During operations at Bienfait observations were made in regard to this problem and coal was purchased
from all the adjoining mines and samples taken. Below is appended a table showing the ash content
and shipper’s name of material received. Each analysis represents a car load, the sample being taken
while the coal was being crushed for processing. In order to note the wide difference between the ash
content of slack and the ash content of mine samples, the 4th column shows ash content of such samples
taken by Alex. McLean, (See Section III P. 37, also pp. 179 and 180).
AsH TABLE
% Ash in mine
Mine Kind of Coal % Ash sample as
determined by
McLean
Bienfait Slack 12.0 5.2
is s 14.4 a ¥F
a s SAK aa
Crescent 2 16.1 ORO
5 ‘ 1525 ate
M. &S&. ss 13.6 6.9
ne My 13.2 (fees
} * 13.8 1221
4 - 12.8 ee
We D.C. st 11.5 6.8
Bien. Comm. ON Ds
Average 12.9 6.8
When it is realized that a briquette made from the slack above mentioned will contain approximately
25% ash, it can readily be seen that a briquetting proposition using slack from this district could never
hope to produce a commercial product which would compete against the better grades of coal. Mine
run coal on the other hand fromseveral of the above mines runs between 6 and 7% ash and briquettes from
this material will only carry 12 to 14%.
(b) CRUSHING
The coal was delivered to the Board’s plant in bottom dump steel cars, and unloaded over a track hopper.
Two lateral conveyors feeding an inclined apron conveyor delivered the coal to a swing hammer pulverizer
where it was reduced to a proper screen size for drying and retorting. The crushing equipment consisted
of a Jeffrey type B. No. H.3, swing hammer pulverizer driven by a 75 H.P. Lincoln electric motor at a
speed of 1,000 R.P.M. This crusher together with the conveyors was designed to handle 50 tons of lignite
_ per hour but as installed it did not exceed 30 tons per hour. Inan attempt to rectify this, the manufac-
ee made certain changes in the installation but no thorough tests has been undertaken since this
change.
The slack coal as received does not carry the water content which is found in mine run coal. ‘This is
probably due to the fact that a large percentage of it is allowed to remain in the mine for a considerable
period before being cleaned up.
Below is appended a table showing the moisture content of slack coal as received.
Moisture TABLE
Mine Kind of Coal % Moisture
Bienfait Slack 30.0
- vi 28.8
“f : 30.4
Crescent ne PAT
a ss bao
M. & Ss. ae 30.3
f a nee
* 28.2
We DiC cc 30.9
Bien. Comm. “ 31.8
Average 29.0
(The mine run coal will average between 33 and 35% from the above mines). Even this with lowered
moisture content considerable difficulty was encountered in reducing the coal below %’. The crusher
would occasionally get plugged up and would have to be stopped and cleaned out. With a higher water
content this trouble would, of course, be increased.
The crusher delivered a fairly uniform product and in this respect was satisfactory. The curve in Fig.
8g, shows a screen analysis of the product. :
APPENDIX No. 23 189
(c) STORAGE.
The crushed coal was stored in two large concrete storage bins with conical bottoms from which the
coal was discharged. The coal as delivered from the crusher is in a finely divided state and in this condition
offers no great difficulties in storage. A rise in temperature in the coal mass was noted but no fire troubles
developed. During subsequent operation when a larger sized coal was used considerable difficulty was
experienced from spontaneous combustion, due to the shape and size of the storage bin. The discharge
spout in the bottom and the manhole in the top caused a current of air to circulate through the coal mass
which resulted in a rapid rise in temperature and ignition. The original plans had provided for steam
jets in the bin but these had never been installed.
In commercial operation, the coal will only remain in storage for a very short time and consequently
this trouble would be largely alleviated.
(d) DryIna.
two C. O. Bartlett & Snow rotary dryers were installed for drying the coal prior to its being delivered
to the retorts. These machines were the single shell multiple division type, 55 feet long, six feet in dia-
meter, driven by a variable speed motor at a speed of from 6 to 8 R.P.M. A special brick setting was
provided and flues arranged so that experiments could be made on the efficiency of various methods of
circulating the hot gases. The dryer was heated by means of a furnace and was also connected by a tunnel
to the carbonizers. The hot flue gases from the retorts were intended to supply a large portion of the heat
necessary for this operation. An induced draft fan was used for circulating the gases and suitable dampers
were provided for controlling their path. Figure 24 shows a diagrammatic elevation of this installation.
The capacity was guaranteed at 150 tons of dried coal per 24 hours.
The first attempt at operation resulted in bad fires and although no damage was done it showed that in
order to dry lignite in this type of dryer very careful regulation of temperatures was essential. The fires
on both occasions started at the discharge end and were swept towards the inlet by the gases which were
travelling in a contrary direction to the flow of the coal and were only extinguished with considerable
difficulty. The operators were not very familiar with an installation of this type, and this may, in part,
have been responsible for the trouble. In subsequent operations the dampers were so arranged that the
hot gases were sent through the shell in the same direction as the flow-of the coal. Temperature of the
discharge was taken continually and samples collected for analysis. By this method of operation very
uniform results were obtained and all danger from fire was eliminated. In practice a recording thermo-
meter with a maximum and minimum alarm would be advisable.
The results in the following table are from a week’s operation and are typical of the results obtained
during the entire period of operation.
Dryer Results
Maximum temperature of discharge EER RRM ate PPE obs Y 5 so Beg UOvF 1h UG Sekealy SHAVES pS UR ode Mayotte: oP 203 degrees F.
‘ ‘ “sé | sé
os 3 ‘ LED E EERE ee ee tenet ene tere tenet e nese ees oe re “
a ; SAND, Seam IT RG Heltrstet diets ater sis Sia BFS laeeeta bags «(eS gia ks nee? :
IMOISCUPORUIELCOUIS, Meewnee Sarde fee teree. Lek ney hs: arc: ccebspeh ade blots auc onic « Luni Shaisiei'e Shave 29%
“es ae
The screen analysis of the product is shown in Fig. 8 f. ;
The dryers were never operated at capacity and the indications were that they would not attain it
No determined effort, however, was made to definitely prove this in view of the subsequent difficulties
encountered with the carbonizers. The operation was intermittent and it was impossible to say what
results would have been obtained had the machines been operated for a long period of time which would
have allowed the entire setting to become thoroughly heated.
The fuel consumption was very high being 380 lbs. per ton of coal dried or 19%. The effect of the flue
gases from the retorts was negligible as this heat was entirely dissipated in the long underground flue
leading to the dryer setting. It must be remembered, however, that during this period of operation
of the dryers only one of the retorts was being operated. Had the waste heat from six retorts been avail-
able very much better results would undoubtedly have been obtained. On reference to Fig. No. 24, it
will be noted that the fans had been designed to remove these gases from the carbonizers, circulate them
around the dryers, and thence discharge them to the atmosphere. Operation determined that they were
not sufficiently powerful for this total load, but at the same time were so strong as to pull (due to their
proximity to dryers) a large quantity of the fine dust out of the dryers which was lost, as no dust collector
had been installed. This fan trouble could have been corrected by installing a fan closer to the retorts
which would have allowed of increasing the suction for removing the flue gas, and a second fan in close
proximity to the dryers could have been used for circulating the hot gases. In this way the dust losses
would have been materially decreased.
Storage of the dried lignite proved to be a very difficult matter. The material was very liable to fires
by spontaneous combustion and at no time during the entire period of operations was the plant entirely
free from fires in the dried coal storage bin.
(e) CARBONIZING.
The main causes of the previous failure were due to leaky construction and failure of floor material.
The floor has been built of carbofrax tiles one inch in thickness and these had cracked badly, allowing the
escape of products of combustion into the carbonizing chamber. In some cases the tiles were so badly
cracked as to allow of coal falling through into the combustion flue. The carbonizing chamber leaked
to such an extent that air entered the retort or gas escaped to the atmosphere as the pressure within varied
below or above atmospheric pressure.
As a result of these troubles it was decided to callin Mr. Chas. V. McIntire of New York, and consult
with him as to the best method of eliminating the weaknesses which had been discovered. This was accord-
ingly done and Mr. McIntire rendered his report on the reconstruction of these units. *
Mr. MclIntire’s recommendations called for the reconstruction of the retorts using six combustion flues
instead of three as formerly. The floor material was to be made of special shapes in high grade clay fire
* This report appears as appendix 24.
‘190 APPENDIX No. 23
brick 12” x 12’ x 2’... The inclined partition dividing the combustion flues and the air preheating flues
were to be at least twice as thick as formerly and were to include a course of insulating brick, as shown
‘in sketch No. 3 appendix 24. Expansion joints were to be provided on both sides of the retort. © The arran-
gement of the floor tiles and the expansion joints are shown in sketches 4 and 5 appendix 24, The side
walls were to be built of 9” firebrick set in a refractory bonding cement.
In order to eliminate the leaks referred to Mr. McIntire recommended that a system of regulation be
‘installed in order that balanced pressures might be obtained within the carbonization chamber and com-
bustion flues. Butterfly valves were to be inserted in the mains which were to be operated by regulators
and a small gas holder was to be placed in the system to take up pressure fluctuations and insure a constant
pressure at the burners. Sketch Nos. 1 and 2 of appendix 24 show, diagrammatically the installation as
‘proposed and the pressures desirable for successful operation. In order to regulate the pressure in the
combustion flues slide bricks were to be placed at the upper ends of ail these flues. Mr. McIntire did not
recommend the use of calorized metal or carborundum for a floor material both of which had been considered.
He concluded his written report by the statement that in his estimation the capacity would be relatively
low considering the size of the apparatus and the cost of construction.
In view of this report it was decided to reconstruct one carbonizer along the exact lines suggested, and
at the same time reconstruct two others similarly with the exception of the floor material. The Carbo-
rundum Company insisted that their product had been improved in the time intervening since the former
tiles were purchased, and suggested that a special hollow tile be tried. This was accepted as one alternative,
and for the other it was decided to use the old carbofrax tiles doubled with the joints staggered, and the
both sections bonded together with a refractory cement, manufactured and recommended by the Carbo-
rundum Co. (This construction is shown in Diagrams 1 and 2, on next page.*)
The decision to rebuild three retorts using different materials was based on the necessity to either
prove or disprove the retort in the shortest time possible, with the smallest outlay of capital expenditure,
and it was felt that this could best be accomplished by doing all the construction work at one time. The
question had been thoroughly discussed in conference at which Mr. McIntire was present, and he had given
his verbal approval to this course of action.
Construction on the new retorts was started in May and finished early in September. In order to conform
to the recommendations above outlined it was necessary to revise the gas system as originally installed,
to include a 5,000 cu. ft. gas holder which was erected outside, close to the retort house. Butterfly valves
were placed in the gas mains and these connected to regulators supplied by the Ratteau Battu Smoot
Engineering Corporation. The makers claimed a sensitiveness of 1 mm. for these machines and subsequent
operation proved this to be correct. The revised layout is shown in Fig. 17 b.
The cement used for bonding the side walls was supplied by the Harbison Walker Refractories Co. and
was sold under the name of ‘‘Fire Bond’’. It proved to be satisfactory in every respect and produced
a very tight wall.
OPERATING RESULTS, 1922.
The first retort to be operated was the one with the carbofrax hollow shapes. A new discharge had been
designed which consisted of metal spouts surrounded by a water jacket and terminating in a paddle wheel.
The speed of the wheel was adjustable so that a uniform discharge from every channel was obtainable.
This arrangement worked fairly satisfactorily. The metal baffles had. been decreased in size allowing
more space for the gas. The former narrow space between the cover plate and the top of the baffles had
been subject to criticism, the objections being its susceptibility to plugging with dust and tar. This pro-
phecy was fulfilled and although no shut downs were directly due to this cause, after every shut down
a large accumulation of dust and tar was found at this point. The increase in this space did not eliminate
the trouble entirely although it had a beneficial action.
The clearance between the baffles and the floor had been decreased which resulted in the elimination
of the former troubles due to fine coal but made the retort entirely too liable to plugging from foreign
matter or large pieces of coal which would accidently fall into the charging hopper. The result of a piece
of coal entering the retort which was too large to pass under the baffles was a consequent slowing up of
the flow, and ultimately caking would occur due to deposition of tarry matter on the stagnant coal. Owing
to the restricted space it was almost impossible to correct this difficulty by poking, and as a consequence a
shut down nearly always resulted from an occurrence of this nature. When this trouble occurred high
temperatures would result in the combustion flue and the smooth working of the retort would be entirely
upset.
It was necessary to have the regulators adjusted by the manufacturers before they functioned properly
but after this was done they left little to be desired as far as regulation was concerned. Pressures were
maintained as follows:-
BGOttomaless ceed sects wi bis cdhane ws Src tace © elt Oe eee eee — .05 inches of water
IMGd Ge 2. 2 oss Banke os Biteee se eae ae Sn e ee eee .00 E othe
os 0) 2 ee oe rer es SE SR ei he yaaa kon doe cee sae one +.03 ‘ ees
The gas exhauster, which was a No. 10 type B. volume exhauster, supplied by the Buffalo Forge Company,
gave continual trouble, and when the temperatures were raised to the desired point the fan would not
handle the gas which rendered the regulators inoperative, and the good effects of balanced pressures were
lost. Pyrometers had been placed in the carbonizing chamber so that the temperature of the coal could
be determined. It was found that the temperature in the coal had to be maintained between 1000 and
1100 degrees fahrenheit in order to obtain the degree of carbonization desired, i.e. between 8 and 12%
volatile matter. Whenever it was attempted to raise this temperature above 950 degrees F. trouble
was encountered at once, and the fan would not handle the gas. In view of this repeated result no further
attempts at correct operating temperatures were made and the subsequent tests were carried out at this
lower temperature. Representations were made to the manufacturers of the fan, but no satisfactory
settlement was reached; and as it was apparent that with a proper installation, the retort would function
mechanically without undue difficulty the remainder of the test was to determine whether the new carbo-
frax floor tiles would stand up. After a few days of operation sparks were seen in the combustion flues
which indicated that the tiles were cracking and a subsequent shut down proved this to be the case.
This retort had been built originally with carbofrax as a floor material in order to get a high capacity.
It was estimated that the capacity per 24 hours would be 16 tons of carbonized residue with a 10% volatile
content. This capacity, however, was never attained, and with the new floor tiles which were much
thicker the maximum capacity was between seven and eight tons per day. The temperature recorded
*For assembly drawing of re-constructed carbonizer, see Fig. 43.
APPENDIX No. 23 191
{oe ricer oa Do oy ae ee oad
M 1%
Gorbotrax slabs
\
ELLA LLL LL LL Lf fk Lh AN fh php h++A¢ A S+DAAASLLLLLL LLL AA TaN
WILT LITITZ TD DID DLL hh Lh Lh hh hbakehend
NS LN Silocel bricks
WAS WAAAY My AANNY ALARA
7
Z PRU ,
Air floes Diagra Aes
Double Tile Floor Constructiom
3: ar 3-0
N
Carbofrax Tes
CY SAR SAS SS QO SSEEMBSSSSAY CSSA ESSE)
NS N jonts Wr ‘ m\\ aN pals .
aN N VN N NAR . NZ
NY N N :
Woe sextet ee
a VU,
JA,
LLC f FEL TEI EE Z a EY yf,
GZ CMMULMUMMET, {LLL LLL LLL Lg ‘
. ZN aE Sal | CIRL SOEN 7/ Paoe
fireclay Shapes 2¢4 127% 2
Diagram -2
Carbofrax Motlow Tile Floor Construction
in the combustion chamber was 2200°F. and the flue gases left the retort at 1000°F. Although this flue
gas temperature is entirely too high the heat was not lost but was conducted, as previously described,
through a tunnel to the dryer setting where it was intended to be utilized in the drying operation.
The gas recovered was never sufficient to carry on the process, being slightly more than 50% of the total
requirements. The difference was made up by burning fuel oil but in case the retort had proved successful
a producer would have been necessary.
Average Analysis of Coal Fed to the Retort
VE OIATUT OS anc hcteeacteatlc ns ote iets’ Acacias cea ae 5.4%
WOlSIMattGr stat ares cc tite ered oie, tested ateetel enters 34.1%
SS RSH CAR Do SOIC o BR CHA OnE 17.3%
Mixed? Carbo ts ay terse syelasie cs oateias atte ee 43.2%
100.0%
Average Analysis of Char Recovered
WEOISGUTE es 52'c:s SARS cinicle chotalel leet Nil
Wolse Matter )3..6'a 0cs cba he Soe eee 16.2%
BEM tes RATS OL) CS Nh ee ae ae eee ent eee 24.0%
PixedsCarboney. fs. eo. oes ee eee 59.8%
100.0
Yield — 72.2% of coal as charged (calculated from ash). The gas recovered amounted to 2.73 cu. ft.
per pound of char. This is equivalent to 3942 cu. ft. per ton of coal as charged or 2910 cu. ft. per ton
ofrawlignite (30% moisture). Theseresults compare very favourable with those obtained experimentally. *
*See table vii “‘Carbonization of Lignites,’’ Part II, by Stansfield and Gilmore, Trans. Royal Soc.
Canada, 1918.
192 APPENDIX No. 23
The next test was made on the retort with the fire clay tiles as a floor material. This test was brief as
it was soon discovered that the capacity of the retort was so low that it could never be considered as a
commercial unit. The flue gases escaped from the combustion flues at temperatures ranging from 1200
to 1300 degrees F. It was difficult to run the discharge slow enough to effect the degree of carbonization
desired, and it was soon apparent that Mr. MclIntire’s prophecy was only too true.
There still remained the retort which had been built of the old floor tiles doubled in thickness. A ten
day test was carried out on this, and a host of mechanical difficulties were encountered which would have
been largely avoided had proper means been provided for the removal of the gases and had regulation
of pressures been possible. The greater part of the test was made with the gas exhausting to the atmosphere
A higher temperature was maintained than in the former runs and a much better char was obtained.
Average Analysis of Coal Charged.
Moisture) 2 eee eee eer eeichoter ere hots ene 4.1%
Vol. “Matter sc tr see ark eect re 34.5%
.\:) I ts 4's es SAS aS Cota oiteronchee 17.6%
Fixed Carboneee eee ato ae eee oe ee 43.8%
100.0%
Average Analysis of Char Recovered.
Moisture: ‘4-4 ideeo e Ea. te Nil
Vol... Mattermeac ee eee SBA in ot eso Ae ape 11.6%
| as Cas art GH ake Sinn ti de pun one 24.8%
Fixed Carbon acorn t aoece ce Corie cine 63.6%
100.0%
Yield — 71.0% of coal as charged (calculated from ash).
Towards the latter part of the test sparks were noticed in the combustion flues and it was assumed that
the floor material had cracked, which was found to be the case, when the retort was cooled down.
During the trial operations of the retorts, detailed reports were prepared outlining the troubles en-
countered. Some of these, in log form, appear as appendix 26, and their value as records lies chiefly in
the fact that they report day by day impressions, uncoloured by the perspective which time sometimes
gives.
The conclusions reached after the completion of these tests were that the retorts as designed by the
Board were a failure, and would have to be abandoned. The process had not proved economic and the
carbonizers had failed to come up to expectations.
The process of drying and carbonizing in two stages is not economical. It involves a large capital
outlay for dryers in addition to the carbonizing units and requires more labour for operating. The power
requirements of the drying apparatus are appreciable, and from the results obtained as shown above,
the fuel requirements for drying are high.
The carbonizers proved to be very low in capacity considering the size of the apparatus and the cost
of construction. The chief disadvantages of this form of retort are:-
1. Angle of Inclination.
The retort was inclined at an angle of 45 degrees which had been found in Ottawa to be sufficient to cause
the coal to slide readily. The coal used at Bienfait, however, contained a much higher percentage of dust
which materially altered the natural angle of repose of the coal mass. The unexpected presence of these
fines resulted in a layer of dust forming on the retort floor which acted as an insulator and probably partially
explains the failure of the evolved gas being sufficient to carry out the carbonizing operations.
2. Metal Baffles to Regulate the Thickness of Material.
The clearance beneath the baffles did not allow of poking and the retort was subject to plugging from
foreign matter and large pieces of coal. The cast iron baffles are subject to warpage and it is questionable
what their life would be under constant operating conditions.
8. Inflexibility.
The operation of the retort depended on the accurate adjustment of feeding and discharge, of temperature
and of pressure, and if any of these factors varied slightly the entire operation was upset.
4. Labour.
The average workman was not able to understand the intricacies of the system and it would have been
necessary to have trained men. This adds considerably to the labour cost.
5. Floor Material.
The fireclay tiles were not feasible on account of the resulting low capacity. Carbofrax floor material re-
sulted in a much greater capacity but even under these conditions only 50% of the estimated capacity
was attained. The failure of the floor material together with the disadvantages above enumerated caused
the abandonment of this type of apparatus.
(f) BriquEeTTING.
_ During the operation of the plant a number of briquetting runs were made in order to test out the adopted
Came ee discover its weaknesses, and make such changes as seemed necessary to produce a commercial
Tiquette.
The conclusions drawn from these tests were that the layout was not suitable for briquetting lignite char,
and that some of the machinery selected should not be included in a plant of this nature. In view of these
conclusions a discussion of the mechanical difficulties encountered during the trial runs of 1921 and 1922
is desirable in order that they may be avoided in any future installations.
APPENDIX No. 23 193
The previous briquettng experience of the Board had been confined to small scale experimental work
where tests on all known binders were possible, and accurate control of all variables could be obtained.
When it was desired to install a commercial plant at Bienfait, the services of the General Briquetting
Company, New York, were retained to assist the Board’s engineers in designing a layout. The layout
decided upon appears in Figs. 18 and 19 and is described in Section VIII of the Secretary’s report.
During Sept., Oct., and Nov., 1921, the operation of the plant was confined mainly to the drying and
carbonizing equipment, but during December of that year two briquetting runs were made. The first
test revealed difficulties with the binder system, and as this gave considerable trouble later a full discussion
of the difficulties encountered will be discussed under Binder System.
The second attempt at operation was more successful although a great deal of trouble was encountered
with the machinery and belting. A few tons of briquettes were made, however, though these could not
be considered of commercial quality. The attitude at the end of the year was that while several weaknesses
in the installation were very apparent, it was felt that these could be corrected, and briquettes produced.
The financial situation existing at the beginning of 1922 has been described in the main body of the report»
and its effect on the operation of the plant is fully shown. As a result of the delay occasioned by securing
additional funds, no further operation of the briquetting machinery was possible until April 1922, but from
then until the close of the year a large number of runs were made, and every effort was put forward to
eliminate the weaknesses in the installation in order to produce a commercial product. It was, however,
impossible to achieve this, and a verbal report was made in January 1923 to the supporting Governments
that an entire revision was necessary. Plans were drawn up and estimates made for this revision, but
unfortunately the recommendations of the Board were not acted upon.
The faults encountered will be covered in a discussion of the various machines under the following heads.
(i) Feeding Arrangements.
Gi) Mashek Mixers.
(iii) Vertical Fluxer.
(iv) Edge Runner.
(v) Belgian Roll Press.
(vi) Briquette Handling System.
(vii) Binder System.
(viii) Belting Trouble.
(ix) Dust and Moisture Troubles.
(x) Revisions Necessary.
A description of the briquetting installation appears on P. 185 et seq. and the flow sheet is shown in
Fig. 6. As wil] be noted the char as discharged from the retorts is elevated to a bin situated at the top of
the briquette room and the flow is by gravity to the various mixers.
(i) Feeding Arrangements.
The feeding mechanism for the char from the bin to the mixer was an inclined apron feeder operated
by a variable speed motor for speed regulation. A gate valve on the spout of the bin, controlled by hand,
regulated the amount of material flowing from the bin to the conveyor, and a scraper blade above the
conveyor controlled the depth of char, thus giving a regulation of the amount entering the mixer.
The main criticism of this feeding arrangement is its entire failure to give the regulation desired. The
conveyor depends on a constant supply of coal from the bin and as the flow is by gravity it is subject to
constant variation which results in either a feast or a famine. .Mechanically also this feeder is far from
desirable as the cheek plates on the conveyor often jam and as these are not easily repaired or replaced a
serious interruption results.
(ii) Mashek Mizers.
These mixers are horizontal machines steam jacketted and geardriven. As they are completely described
in appendix 22 no further description will be given here. Two of these mixers were installed — one being
used as the first mixer and the second served as a temperer or cooler, being the last machine in the mixing
department. The pitch and coal were mixed in the first mixer, and considerable trouble was experienced
due to lack of control of the temperature of the coal entering this machine. The char as discharged from
the retorts was partially cooled before being stored in the overhead bin, but owing to the impossibility of
controlling this temperature the coal would enter the mixer either too hot or too cold. If the former
condition existed the mix would be too dry, and if the latter it would cause the pitch to freeze and form
balls in the briquette. It is essential therefore that an extra tempering mixer should be used for regulating
the condition of the coal as to moisture and temperature before the binder is added.
The mashek mixers were found to be very satisfactory machines and if the above conditions are observed
good results can be expected from their use.
(iii) Vertical Fluxer.
This machine has been fully described in appendix 22. It was manufactured by the Traylor Engineering
Co. and is used in a number of anthracite briquetting plants and apparently gives good results. It was
found at Bienfait that with carbonized lignite 1t did not approximate the results obtained in anthracite
_plants. The char requires considerably more binder than anthracite and this makes a heavy mix. As
a result it was found that the power consumption was high and that it was impossible to fill the machine
to the necessary depth for best mixing. Steam jets are used to raise or maintain the temperature and it
was found that this method is not satisfactory. Maximum temperature should be obtained before the
pitch is added and there should be a gradual cooling of the mass in the remaining mixers. The use of live
steam in the mix after the pitch is added seems to make the mass pasty with resulting trouble at the press.
Judging from the results obtained at Bienfait with this machine it would seem best to eliminate it in
future installations. :
(iv) Edge Runner. (Masticator)
In view of the success attending the use of the edge runner in anthracite briquetting plants and the
claims made regarding its beneficial action, it was felt that an inclusion of this machine should be made
at Bienfait. Tests on the machine previously made at the Nukol plant in Toronto (see appendix 28)
showed that considerable crushing is effected in addition to the mixing obtained. Asa result of this crushing
action it was felt that with a soft material such as lignite char it would supply all the crushing necessary
and thus allow of the elimination of roll crushers,
194 APPENDIX No. 23
The machine was not found to be satisfactory, however, either as a mixer or as a crusher. It did not
give a uniform screen analysis and owing to the loss in temperature in the machine the mix formed into
plates which would not break up in the subsequent mixers. These plates result in a weak briquette which
splits on leaving the press, and fails to hold its shape in the fire. The edge runner also has a high power
consumption and in view of these disadvantages should not be included in an installation of this character.
(v) Belgian Roll Press.
The press installed at Bienfait was supplied second hand by the General Briquetting Co. and was man-
ufactured by the Gilley Machinery Co., Gilley, Belgium. As far as the tests at Bienfait are concerned
the press seems entirely satisfactory. One criticism which might be made is that there is no provision
for taking up the wear on the gears. The wearing down of the gear teeth will cause the pockets of the
opposing rolls to be out of alignment and when this occurs it will be necessary to purchase new gears. The
method of taking up the wear on the press rolls is by placing shims between the bearing block and the frame
which is rather difficult adjustment. The ovoid shaped briquette does not produce as dense a briquette
as the pillow shape owing to the pressure not being as great and it would also appear that the percentage
of fines due to fins is higher than with the pillow shape.
(vi) Briquette Handling System.
The briquette on leaving the press rolls dropped on an inclined metal chute. They were then discharged
on a bar shaking screen and by means of a spiral metal chute descended to the cooling table.
This system of handling is entirely too severe for freshly made briquettes, and it was found that a high
percentage of breakage occurred as the briquettes struck the inclined metal chute. This was increased
at the shaking screen, and still further breakage resulted from the descent to the cooling table.
The briquettes should be removed from the press on a belt and handled extremely gently until they haye
cooled sufficiently. .
(vii) Binder System.
The binder system has been fully described in appendix 22. It gave more trouble than any other part of
the installation but the trouble was mainly due to the failure to place the supply pump close to the reservoir
and provide for gravity feed. When this was corrected the trouble largely ceased but it was found that
gravity flow of the pitch from the small overhead tank to the mixer did not give the constant supply as
was expected. :
In any future installation a pump should be used for supplying the mixer and this should be connected
to a variable speed transmission for speed regulation.
(vill) Belting Trouble,
A study of Fig. 18 will reveal that a number of vertical drives were used for the mixers. This was more
or less inevitable owing to the briquetting building having been erected before the layout was designed,
the necessity for such a course of action being fully described in Section VIII of the Secretary’s report.
These vertical drives gave a great deal of trouble and a slight overload would result in either belts slipping
or coming off. They should therefore be completely avoided in future installations.
(ix) Dust and Moisture Troubles.
A duct was provided from all closed machines for the purpose of carrying away the dust and steam
incidental to mixing coal and pitch. This installation was satisfactory but the inclusion of the edge runner
resulted in considerable dust and steam being present in the building.
The roof of the building was corrugated iron and during cold weather the steam would condense. This °
made poor working conditions and the moisture increased the troubles with the belts. The excessive
dust and moisture resulted in the burning out on one occasion of the 200 H.P. motor which was used for
driving the machinery.
To correct these faults a wooden roof should be used and all open machines eliminated.
(x) Revistons Necessary.
In order to make this installation workable it is necessary to make the following revisions:—
(1) Install positive feeding mechanism at char storage bin.
(2) Provide rolls for crushing char.
(3) Insert a bin for crushed char.
(4) Install accurate feeding mechanism from crushed char bin to mixer.
(5) Replace fluxer and edge runner by a horizontal mixer.
(6) Correct binder system and install pump for feeding binder to mixer.
(7) Correct briquette handling system.
(8) Insulate present roof of building to eliminate condensation.
(9) Correct drives.
(g) PowrErR Hovse.
The power house was equipped with three 150 H.P. H.R.T. boilers of Vulean Iron Works Manufacture.
A 400 K.V.A. unit and a 100 K.V.A. unit with a 25 K.W. exciter supplied the electric power for the plant.
The former machine was entirely satisfactory but the latter gave continual trouble. It was a very old
style engine purchased second hand and was in poor state of repair, consequently the maintenance cost
on this unit was high.
It must be remembered that during the years of 1919 and 1920 it was practically impossible to purchase
new machinery with the promise of immediate delivery. This condition made it necessary to purchase
peony hand equipment in order to save time, which accounts for the inclusion of this old style 100 K.V.A.
unit.
(h) WatTER System.
The water used in the plant was obtained from the Souris River through an existing pipe line. It was
received in a concrete reservoir and pumped to an elevated tank.
APPENDIX No. 24 195
Wood stave pipe had been used for distributing the water to the plant and houses. This proved very
unsatisfactory as it continually leaked and caused all the pits in the plant to fill with water. The pumping
necessary to keep these free of water adds considerable to maintenace costs.
(i) Szewacp System.
A septic tank had been installed to take care of the sewage from the houses and the waste water from the
plant. It has never operated to the capacity for which it was designed and shows no indication of being
able to attain this. The seepage from the weep drains is a source of annoyance and has caused considerable
complaint from the neighbouring mines.
APPENDIX 24
Recommendations Covering Re-Construction of Carbonizer of Lignite Retort
at Bienfait, Saskatchewan.
CHARLES V. McINTIRE
Engineer
66 Broapway, New Yorrk
(Associated with A, StePHEN KNOWLES)
January 1, 1922.
BY PRODUCT COKE OVENS
LOW TEMPERATURE COKE PROCESSES
INDUSTRIAL AND COMBUSTION ENGINEERING
R. A. Ross, Esq., CHAIRMAN,
The Lignite Utilization Board of Canada,
288 St.James Street,
Montreal, Canada.
Dear Sir:—
Referring to my interview with you of the 22nd ultimo, in regard to your lignite retort at Bienfait,
Saskatchewan, I am not yet prepared to report on the coal drier, by-product apparatus or the briquetting
system of the plant, but, in order that your re-construction program may be worked out and acted upon
at the earliest possible moment, I offer at this writing recommendations concerning the most suitable
methods of improving the operating conditions of the lignite carbonizer.
My knowledge of the apparatus and the plant is based upon observations made during one day’s stay
at the plant at Bienfait, during July, 1921, on behalf of Messrs. Coverdale and Colpitts of New York,
and upon information imparted to me by Messrs. Strong, Roche, French and Thomson of your staff during
my visit at your office on December 22 and 23, 1921, and is, in brief, as follows:—
1. The mechanical features of the apparatus, which involve the charging of the lignite, its passage
over the carbonizing surface and its withdrawal from the discharge gates, now operate satisfactorily.
All changes necessary to bring about this resu't have been completed. The carbonizer has operated
continuously over a satisfactory period at the rate of 1200 pounds of carbonized lignite per hour.
2. During the trial runs the gas condensing system was not successfully used for the reason that the
gas, after passing through the system and being returned to the carbonizer, was of insufficient quality
and of inadequate quality to ignite in the combustion chamber. All of the gases of distillation were
allowed to pass directly to the atmosphere through the bleeder pipe.
3. With respect to the heating system, the following conditions prevailed: The oil burning system,
which supplied the preliminary heating, was satisfactory in part, but did not distribute the heat as desired
over the carbonizing surface. The system of heating with distillation gas was not used successfully
because sufficient gas was not available. The structure which comprised the heating flues and the
air preheating flues was in a leaky condition that permitted the escape of products of combustion into
the carbonizing chamber and the passage of air into the combustion flues. The products of combustion
were not passed through the coal drier as intended, but were piped directly to the air from the top of
the carbonizer.
4. The carbonizing chamber leaked to such an extent that gas escaped to the atmosphere, or air
entered the retort as the pressure within varied above or below atmospheric pressure.
While your engineers asked solely for advice concerning ways and means of making the Bienfait carbon-
izer gas tight, yet, as I pointed out during my visit at your office, such a structure can be made only relatively
tight, that cracks, or openings, are likely to appear, and that to obtain satisfactory operating results it
is necessary to maintain constant pressure as closely as possible to atmospheric pressure within the retort
in order to reduce to a minimum leakage through such cracks. Therefore, before making recommendations
for improving the structural features of the oven, I analyze below the factors bearing upon the relation of
pressures and the flow of gases in the various compartments comprising the carbonizing apparatus.
The brickwork forming a retort for the carbonization of coal is seldom tight and frequently more or
less porous. The carbonizer at Bienfait cannot, in my opinion, be made impervious to the passage of gas;
its brickwork will probably be even more permeable than the corresponding parts of an oven or retort
which treats bituminous coal of a coking nature, for the bitumens of the latter often deposit carbon on the
walls and in the cracks of the brickwork which assist in closing the crevices.
.196 APPENDIX No. 24
The successful operation of the oven under such conditions requires balanced pressures within the chamber
andthe combustion flue, and these, I believe, should be about as shown on Sketch No. 1. These pressures
are stated in inches water gauge relative to atmospheric pressure at the points indicated and should not
be confused with absolute pressures. The pressure at the center of both chambers is shown at zero,
while the difference between the average pressure in the top of the oven, A2, and the top of the heating
flues, J2, is .03 inch water gauge. The corres-
ponding difference at the bottom is .03 inch
Re water gauge. If in operation it is found desirable
DIFF.OS to use a high or lower average pressure in the
oven, then the flue pressure should be raised or
lowered a corresponding amount. The total
variation in pressure in either compartment
should not exceed .06 inch, or a variation of .03
above or below a given point. Constant fluc-
tuations within the above range may be expect-
ed and such fluctuations in the two compart-
ments will not synchronize, which means that
at times the extremes of pressures will meet, for
example, the pressure, say at Ai,will reach —
.03 at the moment the pressure at J1 reaches
— .10, making a differential of .07 inches.
The realization of this desirable balance
demands the accurate control of three systems
of fans: the gas condensing system, the forced
draft fan, and the fan which exhausts the waste
products of combustion, all as shown schematic-
ally on Sketch No. 2.
The gas pressure within the earbonizing
chamber is influenced by the speed of the
blower, E, which speed is subject to voltage
changes in the electric power; by the operation
of the regulator, F; by the cleanliness of the
pipe line, C; the scrubbing apparatus, D; and
SKETCH No. 1. the operation of the valves, B and G; which
latter are intended to relieve the system of
any surplus gas.
K “x
y
v8
1
;
1
!
ib
i]
2 «
1¢
1
10
i)
iy ,
, —
peiss P
SAS BLOWER
WASTE CAS
SKETCH No. 2.
APPENDIX No. 24 197
In my opinion, the gas condensing system must be altered to include a small gas holder and more sensitive
regulating devices. *
The gas pressure within the carbonizing chamber is also influenced by temperature changes, which alter
the pressure differential between the bottom, A1, and the top, A2, which differential is caused by the buoyant
effect of the heated gases within as compared with the air on the outside.
_ In the combustion chamber, I, and heating flues, J1 and J2, the pressure is influenced by: variation
in the velocity of products of combustion through the heating flues, which is determined by the quantity
of gas or oil and air consumed; and variation in temperature which would influence the differential between
the bottom, J1 and the top, J2.
It should be noted in this connection that the distribution of the products of combustion must be uniform
among the heating flues. Uneven distribution will result in uneven pressures, the hotter flues tending
toward reduced pressures at J1, which would, in turn, tend to increase the amount of products entering
them and cause further increase in temperature. As a safeguard against such a possibility, I recommend
the installation of a regulating damper at the top of each heating flue.
The pressures at J1 and J2 are also influenced by the operation of the fan, H, the temperature of the coal
drier and the condition of the ducts leading from point K to the drier and fan.
_ In my opinion, the waste gas system must include a regulating device to control the pressure. Also
it appears necessary to make certain changes in the arrangement of the ducts and fans in order to obtain
sufficient draft.**
The pressures within the heating flues, J1 and J2, are also influenced by the operation of the air supply
system which includes the fan, P; the regulating damper, Q, the preheating ducts, Rl and R2. Any
pressure variations at the fan, which may be caused by voltage changes, atmospheric condition, or other
causes, will be felt in the combustion flues. Also temperature variations in the flues will influence the
buoyant effect therein, which will affect the downward flow of air resulting in variations in pressure at Rl,
which in turn will affect Iand J1. To avoid such possibility, either the air supply system must be equipped
with a suitable pressure regulating device or the present system must be abandoned.
In operation, the air passing through the preheating flues withdraws heat from the combustion flues
and returns such heat to the combustion chamber, I, where it is utilized. The air is preheated, but at
the expense of the useful heat from the combustion flues. If the heat for preheating the air were withdrawn
from the waste products of combustion at some point beyond the carbonizer, as in a recuperator or regene-
rator, there would be a direct recovery of heat which would be wasted unless provision were made to utilize
such heat elsewhere. But the present arrangement contemplates the use of the sensible heat in the products
of combustion for heating the coal in the coal drier, a use which will probably require the entire amount
available, so any diversion of heat units for preheating the incoming air will not bring about any further
economy.
While I am not fully informed as to the temperature requirements for{carbonizing lignite in your retort,
I understand that the temperature in the lower part of the carbonizer at a point one-half inch above the
heating surface should be 1000 F., and I believe that this temperature can be readily attained without
the necessity of preheating the air for combustion.
It is therefore apparent that, on account of its influence on pressure conditions, the preheating system
cannot be successfully operated without the addition of suitable pressure regulating devices, that the pre-
heating of the air for combustion is not a necessity and that such preheating does not result necessarily
in an economy.
In view of the above, I recommend that the preheating system be abandoned, for the present at least,
and that the air for combustion be drawn into the combustion chamber by the draft. It may be found
advisable to allow a small current of air to pass upward through the preheating flues to prevent over-
heating the brickwork, which overheating might result in injury to the concrete supporting slab.
If it should develop that suitable temperatures cannot be obtained in the carbonizing surface with cold
air in combustion, then it will be necessary either to put the present preheating system into use, (after
adding the regulating devices) or to provide some other means for preheating, which means might involve
the withdrawal indirectly of heat from the outgoing lignite. The latter method is employed at the plant
of the School of Mines, University of North Dakota, at Hebron, N.D., and there is apparently some useful
recovery of heat, at least there is no lack of temperature in the combustion flues.
RECOMMENDATIONS COVERING RE-CONSTRUCTION OF CARBONIZER.
Structure of the Carbonizer: To withstand the pressure differential indicated on Sketch No. 1, the
design of the brickwork comprising the floor and walls of the carbonizing chamber need not depart from
the established practice of retort or coke oven construction.
In the original construction of the carbonizer the heating flues were too wide, the heating floor too thin
and the lap joints in the latter could not be kept tight.
For the new construction I recommend that the brickwork be torn out to the base of the preheating
flues and re-built in such manner as to provide six heating flues of approximately 12 in. centers. The
division walls should be 4 in. to 4% in. thick, made of special shapes and arranged to interlock or bond
with the flanges of the floor tile resting thereon, all as shown on Sketches Nos. 3 and 4. These shapes need
not be provided with grooved joints. The inclined partition dividing the combustion flues and the air-
heating flues should be at least twice as thick as before and, preferably, should include Gif my recommend-
ations for the abandonment of the preheating system are followed) a course of insulating brick marked
with dots on Sketch No. 3, such as Silocel. This would result in a reduction in the area of the preheating
flues, which reduction I do not consider a disadvantage.
For the floor tile I recommend the use of special shapes made of high grade clay firebrick, thesize and arran-
gement to be about as shown on Sketches Nos. 3 and 4. Each tile should have flanged sides of 4 in. and
of 3 in. depth; there should be grooved joints on sides and tongue and groove joints as per Sketch No. 5
on the ends. The flanges should be tapered on the inside and slightly tapered on the outside; the latter
would tend to compensate for the spreading which usually occurs in the burning of L or U shaped bricks
*At the request of Mr. French, I am making definite recommendations for the above alterations in a
subsequent report.
**At the request of Mr. French, I am making definite recommendations for the above alterations in
a subsequent report.
‘
198 APPENDIX No. 24
The tile should break joints laterally as shown on Sketch No. 4. There should be expansion joints on both
sides of the retort, each as shown on Sketch No.6. These should be filled with sawdust during construction
and the joints sealed with pitch to prevent dirt from falling in. The expansion lengthwise of the floor
must be taken up by an expansion joint at the top located at a point accessible through the charging hopper.
This must be left open until the floor is hot and then pointed up. At intervals during the operation it
will need further attention to repair openings caused by temperature changes.
Concerning the quality of tile the following facts should be noted:
The material must not shrink, or grow, at a temperature of 2,500°F.;
The tile are not subject to load;
SKETCH No. 3.
SKETCH No. 4.
They are unusually thin and subject to some abrasion; _
The clay for their manufacture should be chosen for its toughness.
I do not recommend brick made of silicon carbide, such as Carbofrax made by the Carborundum Compa-
ny. My experience with it has been as unsatisfactory as your own, and, while there is promise of the
material being perfected in the future, (the manufacturers claim it is now much improved in quality) there
APPENDIX No. 24 199
is no reason why you should assume any further risks. Undoubtedly carborundum brick has better heat
conducting properties than fire brick, and theoretically this fact should render it desirable for retort heating
surfaces, for with a given input of heat units it should require a lower temperature head, or gradient, than
fire brick. But it appears that the controlling resistance to the passage of heat is not the heating wall but
the coal mass itself, which, being of open granular formation, is a poor conductor, and this condition holds
true, in my opinion, for all types of retorts or ovens. Even though the coal in your retort is in turbulent
motion, it can not remove heat from the heating surface faster than the refractory material can conduct
such heat from the outside. It follows that the temperature heads required for carborundum or fire brick
bear no relation to the wide difference in the conductivity of the two materials.
I believe that your retort, if made of
fire clay tile, will require somewhat
higher flue temperatures, and, therefore,
somewhat more fuel gas than it would
require if made of carborundum tile, but
the total requirement of fuel gas will not
exceed the available supply, and the
capacity of the retort will not necessa-
rily be reduced.
Calorized metal has not, to my know-
ledge, been successfully used in carbon-
ization retorts. My experience with
the material leads me to believe it will
not withstand the temperatures at
which your carbonizer is designed to
operate and I do not recommend it. But
if you desire you might try a few sec-
tions of calorized metal in the upper
portion of the floor. Preferably such
SKETCH No. 5. sections should be made approximately
the same size and shape as the brick tile
and set with rust joints.
It has been suggested that the combustion flues be made of hollow tile about as shown on Sketch No. 7.
This construction, I understand, has been successfully applied for a number of years on Semet-Solvay coke
ovens in Europe; also it has been used in the combustion flues of the Dressler Tunnel Kiln, and is said to
have given satisfaction. On the other hand, I know of cases where it has failed. There is necessarily a .
difference in temperature between the top of the flue, which is exposed to the coal, and the bottom, which
is backed up by insulating material, and this difference is certain to result in uneven expansion which may
lead to distortion and cracks. ‘The shape is difficult to make in high grade fire brick. Ido not recommend
its use.
Regarding Mr. Thomson’s inquiry as to the advisability of abandoning the common combustion chamber,
I believe it would be better to arrange an individual heating system for each of the six inclined flues. The
present chamber is desirable when burning oil, but it will always be wasteful of heat, and there will always
be difficulty distributing the products of combustion into the six inclined flues. For the present, however,
since economy of operation is not a factor, and since you desire to re-construct the retorts as quickly as
possible, it would be advisable to continue the use of the combustion chamber.
I recommend the installation of regulating dampers, or slide brick, at the upper ends of all combustion
flues at point marked K on Sketch No. 2 to permit the adjustment of pressures within the flues. As ex-
plained to Mr. French, these can be readily applied by extending the flue division walls and by building
an arch over the large downtake flue in which arch will be set holes, approximately 3 in. by 6 in., and upon
which holes the slide brick may beset. Access to regulating dampers may be had through suitable openings
in the brick work above.
SKETCH No. 7
SKETCH No. 6,
To install the above dampers and their openings it will be necessary to remove the steel hopper plates,
which now form a ridge in the center of the charging hopper. These may be replaced with vertical plates
which will form two separate hoppers, leaving the central space open.
The side walls of the oven should be re-built of 9 in. fire brick carefully laid with all joints overlapped and
set in Hytempite, or Thermolith, Every second course should be set in headers. The insulating brick
now forming a part of the wall should be replaced with fire brick. This construction should be sufficiently
tight for your requirements, but undoubtedly cracks will occur from time to time which will require
attention.
200 APPENDIX No. 24b
The leakage in the joints of the cover plates is readily understood, for the thin plates forming the expan-
sion joints are not sufficiently stiff to compress a gasket. A stiffener bar placed on the outside of each joint
would probably assist in making the joint tight, but this addition would be difficult and expensive and the
removal of plates would always be slow and tedious work. I recommend that the present bolted joints be
eliminated and luted joints substituted. This can be done readily by adding a small strip, A, Sketch No. 8,
welded to the side of one of the angles of each joint and filling the space with a mixture of red clay and
sand, or fine coke. The top of the joint should be washed occasionally with a slurry of clay.
When your draughtsman has finished
work on the detail drawings to be made
in accordance with my suggestions of
December 22, 1921, and along the lines
recommended above, I should be glad if
you would send a set to me for inspec-
tion and comment.
In conclusion I might state that if the
carbonizer is re-built in accordance with
the above recommendations and oper-
ated at the pressures approximately as
given on Sketch No. 1, and if the by-
product apparatus and the waste heat
exhausting system are equipped with SKETCH No. 8.
suitable gas regulating devices as re-
commended in a supplementary report, the retort should operate as intended. I believe, however, that
its capacity will be relatively low, considering the size of apparatus and the cost of construction.
Faithfully yours,
CHARLES V. McINTIRE.
APPENDIX 24b
CHARLES V. McInTIRE
66 Broadway, New York.
January, 6th, 1922.
R. A: Ross, Esaq., Chairman,
The Lignite Utilization Board of Canada,
288 St. James Street,
i Montreal, P. Q.
Dear Sir:—
In accordance with my report of January 2nd, I offer herewith a fuller criticism of the piping and appa-
ates which comprise the by-product recovery or gas condensing system of your plant at Bienfait, Saskat-
chewan.
As I have pointed out, the present system can not operate in its present state without setting up unusual
and undesirable pressure fluctuations either in the oven chamber or in the line leading to the gas burner,
or both. It is a closed system leading from the oven through the by-product equipment, through the
blower and back to the combustion chamber of the oven; it is equipped with means for bleeding out a sur-
plus of gas at B and at G, Sketch A, but, since these devices are operated by hand at the discretion of the
operators and are not operated automatically, they can not be expected to compensate for any but the
most extreme variations in pressure. The by-pass valve, marked F, leading from the discharge side to
the suction side of the gas blower is intented to work automatically and will probably doso. Itis, however,
decidedly limited in range; it can do no more than re-circulate a portion of the gas, which re-circulation will
be of absolutely no benefit at times when the supply of gas is greater than the amount needed for combustion.
Furthermore, such re-circulation may at times have an effect opposite to the one expected, for it is possible
the characteristics of the blower fan are such that an increase in volume of gas handled through the blower
may result in ‘an increase instead of a decrease in pressure. The type of automatic apparatus controlling
the valve, F, is not sufficiently sensitive to give accurate control even were the above conditions not true.
I recommend changes in the piping system in accordance with a schematic drawing, Sketch A, attached
herewith, which changes are briefly described as follows:
(1) Install a gas holder of at least 10,000 cu. ft. capacity and connect it to the gas line at the pressure
side of the blower;
(2) Place a bleeder valve at the gas holder operated by the holder bell itself;
(3a) pemiore ah agar by-pass, F, with its governor and install instead a sensitive throttling governor
at poin :
(3b) Place a second sensitive regulator at point T2;
(4) Install a large hydraulic main, GG, to connect all of the carbonizers.
1. Gas Holder. — This should be at least 10,000 cu. ft. capacity, erected preferably indoors. Such a
location would probably not be convenient at your plant, so adequate provision must be made to prevent
freezing — usually a steam pipe arranged to blow jets of steam into the water surrounding the bell is suf-
ficient. If possible, pipe up the holder as shown on Sketch A with all of the gas leading through it. Also
provide means in the gas piping to by-pass the holder entirely as at W on Sketch A.
2. Gas Bleeder.— The gas bleeder should lead off from the outlet side of the holder to a convenient
point away from the buildings. The bleeder valve should be an easily operated gate valve of the quick
opening type; it should have a long lever connected by means of a chain to an arm extending from the top
of the bell. It should open when the bell reaches within 18 in. of the top of its travel, and it should close
by means of a weight when the bell passes the same point on its downward travel.
mote FUEL GAS
™~
CoNTROL LINE
i | PRESENT 7 lainin
D : GBLEEDER '
fon | pe G a WEIGHT
Fi; / LEVER
ed A ~
PRESENT [err ss tL
aoe meee oe
7 oR [ vase
Rapastt tai | amt
; cB w
i eZ | e
fam BLOWER.
REGULATOR
SKETCH A.
The regulator may be located at any convenient point and connected by means of a rod to the bell crank
of the butterfly valve; it must be piped up by a control pipe of about 2 in. diameter to the raw gas line be-
tween the regulator, T2, and the first scrubber, D, and must be adjusted to maintain pressure at this point
to a total variation of 4”’ water gauge, or %4”’ above or below a given point. Its function is to compensate
for all fluctuations in pressure set up in the gas lines and the gas scrubber and all fluctuations caused by
the fan or blower. I am not familiar with the characteristics of the blower, therefore I am not certain
what its performance in this respect would be.
3b. — A control valve, T2 on Sketch A, should be located about midway in the 10 ft. horizontal pipe
leading to the first scrubber; it should be of the butterfly type, preferably of light cast iron construction,
and set with free moving bearings without a stuffing box in a vertical position about as per sketch on next
page. It will be noted there is a space below the valve to permit the passage of the flushing liquor.
This apparatus should correspond to the ‘‘suction main governor” of the coke oven industry. Its func-
tion is to throttle the gas leading from the hydraulic main and smooth out pressure fluctuations which may
be caused by the regulator, T1; by alterations in temperature in the suction main or the hydraulic main,
C; or by changes in the rate of gas production. The machine may be located at a convenient point and
connected by means of a rod to the bell crank of the butterfly valve in the suction main. Its control pres-
sure should be piped from a point in the hydraulic main, such as half way between the first and second
carbonizers of the battery.
There are several types of regulators, or controllers, or governors suitable for service at Tl and T2,
Sketch A, as follows:
The Northwestern Governor manufactured by the Northwestern Manufacturing Company, Milwaukee,
Wisconsin, consists of a small bell float, which rising or falling with the fluctuations in gas pressure below
it, makes electric contacts and, through relay switches, caused a small motor to turn forward or backward,
and this motor is geared to a quadrant which operates a bell crank connected to a similar crank on a butter-
fly valve in the gas main. It is quite sensitive within certain limits. A recent modification consists of an
electrical connection between the suction main governor (corresponding to T2) and the “‘exhauster gover-
nor’’ (corresponding to T1), by means of which the exhauster governor reaches the extreme of its range,
thus the two machines complement one another in an effective manner and there is no hunting. It has
given satisfaction in service.
The Tagliabue Governor is made by the C. J. Tagliabue Manufacturing Company, Brooklyn, New York,
and is quite simple in all its elements. It consists of a diaphragm valve, called by the manufacturer a
202 APPENDIX No. 24b
‘‘motor valve”, which moves the bell crank of a butterfly valve by pneumatic pressure, a degree of such
pressure being controlled by a Tagliabue ball valve working in conjunction with a small float, the latter
being moved by the fluctuations in the gas pressure to be regulated. It is similar to the Tagliabue tem-
perature controllers or thermostats.
* ES *
The Smoot Governor manufactured by the Rateau, Battu, Smoot Company, 90 West Street, New York
City, is built in several types. The one which would be suitable for your job consists of a pneumatic
cylinder, the piston of which is connected by a rod to the bell crank of a butterfly or a balanced globe valve.
The pressure supplied to the cylinder is varied to meet the fluctuations in the gas pressure to be regulated by
means of an ingenious floating valve connected to a diaphragm. The apparatus will operate on either
steam or air but the latter is preferred.
The Koppers Governor. — Its principle of operating is somewhat similar to the Smoot, except that its
motor is a hydraulic cylinder; its power is supplied by a small pump running continuously; and its control
is by means of relay valves connected to the usual float.
* * *
Any of the above described machines is sold by the manufacturer with a fixed guarantee as to the degree
of regulation to be maintained. It is customary to specify a total variation of 2 m/m or 1 m/m above or
below a given line.
Of the four regulators above des-
cribed I recommend the Smoot, for
I believe the manufacturer is best
equipped to install and adjust the
regulators,and I have found the field
adjustment to be the most impor-
tant consideration in the operation
of apparatus of this sort. The
Smoot apparatus is less expensive K
CLEAR ANCE
(a regulator for your requirements
would cost about $300.00 f. 0. b. 3
\
iN
SS
New York) than the Northwestern, |
but it costs somewhat more than
the Taglibue. Ce ee aa
A further outlay which must be =
considered in connection with the SKETCH A1. SKETCH A 2.
purchase of a regulator is the charge
for the service of an expert to adjust the governor. It would take at least a week at the plant to make the
adjustment and the rate would be approximately $10 to $12 a day plus travelling expenses and time of
expert while travelling to and from Bienfait.
4. Hydraulic Main. — In my judgment the present hydraulic main which connects the carbonizers
with the by-product apparatus is too small to permit of even distribution of pressure or suction throughout
the entire battery. Its rigid construction required the installation of sliding expansion joints at five places
and these joints, in my opinion, will always be a source of trouble and will not function as expected.
I recommend the installation of
a main of 18 in. diameter in appro-
ximately the same location as the
SPACE”
ABOUT A
Zz present one, but with alterations as
q follows:
| On Sketch B, I have indicated
<6 a Ale roughly the manner in which I
GAS CUTLETS From believe the main should be connec-
CARBONIZERS 2 Fe ted to the by-product system; it
Ze: BEARING
D>
Ce 1 SLOT 1M PIPE
For TRE rveva Le af
444 VALVE,
ee Z* KEGULATOR
gS
la a ie Ee
OreET
PUST CATCHER
SKETCH B. SKETCH A 3.
should slope from thecarbonizers at about 3/16 in. per foot; it should connect at the end of the
battery with sloping lateral pipes meeting in a T and proceed downwards into a short sloping section
leading to the present connection at the dust catcher or scrubber. In this latter section should be
placed the butterfly valve of regulator T2. While I have not laid this main to scale on a drawing and am,
therefore, not fully apprised of the exact limitations, I believe the above described arrangement would
necessitate raising the main a foot or so above the location of the present one. The main may be of light
steel construction without expansion Joints and supported by hangers in such manner that it may move
freely at all points except the point of anchorage, which should be, preferably, in the lateral connection
above the butterfly valve. It should be fitted with water sprays at intervals and also with spooning holes
of about three in. diameter set at three or four ft. centers, and a platform or gallery should be provided to
give access to the latter. I think it would be well to provide a positive flow of tar, or a mixture of tar and
APPENDIX No. 24b 203
hot water, in the bottom of the main to flush out deposits of dust, but I am not familiar enough with the
nature of lignite tar to advise definitely on this point. This is a matter which must be worked out by the
operators.
To raise the main from its present location and to permit its free expansion would require a modified
standpipe connecting the main with the carbonizers. A desirable design is shown on Sketch C, in which
there are two luted bell joints to allow a limited movement. The connection from the vertical pipe to the
main should be inclined and there should be a removable plug at the top to give access for cleaning in both
directions. A gate valve could be placed at the main, but a simple plate damper such as shown would
suffice. The bleeder connection may be taken off at the side as indicated.
SUPPOR T
Cz
\
CLEANING AND MALY
PLUG
SPOONING
HYDRAULIC
NMIAIN
g
Gb ~?
SKETCH C.
This suggested construction is in all respects superior to the one you now have, for there is no horizontal
run in which dust could settle, and there is not the rigidity of the present one. Its installation would
involve a rather expensive alteration requiring the manufacture of special patterns and castings. The
most desirable construction, of course, would be in cast iron but, as an alternative, you might consider the
building of these six standpipes and their connections of steel pipe by the acetylene welding process, which,
if your welder had moderate skill, should be satisfactory and relatively cheap.
Another choice in the construction of a standpipe is furnished on Sketch D, in which the connection to
the main is made from your present gas offtake casting by means of standard fittings. This has not the
facilities for cleaning possessed by the design proposed in Sketch C, but it is reasonable in cost and has a
certain degree of flexibility.
While I have recommended certain definite changes to the hydraulic main and to the standpipes,” I
realize that your policy, in regard to expenditures and to the amount of time allowed for changes in the
plant, may not permit the completion of such an extensive program as I have outlined, and I therefore
submit below an alternate program somewhat less comprehensive and less costly.
Install changes Nos. 1, 2, 83a and 3b. They are, in my opinion absolutely essential.
The installation of a larger hydraulic main, as detailed under paragraph 4, while highly desirable, may be
postponed. The plant could be operated in a fairly constant manner if the present main were continued
in use with its connections altered to include regulating valve F2. With the present main it would be more
difficult to maintain uniform pressure conditions on all the carbonizers, but I am not prepared to predict
just what the departure from perfect regulation would be. There would be some difficulty in keeping the
expansion joints tight.
I further recommend the installation of ‘‘Hydro’’ recording gauges such as manufactured by the Bacha-
rach Industrial Instrument Company, Pittsburgh, Pa., as follows:—
To indicate and record the hydraulic main pressure: Two recording gauges with four in. or six in. chart
reading in inches or millimeters from zero to minus 10 mm. water gauge and from zero to plus 15 mm.
water gauge.
204 APPENDIX No. 25
To indicate and record the suction on the raw gas line in front of the dust catcher: One recording gauge
with four in. or six in. chart reading zero to 120 mm. water gauge.
To indicate and record the fuel gas pressure: One recording gauge with four in. or six. in. chart to read
zero to plus 120 mm. water gauge.
I also recommend the installation of a recording meter to register the quantity of fuel gas consumed, and
I believe it would be found desirable also to install a meter to read the total make of gas. _ For this service
either Bailey, Thomas, the venturi meter made by the Builders Iron Foundry, or the Bacharach would be
satisfactory. I prefer the latter as it is cheaper than any of the others in first cost and installation cost and
sufficiently accurate if its pitot tube ororifice is properly placed in the pipe line.
SKETCH D.
I am not familiar enough with the details of construction of the by-product apparatus at Bienfait to
discuss its sufficiency from the standpoint of by-product recovery or gas cleaning. If it is found lacking
in this respect the result will be a certain amount of tar in the burner pipes which may prove troublesome
until additional apparatus is installed but which should not greatly hinder the operation.
The entire plant as now equipped depends upon the operation of a single blower, and this I consider
decidedly a risk. Either an additional blower (preferably a positive blower) should be installed or a ful
set of spare parts, such as motor, bearings, rotor, etc., should be carried for making quick repairs on the
present apparatus. ;
Sincerely yours,
(Signed) CHARLES V. McInTIRE.
———}—_—
APPENDIX 25
Record of Tar Distillations — Small Tar Still.
By R. A. Strona.
During the operations of the Hood-Odell shaft carbonizer at Bienfait, a large quantity of tar was
recovered, and laboratory tests were made on small samples the results of which are given in Appendix 27.
APPENDIX No. 25 205
In order to determine whether the tar would present any serious difficulties in distilling and whether the
pitch obtained would be suitable for a binder, it was decided to erect a small still, and distill enough tar to
provide the pitch binder necessary to briquette a car load of char. The lignite pitch was to be mixed with
coal tar pitch in the proportion of one part of lignite pitch to 3 parts of coal tar pitch, as it was estimated
that in commercial operation only 25% of the binder requirements could be met by the pitch obtained from
the lignite tar. A number of tar distillations were, therefore, made. The pitch received was forwarded to
Hebron for the briquetting test, and the oils were sent to the laboratories of the Department of Mines,
Ottawa, in order that they might be analyzed and a test made as to their applicability as a fuel for a semi-
Diesel type of engine. The results of the briquetting test with the lignite pitch are givenin Appendix 30,
and an analysis of the oils, made by the Department of Mines, appears in Appendix 27. Unfortunately
at date of writing the Diesel engine test has not yet been completed.
In order to carry out the distillations a small tar still was constructed from an old 40 gallon gasolene
drum. The drum was set horizontally in brick work, and insulated with magnesia. Brick checker work
was used in the combustion chamber, and a 2” line was piped from the gas supply line for fuel. A 2” off-
take was provided which was connected to a 2” pipe, water jacketed, serving as a condenser. Provision
was made for inserting a thermometer at the offtake in order to observe temperatures, and to control the
quality of the pitch. The drum was placed at a slight inclination from the horizontal and a small pipe
with a cast iron cock was used for draining the pitch from the drum after the distillation was completed.
The tar was taken from the tar storage tanks, but was not a representative sample of the total tar recovered,
as considerable condensation naturally had taken place at the water seal and at other places along the line
before the gas reached the wet scrubber. As taken from the tanks, the tar was in the form of an emulsion
containing approximately 70% of water. Heating had no effect in breaking up this emu!sion, and in order
to get the water content down to 30%, it was necessary to cool the tar, work it with a paddle, and pour
off the liberated water as it appeared. In commercial operation of this character, it would be necessary to
recover the tar in such a way as to avoid these emulsion difficulties. In the first attempts at operating the
still no record was kept of the time required to bring the temperature to the desired point, and as a result
considerable variation in the melting point of the pitch was found. In subsequent operations, the tem-
perature was raised to the desired point in a definite time, and as a result very uniform pitch was obtained.
It was found that to approximate a pitch of 140°F melting point the distillation had to be stopped at 265°C.,
with a distilling time of 75 minutes.
A record was kept as to the quantity of gas required to complete a distillation, and from the results
obtained it is safe to assume that with a tar emulsion carrying 30% of water 5,000 cu. ft. of gas of 100
B. T. U. is required to distill 100 lbs. These figures are of course only applicabie to the small installation
used, and could be materially reduced in a properly designed still of larger dimensions.
The oil as recovered has an average density of 0.965, and has a decidedly objectionable odour of hydrogen
sulphide. It shows no signs of congealing at ordinary temperatures and from all appearances would make
an acceptable fuel oil. The pitch is somewhat different in appearance to coal tar pitch, being more oily.
It has a dull lustre and somewhat resembles asphaltum.
A total of 1,715 Ibs. of tar was distilled having an average water content of 32.1%. This yielded a total
of 1,200 Ibs. of pitch (with average melting point of 145° F.) which is a 70.0% yield on the dried tar basis.
The record of a number of these distillations is included below as a matter of interest. The conclusions
to be drawn from the tests are that no difficulty is to be expected in converting the tar into oils and pitch
provided proper methods are followed in recovering the tar, in order to eliminate as much as possibie the
formation of persistent emulsions. It is quite difficult to distill tar with 30% of water without having it
froth over but by practice and careful observation it can be accomplished. It is desirable, however, to
reduce the water content of the tar to a minimum.
DISTILLATION RESULTS.
' 1st DISTILLATION
Weights not recorded.
2nd DISTILLATION
Cut at 260 degrees — Taken up slowly.
LAT. 5 etter es ee (22obs.~ 0) -))) ho Cree 2s ee eingken
IWATErE semi oo, 21.45 29D OGM MATS a 7 | dors s svete
Or Sheen os aka te ahs 11.45 15.7% 22.3%
EIbC haere 2 ee eats 34.00 46.8% 66.4%
Mogae se 3 ee ee 5.85 8.0% MADR YA
3rd DISTILLATION
Cut at 260 degrees F.
SLAP Sei eeetn. te G1E25 Ibs) ee eee ee ios ee ete
WALCIA SSO cee 5.53 SOESe ee ) eee
Ore eee 9.59 13.5% DAG
Pitch sete ck oes 34.75 48.8% 76.1%
LOSS ene petecen ts 1.38 1.9% 2.8%
Gravity of oil 0.965.
M. P. of pitch 138 degrees F.
4th DISTILLATION
Cut at 260 degrees F.
FAT See ern te eonc ls oe 69':00: baht am en rete Gt SP Ge De Ate! oe
Vretors sy ra . sa «a 25.65 BYR eh Meee LS! ) Bika ta
11 2s enter 1 pO ARN 9.10 1322 1.1%
Piteneecnrs trae, © 32.50 47.1 TAG,
LOSS Ne ee hes cic LAY aa, Phila 3.9
Gravity of oil 0.965.
M. P. of pitch 138 degrees F.
206
ee ee ee
M. P. of pitch 147 degrees F.
Density of oil 0.965
M. P. of pitch 136 degrecs F.
Density of oil. 0.965
M. P. of pitch 149 degrees F.
Density of oil 0.965
M. P. of pitch 147 degrees F.
Density of oil 0.965.
APPENDIX No. 25
5th DisTiILLATION
Cut at 270 degrees F.
60:00 Ibsa" Fl Tawa ree
19.12 31.9%
10.63 LiAt%
27.00 45.0%
S225 5.4%
6th DisTILLATION
Cut at 270 degrees F.
67.00/13: 2 ee ee cee
21.10 31.5%
12.65 18.9%
o2lZ20 48.2%
1.00 1.4%
7th DISTILLATION
Cut at 270 degrees F.
66 .25:Ibss tie Pir ee ae
20.33 30.7%
11.67 17.6%
30.00 45.3%
4.25 6.4%
8th DISTILLATION
Cut at 270 degrees F.
73i'75ilbex V8 SA le Meace
24.06 32.6%
11.94 16.2
34.00 46.1
3.75 5.1
85.00 lbsiiy ay Giueiehe a eee
25.07 29.5%
15.43 18.2%
43.00 50.6%
150 1.7%
10th DistTi1LLATION
Cut at 268 degrees F. — Time 58 min.
$100 Tbs:y a eee
PAT ATR/ 29.3%
12.98 16.0%
42.00 51.9%
PA PAS 2.8%
11th DistTILLATION
Cut at 270 degrees F. — Time 1 hour
72,00;ibs.., |) eee ee
3.45 32.6%
12.55 17.4%
33.00 45.8%
3.00 4.2%
12th DisrinLaTION
Cut at 269 Degrees F. — Time 59 min.
79.00 Tbs)! jet pees
23.19 29.3%
13.81 17.5%
40.00 50.7%
2.00 2.5%
ereeee
ovreees
eee eee
eee e ee
eee eee
oe fo. avcele
see eee
APPENDIX No. 25
13th DisTILLATION
Cut at 271 Degrees F.—Time 45 min.
OS thee legs Ch A Meee SOOO Tbe. 5 29) .. Mele acter st dig ce ae
VV LOL ete ance c 24.55 SOO TA! aio, ier s eee ee
PREC oRoehsl sah ttenete 14.20 17.8% 25 .(%5
Pome cd 38.00 47.5% 68.4%
MOREE «4, Gn is wat ate o's 3.25 4.1% 5.9%
14th DisTILLATION
Cut at 265 degrees — Time 75 min.
RENE BO pad ea a 2 TOLOU LOS meee 7 DPS. ee tS UAE ee
Wistert soo y fans 23.9 Sly ee ee Re ae
Orbe eee ae eee 11.03 14.6% 21.3%
Pitcher. soe 39.25 52.0% 76.2%
LOssi eee ec ete cere 1e25 1.7% 2.5%
M. P. of pitch 142 degrees F.
Density of oil 0.965.
15th DisTILLATION
Cut at 265 degrees — Time 75 min.
HOT ees ane tates Sopcoubsta met ee hee ee, wy ww eae
Winter fen reece Slel2 Seam yh oe ecReTe
Oilvand) Wosss.c ces, 14513 17.0% 212%
Pitch ee eo iter 38.00 45.6% 72.8%
M. P. of pitch 142 degrees F.
DISTILLATION FRACTIONS
0°C 110 °C 690 C.C. 0.950 density 12.3% by weight
110 —170— 285 ‘ 0.965 a ete 7
1760 — 200 — 555 ‘ 0.980 ae 1Os295au ip
200 — 210— 280 ‘ 0.975 i iota a
210 — 235— 575 *' 0.975 ne LOGO ns e
235 — 265 — 3,083 “ 0.975 : 56.6% ‘‘
5,468 ~* 100.0%
DISTILLATION No. 16.
Cut at 265 degrees — time 80 minutes
LAT ey ce eee TH UO ethe, eo We i edt,
Water, ere ns ot TORTS 2 Loe ne eee ee Poe
OUN EES eee 12.00 15.6% 20.9%
Pitch werner aie, tes 40.00 51.9% 69.9%
TOSSES et. eee ee 5.25 6.8% 9.2%
M. P. of pitch 138 degrees F.
DIsTILLATION No. 17
Cut at 265 degrees — Time 70 minutes
PPTs ar eee d cee ocee 9300 bSi* © 05 AMA! (li arse teen Gel eal el a Nol eoeete
Watery) iy ie 2 eine. 25.50 Dig 4 Foe ee ee, TEAS
eae RS RET cee P5200 16.7% 23.0%
PEC heat ee iran 47.00 50.5% 69.6%
ORES Con ne Senses 5.00 5.4% 7.4%
M. P."of pitch 138 degrees F
DisTILLATION No. 18
Cut at 265 degrees — Time 76 minutes
AL ATER eee ert tice ss. s $9'.50 lbs. > = a eee a TS ho
IWiStereernry ts oe 242 2 TE Came Ma uw! ) tacts aid
OT Re Sere cs 15.25 17.0% 23.3%
Bitchin peine incvde 50.00 55.9% 76.7%
M. P. of pitch 140 degrees F.
DisTILLATION No. 19.
Cut at 266 degrees — Time 70 minutes
DOT Wee clas ath ciel clare, Ore 95.50 Ibs SMe? | hu ka ha bits wis wea
Wa GeLyy us aaitarte cto 24. Die OS meee Paes ply wal hs tos ste ers
rh eS Sa ee eu aa 17.00 17.8% 23.9%
ab Olenbie. toni oe Srat 49.75 52.1% 70.1%
ISOSS ME Re hehe en ohooh AG 4.5% 6.0%
M. P. of;pitch 138 degrees F.
208 APPENDIX No. 28
DisTILLATION No. 20.
Cut at 265 degrees — Time 74 minutes
CATON ete eso covers ehtkes 92) 50 Ibsf .° | © SLEEP eee eee
SRT RIC ee aes ean De 24.00 2559%)
when the gas was not removed from the carbonizer as fast as made it was impossible to maintain tight joints
by luting. The movement of the charge through the carbonizer was perfectly regular throughout the
entire run. No indication of any leak between combustion and carbonizer flues could be observed.
During a period of 14-14 hours of regular operation the retort was heated by gas for 62% of the time
and by oil for 38%. This gives an indication of the extent to which the gas produced would be insufficient
to heat the retort under the conditions of operation employed in thisrun. Owing to the lag in temperature .
readings it is difficult to determine whether the retort was heated equally during gas and oil firing periods. .
(Signed) R. A. STRONG.
Brenrait, SasK., September 22nd, 1922
CARBONIZER TRIAL Run No. ‘“D-3”? SepremMBER 15TuH., 1922.
Before attempting another run it was necessary to make some improvements in the jointing of the cover
plates as the gas leaks referred to in journal sheets of run D-2 were very annoying and dangerous to oper-
ators. It was decided to make channels of sheet iron about 18” high running along each joint. These
were to be filled with sand. A constant depth of sand on the longitudinal joint was maintained by means
of baffles. Several days were occupied in making this alteration and in the meantime a dryer was operated
as the supply of dried coal had been exhausted during the previous run.
_ Several other changes were made during this shut down which seemed necessary from experience gained
in the previousrun. These changes consisted of the following.
1.— pocauatable blades were put on impellors Nos. 5 and 6 in ‘order to correct for unevenness in
ischarge.
2.— Stopes tee at exhauster fan to an elbow in order to allow fan to blow out accumulation of tar
an water.
3.— Put drain in exhauster for tar removal.
4. — Moved valve on pressure side of exhauster to a position in front of control house to allow tar to
settle before reaching valve.
5. — Put drain on pressure side of exhauster behind valve.
APPENDIX No. 26 211
6. — Put gauge on pressure side of exhauster also test burner.
7. — Put pyrometer couple in combustion flue.
8. — Put gauges on combustion chamber and downtake.
During the night of September 14th., heated the carbonizer with wood and coal and started charging
the following morning at 10.15 a.m. Dried coal was charged at noon.
At 7.20 the exhauster was turned on. Very irregular pressures were experienced during this run as
soon as the gas was turned into the purifying system, and in order to operated it was necessary for one man
to continually operate the hand valve on the pressure side of exhauster. The regulator continued to function
but would fail to check either big increases or decreases in pressure. This meant that the flow of gas
was so small that it could all pass through the clearance between the valve and the diaphragm. In the
previous run the leaky condition of the cover plates had acted as a regulator allowing air to be drawn in
when the retort was under suction and gas to escape when it was under pressure. Evidence also pointed
to a block in the gas lines. At 9.15 the exhauster was turned off in order to put gauge connections at
suction inlet to fan also between scrubber and fan. Opened scrubber and found everything quite clear
and free from tar. At 11.00 turned on exhauster again and took readings at new gauge connections.
Found the suction to be practically negligable and no improvement in operating conditions so opened
bleeder valve at 11.15 and discontinued run.
In this run as in the two preceding ones the mechanical operation of the retort itself left small room for
improvement. The flow of coal through the retort was uniform and no evidence of any irregularity in
feeding hopper was noticed. The coal used is of a slightly coarser screen analysis than that used in last
year’s trial runs, but is still much finer than was used in the model carbonizer at Ottawa.
(Signed) R. A. Strona.
BIenFaiT, SAsK., SEPTEMBER 23RD, 1922.
CARBONIZER TRIAL Run NuMBER “D-4’’ SEpTEMBER 18TH, 1922.
As mentioned in the journal of the previous run, the damper valves had been found to have too much
clearance when shut which allowed the small amount of gas obtained when operating one retort to pass
through. Under these conditions the regulators could not be expected to do any real regulating. A ten
inch valve had been placed in the line from the scrubber to the fan and for one retort this was considered
too large. Both valves were removed and the clearance reduced. A six inch valve was used to replace
the teninch. The following day (Sunday), Mr. King the expert from the Rateau Battu Smoot Co. arrived
and several tests were made as to the drop in pressure across the valves, using air instead of gas. There
was still too much clearance and during the night the valves were again removed and this reduced to a
minimum. A fire was also built in the retort and preparations made for a run the following day. Con-
tinued this heating with occasional periods of oil until 12.30 p.m. Sept. 18th, and then charged carbonized
coal. At 3.10 p.m. dried coal was charged in feeding hopper. At this time the temperatures and pres-
sures were as follows:—
Bottom 880 degrees F. — .05” water gauge
Middle 670 ae F, — .00/ “ ts
Top 300 “ F. plus 03” “ a
The temperatures continued to rise for a short time but at 5.00 p.m. started to fall and although the oi
was full on the decline could not be checked until 8.00 p.m. The discharge was at a somewhat larger
rate than previously which probably accounts for this drop in temperature shortly after the introduction
of the dried coal. This gives an indication of the heat required for carbonization of green coal. The drafts
were also very bad owing to the brickwork leading to the stack being quite cold. This improved as the
brickwork became hotter. At 8.00 p.m. the exhauster was turned on and all the gas lines and holder
purged of air. At 8.45 the gas was turned into the retort to augment the oil burner and from then on the
temperatures rose.
Mr. King made several adjustments on the regulator nearest the retort and at midnight had it functioning
perfectly. The pressure variations during the night did not vary more than a millimeter. The second
regulator had not been adjusted and this was left until the morning when it was expected that with higher
spiaberatures a bigger flow of gas would give a sufficient drop in pressure across the valve to allow the regu-
ator to function.
Gas and oil were burned alternately during the night and records kept of the time each was on. A
record of production of gas was kept by observing the height of holder at givenintervals. Flue gas samples
were taken and analyzed during gas burning periods in order to regulate the amount of air admitted through
the explosion door. No conclusive information was gained in this connection.
From midnight until 10.30 a.m. September 19th, operation was very regular and smooth leaving little
to be desired. The gas generated was insufficient for the requirements of the retort averaging slightly
over 50%. The methods of measuring were however not sufficiently accurate to accept this figure as
final. With continued operation the heat requirements may be considerably reduced and with an in-
wees in the discharge more gas can be obtained. At present it is sufficient to say the retorts were not
se sustaining.
At 10.30 a.m. the temperature had risen to over 1000 degrees and operation immediately became very
irregular. The exhauster appeared unable to remove the increased quantity of gas. At 11.30 the discharge
was increased on number 5 and 6 as these channels were becoming quite hot being over 1200 degrees F.
The average temperature at the bottom of the retort at this time was 1120°F. The temperatures started
dropping almost immediately. During this period the voltage of the fan was tested and found to be in
the vicinity of 550. The speed was 1807 r.p.m. At noon the gas was sent through the bleeder valve
and the fan stopped for three minutes. Tested drain cocks for tar accumulation but found none. The
suction increased slightly immediately after starting fan again but the improvement was only temporary.
It should be noted that the control valve on pressure side was at this time full open as well as two six
inch damper valves. The temperature of the gas was taken at the fan and found to be around 40 degrees C.
At 3.15 cut down the discharge in order to decrease gas volume and cut down gas burners to lower temper-
ature. The failure of the fan had upset all regulation, and at 5.00 p.m. it was decided to discontinue
run and dismantle fan. This was done and the fan was found to be in perfect condition and with very
little tar in it. A telegram was then sent to the makers. F
_ During the morning of September 19th, the supply of dried coal was becoming low so a fire was started
in the east dryer. The suction in the combustion chamber and downtake immediately increased. Coal
212 APPENDIX No. 26
was fed to dryér at one o’clock. For a short time during the afternoon the damper to west dryer was
closed and the hot combustion gases confined to the east dryer. Prior to this the gases had been sent
through the west dryer. The suction decreased but no difficulty was experienced in getting sufficient draft.
This was the first attempt at operating a dryer and carbonizer simultaneously. It was not continued
long enough to draw any certain conclusions, but gave no indication that difficulty will be encountered.
This run is the first in which flushing liquor was used in foul gas mains also spray employed in the dust
trap. It resulted in a large percentage of the tar separating at the dust trap from where it passes to the
sewage system. Steps must be taken to prevent this loss of tar and damage to sewage plant.
With regard to the failure of the exhauster to handle the hot gases in any quantity it might be noted
that high temperatures in the carbonizer have been obtained before without resulting trouble but in such
cases a lower rate of discharge was used. Also higher discharges have been employed with lower temper-
atures but it is now clear that trouble was always experienced when the gas output became notably in-
creased. As the gas flow increases as indicated by flow meter, the suction behind the exhauster gradually
decreases to zero, and in some cases even a slight pressure from the carbonizers was registered there. This
clearly indicates that earlier idea of a tar block in the system was entirely erronous.
(Signed) R. A. STRONG.
BienFaiT, Sask., OCTOBER 77TH, 1922.
CARBONIZER TRIAL Run “D-5"’ SEPTEMBER 25TH, TO 30TH, 1922.
SEPTEMBER 25TH.
Heated carbonizer during Sunday and Sunday night with wood, and at 1.20 p.m. Sept. 25th, turned
on the oil. Carbonized coal was fed into the retort at 4.15 p.m. at which time the average temperature
across the center of the retort was 850°F.
On Saturday night previous to the run had thoroughly tested out fan and found that the maximum
resistance overcome was over 8” and that the volume delivered was not materially affected by either
increasing or decreasing the back pressure. As stated in previous journal the 8’’ orifice for flow meter
had been changed to a 4” in order to increase the reading of the flow chart. This was changed again
and the 8” orifice replaced. With the two 6” regulating valves open the fan delivered 25,980 cu. ft. of air per
hour against a pressure of 7.42 inches and a suction of 2.0 inches. The scrubber was opened in order to
eliminate one of the regulating valves and with the bleeder at the holder open the fan. delivered 70,800
cu. ft. of air per hour against a pressure of 3.05 inches and a suction of 5.6 inches. The hand control valve on
the pressure line could not be opened full as the reading otherwise could not have been contained on the
flow meter chart. It was decided to leave the 8” orifice in during the run as the flow was increased thereby
Bud ie was hoped that this increase would allow operating at higher temperatures and with a bigger
ischarge.
_ A 6” orifice was placed in the line leading from the holder to the burners and the flow meter connected
in order to read directly the gas consumption. :
At 7.55 p.m. the dried coal was fed to the retort and although the discharge had been materially decreased
from the previous run the temperatures dropped as soon as the dried coal got into the retort and were
very erratic until 10.30 p.m.
At 9.10 p.m. the exhauster was turned on and no trouble was experienced until 12.00 midnight. One
of the middle thermo couples at this time showed a big increase in temperature, being 940 degrees F.
The discharge was increased in this channel and the fire end adjusted but the trouble still continued and
spread to thé other channels. At 2.00 a.m. one of these registered a temperature of 1,220degrees. The dis-
charge was increased in all channels but this did not remedy the trouble. At 2.25 a.m. were forced to cut off
the exhauster as it would not handle the gas. A pressure was recorded at the suction inlet to the exhauster
and this caused a big pressure on the retort which completely upset the feeding. The gas was bled to the
atmosphere and an inspection made. A slight leak in the combustion flue was noticed. The induced draft
fan at the dryer stack was cut off and the leak immediately disappeared. A much greater suction, had
been employed in both the combustion flue and down take than previously, which was accomplished by
putting a temporary baffle in the dryer stack and employing fan. This gave the full effect of the fan
toward removing the gases. This point brings out the importance of balanced pressures in order to maintain
uniform operation. When the trouble started the oil had been cut off and at 4.40 a.m. the temperatures
were again normal. Gas was then turned on and dryer fan speed was reduced considerable and operation
was resumed with notably lower suction in both combustion flue and downtake. At 5.30 the exhauster
was turned on and trouble started immediately. At times there was 15 millimeters of pressure at the
suction inlet to exhauster. At 7.30 all hope of straightening out the operation was abandoned and it was
seriged to feed carbonized lignite, exhausting gas to atmosphere until the temperatures and feed were
normal,
SEPTEMBER 26TH.
_ At 11.30 a.m. the feed was found to be very uniform again and at 11.45 dried coal was again fed to retort.
At 3.00 p.m. the exhauster was turned on and until 6.45 operation was very erratic. Several times during
this period pressure was registered at the suction inlet and the feed again became irregular. It is rather
difficult to say whether the irregular operation of the retort causes this pressure at the fan or whether
the pressure at the fan, which naturally puts a rather big back pressure on the retort, causes the irregular-
ities in the feeding. I am inclined to the latter opinion in view of the apparent smoothness of operation
when the gas is bled to the atmosphere. At 6.30 the temperatures started to drop and the suction at
exhauster inlet increased until at 9.00 p.m. the average temperature across the bottom was 850 degrees F.
and the suction registered 2.5 inches.* There seems to be considerable relation between the temperature
of the retort and the suction. The temperatures were plotted on the same chart on which the suction is
recorded and this relation is very marked in a large number of instances. It does not always follow how-
ever, so that some other factor as well must have a bearing on the behavior of the fan. At 10.00 p.m.
the operation of the carbonizer became very uniform and for a number of hours the recording pressure
gauge on the retort did not vary one millimeter. The feed was remarkably uniform and gas was burned for
large part of the time, on one occasion for three hours, two burners being sufficient to maintain the tem-
*Suctions are registered close to the exhauster on the suction side.
APPENDIX No. 26 213
~
perature. Thesuction recorded during this period varied between one and two inches. This seems to be
the amount necessary for smooth running. It might be noted that there is no regulation on the exhauster
and as previously stated there is insufficient drop in pressure ordinarily with one retort operating to put
the second regulator into service. It has been suggested that a by-pass on the exhauster would help matters
considerably such as was intended with the Isbell Porter compensator, but with the small flow of gas when
operating one retort this hardly seems necessary. It is used however, on all constant speed exhausters
and may have a bearing on the situation.
SEPTEMBER 27TH.
*Nothing worthy of note occurred until 8.00 a.m. Sept. 27th, everything running as smooth as clock-
work. The temperatures were easily maintained at about 950 degrees F. and the discharge was maintained
at about 12 pounds per minute. At 8.00 a.m. another period of low suction occurred and trouble ensued
but this did not last long and at 8.30 operation was again smooth. At 8.35 a fire was lit in the west dryer
which increased the suction in the combustion flue and downtake slightly. At noon started drying coal
but still used east dryer for removing combustion gases. At 3.00 p.m. operation again became irregular
as suction decreased at fan. Except for the slight trouble at 8.00 a.m. this period of twenty hours operation
was ideal. As previously stated when an attempt was made to raise the temperature to 1000 or over
trouble immediately ensued and no further attempts were made. From 3.00 a.m. until 8.00 p.m. operation
was almost impossible owing to low suction at fan.This caused a big back pressure on the retort registering
as high as 17 millimeters. Shortly after 6. p.m. a pressure of 10 millimeters was recorded at the fan and owing
to the gas escaping into the room due to these high pressures working conditions became impossible. Sev-
eral of the operators became sick so at 6.50 cut off fanand bled to atmosphere. Previous to this trouble
the discharge had been increased and this was again reduced and fuel oil was cut off in order to allow con-
ditions to readjust themselves. At 9.30 p.m. the temperature and feed was readjusted so started the ex-
hauster. No suction whatever could be obtained so were forced to again resort to bleeder. During
the long period of operation preceding this trouble the fan had become quite warm so no attempt was made
to operate until the fan had cooled down. At 1.00 a.m. made another attempt at operating the fan and
after an hour and a half of uneven operation conditions again became normal. In the meantime a second
spray had been put in dust trap as considerable tar was being collected at the fan. This assisted in cleaning
the gas also to cool it which seemed to help the fan considerably. Nothing further occurred during the
remainder of the night worthy of note. Feeding was very uniform and pressures steady.
SEPTEMBER 28TH.
_ Between 12.00 noon and 1.00 p.m. Sept. 28th, it was necessary to open the bleeder for a new minutes
in order to relieve the pressure on the retort but with this exception operation was very smooth throughout
the day. At frequent intervals it was necessary to drain the fan and gas lines of tar. This does not speak
very well for the scrubbing system. The temperature of the gas entering the fan was not allowed to get
Baty hot ee peaaent temperatures were taken for this purpose. Temperatures were also taken frequently
of gas at offtake.
_At 1.10 p.m. the east dryer was cut off and gases were sent through the west dryer. No appreciable
difference was noted in the suction at the combustion flue and downtake. From this time on until the
run was discontinued the two units were operated together. Between 8.00 and 9.00 p.m. another period
of low suction occurred but after an hour of irregular operation smooth running was again experienced
which continued until 3.30 a.m. The suction again became very slight and irregular feeding and high
pressure resulted. The suction improved later on but smooth operation did not result. This seemed to
oes gee other trouble starting. It was hoped the trouble would gradually straighten itself out which
it did at 8. a.m.
SEFTEMBER 29TH.
From 8.00 a.m. until 10.30 no trouble was experienced but at that time the suction rapidly decreased
until 11.00 a.m. the gauge at the fan was registering 6 millimeters of pressure. A big back pressure was
put on the retorts as a result registering as high as 16 millimeters. At 1.00 p.m. the temperature started
dropping and the suction immediately increased and smooth operation resulted which continued until
6.00 p.m. when another period of low suction was experienced. This was overcome and no trouble was
again experienced until 9.30 p.m. At this time the gauges on the retort were jumping up and down, first
registering a large pressure and‘then a large suction. The recording gauge registered 5 mm. of suction
and the evidence pointed to a big block in the line. Owing to the gauge at the bottom of the retort lagging
behind the other two it was thought it might be in the gas clearance space in the retort or very close to the
offtake in the line. The spooning hole at the offtake was opened and found to be perfectly free. The gas
was then bled to the atmosphere and an attempt made to release the obstruction by working the butterfly
valve. This improved matters and at 10.30 the exhauster was again turned on but smooth operation seemed
impossible so the run was discontinued at 12.30 a.m. The holder at this time was full of gas which was
used to calibrate the 6” orifice referred to above. It was intended to run the retort bleeding to the atmos-
phere at a much higher temperature after the run had been discontinued in order to find out if any evidence
of unevenness of operation could be detected but owing to the fact that the high pressure had entirely upset
the feeding it was abandoned. One of the channels was not functioning at al) although the discharge was
normal. The thermo couple in this channel at the top was very much higher than the other two and as the
adjoining channel was feeding much faster it was presumed the coal was passing unter the baffles. There
are two A baffles at the top of the retort and as the middle leg of these does not rest on the slab this is
possible. An inspection was made the following day and this was found to be the case. During the latter
part of the run the feed seemed finer than during the first part, A screen analysis was made and this was
found to be the case. The coal being used was from the storage bins where it has been for over a year and
considerable slacking has resulted. The new baffles will handle this finer product without much difficulty
oe a coarser feed is desirable for the best results. This will be attained when operating on freshly crushed
coal.
As soon as the retort had cooled down a thorough inspection was made. Theshort run of 8” pipe leading
from the offtake to the collecting mains was found to be practically choked solid with tar and dust. It
was necessary to dismantle this and chip out the obstruction. The butterfly valve seems to increase this
tendency to deposit as the greatest accumulation occurred at that point. It is proposed to eliminate
*Discharge was increased at 7 a. m. which caused the irregularity noted at 8 a.m,
214 APPENDIX No. 26
these valves and replace them with gate valves which will offer less resistance to the passage of the gas.
A spooning hole is to be provided in the elbows so that frequent cleaning of this section can be made during
operation. The concrete retaining walls are cracked badly and are the source of big leaks whenever any
suction is on the retort. I do not believe the life of these retorts will be very great, and it therefore be-
hooves us to devote our entire attentions to overcoming the difficulties in connection with briquetting
so that the product may be placed on the market, before the necessity of rebuilding the retorts arises. In
any future construction a single channel for each retort should be employed and if possible drying and
earbonizing carried out in a single operation. An inspection of the flues was also made and it was found
that the carborundum shapes are cracking which demonstrates that this shape will not be successful.
Out of 12 shapes visible from the combustion chamber 11 show cracks. I do not believe these cracks
will interfere with the operation of the retorts for some time, provided the proper pressures are carried,
and it is quite possible the shapes will last as long as the rest of the retort. Two more runs are yet to
be made in order to complete this series. ‘They will be made on the other two retorts and after these it
will be possible to make some observations on the different types of construction.
RESULTS.
Temp. Stack.
Minimum 30°C
Maximum 39°C
(During time gases were being sent through east dryer)
Gas Offtake Temperature.
Maximum 360°C.
Minimum 264°C.
Temperature of Gas at Fan.
Maximum 50°C.
Minimum 35°C.
ANALYSES,
Samples of Carbonizer Feed.
Note. — Samples were taken half hourly over period stated below.
Date Time Moisture Content
9/25-26 11 p.m. to
6 a.m. 5.0%
9 /26-27 6 a.m. to
1 a.m. 4.8%
9/27- 1 a.m. to
12 noon 5.2%
9 /27- 12 noon to
8 p.m. 7.3% Average moisture in dried coal fed to
9 /27-28 8 p.m. to 3 retorts — 5.4%
5 a.m. 4.5%
9 /28- 5 a.m. to 7
8 p.m. ; 3.7
9/28/29 8 p.m. to @
4 a.m. 5:3
9/29 4 a.m. to o
8 p.m. 7.0%
Samples of Dryer Discharge.
Note. — Samples were taken half hourly and made into a daily composite.
Date Moisture.
9/27 5.2%
9/28 5.7%
9/29 6.2%
Dryer Results.
Maximum temperature of discharge 95 degrees C.
Minimum se bs s 68 een CL
Average pi se ¥ 79 PH OE
“moisture content 5.7%
Screen Analysis of Dryer Discharge.
Screen No. % Cum %
4 4 4
6 U4 2.1
8 6.8 8.9
10 12.4 PH bis
14 18.7 40.0
20 Mies 57.3
28 13.8 et
35 12.1 83.2
48 7.0 90.2
65 4.7 94.9
100 2.8 O77
100 (Through) 100.0
This analysis shows a slightly finer feed to carbonizers during the latter part of run D.5. -,
wt
Ww
APPENDIX No. 26 215
ANALYSES.
Samples of Carbonized Discharge During run “D-5”’.
Temp. % hour Temp. at time % V.C.M.
Date Time previous to sample. of sample.
9/25 11.00 p.m. 810 degrees F. 840 degrees PF. 18.2
9/25 12.00 p.m. 810 860 19.6
9/26 1.00 a.m. 830 te Bene" 860 as SL 22.4
9/26 2.00 a.m. 870 See tA 890 ait 16.5
9/26 3.00 a.m. 960 seat Oe 16.4
9/26 4.00 a.m. 840 ee pas 920 eS 11.9
9/26 6.00 a.m. 790 1 730 ze # 24.0
9/26 7.00 a.m. 760 Nid Waka 800 fs i 23:3
9/26 7.00 p.m. 1000 nS eat 950 A pe 14.9
9/26 12.00 Midnight 960 ie bee 955 a it 14.2
9 /27 1.00 a.m. 950 St Be 950 gis 13.9
9/27 2.00 a.m. 920 saath ts 15.8
9/27 3.00 a.m. 930 “Senatess 960 +a Huh Thr 1
9/27 4.00 a.m. 945 a i 910 eid 16.5
9/27 5.00 a.m. 915 iSiers 890 AWAY oF 14.9
9/27 6.00 a.m. 950 at Pee 950 Seo 14.0
9/27 7.00 a.m. 900 ‘s o 905 ss 2 16.6
9/27 8.00 a.m. 890 ee iss 915 Set Hiss eee
9/27 10.00 a.m. 925 routine 930 stu tHe) 14.5
9/27 11.00 a.m. 920 be Say 950 SSty ate 12.9
9/27 Noon 950 Seti deate . 945 oad 1253
9/27 1.00 p.m. 930 me EES 940 ih aed 5 12-5
9/27 2.00 p.m. 850 tetas 860 ate oa 15.9
9/27 3.00 p.m. 805 ep amas! 795 ete 21.8
9/27 4.00 p.m. 835 free 915 [Sarees 16.8
9/27 6.00 p.m. 850 eee 875 fT iets 18.1
9/27 7.00 p.m. 875 sy ie BY,
9/27 8.00 p.m. 1040 epee 990 ery 10.0
9/27 9.00 p.m. 960 N 4 920 Me " 14.2
9/27 11.00 p.m. 800 Tl a! 825 aes 14.2
9/28 9.00 p.m. 906 rae 930 pcsag tt 16.3
9/29 1.00 a.m. 860 et he 860 hts. as 15.8
9/29 3.00 a.m. 875 i ‘ 850 % . 20.2
9/29 5.00 a.m. 915 Senile: 930 ae 16.2
Average 16.2
Discharge.
Dried coal fed to retort — 7.55 p.m. Sept. 25th, 1922.
Run discontinued — 12.30 a.m. Sept. 30th, 1922.
Average discharge per cheese — 959 grams — 2.1 Ibs. per min,
Total coal carbonized 38.2 tons.
Gas Results.
Fuel consumed from 3.00 p.m. 9/26 —2 p.m. 9/27
Minutes oil 443
Minutes gas 913
% oil. 32.7
% gas 67.3
Fuel consumed from 2.00 a.m. 9/28 —12.00 midnight 9/30.
Minutes oil 1004
Minutes gas 1773
% oil 36.4
% gas 638.6
Average percentage gas 65
oil 35
Average temperature 950 degrees F. approx.
Average yield gas 2.73 cu. ft./lb. residue.
Note. — No account. was taken of those periods during which oil and gas was burned together, or those
periods when gas was allowed to escape to atmosphere.
(Signed) R. A. STRONG.
’
BrenraltT, Sask., January Sth, 1923.
Run on No: '3 CaRBONIZER FROM DECEMBER 21s 1922 To JaNuARY IsT, 1923.
el BS
This carbonizer is constructed of double slabs bonded together with the joints Nfaceered! The floor is
2” thick and a sliding joint is provided at both sides and top to allow for expansion. ‘The baffles used were
called type F and are exactly the same as type E except in the width which is 11-4” instead of 11-38’.
The shortening of this dimension was made necessary in order to allow for an overlap of the side. walls.
At the bottom of the retort resting against the end plate is one row of ‘‘D’’ baffles. Following this is one
row of “‘C’’ and then two rows of ‘‘C’s’”’ cut down to 7-4”. 57 rows of ‘‘F”’ baffles are used which leaves
2”’ between the last row and the hopper plate.
216 APPENDIX No. 26
The carbonizer was heated with a wood and coal fire for several days and then brought up to the desired
temperature with oil. Dried lignite was put in at 3.00 p.m. December 21st. As soon as the gas was
rich enough to burn the fan was turned on but it was found that during the cold weather the oil in the
dash pot of the sensitizer had congealed and this had to be changed before it would function. In the
meantime operation was continued using the bleeder. Operation was fairly smooth except for some small
difficulty in adjusting the blades in the paddle wheels in order to get a uniform discharge. At 5.30 a.m.
the middle pyrometer indicating the temperature in one of the channels was mounting rapidly while
that at the bottom was dropping. This indicated that the coal was not moving although the discharge
remained constant. The coal over this channe!in the hopper was not moving at all and in the adjoining
channel was feeding at a much faster rate than any of the others. This indicated that the coal was moving
under the mid rib in the old style baffles used at the bottom of the retort. This had occurred during the
other runs and could hardly be conceived to be the cause of the stoppage. Carbonized coal was
introduced and the retort emptied. The burning seemed to eliminate the trouble so coal was again fed
and at 1.15 p.m. December 22nd, dried coal was put in the hopper. At 3.00 p.m. the gas system was
tried and continued using the fan to take off the gas until 8.00 p.m. Im order to maintain the
necessary suction the holder was never allowed to go above one foot in height. The gas was burned
as it was made and no attempt was made to measure it in the holder. Owing to leaks we were forced
to operate on a slight vacuum and analyses were made on the gas to keep the oxygen within safe
limits. At 8.00 p.m. there was evidence of burning in the retort so closed down gas system and operated
again on bleeder extinguishing the fire by putting a pressure on the retort. About this time the middle
channel (hereafter called No. 3) again gave trouble and it was necessary to again clean out the
retort. The evidence as to cause was not quite clear so it was decided to carry on again and see if the cause
of the trouble could be deduced. There was a large accumulation of dust and tar in the offtake and this
was removed and carbonized coal was introduced at 12.25 a.m. Dried coal was fed at 4.30 a.m. December
23rd. No trouble was experienced until 3.00 p.m. when No. 3 again stopped feeding. The safety valve
and offtake covers were removed and another large accumulation of tar and dust was found to have collected
in the offtake. One of the holes in the cover tiles over No. 3 channel was directly under the offtake and it
was supposed that some of this material would fall through the hole and plug the channel. To eliminate
this a plug was inserted in the hole and the retort started again. It must be remembreed that all this
operation was carried on allowing the gas to come off thru the bleeder. ‘The gas system had shown that
it was impossible to maintain the desired suction so no further attempts were made to use it while awaiting
the arrival of the turbine.
Owing to the programme adopted, which was to keep the retort going we did not want to shut down
and take off the cover plates in order to determine the cause of the trouble so at 7 a.m. Dec. 24th. raw coal
was again fed to the carbonizer but No. 3 again have trouble and at 10.30 a.m. were forced to clean out
again. Operations were resumed at 4.45 p.m. Dec. 24th., and continued until 4.30 a.m. Dec. 25th, when
the same trouble became apparent. Started up again at 7.00 p.m. Dec. 25th, after having cleaned out
the retort but were forced to discontinue operations at noon on Dec. 26th, This kind of operation was
impossible and it was decided to take off the bottom cover plate to see if the cause could be discovered.
A few small remedies had been applied each successive time we closed down but they did not get at the
cause of the trouble. Inspection showed a considerable accumulation of ash on the cover tiles which means
that the gas clearance space will ultimately plug up. From our experience with No. 5 carbonizer I think this
is a very serious difficulty. The old style baffles were badly warped and did not offer any resistance to the
passage of the coal from No. 4 to No. 3 channel. The gas chamber was cleaned and the baffles remedied
and operations were started again on Dec. 29th, at 6.20 a.m. after having brought the carbonizer up to
heat with carbonized coal. At 9.30 p.m. No. 3 channel plugged again and this time decided to risk getting
gassed to find out the cause of the trouble so closed the bleeder valve after the seal in the hopper was broken
and allowed the gas to come into the room. In the meantime we opened up the offtake and discovered
the tar was running back into the carbonizer. The level indicated an upward tilt to the bleeder pipe
and this was remedied. This shows that the bleeder through the roof would never have functioned very
long without causing the same trouble.
The carbonizer was again started and raw coal was fed at 8.00 a.m. on Dec. 31st. During the previous
attempts the weather had been fairly mild and there was very little wind. About this time the weather
suddenly became quite cold and high wind arose from the north east which incidently is the prevailing
direction. The back pressure caused by this wind sent the gas through every leak and crack in the retort
of which there are many. Working conditions were absolutely impossible although the-men gamely
stuck to their posts until they were badly gassed. Heptinstall reported that the men would not
work in these conditions any longer and it seemed as though there was no remedy but to shut down. We
were saved this necessity however owing to No. 3 channel plugging at 7.15 a.m. on Jan. Ist. In this ins-
tance liquid tar was running out the discharge spout and as soon as this was cleaned out the entire volume
of gas poured out of this spout while none came through the bleeder. One of the men had to discontinue
work through being gassed and Mr. Heptinstall required the services of a doctor. The retort was emptied
however and an examination made. It was found that the icy cold wind which was blowing into the
bleeder caused the tar to condense at the elbow and this had built up in the offtake until the slope allowed
the liquid tar to run back into the retort. No. 3 channel being directly under the offtake had received
the full benefit and the coal had coked to a solid mass in the retort.
An examination of the retort was made and five out of six visible tiles are found to be cracked. The
cement is badly cracked both at the bottom and at the top and it seems impossible to stop these leaks.
In conformity with the decided programme No. 5 retort is being heated up and we will operate this for
a trial run in order to determine its eccentricities and as soon as the turbine is installed the three will be
put into action for as long a period as is possible.
The total time of the run was 255 hours including shutdowns. The total time running on dried coal
was 81 hours. Average discharge was 750 pounds per hour or a total of 30.4 tons of coal carbonized.
the temperatures during the operation periods were maintained between 1000 and 1100 degrees F.
Phis was considerably higher than the preceding run. The samples analyzed during the run are as follows:
Composite Samples.
Dee. 24th, 25th. 9.00 p.m. to 4.30 a.m. 10.6% V.M.
29th 3.00 p.m. to 5.00 p.m. 14.6% V.M.
29th 5.00 p.m. to 8.00 p.m. 14.6% V.M.
31st 2.00 p.m. to 8.00 p.m. 8.2% V.M.
31st Jan, 1, 8.00 p.m. to 8.00 a.m. 10.3% V.M. -
These are distinctly better results than the previous run on retort No. 1.
(Signed) R. A. Srrona.
APPENDIX No. 27 217
APPENDIX 27
Report on Operations During 1923.
By R,. A. Strona.
This report is divided into two sections: —
(A) Report of Hood-Odell oven operations-at Grand Forks, N.D., during experimental run in February,
1923.
(B) Report of Hood-Odell oven operations at Lignite Utilization Board plant, Bienfait, July-December,
1923.
(A) In view of the decision to abandon further work on the retorts installed at Bienfait, it was decided
to investigate a retort which had been evolved under a co-operative agreement between the United States
Bureau of Mines and the University of North Dakota. This retort, of the shaft carbonizer type, was
referred to as the Hood-Odell oven, and carbonization was effected by burning a portion of the fuel. The
burning of the gases in direct contact with the lignite gave sufficient heat to carbonize the mass of lignite
with a very small loss in fixed carbon. The excess gas was not recovered but was burned at the top of the
oven. A diagram of this retort is shown in Fig. No. 53.
A small retort of this nature was built at Bienfait in order to test out the principle, and the results were
sufficiently promising to warrant a recommendation that 100 tons of Souris iignite be carbonized in the
retort built at Grand Forks, N.D. This recommendation was accepted, and accordingly in February
1923, a shipment of this amount went forward, and a test was made.
The oven erected at Grand Forks had not been provided with any shelter. It was built for experimental
work only, and it had not been intended to operate it during the extreme winter temperatures. The
weather prevailing during the attempted experiment was very severe, and it therefore became extremely
difficult to maintain the heat necessary for proper carbonization, which in turn markedly reduced the
capacity of the retort. Several runs were made, however, and observations taken on: —
1. Character of char.
2. ‘Analysis of char.
3. Effects of different screen sizes.
4. Clinkering, etc.
The results obtained are shown below.
RUNSNO Rw!
Coal used — Nut slack, Bienfait Mine.
ANALYSIS.
As received Moisture free
Moisture 33.9% 0.0%
Vol. Matter 26.6% 40.0%
Ash 8.5% 12.8%
Fixed Carbon 31.4% 47.2%
BLU. Alb: 6974 10476
. Screen Size.
Inches %
2 —1% 19.3
14%—1% PN Es vf
1%—1 10.7
ib 5 84 12.8
33— 14 12.8
Pie BG 10.1
%—1/8 3.6
1/8 — 0 Sonu
Analysis of Char Moisture Free
IN Rei CLD. SEU ein tab bee eet 1 OF nae ce EA Soe ee eee
ta ADL OR iecieme ae whee) scale 19 4 te chocik’s Gee pe aes i 20.8%
FAS 1 ee tn mrtryt se 8 oc si cic. fs 163195 Fn i Sa ee ee 17.5%
xaos @arborignre ne siere.e sus 6 pesos" 5679 GG dicta Sc eRe 61.7%
AEA AOL ID ekeye Sistas war orale 3. 9892 54: Sas fee arene Deter eee 10690
Analysis of Screen Sizes
On YN On 14”
Moistitesai te howias sass 3 os. 10: 99-9448 14.8% ee,
Viole Matteraeenicy hia: cc's «.c0s-s 25.5 28.7% 29.5 34.5%
(Nahm Dene ere ae aco nsstclans 18.7 21.0 16.2 19.1
Bixed Garbo ance... 44.9 50.3 39.5 46.4
On 1/8" Thru 1/8”
WVEDIBLULG Me eitiie eee ree cis evaleie S375 eee 6.2% RAs
RPE OAGLILOT 0c. es 6 ae less 22.0 24.1% pe 18.4%
LA oy. 8 Si Ae te, TIC ORR Sora ie 18.2 1 (ol 18% 2
Paxed: Carbon... 6. sss cies 2 53.0 57.7 59.5 63.4
The yield on the basis of the ash content is 48.5% (moisture free char). The fixed carbon in the char
on this basis should be 64.8%. The actual fixed carbon is 61.7% —a difference of 3.1% of the char,
or 1.5% of lignite used.
218 APPENDIX No. 27
RUN NO. 2.
Coal used — Same as in Run No. 1.
Screen Analysis — Same as in-Run No. 1.
Analysis of Char.
IMOIStUre | tac oe errors easians 14.4% FAG
y 1. Matter ptr. sommes 22.1% 25.8%
ANORECTAL E at 15.6% 18.2%
Tired Carbone. paces toc 47.9% 56.0%
B.T.U> periib: ) Us hG ses os 8820 10300
d th h basis (moisture free char) is 46.7%. The fixed carbon in the char on this basis
se ve 7 405. * The sre fixed carbon is 56% or a difference of 11.4% of the char, —5.3% of the
lignite used.
Screen Analysis of the Char.
; Inches %
3445 11.8%
1G =e 16.3%
1% o— 1/8 24.8%
/8—0 47.1%
RUN NO. 3
Coal used — Western Dominion Collieries — Screenings.
The coal was much finer than in the previous runs.
Screen Analysis.
ae hg
— I
evga! 10.7%
1 —xX% 2.7%
%—% 37.3%
4% 26.1%
%—1/8 8.8%
1/8 —0 5.6%
Analysis of Coal.
As received Moisture free
Moisture in. sec naeie s stein 32.8% Hed ae
Vol: Matter e.\0 onus soc PA GE 40.3%
A sho? 5 1somi anas se eee raves tocoterstete 6.9% 10.3%
Fixedi@arbonee cnc cts 33.270 49.4%
BoD. U . Petal e stem ce ste oie oie ae 7329 10915.
Analysis of Char
IMEOIStUTG tence cine ree 7.4% Btaicrs
Viol."Matters® mctcene reece 18.5% 20.0%
Ash a). c ae eect estes ere ener 14.7% 15.8%
Bixed'Carbotiueen nett 59.4% 64.2%
Bil. Usperibie eee eee 10156 10980
Yield on ash basis (moisture free char) 43.7%.
The fixed carbon in the char, on this basis, should be 76.0%. The actual fixed carbon was found to be
64.2% —a difference of 11.8% of the char, or 5.2% o ithe lignite used.
Screen Analysis of Char.
Inches %
%—% 4.4%
34 — 11.9%
%—1/8 33.7%
1/8 —0 50.0%
RUN NO. 4
Coal used — Same as in previous run.
Screen analysis— Same as in previous run.
Analysis of Char.
MOIsture: Sisee etc orca 8.6%
ee Matternwee "ou dee eee 21.1% 23.21%
Oe ee BE Pere Re Oe eee 14.6% 15.9%
Rivet Carbon oth. aoe 55.7% 61.0%
Be Taeperlbseeenon Seen 10042 11000
Yield on basis of ash (moisture free char) 43.4%.
The fixed carbon on this basis should be 76.5%.
ihe actual fixed carbon was found to be 61.0% — a difference of 15.5% of the char or 6.7% of the lignite
used.
APPENDIX No. 27 219
The average results of the four tests show that the fuel used in processing, expressed in percentage by
weight of the total lignite charged, is 4.9%. This is, of course, in addition to the gas evolved most of which
was wasted. Since this figure represents combustible material it is probably safe to say that the fuel
consumption on a basis of heating value is (4.9 x 2) —9.8%*. (Carbon has practically twice the heating
value of lignite).
No further tests were made. Sixty tons of coal had been carbonized, and considerable information
secured. An average of the results obtained showed 21.4% of volatile matter left in the char. This was
far too much but considering the conditions under which the test was made it was very favourable. The
loss in fixed carbon amounted to 10.4%, and it was estimated that this could be materially reduced by
some changes in the design.
Clinkering caused very little trouble using the two scale mentioned above. It was found necessary to
clean the air ports by poking about once an hour but the clinker formed did not adhere to the walls of the
retort or cause plugging within.
Screen size of coal is an important factor and has a direct bearing on the capacity of the retort. If
the coal is not crushed fine enough, the large pieces will not break up and become carbonized in their passage
through the retort, while a high percentage of very fine sizes tends to increase the loss of fixed carbon.
The top size should not exceed 114”, and % inch is a good size for the lower limit. The dust should be
kept at a minimum.
The char is grey in colour, has a metallic ring, and is quite hard.
The conclusions arrived at from the experiment were that the retort was sound in principle, cheap to
construct and easy to operate. It was recommended to the Winnipeg meeting of March 8rd, that one
should be built at Bienfait incorporating several changes in design which were felt to be necessary.
(B) Operations at Bienfait, July to Dec. 1923.
The retort as built at the Bienfait plant is shown in section in Figure 54. In this installation provision
was made for recovering the gas. This was accomplished by inserting a slotted pipe with a metal curtain
in the coal mass, directly above the upper combustion zone. The offtake was connected to the gas system
as installed for the former retorts, and the line was continued to the power house where the gas was burned
under the boilers. Water seals were provided at the offtake and at the burner.
The air for combustion was provided by means of a Buffalo Volume Blower which was connected to the
four cast iron air ducts in the combustion zones. These were perforated allowing even distribution of the
air throughout the length of the retort. The air was delivered at a pressure of }4 inch of water.
The side baffles were made of cast iron suspended on the cast iron air ducts. The central baffles were
made by placing three cast iron pipes in the position shown. A few minor changes were also made in the
creel Spe order to seal more effectively the bottom of the retort, and provide a more uniform discharge
of the char... ;
The retort was built in the open, and was connected to the existing system of crushing and handling
It was necessary to change the crusher however, and a Jeffrey Single Roll Crusher was installed. This
machine worked very satisfactorily and gave a fairly uniform screen product. A view of this retort as
erected is shown in plates Nos. 11, 12 and 13.
The oven has been operated continuously for six months with only a few interruptions mainly for
purpose of making slight alterations. Operating results are shown below.
Tote) Col GHATZED ch ca meals he TOR Hal Falehalind av inthe ee nic sad ee Sob ee 8 3,000 (opal pepronimste
Motal char recovered Gees ete ake ohne waren a eale carnvaate mle 1,300 tons{ figures.
Analysis of coal as charged
MM OIStUre Suet rere MIT cea fon GG sede uaearamsiote 4 @ aalcieah.es ati MEME, 6 33.3%
Vig IN IVE a Eber es erie etc Reece etre rare cate et a anti meee 27.6%
sha ee eye as Ai ahs dS DE AES ae ARGS eee es 6.4%
Kixedsarbort ois . Seotim. ee. ide Cs eo kos HOR BI Poe 32.7%
Tee Deeds fa thse hie Hare cecka's wig sol Qoteard gy x bleta fend wieamer atrety 7,390
Analysis of Char
WEOIStUT Oc ae oF uk Cae Oe me tle nk COR CERT SEN Cae a ag Nil
VOMIT AEE OI ee crt reer oo ee ee nisl ca te re ere aT ne ener ets 12.295
Ash Ue are) Hater cy ONE M a shel a, eM MEM Cus 6, 5) itadrvehar od ora Pelee barks excite! OMALECO LEP Sean Muck oe 15.1 ()
Wixode CAarpon 6... co1 eee cae. alin st how Cedaamal See te ee 72.7%
BOTeUr per lb 2503 2 anette Moe Dee aes 8 Sauna te eae eee 11,800
Screen Analysis of Lignite
Ce ee cree oa ls Fs, aaa ob if Coe aie OS eae Ate etree cae as inca rn tise alee
Ph Le dirs coca eat = & ashe ti ale hs, 2°00 Oa ale, ia oko Dae et eceagiar oo amas ab aaa 30.5%
LEG eC ROS. Sh ER! et TR Be EN Ge 17.3%
OE] MRL) Leib 4 teva! A” soy SNS. chal Eto esi ath a EE eS A gs re
BE She Pie ence fi Sige. SF ee 8a Wik BATS, ofertas 5%
Pa Abo edhe’ ad « Have WATTS, Ser ORES ee are ed ctealare ss 13.6%
OE TRY Le Se ee eee MT eae eS ot ai nt eee 9.0%
er ea ake oe Pach Dee tn: Pee OMe ee ere oe. ss 6.0%
EC PY Re oer ee Pee Shao atc cate eater ete os Reece 6.1%
Screen Analysis of Char.
Ci S4. ea wages a1 Fa cin aiticie a oiceuceed a dan savin ee Rune deve, 5 reo Poi how -
i 9 OLR pS a ere Se ere ORT 6.4%
SO hia EI YE oh atid y Cas als, AMO Me Me meretity SuebrRee id oe 22 5%
58 1 Bits, ETN AL, ode OLA Solo, SCOR RUNES) cL AE IN Gee MIU) Miho neta 28.8%
EER UD: 2 {25 oni couse herd os Ge muta pole ee ed ne Re, BR ees oo 40.4%
*This figure was materially reduced with the improved setting erected at Bienfait.
220 APPENDIX No. 27
The ab fi are the average of results obtained during a ten day test. The average yield of char
is 42.3% eeedion the ach content. The fixed carbon in the char on this basis should be 77.6%. The
actual fixed carbon in the char is 72.7% — a difference of 4.9% of the char, or 2.1% of the lignite used. *
Assuming this to be combustible, and that its heating value is twice that of lignite, the fuel consumption
on a basis of heating value is 2.1 x 2=4.2%. This is a marked reduction over the results obtained in
February. Tak: ; : ee .
The gas recovered is of low heating value being mostly producer gas. ne quantity recoverable is
16,000 aa ft. per ton of lignite charged, and its average heating value is about 110 B. T. U. It is estimated
that, in a commercial installation, there would be sufficient gas available to supply the power requirements
of the entire plant, crushing, carbonizing and briquetting, and in addition a large surplus would be available
during the night time when the load is light. This can be utilized for operating a still for the distillation
of tar or other purposes as desired.
An average analysis of the gas is shown below.
O11 See CAE Marre eh Mar Apgsi AG San eee ac ade tf Boe Pc 10.2%
TUL ck ouhen 13.7%
Hence a boats ehade re locere lagakstayebel plcka le waG etal gon see eee een rece eae 11.5%
61: VER ee eo Soha oc tha ee Shoop dots Soe Owe A 2.4%
1 PRE eer A Si os Ger as hieney GAS 5th g.0 bald Aug io aomied 60.8%
This method of carbonization materially reduces the by-product yields, but as these are of uncertain
value it is not a material objection. Tests were made to determine the quantity of tar recoverable, and
the average of a large number of determinations was 2/4 to 3!4 imperial gallons per ton of lignite charged.
Distillation of the tar yielded the following results:
0=200 degrees’ Ci casearie | Ai een einen ete 7.0%
2002210: degrees Claes fae ee ere ein 2.7%
210-235 degrees Casicach oe cette ae ee ete 8.8%
235-270 degrees C......... LAS hae te aa S 12.2%
Pitch). 235 eee eee Ue ae ES BAA RLS age oy" 66.3%
T0885 5 a5 ass tals arb! oho (has ele eles Saeki eaeunenrEy: laden 3.0%
Melting poiht.of pitch? oe ema en were 140°F. (Cube method)
Free carbon-i1n; taric.iteieceieee ee sia asenne Gs 1.4%
Density of tars... 5 or cere he eee ere ee 60/60°F. 1.0503
The oils should be valued only as a liquid fuel, but the pitch can be utilized as a binder for the briquettes.
Tests on the pitch show that it mixes with ordinary coal tar pitch, and hence is value is equal to that of
the latter material delivered at the plant. The amount recoverable in a 100 ton plant is equivalent to
about 25% of the binder requirements. Briquettes have been made using lignite pitch in the above pro-
portions. This will be discussed in appendix; 30.
Tests on the oil yieded the following results:
Grawityeeeeeee 21 ONEIE AA cer eter tee eens orn 0.980 @ 60°F.
Flash Pointe... 00s s/qs 2 a ies es 132° F. (P. M. Closed test)
Bire Point caee ee ioe cas ee eee 223° F. (P. M. open cup)
Freezing Pointy. 645.0acicle teeth eee Sod ae ;
WiSCOSIEY 60 ibs cioa tance eee aC eae ea ae eae 14 sec. 3 cee ees:
Sulphur: itiauis oa e ecetticla © ae mean ener ene 0.6%
BRESU? per Ibis seen eRe eee 16,500
The recovery of the tar offers some so far unsolved problems. It forms a most persistent emulsion con-
taining as much as 65% water, and does not respond to the ordinary methods for reducing the water
content.
OPERATION RESULTS
During the operation of the retort observations were made on:—
Uniformity of discharge.
Life of structure.
Life of Cast Iron Baffles.
Possibility of housing retorts.
Clinker troubles.
Screen analysis of coal.
Efficiency of the apparatus.
Costs.
Capacity.
Possibility of operating for a higher yield.
Possibility of using char direct as fuel.
SO GOI Ve OO NO
="
UNIFORMITY OF DISCHARGE
It was found that with a little experience the operators could easily maintain the char at the desired
volatile content. During the first part of operations char ranging from 9 to 19% of volatile was obtained,
but ee more experience was gained it was found quite easy to operate between the desired limits of 10
to ‘O*
LIFE OF THE RETORT
Standard firebrick is used throughout the structure, except for Sil-o-cel insulation, and as the operating
conditions are not severe it should have a reasonable life. No definite statement can be made in this con-
nection as the time of operation does not warrant. After six months, however, the interior lining of the
retort showed little or no deterioration.
*Compare these figures with those obtained during test made in Grand Forks installation.
APPENDIX No. 27 221
Lire or Cast Iron BaArriEs
The side baffles are subjected to rather severe treatment and some of these were burned out in a very few
days. More careful regulation resulted in a much longer life, however, and the use of a small jet of steam
immediately below the baffles has increased the life to approximately three months. The cost of renewal
is small and could not be considered excessive. The use of heat resisting alloys might decrease the cost
of renewals but this could only be determined by experiments over an extended period of time.* The
central baffles and air ducts show practically no signs of deterioration after six months of operation, and
a reasonably long life can be expected from them. The gas offtake and metal curtain will last indefinitely
as the temperature at this point is below 200 degrees Fahrenheit. A slight change in design will make the
removal and renewal of all baffles a very simple operation.
Possipitity oF Housine ReErorts.
The retort was built outside in view of the uncertainty of gas leakage. It was found that after a few
minor changes this trouble could be entirely overcome by operating under a sufficient vacuum. It is
necessary to operate at a slightly higher vacuum than the pressure at which the air is delivered and the
prevailing suction was 34 to 1’ at the offtake. The retort is started up by filling it to the lower combustion
zone, and then starting a fire with wood. Raw lignite is thrown on and air supplied, the fire being gradually
built up until the offtake is sealed when the fan for removing the gas is turned on. Previous to this a large
quantity of gas necessarily escapes but at all other times it is quite free from this nuisance. If a vent
press provided for these occasions no difficulty would be encountered from placing the retorts within
a building.
CLINKER TROUBLES
If a coal with a low ash is used very little trouble results from clinkers. Those that are formed do not
adhere to the metal baffles but form on the walls immediately above and can easily be disloged with a poker
bar without disrupting the operation.
ScrREEN ANALYSIS OF COAL
It is rather difficult to maintain a constant screen analysis in view of the large amount of breakage
before the coal is charged in the retort. Considerable trouble was expected from fines, but it was found
that the retort was very flexible in this respect, and while the best results were obtained when the coal
conformed to the sizes given above, no great difficulties were encountered when using coal with a high per-
centage of dust.
EFFICIENCY OF THE APPARATUS.
Tests were made to determine the efficiency and the results are shown in the following table.
Heat Balance
Sensible;beatil Pas waters see BPRISC TE APA Ble
* : ae WECOR. «75, eer nt ore 96,444 ve
a: ede CURT. OL meat fs tae 188,700 ss
4 ee CAL ART. che intakes 1,357 So
318,540 2.16%
LatenteHeatein pasties cone 1,793,000 B.T.U.
ne ate Se oharen Ave u ae see 10,030,000 *s
ad ey Of eidae ee A) MN ae 595,000 se
12,418,000 84.02%
Hea trlostiree tas coat Neo areas aus Shel eaves 2,043,460 13.82%
Heat in one ton of coal @ 7,390 BTU
per base Wei eee ee Lt eae 14,780,000 100.00%
Recovered.
(EET OS Lo ER ee a aye ae 42793000 2) a. ne een ee 12.13%
Charro he eed 10030000 Sista eee ee 67.86%
[Are ereieersne tnt Uber: costar 595 000k. cai.ah. Base ee ae 4.03%
84.02%
Costs
The oven erected at Bienfait cost $3,874.24 including accessories. This figure could be materially
reduced when building a number, and it is estimated that in a battery formation the setting would cost
approximately $3,000.00 per retort. The cost of repairs is estimated to be within a reasonable figure,
and the labour cost is decidedly low. Three men per shift would be the labour requirement for the opera-
tion of a battery of 10 ovens.
CAPACITY
The capacity of the oven is dependent on several factors. Capacities ranging as high as 14 tons of char
per 24 hours have been attained, but when operating under these conditions it is’practically impossible to.
keep the top of the oven free from gas leakage. The capacity is reduced when excessive fines are encounter-
ed, as it is difficult to get the air blast through the bed of finely divided coal. Large coal also decreases the:
capacity as the rate of travel has to be slowed down in order to effect the proper degree of carbonization.
*Two baffles of Hybnickel and two of Fahrite were tried out and no signs of deterioration could be de-
tected after 20 days operation.
222 APPENDIX No. 27
The oven can be operated under varying conditions of feed and kept free from gas leakage, at an average
of 10 to 12 tons of char per 24 hours. Taking an average of 11 tons per day with a yield of 42.5% the
lignite treated will be equivalent to 25.9 tons per day. Assuming an oven cost of $3,000.00, the capital
cost per ton of coal charged is $116.00, a very reasonable figure.
POSSIBILITY OF OPERATING FOR A HIGHER YIELD
It was suggested that the cost of operation might be materially reduced by operating at a higher capacity
producing a char that would contain approximately 25% of volatile matter. This experiment was tried
and it was found rather difficult to maintain a fire in the upper combustion zones. This makes the opera-
tion a much more difficult one and requires the constant attention of the operators. In addition to this
the gas is so weak as to be of no value which is a big loss. If the retorts were to be housed this gas would
have to be removed which would be adding an expense for a valueless product. The theoretical yield, not
allowing for loss of fixed carbon due to combustion, would be 48.8% or a difference of 6.3%. This would
not make up for the loss of gas for power which is the equivalent of 24 tons of coal per day in a battery of
10 ovens with 80% operation. It is also likely that the briquettes from this product would not be held in
the same favour as those of a lower volatile content.
PossiBILiITiIES OF Usinac CHAR DIRECT AS A FUEL
In the belief that a market might exist for the char as recovered from the oven, tests were made on various
types of stokers designed for handling a finely divided fuel. A carload was forwarded to the Government
Power House at Regina and burned in the Laclede Christy chain grate stokers installed there. The fuel
was very unsatisfactory when used alone, and a large percentage was lost through the grate openings; but
a mixture of 50% of this fuel with Alberta steam coal gave excellent results and was much superior to the
Alberta coal alone.
Another car was forwarded to the Municipal power house at Regina to be tried on a Riley stoker. This
test was more satisfactory than the former but the percentage of loss through the grate openings was high.
The engineer in charge believed it could be used to advantage but from the report received of the test it
would appear that in this case also, mixing would be necessary.
_ Another test was made at the Swift-Canadian plant in Winnipeg under hand fired conditions with her-
ring-bone grates suitable for a finely divided fuel. As the results from this test were also unsatisfactory
no further shipments were made.
The char was also tried as a gas producer fuel and tests were conducted at Souris, Melville and Gull Lake.
The Souris installation consists of a Mond type of producer and the fuel used has been nut size lignite. It
was found that considerably less char was necessary but the saving did not offset the increased cost of the
char. Considerable operating difficulty was caused by the fineness of the char, but as this plant does not
operate with an exhauster, the suction being provided by the engine, it is possible that better results might
be obtained if an exhauster were used.
The reports obtained from Melville and Gull Lake were to the same effect.
The conclusions from the above tests are that the possibility of using char as a fuel for either gas producer
or power house work is at present negligible owing to:—
1. Its cost compared to raw lignite.
2. Its screen size.
No tests were made using char in pulverized fuel installations but it would seem that this fuel could be
economically used under those conditions.
During this year’s operations the other departments of the plant were operated more continuously than
during the previous year and an opportunity was had of observing their weaknesses. Three main diffi-
culties presented themselves which have a distinct bearing on the location and operation of a commercial
plant. These are namely, water supply, switching, and sewage disposal.
WatTER SUPPLY
_ The plant is located one and a half miles from the river and a pipe line, owned and operated by an adjoin-
ing mine is used for supplying water to the plant. The line is in a state of poor repair and the supply is
constantly jeopardized. At no time during the year was the quantity used equal to the requirements of
a commercial plant of 100 tons per day, yet operations were constantly in danger of being suspended from
the uncertainty of the supply.
SwITCHING
The plant depends on a neighbouring mine for its switching and an agreement has been entered into
between the respective parties for this service. It has been found that this is not an entirely satisfactory
arrangement in view of the necessity of a definite time schedule for the deliv i
of finished product in order not to disrupt operation. aalatcciiheg i = oS
The mining company could not supply such service without interfering wi i iviti i
J g with their own activities and it
would therefore seem that the best arrangement for this plant would be to secure a locomotive of their own
and either obtain running rights over the existing spurs or have its own outlet.
SEwaGE Disposau
As stated previously the disposal of sewage and water constitutes a i
; : ; considerable problem to a plant
alae Ie Woanapabibea ieee nines: mars priate continued to be a source of ahno vanes Linromations
on of flooding neighbouring lands is a serious one. i ime i
an outlet be provided for drainage in all plants of this nature. Sb Ea ee eet ee 9 ee
ACKNOWLEDGMENT
Grateful acknowledgment is made to Messrs. O. P. Hood and W. W. Odell of the United States Buren
of Mines also to Dean E. J. Babcock and Mr. R. L. i i i
Bee eoperenoh ake wrk ee IE seks Sutherland of the University of North Dakota for their
APPENDIX No. 28 223
APPENDIX No. 28
Report on Inspection of Nukol Briquetting Plant.
Toronto, Ontario November 1st., 1920.
by
R. A. STRONG and H. JOHNSON.
INTRODUCTION.
_ The inspection was conducted under arrangements made with Mr. F. H. Slater, of the Nukol Briquet-
ting Co., Toronto, with the consent of Mr. McGraw of the General Briquetting Co., New York, engineers
for the Nukol Company.
The writers received instructions from the Lignite Utilization Board to examine and report upon, the
layout, equipment and operation of the above briquetting plant; to conduct tests to gain all possible in-
formation of value to the Board for the erection and operation of their plant near Bienfait, Saskatchewan;
and to conduct any other tests desired by Mr. Slater for the information of his company. No tests were
to be conducted, however, which would interrupt the operation of the plant.
In accordance with the above instructions the writers reported to Mr. Slater in Toronto on April 19th,
1920, and spent seven working days investigating his plant.
The following report enumerates the specific points on which information was desired; it gives a general
description of the plant as a whole, and a more detailed description of the principal machines; it alsoincludes
an account of the tests conducted and the information gained thereby.
OBJECTS AND RESULTS OF INVESTIGATION
(1) To obtain the general layout of the machinery and to trace the movement through the plant of raw
materials and finished product. This was done.
(2) To study the method of receiving, storing and handling the raw coal. This was done.
(3) LO asudy the method of receiving, storing, heating and circulating the binder employed. This
was done.
(4) To study the construction and operation of the coal dryers to determine the fuel consumption and
the water removed. No data as to the thermal efficiency of the dryers was obtained. i
(5) To study the method of regulating and proportioning the dried coal and binder fed to the mixing
system. This was done.
(6) To study the construction, operation and efficiency of the different mixers employed. It was found
to be impossible to gain exact information as to the efficiency of any mixer without modification and
consequent interruption of the plant.
(7) to determine the crushing undergone by the coal in its passage through the masticator.’ This was
one.
(8) To study the construction and operation of the briquetting press and to especially note the effect
of the physical condition of the charge on the quality of the output. This was attempted and some
information gained.
(9) To study the effect of water cooling on the briquettes. This was done.
(10) To study the time taken by the coal and binder to pass through each machine and their temperature
when entering and leaving the principal machines. This was done.
(11) To determine the power requirements of the different operations. The total horse power was
ascertained but not its distribution.
(12) To determine the steam consumption of the plant. No information was gained on this point-
(13) To sample and analyse the raw materials and finished product. This was done.
(14) To ascertain the staff and labour required to operate the plant. This was done.
DESCRIPTION OF THE PLANT.
The plant is situated at the foot of Cherry Street on Ashbridge Bay, a new industrial district of Toronto
and has water and rail transportation facilities.
The coal briquetted is anthracite culm dredged from rivers and creeks in the Pennsylvania anthracite
district. The binder employed is asphalt obtained from the Montreal refinery of the Imperial Oil Co.
The 7 oz. egg shaped briquette made is either delivered by truck direct from the plant to the consumer
in Toronto, or shipped by rail to outside parts. The briquettes are bagged for the local trade.
The buildings are old, of frame and corrugated iron construction and have been adapted to their present
use from previous occupation. ‘The plant comprises a coal storage yard; a small boiler house; the briquet-
ting building, with storage bins and loading facilities; also workshops, wash room, stores, work office, and
ire scales. The main office of the company is situated in the Exchange building in the business district
of the city...
Figure 64 is a flow sheet of the materials through the plant, shown in diagrammatic elevation.
‘The rated capacity of the plant is 100 tons of finished briquettes per 8 hour day.
Coal Handling and Storage.
The raw coal whether brought in by water or railis stored in the yard by means of a crane with a clam
shell bucket. From this pile the coal is elevated by the same crane to a bin whose capacity is 40 tons. This
loading system will only allow 35 tons to be placed in the bin and it is necessary to operate the crane for a
longer period than the plant in order to keep a constant supply. This method is to be replaced by a fixed
bucket elevator supplied by a portable belt conveyor.
294 APPENDIX No. 28
The bin discharges over the centre of the two dryer feeds, and the coal is delivered to two inclined chutes,
by a short belt conveyor running under the bin. These chutes instead of being straight have a 90° bend
at which points it is necessary to keep men for the purpose of keeping the coal moving. The coal being
wet will not follow this system of feed and is inclined to clog. A third man is kept at the junction of the
chutes to remove pieces of wood etc. which get into the bin by the crane method of loading. This fault
is to be remedied by a vertical drop from the bin and the installation of a screw conveyor leading to each
dryer.
Dryers.
There are two rotary type dryers, each 40 feet long by 4 feet inside diameter with a pitch of 14 inch to
1 foot. They are made of one half inch plate, five sections in length, each section being a single plate
lapped with two rows of rivets. There are six ‘‘Z’’ bars in the circumference running the length of the
dryers. They are operated at a speed of 10144 R. P.M. The capacity of each dryer was found to be about
15 tons of dried coal per hour. The dryers were purchased second hand from a cement plant in Sudbury.
The tires are at present a source of dissatisfaction. They are attached to the dryer by means of grip blocks
which are out of alignment.
The furnace which is located at the lower end is supplied with draught by a perforated 1” steam pipe
ring,.6 inches in diameter, beneath the grate. Six tons of coal are consumed in these furnaces per eight
hours. The fuel used is the dried oversize from the screen.
The fan used is a suction type, 4 feet in diameter and 16 inches wide with a speed of 620 R. P, M. driven
by a motor at 1440 R. P. M. A 24 inch pipe connection leads from the dryers to the fan. A similar sized
pipe connects the fan with a 40 foot stack. The pressure taken with a gauge was 1.4 inches.
The coal is taken from the dryers by means of a horizontal screw conveyor to a bucket elevator which
delivers it to a screen.
Screen.
The screen is a trommel type with 14 inch square mesh, 8 feet long and 36 inches in diameter with a pitch
of '4 inch per foot, driven at a speed of 27 R. P. M.
The oversize from the screen is delivered to the furnaces of the dryers by means of a chute; the undersize
going by the same method to a bucket elevator which delivers it to two conical feeders.
Feeders.
The feeders regulate the flow of coal through the plant. They consist of two conical bins with a revolving
plate at the base travelling at 11144 R. P. M. The coal passes on to the plate through vertical gates which
are adjustable. The average height of these gates is 15 inches. A fixed scraper above each plate set at
an angle of 20° to the line joining the centres of the two feeders, discharges the coal into a helical mixer.
Regulation of Binder Flow.
The binder is delivered through a 1 inch pipe directly into the coal as it is fed into the helical mixer. A
man is stationed at the feed end of the mixer to watch the supply of binder. At present there is no mechan-
ical method of regulation, although they contemplate the use of a needle valve. The operator judges the
supply necessary by experience only. A binder chart is used to determine the average percentage of binder
in the product. The amount used is measured each day in the tanks and the percentage determined by
the total output. One inch depth in the tank is 163.8 gallons or 0.73 tons, as one gallon weighs 8.87 pounds.
The average consumption per day is 7 inches in the tank. This is equal to about 5 percent on a hundred
tons per day basis.
Helical Mizer.
This mixer is 10 feet long and 20 inches in diameter with a removable cover. The binder is added to
the coal as it passes through this mixer at a distance of 2/4 feet from the feed end. The discharge is through
an 8 inch opening directly into a vertical fluxer.
Fluzer.
The fluxer is of the vertical paddle type 7 feet high and 3% feet in diameter. It is supported on four
circular posts 10 feet above the floor, and is placed directly beneath the discharge from the mixer. It is
operated at a speed of 25 R. P.M. Both water and steam pipes are connected to the fluxer and the re-
gulation of each is gauged by a man at the discharge, who judges the quality of the mixture by means of
its stickiness. If the mixture does not contain the correct amount of binder the operator signals to the
man at the mixer to increase or decrease the binder flow. The depth of material is gauged by means of
small holes in the side of the fluxer and the discharge gate regulated accordingly. Common practice is
to keep it half filled. The discharge from the fluxer is carried by means of a small belt conveyor, neces-
sitated by means of an error in erection, to the edge runner.
Edge Runner.
The edge runner consists of two solid metal wheels, 5 feet in diameter and 34 inches wide on opposite
ends of a horizontal shaft which revolves about its centre in a horizontal plane. A steel plate forms the
base. Their practice is to keep 1 inch of materialin the machine. This is ground and mixed between the
plate and the wheels. Two scrapers directly in front of each wheel on a shaft at right angles to the wheel
shaft, serve to agitate the material and discharge it from the machine. The scrapers are set at about 15°
to the line of travel, the outside one being 14 inch, and the inside one % inch, above the bottom plate.
They require constant adjusting as considerable wear takes place. The machine is 11 feet in diameter
and has a casing 2 feet high surrounding it. Its total weight is 40 tons. The machine is driven from below
by a large gear wheel, at a speed of 18 R. P. M. Considerable trouble has been experienced and frequent
shut downs necessary, owing to the teeth in this gear wheel breaking. The discharge is in the centre and
is taken by means of a screw conveyor to a bucket elevator which delivers the material to the agitator.
Agitator.
The agitator is situated directly above the press and contains two agitating paddles revolving on their
own axes and four arms revolving around the axis of the agitator at a speed of 48 R. P. M. A steam con-
APPENDIX No. 28 225
nection allows live steam to be injected into the mixture as required through holesin aring. The objection
to this method of adding steam is that the holes in the ring frequently clog. The agitator is 4 feet in diame-
ter and 16 inches high. There are guides on the openings to the rolls which are not adjustable to allow
for the wearing that takes place. They are now 4” above the rolls causing considerable loss of fines.
There are two gates 8 by 12 inches to allow the material to be fed to either pair of rolls in the press.
Press.
The press is of the Belgian type, with two pairs of rolls, separated by the driving gear. The rolls are 33
inches in diameter on a 12 inch shaft. There are 160 pockets in each wheel which make 7 oz. egg shaped
briquettes. Alternate feed is employed. The rolls are operated at a speed of 8 R. P. M. and have a capa-
city of 20 tons perhour. The briquettes are taken from the press by means of a 30° steel chute to a bucket
elevator which carries them to a screen.
Screen.
The sereen is the squirrel cage type 8 feet long and 36 inches in diameter with a pitch of 1 inch to 1 foot.
The bars are 1 inch apart. It is operated at 16 R. P. M. The fines are returned by means of a chute to
the edge runner. A large amount of breakage is caused by this screen as well as by its discharge. The
briquettes drop from the revolving screen on to a bar screen which is inclined at 30°. This screen is 6 feet
long and 20 inches wide and made of 4% inch bars 1 inch apart. It discharges to a 30° meta! chute which
carries the briquettes to the cooling trough.
Cooling Trough.
The cooling trough is of concrete, 33 feet long 20 inches wide and 21% feet deep. It is equipped with a
continuous flow of water. A scraper belt travelling at 30 feet per minute, scrapes the briquettes along the
bottom of the trough, which slopes upward at the discharge end. The discharge is to a bucket elevator
which carries the briquettes to a storage bin.
Briquette Storage Bin,
The briquette bin is 40 feet long and 24 feet wide. It is 5 feet deep at the high side and 10 feet deep at
the discharge side. It is filled by a bucket elevator at one end. There is a discharge by a vertical chute
to the bagging shed, and four chutes to the cars. Owing to the lack of a belt conveyor over the bin which
will distribute the briquettes in the bin, two men are required to shovel the briquettes to the different dis-
charge chutes. This error is to be eliminated.
Binder System.
The binder is delivered in tank cars which contain steam coils. They are placed in a heated shed and
steam applied. The binder when fluid is pumped by a McKinnon Rotary plunger pump travelling at 200
R. P. M., whose capacity is 1000 gallons per hour, through a three-way valve, which allows delivery either
to a small tank placed above the mixer or to one of the two large storage tanks. The overflow from the
small tank is returned, and by means of a three-way valve can be delivered to either of the storage tanks.
By means of a valve in the system, the small tank can be cut off from the supply and the binder pumped
direct to one of the storage tanks. The only means of filling the other storage tank is from the over-
flow from the small tank. The binder may be drawn from either of the large tanks and delivered to the
small one, the overflow being returned to either tank desired.
The two storage tanks are 18 % feet in diameter 12 feet high and are made of 1-8 inch galvanized plate.
The plates are 2 feet wide and 7 feet long laid horizontally with bracing angles at each joint. The bracing
angles are 1 x 1% x 3/16 inches and are packed with asbestos. The tanks were made by the American
Sheet and Tin Plate Co., Pittsburg. Square nuts and bolts should be used instead of the screwbolts at
present employed, to facilitate the tightening of the joints. The small tank is made of steel and is 2%
feet long and 2% feet in diameter. It is located 4 feet above the helical mixer. The discharge is from a
1 inch pipe steam jacketted in a 2 inch pipe and the flow is regulated by means of a stop-cock.
Circulation of Steam in Binder System.
Seven lengths of 1 % inch pipe are placed on one side of the tank car shed with connections for the coils
inthetank cars. The coils in the storage tanks are 12 inches from the bottom of the tank. There are two
separate feeds of 2 inch steam pipes having a common discharge. The coils are return bends, covering the
full cross-sectional area of the tank. The binder suction is a 2 inch tap in the side of the tanks 5 inches
below the steam coils. Considerable trouble is occasioned by having the coils at such a distance from the
bottom, as the material below is not always fluid enough. The binder pipe from the pump and from the
storage tanks as well as the overflow pipe from the small tank, are 2 inch pipes packed in insulation with
234 inch steam lines. These steam lines circulate twice in the small tank and return to the fluxer. All
valves are also steam Jacketted.
The binder tank car shed is 45 feet long, 16 feet wide and 16 feet high made of clap board and tar paper.
Elevators, Conveyors, Chutes, Etc.
A track crane and clam shell bucket delivers the raw coal from pile to bin.
A Belt conveyor under raw coal bin. Linear velocity 24 feet per minute. Length 5 feet, width 16
inches.
Screw conveyor at discharge of dryers, 12 inches diameter, 21 feet long, capacity 23 tons per hour.
Bucket elevator No. 1, from screw conveyor to screen. Vertical, 35 feet high, buckets 6 by 12 inches, 2
feet apart on a single chain, Jeffrey Manufacture, in metal housing.
A wooden, metal lined chute, at 45° incline, carries oversize to drier furnace. A similar chute carries
the undersize to elevator No. 2.
Elevator No. 2, 25 feet high, vertical, 6 by 12 inches buckets on a single chain, Jeffrey Manufacture,
elevates screened coal to a chute over the feeders. Chute to feeders is inclined at 45°.
A belt conveyor 11 feet long, 12 inches wide, travelling at 260 feet per minute on a 20° incline, carries
the material from the fluxer to the edge runner.
226 APPENDIX No. 28
A screw conveyor 20 inches in diam. 10 feet long, conveys the material from the edge runner to elevator
No.: 3.
Elevator No. 3, 25 feet high, vertical, similar to Nos. 1 and 2, discharges by means of a 50° chute, 15
inches wide, to the agitator on the press.
Bucket elevator No. 4 elevates briquettes from the press to the screen. It is 25 feet, vertical, with
wooden casing. The buckets are 12 by 6 inches, 18 inches apart on a double chain with 9 inch links, dis-
charging briquettes into a 30° chute, 6 feet long, 12 inches wide, to the screen. The fines from the screen
are conveyed by a vertical chute to the edge runner.
The briquettes are conveyed from the screen to the water trough by three chutes 15 inches wide, at «
30° slope. These chutes are placed at 90° to each other and have a total length of 20 feet.
Elevator No. 5 is 40 feet, vertical, in wooden housing, open to weather with 14 by 6 inch buckets 2 feet
apart. It travels at 200 feet per minute and carries the briquettes from the cooling trough to the briquette
storage bin. Elevators Nos. 4 and 5, are second hand, purchased from the Cement Plant at Sudbury.
Power.
The power is supplied by five motors, on the hydro-electric system.
1. 100 H. P. Westinghouse moter, 720 R. P. M. 550 volts, 94 amps per phase, 3 phase, 25 cycle. This
motor drives direct to a line shaft giving it a speed of 200 R. P. M. It furnishes power for both
dryers, screw conveyor at dryer discharge, bucket elevator No. 1, screen, bucket elevator No. 2,
feeders, mixers, fluxer, belt conveyor from fluxer to edge runner, screw conveyor from edge runner.
2. 116 B. H. P. Lancashire motor 550 volts, 720 R. P. M. 3 phase, 110 amps per phase. This motor
drives direct a second line shaft, giving it a speed of 200 R. P. M. This furnishes power for the
edge runner, elevator No. 3, briquette screen, cooling trough drag belt, elevator No. 4 agitator,
elevator No.
3. Wagner A. C. Motor, 10 H. P. 3 phase, 25 cycle, 1420 R. P. M., 550 volts, 10.2 amps. | Drives direct
to dryer fan only. :
4. 75 H.P. Crocker-Wheeler motor, 550 volts, 750 R. P. M.3 phase, 70 amps. 25 cycle, furnishes power
for briquette press only.
5. 5H. P. Westinghouse motor, 1420 R. P. M. 25 cycle, 550 volts, runs binder pump only.
Coal Consumption.
5 tons steam coal are used by the steam shovel and boilers in 24 hours. Six tons of oversize from the
screen are used in the dryer furnaces.
Men employed.
4 men in office, 1 man at press.
4 men on steam shovel — 2 shifts. 2 men in briquette bin.
3 boiler firemen — 3 shifts. 2 men bagging.
2 foreman. 1 machinist.
3 men at dryer feed. 1 electrician.
1 man firing dryer. 1 carpenter.
1 man at mixer. 1 truckman.
1 man at fluxer. 10'labourers.
TrEsts CONDUCTED.
Test of Dryers.
The capacity of each dryer was determined by the amount of coal delivered at the feeder. This was
found to be 28,400 pounds per hour which does not include the oversize taken out by the screen. The
amount of materialin the dryer at any one time,.on this basis, is 2:2 tons, to which must be added the per-
centage of oversize.
An attempt was made to determine the efficiency of the dryers, but the sample obtained was not satis-
factory. The analysis of the raw coal shows a total.water content of 11.8 percent, and the dried undersize
2.9 percent. ,
Test of Crushing undergone by Coal in Edge Runner.
A sample of the material after passing through the edge runner was taken for the purpose of determining
the amount of grinding done by this machine. The material was freed from binder by extraction with
carbon bisulphide and a screen analysis made. As shown in the accompanying curve (A) the material
has undergone considerable crushing, 8.8 percent passing through a 200 mesh screen as against 0.2 percent
on the dried undersize. See figure 8-h. :
Test of Physical Condition of Charge to Press on Quality of Product.
An attempt was made to secure definite information with respect to the best temperature for briquetting.
The temperature of the material in the agitator above the press was varied and samples of the corres-
ponding briquettes were taken and their density determined.
Temperature — Density table.
Temperature of feed. Degrees FAHRENHEIT. Density.
132 . 1.326
136 : 1.340
140 1.311
‘145 1.333
150 1331
153 : 1.343
155 1.338
158 1.328
158 | 1.333
ao
APPENDIX No. 28 227
Test on Effect of Water Cooling on Briquettes
Samples of the briquettes were taken both before and after cooling in the water trough and their moisture
content determined. The increase in moisture due to immersion was found to be negligible.
Briquettes before water bath percent moisture..............+++: 3.0.
Briquettes after water bath percent moisture.................0. 3.7
Tests of Time of Flow and Temperature Material Through Plant.
The time required for the coal to pass through the dryer was determined by means of an identifier. A
pean of wo, 9 x 3 x 3 inches was dropped into the chute and 9 minutes elapsed before it appeared at the
ischarge end.
The time required for the material to go through the edge runner was determined roughly by stopping
the feed and timing complete discharge. The time required was 344 minutes.
Temperatures
Discharge. of dryeni :<¥ ches. putea. vt fel, we 180 degrees FAHRENHEIT.
Air from the-fan. 2.370. .dbinctinls i wake od 147 iy ‘
Binder at discharge pipe.:......% 2.2.0.0 260 if a
Helical mixer discharge............5..... 170 ee :
Fluxeridischargers 5. dan ath onda aes. 180 i ‘ie
Material after edge runner........ NG anne 122 is Ht
Material imazvitatoriciasies cl. Shraer ees 135 i sf
‘Before .watermtan kena tac dolce tee oo cs e
ATUGIEWALCY CAT Ks. caret eae tcomie tent deiabon. 119 i vs
The temperature of the rolls in the briquetting press is barely perceptible. They are not cooled but by
alternating the feed to the press a low temperature is maintained.
CHEMICAL ANALYSES
Original Coal.*
SAMPLE A. SAMPLE B,
as received % dry % asreceived % dry %
Moistures iv)... 6. v PS Shy.
Vol. Matters? 29000. 7.5 TG 7.8 8.0
Agha cee meta cna 21.9 22.4 21.8 22.6
Fixed Carbon..... ;. 68.3 70.0 66.7 69.3
Calorific Value...... 11065 B. T. U. per pound.
Dried Coal t+
asrecelved % . ‘dry. %
Moisture? ei £3.72 2 ARS 2.9 ;
Volatile'matters [2 Be Ps 8.0 8.2
Wa hs8 ES SIR es ae eae 21.0 21.6
Hixed! Carbonize ceca: cer ee Oc ; 70.2
Calorific Valueie. oi. i's ae ed Xan 11,083 B. T. U. per pound.
Briquettes.
Asreceived % dry. %
MOistOre: os ccs tae ceed wast «heen 3.0
Wolatilesmatters a. tudes «circ ats 10.7 11.0
JN YC SAL pic apa Pay a Baines Mes Se oo 20.2 20.8
Fixed Carbon....¢..-:..>.westeee 66.1 68.2
Calorific Value................... 11,414 B. T. U. per pound.
In view of the high ash content a washing test was made on sample A. A solution whose specific gravity
was 1.5 was selected because its specific gravity approximates the density of the most impure coals that
can{be profitably burned for commercial purposes.
Sink and Float Test on SAMPLE A.
SOECINOLGLAVILY: SOLULIONG 5.05. clelenvicae serene tere tei 1.5
'Péercentare of Hloat? a c.c...5 sutte « arcicne erate ciohiveds lee 60.6
Percentage Of Silk ws sa sche oe home netic ere cher aie 39.4
PATRHIITIE OSG ro cos ee pere ceed cere rai neeercear ae hiccicne 10.8
(Ashi si news? 5.0.6 sisceals Sete. Ot cde are neater cles clas 41.0
Binder
The melting point of the binder used was determined by the ring and ball method from a sample secured
from the binder feeder pipe.
Melting point of Binder....... »».+-e145 degrees FAHRENHEIT.
“Samples were air dried before analysis.
+After removal of oversize for use in furnace.
228 APPENDIX No. 28
Screen Analysis.
A screen analysis was made of the raw coal, the dried undersize and the coal after passing through the
edge runner. The tables and curves are shown on Fig. 8-h.
ConcCLUSION.
(1) It is evident from the sink and float test on the raw material that the installation of a small washing
plant at the place where the coal is obtained, would be instrumental in reducing considerably the
ash content of the coal and a much higher grade fuel could be made. This would also save freight
on a large weight of material which is worse than useless. It might also be advisable in view of the
analysis of the raw material to keep chemical control on the quality of the coal received.
(2) Considering the amount of crushing undergone in the edge runner we are inclined to believe that this
machine tends to increase the amount of binder required; as theoretically, the larger the number of
particles to be coated with binder the greater the amount of binder necessary. On the other hand
it is quite possible that a proper proportioning of coarse and fines has been accomplished, thereby
reducing to a minimum the voids which would have to be filled with binder.
(3) The results obtained on the best briquetting temperature as shown in the Temperature — Density
Table, are not entirely satisfactory owing to the number of variable factors which cannot be control-
led such as the amount of material in the agitator, pressure, etc. The table shows however, that the
tendency is toward greater density with higher temperature, the maximum being reached at 153
degrees Fahrenheit. This is in accord with our experimental results at Ottawa. The present tem-
perature employed averages 132 degrees Fahrenheit and we would suggest that this be increased.
It is quite possible that an increase in breakage would result from this practice which would offset
the benefits, but definite proof of this could only be determined by trial over an extensive period
In conclusion the writers wish to express their appreciation of the treatment they were accorded by ail
members of the staff with whom they camein contact. Every assistance was rendered them by Mr. F. H.
Slater, President of the Nukol Co., Mr. Fletcher, Plant Manager, and Mr. Williams, the General Bri-
quetting Co’s representative at the plant.
REporT ON VisiT TO ANTHRACITE BRIQUETTE Co., PLANT,
Toronto, OnT.
The capacity of this plant is 1014 tons per hour, operating 24 hours per day. The Gambite process, a
binder of sulphite liquor and hydrolene, combined, is used.
The coal is taken from storage outside by a drag chain into an elevator boot.
A bucket elevator at 45° slope, about 50’ centres conveys the coal to a 7/8” square mesh screen8’ long, 3’
diameter, trommel type, over the dryer. The oversize is used in the boilers and dryer furnace. A straight
chute carries the screened coal into the dryer.
The dryer is 45’ long, 4’6’’ diam., made of %”" plate insulated with asbestos, travelling at 8 R. P. M..
slope %”’ to 1 foot. It is fired from a furnace at the high end, with a suction fan at the low end. The
coal takes 7 minutes to pass through the dryer.
The dried coal is elevated by a bucket elevator at 40° slope, 15’ long to a chute to the pulverizer of K.-B.
type. The top of the pulverizer is 6’ from the floor.
The pulverized coal is conveyed by a 45° scraper conveyor 30’ centres to a 20-ton vertical fluxer, set
about 10’ from the floor. Hydrolene and sulphite liquor are added through pipes in the fluxer. These
binders are pumped up separately, and the required amount, once it is found by experiment, is kept cons-
tant by conical pulleys on the pump. The quality of the mixture is judged by a man at the fluxer. The
mixture is discharged from the fluxer into a 16” helical conveyor type horizontal mixer, 10’ long, which
discharges the mixture into a hopper over the press.
This hopper has four scraper arms at the bottom revolving on the centre axis.
The briquette press is Belgian Roll type, 15 ton capacity, making a 2 oz. briquette.
The briquettes are discharged from the press on to a rocking bar screen actuated by a cam from the press
shafting, from which the fines are carried by a belt conveyor to a small bucket elevator to the press hopper.
The briquettes slide from the rocking screen on to a 200’ centres cooling belt, 24’” wide, at 20° slope, to the
briquette storage bin of 600 ton capacity. This bin has 6 compartments with a belt conveyor running the
full length. The power is electrical, furnished by two 100 H. P. motors.
Binders.
Hydrolene 140° F. melting point. The binder tank cars are unloaded in a heated shed. Hydrolene is
pumped into an 8000 gallon, horizontal, cylindrical tank having steam coils on the bottom, and suction
directly above the coils.
The sulphite liquor is unloaded cold. It is discharged into a similar storage tank, without steam coils.
This plant seemed to the writers, to be quite efficient.
_ The cooling belt does not give enough cooling, but the briquettes are allowed to season for a day or two
in the storage bin.
: Only four men are employed in the plant proper. This includes a foreman, briquette man, 2 boiler
remen.
Analysis of A. B. C. Briquettes.
As ree’d % Dry Basis %
INT OIStUTES ees See ete oe ee a.
Volsinatternipeetr siete: 5: shee veal W AE? '
RAIA ae oe A 13.3 13.5
Kixedtearbon. wees rer ee ae 68.2 69.3
Calorific;valuiexieccus tic... ae 12,172 BT. U.y Ib.
APPENDIX No. 29 229
APPENDIX No. 29
Brief Description of the Carbonizing and Briquetting Plant at the North Dakota Mining
Experiment Sub-Station, at Hebron, N.D.
By R. A. Strona.
The plant is situated at Hebron, N. D., a small town in the central western portion of the State. There
are several mines in the vicinity of the town from which coal can be readily obtained, but as the plant is
located at some considerable distance from the railway, all the coal must be teamed.
DESCRIPTION OF PLANT
The buildings, of brick with wooden roofs covered with some patent roofing material, are comparatively
new and in good condition. The plant comprises a retort house in which is included a small boiler room;
a briquetting building; a storage bin, and an office building. The yard is equipped with track for small
cars which are moved by hand.
The briquette produced is pillow shaped and weighs about 114 ounces, flour and pitch being used as
binder. The capacity of the briquetting unit is 25 tons per 10 hour day but this is dependent on the car-
bonizer which has a capacity of 20 tons of lignite per 24 hours.
Coat HANDLING AND STORAGE
The raw lignite is brought in by rail from the various mines throughout the State, as it is the purpose of
the station to test the coal from all the different developments in order to determine which coals are the
most suitable for carbonizing and briquetting. It is teamed from the railroad to the plant in wagons and
is shovelled into a concrete bin. A roll crusher is available for crushing in the event of smaller sizing being
rps At the time of the writer’s visit this was not being used and lumps up to six inches were being fed
to the retort.
An elevator carries the coal from the storage bin to a bin slightly above the charging floor of the retort.
It is then fed by hand into a dump car which passes over a scale where the coal is weighed, and then dumped
into the charging hopper of the retort.
RETORT
The retort is of the by-product recovery type inclined at an angle of 45 degrees. It is composed of six
double chambers 16’ 4’’x30” x 8” superimposed, with heating flues on top and below and a common charg-
ing hopper. There are three gas offtakes provided although the lower two are at present only being used.
The retort is constructed of fireclay shapes resting on concrete foundations. ‘The cooling chambers are
vertical and the hot char is cooled by air flues which preheat the air before it goes to the combustion flues.
The cooling chambers are 2’ x 30’’ x 8’ and are discharged by a revolving star wheel feeding a screw con-
veyor. The discharge is intermittent. Figure No. 51 shows a diagrammatic elevation of the retort. *
The gas from the lower and intermediate offtakes is taken off by means of 4’” standpipes which dip into
a standard hydraulic main installed by the Cleveland Gas Co. It then goes to a large cooler, which is an
old coverted boiler, and then through two vertical scrubbers where the tar is removed. The clean gas is
fed direct to the combustion flues, a burner being provided in the first three of these. A small positive
pressure Sturtevant exhauster is used for extracting the gas. A bypass bell governor regulates the pressure.
The gas from the upper offtake is drawn off by another small Sturtevant blower, is conducted through a
similar train of scrubbers and is then burned under the boilers. This use is made of the gas, (mostly C02
and water vapor) on account of its very low heating value. A small gas producer is provided which is
used for heating up the retort, but this is not used when the retort is operating. The gas from the coal
being treated is sufficient for carrying on the process but there is no excess.
The residue when discharged from the retort is elevated to a bin above the charging floor and is discharged
into dump cars and weighed. It is then dumped by means of a chute on a storage pile outside of the
building. From here it is loaded into small cars and moved by hand over to a bin outside of the briquetting
building.
BRIQUETTING INSTALLATION
The briquetting building is 30’ x 40’ outside dimensions, being 15’ above grade and 10’ below. The
plant is divided into three departments, i.e.; crushing, mixing and briquetting{, a flow sheet of which is
shown in Fig. 52
Crushing.
The residue bin is a double compartment bin, one side of which is used for coking coal. These compart-
ments are of 2 and 1-34 ton capacity respectively. A double plunger feed mechanism of standard design
delivers the coal from these bins to roll crushers. The speed of the plungers determines the amount of
coal fed. It is customary at this plant to use about 10% of bituminous coal in the briquette, although
briquettes of excellent quality have been made without this addition. The bituminous coal adds to the
coking properties of the briquettes and makes them harder during burning.
The first is a crusher Sturtevant 12’ x 12” smooth roll operating at a speed of 150 r. p.m. The amount
of reduction obtained with this machine is shown on the curve, Fig. No.8b. The crushed coal is delivered
to a screw conveyor which empties into an elevator boot.
The top of this elevator is connected to a No. 6 C.I. exhauster fan which removes a considerable portion
of the dust carrying it to a cyclone dust collector located outside of the building. The discharge from the
elevator is to a second pair of Sturtevant rolls 22’ x 10” operating at a speed of 200 r. p.m. These rolls
crush the coal down to the proper size for briquetting and deliver it to the crushed coal storage bin which
has a capacity of 2144 tons. Fig. No. 8b gives the screen analysis of the material as briquetted.
*A drawing of this carbonization plant can be found in U.S. Bureau of Mines Bulletin No. 221, Page 26.
tPhotographs of this plant will be found in U. 8. Bureau of Mines Bulletin No. 221.
230 APPENDIX No. 29
Mixing.
The crushed coal is delivered from the residue bin to an elevator boot by means of a Gauntt feeder which
allows of very fine adjustment. A small flour bin is located beside this elevator, and a Gauntt feeder de-
livers the flour into the elevator where it is mixed with the coal. This feeder allows of very close regulation,
each tooth on the ratchet corresponding to 4%. It is customary to use about 114% of flour in the bri-
quettes. This materially reduces the pitch necessary and as a consequence the briquettes are much less
smoky. The coal and flour mixture is then elevated to mixer No. 1 called a ‘‘preheater”. This mixer is a
horizontal steam jacketed machine with paddle arms revolving on a central shaft. It is 10’ x 10’ and has
been made to an original design. It is operated at a speed of 100r. p.m, Steam at 80 pounds pressure
is circulated through the jacket and a small 14” pipe line introduce steam at the same pressure into the
mixer. The live steam in the mixer serves to moisten the coal and convert the flour into a paste. It also
brings the coal to the proper temperature for the addition of pitch. In this respect it is very efficient as
a rise of 80 degrees F. was noted in the temperature of the mix, which is next discharged to a second hori-
zontal mixer of similar design. ‘This machine called a ‘‘mixer’’ is somewhat larger being 12” x 12’ and is
operated at 100 r. p.m. Steam is used in the jacket of the mixer but none in the mix. Very little heat
is gained during the passage through the mixer. Pitch binder is added as the coal enters the machine.
The discharge is to a third horizontal mixer of similar design called a ‘‘cooler. This machine is 12” x 12’
operated at a speed of 50—60r.p.m. All three mixers are connected to a stack but in the case of the
cooler a connection has been made to the fan. The ends of the cooler are removable and in this way a
draft of air is circulated through the machine which reduces the temperature to the desired point for
briquetting.
Binder System
The binder system consists of two rectangular shaped tanks, one directly beneath the other. Both are
open and contain steam coils for heating the pitch. The pitch is received in barrels and is dumped directly
into the first tank. When it becomes liquid it is discharged into a second tank where the temperature is
equalized. A small pump delivers it from the second tank through an 134” pipe to the “‘mizer”. A 3/8”
steam pipe is inserted at the nozzle in order to atomize the pitch and spray it on the incoming coal, The
pitch pump is a small Rockford water pump having a maximum speed of 7r. p.m. It is connected to a
Reeves variable speed transmission which allows of speed adjustment.
Briquetting
The discharge from the ‘“‘cooler’’ is directly above the press and the mixture is allowed to drop into a
small hopper where it is fed continuously to the rolls. The briquettes are removed by means of a belt
conveyor which carries them to a continuous bucket elevator. The discharge from this elevator is to an
inclined grid which removes the fines and. the finished briquettes pass on to an adjustable belt conveyor
which distributes them in the bin.
The bin is a circular structure made of brick and hollow tile. The hollow tile forms perforations in the
sides of the bin and allows a current of air to circulate. This assists in cooling and prevents mould which
is liable to form when flour is used if the. briquettes are not sufficiently cooled.
PowER AND PROCESS STEAM
Power is supplied from the town power plant at 2300 volts 3 phase 60 cycles and is transformed at the
plant into 220 volts 3 phase 60 cycles for power purposes and 110 volts single phase for lighting. ‘There
are two Western Electric 35H. P. 900 R. P. M. 220 volts 3 phase 60 cycle motors one driving the crushing
equipment and the other the mixing and briquetting. These are ordinary standard motors and possess
no special features. eth
Steam is supplied by a 50 H. P., H. R. T. boiler in the carbonizing building. The working pressure varies
between 80 and 100 pounds per sq. inch. About two tons of lignite coal are used per 24 hours but as some
steam is used for heating the building it is difficult to estimate the amount required in the briquetting
process. Steam is used in the following places:—
Small coil in each binder tank.
1-14” spray in preheater.
1-14” spray in binder discharge pipe.
Steam jacket in mixer.
1-44” steam jet exhauster for mixer. We
1-3/8” jet used occasionally in binder piping. ’ ew ‘
SP Ot G0 bo
Men EMPLOYED
2 men on carbonizers per shift — 3 shifts.
1 man on briquetting per shift — 1 shift.
2 men in yard per shift —1 shift.
1 supervisor. oF
Tests ConpuUcTED
Even though this report is a description of a plant, and not strictly an operating record, it may be well to
record some tests conducted and give some operating data obtained in February 1923, in order that it may
ae poeeeror with similar results obtained at the same plant 9 months later, * when using char shipped from
ienfait. SDS
Test on Temperature of Material Through Plant.
Temp. of residue after crushing........ Gin eSxyetpnehink: Oe A Norge Rack oe ak,
‘after Preheater./... 0.4: ak EL Nay elena ep Rict coe ceeeeds Ce Aarers , 162°. KH,
* * Mixes Sebi suey Be eR atere (bee ere e needle 162° F.
PE COGIED ie cio ele een t a
also briquetting temperature/ TPIS SCAT ecw 155 F.
gem eOLUPAtC hy st), cca See pee en PERE - eeteests ce PRION
*This test is described in Appendix No. 30.
APPENDIX No. 30 231
Test of Crushing effected in each Roll Crusher.
Screen Analyses
Mesh Residue% After lst Crusher% After 2nd Crusher%
On 4 52.4 120 0.0
6 21.4 3.0 0.0
8 14.2 9.8 0.0
10 5.8 19.8 2.4
14 2.3 14.0 7.5
20 120 15.4 15.1
28 no 8.8 15.1
35 4 8.9 14.8
48 3 7.8 10.4
65 3 5.5 8.9
100 3 3.0 8.5
Through 100 1.1 3.0 Vif bes
These results are shown plotted on curve Fig. 8b.
Chemical Analysis of Brijuettes.
SVROINUUT Once aoe als oes Mel Ae aan ee cians a iets aie hi ade © aveens 7.3%
WOFFA CUGI Ysera se ele eo arethie core cis eta caters, Re METS stotshere 4 19.2
UAL a Wee ole Lc Seaeiee CACy arc ALA“ WT SECS CCL PCA? CIPER h a ent eee 11.8
PROC CAE QTY. eae SRI atl ath oe Ns oak ne ha ale 6 aa ala nd aide ss 61.7
SOM OO Sa ke iat pette, Paes. ete eee, Seber et Nee tRege See Sagi AUF 9.9
Bela lb ft ieetaey ee ee vee Tae oe Maan: Sar) 6 tie seers 3 11,182
Density (average of 10 Spauettga) OS Rte ee Re eas) ae a ree 1.244
Test of Burning Qualities
A barrel of the briquettes was forwarded to Bienfait where they were burned in an open grate and obser-
vations made on their burning qualities. The briquettes were found to give off very little smoke and were
exceptionally strong in the fire. They did not burn too rapidly and no evidence of sparking or cracking
in the fire could be detected.
CONCLUSION
The outstanding feature of the installation at Hebron is its simplicity and ease of operation. A very
small staff of men is required to operate the plant and even these could be materially reduced by the use of
automatic handling machinery.
The. retort is of very sturdy construction and apparently stands up very well under ordinary operating
conditions.
The briquetting layout is a very efficient smooth running installation. One man is all that is required
within the building and he is able to control the three departments i.e., crushing, mixing and briquetting.
All feeding devices are very closely regulated and capable of fine adjustment.
A notable feature is the entire absence of dust and steam in the building. The result of this is that no
trouble is experienced with belts or motors. The mechanical details have been very carefully worked out
and the result is a very efficient plant.
--~ ~~ S$
APPENDIX No. 30
Report on Briquetting Tests at Hebron, N.D., Decmber 1923.
| By R. A. STRONG.
In accordance with the request of the Dominion Government, 125 tons of char
containing from 10 to 20% volatile and 25 tons of char containing from 20 to 30%
volatile was shipped to the Mining Experiment Sub-Station, Hebron, N.D., for a
briquetting test. The objectives of the test were:
(a) To determine whether the char as produced during normal operations in the
vertical shaft oven erected at the demonstration plant of the Lignite Utilization
Board would present any peculiar difficulties in briquetting.
(b) To determine whether a satisfactory briquette could be produced from a char
containing a somewhat higher volatile content.
(c) To determine whether lignite pitch as made from the tar recovered in the
above mentioned installation, could be utilized as a binder.
232 APPENDIX No. 30
(d) Obtain all information possible in regard to plant operation.
(e) Make all chemical and physical tests necessary to determine the quality of the
briquettes produced.
(a) — TEST ON NORMAL CHAR.
The char selected for this experiment had been produced some months previously,
and had been stored in one of the concrete storage bins. The reason for selecting
this material in preference to some freshly carbonized char, was due to the increased
fire hazard in shipping the latter. The rapid deterioration of char in storage, due
to the absorption of oxygen, makes this material considerably inferior for briquetting
purposes than that which has been freshly carbonized. The necessity for thorough
wetting in order to prevent burning also contributes to a more rapid deterioration while
in storage. It is to be regretted that freshly carbonized char could not have been
selected in order that the briquettes produced would have represented the best results
obtainable. On the other hand if stored char will produce a good briquette it can be
confidently stated that better results can be expected from a commercial plant where
the char is briquetted soon after being discharged from the retorts.
The char was subjected to considerable loss in dust and fines between the plant and
the final briquette, owing to the necessity for several handlings. The result of this is a
considerable difference in the chemical analysis of samples taken previous to shipment
and of samples taken during briquetting operations.
In a previous report* a table showing the analysis of the different screen sizes of
char is included. This reveals the fact that the degree of carbonization is greater in
the finer sizes than in the larger, and hence a loss of fines causes a material difference
in analytical results.
The mechanical operation of the plant during the briquetting of this char was in
all respects comparable to the results previously obtained using a char produced in the
inclined retort, designed by the University of North Dakota and installed at the Hebron
Experiment Station. The only difference noted was that the char from the Lignite
Utilization Board’s plant seemed somewhat softer than that produced at Hebron.
This resulted in finer grinding, less power required for grinding, smoother surface
on the briquettes (due to the altered screen analysis) and a higher binder requirement.
Flour and coal tar pitch were used as a binder and it was found that 2% of the former
and 10% of the latter were necessary for a strong briquette. This is higher than was
anticipated but it is quite possible that with fresh char containing a somewhat lower
percentage of volatile matter the amount of pitch could be considerably reduced.
In conclusion it may be stated that the char produced in the vertical retort as erected
at the Lignite Utilization Board’s plant does not offer any new problems in briquetting.
The entire absence of mechanical troubles during the test has demonstrated that a
duplication of this installation would operate smoothly and efficiently and produce a
high grade product on a commercial scale.
(b) — TEST ON HIGH VOLATILE CHAR.
In order to determine whether briquettes could be made from high volatile char
without undue difficulty, 25 tons of char containing from 20 to 30% of volatile matter
were shipped to the Hebron plant. The argument advanced in favour of a test of
this nature was that by leaving a higher percentage of volatile matter in the char, a
greater yield could be obtained without materially sacrificing the quality of the product.
The higher yield would also materially reduce the cost of the briquette.
The disadvantages of operating the retorts under these conditions has been discussed
in Appendix 27, so that further comment here is unnecessary. Suffice it to say that
this kind of operation is attended with certain disadvantages which do not make for
real economy.
In order to produce this high volatile char it is necessary to discharge from the retort
at a very rapid rate and as a consequence some of the lignite passes through without
being carbonized at all. This raw coal gives trouble in the crushing operation by
“plating” on the rolls. These “‘plates’’ do not always break up and are liable to cause
weakness in the briquettes.
*See appendix No. 27.
APPENDIX No. 30 233
During the operations it was noted that the high volatile char has a tendency to
“surface pit’. This is due to the mix being somewhat sticky and not clearing properly
from the rolls. In every other way operation was entirely normal and no additional
binder was required to make a satisfactory briquette.
In conclusion it can be stated that from a mechanical standpoint no difficulties
stand in the way of making a briquette from relatively high volatile char. This is
contrary to expectations and is highly gratifying in view of the wide range it allows
the operator to carry out the carbonizing operation. It is probable that these briquettes
will not stand storage as well as those containing less volatile but for immediate con-
sumption, this is not an objection.
(c) — TEST USING LIGNITE PITCH AS A BINDER.
_ In a commercial plant using the vertical retort installation a large quantity of tar
is recovered which-at present can only be utilized as a fuel or distilled and used for fuel
oil and binder. It is essential therefore to know whether the pitch from this tar will
mix properly with the pitch as obtained from gas works tar, and produce a good briquette.
In order to determine this question a small still was erected at the Bienfait plant
and sufficient tar distilled to obtain enough lignite pitch to briquette a car load of char.
It was estimated that the quantity obtainable in a commercial plant is equal to at least
20% of the requirements. It was therefore mixed in this proportion.
No separation of the lignite pitch was noticed in the binder tank so no difficulty
may be anticipated on this score. The lignite pitch will displace the coal tar pitch as
a binding agent in equal proportions and in view of its more oily nature the indication
is that it reduces any tendency of the ‘‘mix”’ to stick in the rolls.
In conclusion it can be stated that the tar can be utilized in this way and a con-
siderable saving thus made in binder costs.
(d) — OPERATING DATA.
During the operation daily tests were made as to quantity of binder used, tem-
peratures of the mix in the various machines, speed of machines and percentage of
fines. As these details have an important bearing on the smooth operation of a plant,
an average of the results of these tests is given below.
Quantity of Binder Used.
% Binder Mixing Ratio
Flour ae oe % Z
Bitchy se @ 5526 let eee et 10% i
Temperatures.
(eID. sOnCOALIeHe, = te es dere UTE TE! 20°F.
POM s alcer Preneaten soe. Fo ts te th ele ene 195 °F.
pPUITID A AILET I ReT ater et oh Pe IER Ae. 185 °R:
Temp. after cooler (also briquetting temp.)............ 155 °F.
DERI ps Of DICCHI ns ine Bree ee tae See CES A eee 2 264 °F.
Speed of Machinery.
Speed Size Tangential Speed
CrishineRolisy sear = oe, oe. gS Pho CRN St exe 575’ per min.
IPYGHCALED ae oe ee Bess Axa 1s
Mixer nan eines Bass 99 * 127x212!
RCOOIER ees er are woe 34 iy UES ad Wed
PT CSS ee yet ee tee oS Cate Mashek—22” rolls 39.3’ per min.
Binder muy seeee ee O22 Rockford No. 3 water pump.
Percentage of Fines.
In order to gain information for estimating the amount of material to be rebriquetted
in a commercial plant tests were made on amount of fines passing through the press.
The average of several tests was — 3.8%.
234 APPENDIX No. 30
These fines are due to the breaking off of fins on the briquettes and the small amount
of material which passes through the press without being briquetted. No account
pect taken of the breakage which will occur in the bin but an estimate of 3% is
made for this.
It can be stated that the total amount to be rebriquetted will not exceed 7% with
proper operation. This figure is the same as determined in previous operation at the
Hebron plant.
(e) — TESTS CONDUCTED ON CHAR AND BRIQUETTES.
In order to determine the quality of the briquettes produced, samples were collected
at intervals daily of both char and briquettes. These samples were forwarded to the,
laboratories of the School of Mines of the University of North Dakota, Grand Forks,
where exhaustive tests were carried out. The nature of these tests was as follows:—
(1) Analysis of char as loaded.
(2) Analysis of char as briquetted.
(3) Screen analyses of char as received; after passing through first set of rolls and
after passing through second set of rolls.
(4) Analysis of briquettes.
(5) Miscellaneous analyses.
(6) Drop test on briquettes.
(7) Stove test with briquettes.
The results of these tests are given below.
(1) Average analysis of char as loaded at Bienfait.
10-20% Vol. 20-30% Vol.
Dry Basis. Dry Basis.
Mba ora 9.7 re a 13.5 oe
WANIMRIIIAELETs... vip + allan, oa eae 13.9 15.4 P35 pet §.
(2) Average analyses of char as briquetted at Hebron.*
10-20% Vol. 20-30% Vol.
Dry Basis. Dry Basis.
(sy hoif i» Py oe eg rrr ame te AR 15.6 ee 15.4 . eed
RATT OL se, | bsie seta ce P7i3 20.5 28.3 33.4
see Caron (eis ee ks os 54.3 64.3 45.0 53:2
(BESO 2 ae a ee a 12.8 15:2 11.3 13.4
Peper per-lD. 5 2.3. 2s a 9,027 10,692 8,753 10,340
(3) Screen Analyses.
The curves, Fig. 8, c, d, e, show the plotted results of this test. A comparative
curve is inserted which represents results obtained in this connection with char as
produced in the inclined retort at the Hebron Station. As the screen analysis has a
direct bearing on the strength of the briquette it is important that a standard should
be adopted and in plant operation attempts made to conform to this standard as closely
as possible at all times in order to produce a uniform product.
(4) Analysis of Briquettes.
10-20% Vol. 20-30% Vol.
Dry Basis. Dry Basis.
MACNSELIY Ge eae ees eae 11.4 rises 8.6 ae
eM IALLED fs Pica Glas ldne 227, 25.6 33.9 BY AIR
HARE CATDON ferns cas nek ee 55.0 62.1 47.8 GyAL BY
EAS clevly aa ee Ape 10.9 12.3 9.7 10.6
oi At AE ojo) ced kien Sm eer 10,156 11,462 10,307 Liaise
(5) Miscellaneous Analyses.
Miscellaneous proximate analyses of materials used in the briquetting tests at the
Mining Sub-Station at Hebron in Dec. 1923. — 4
*See table in Fig. 44.
APPENDIX No. 30 235
Fines from dust collector.
As received Dry Basis
MOISCUTE =. cht. eee emits as to che 12.00 eet
VOL; Wat lerecenr eee are. 19.10 Zi
Fixed, carbone) oa. oe. 54.65 62.10
1A Chi * EP Daernemeee ote fon 14,25 16.20
B.T Yeper lees er s.r. 9.315 10,583
Flour used as binder.
As received Dry Basis
NIGISTOTG a baat fe eles oc 11.88 nee
VOlumatteresem ee o0Ns pa oe 68.92 78.20
Pisecdscarnorwers ate ceo a, 17.83 20.25
‘ASH Mere eee te ha, eSye 55
BiTe Lia petal nate sank a terct sos 6,926 7,860
Pitch used as binder.
Coal tar Lignite 20% Lignite pitch
pitch pitch 80% C.T. pitch
WiGistires e.mail ie .78 83 19
Vit eIYIALLOY ch he tui Sak aAF Baiene 66.59 76.02 64.52
Fixed-carbon yah 22ers 2h 32.61 22°63 34.50
Cre Ye ee ee eee eee ie 52 19
(6) Drop Test.
The method of making the drop tests is the same as described in U.S. Bureau of Mines
Bulletin No. 221 (Babcock and Odell) pages 71 and 72.
“The apparatus for making these tests consisted of a tight wooden enclosure 18 inches square at the base
reduced to 8 inches square at the top and 6 feet high. The top terminated in a small reservoir and a double drop
gate so arranged that the whole charge of coal could be simultaneously released and dropped. The coal struck
on a 2-inch cement slab fitted tightly to the bottom of the drop box. Each charge of coal or briquettes tested weighed
10 lbs. and was sized to pass a 2-inch ring but not a 11-inch ring. Each charge was dropped five times. It
was then screened into the sizes given in the table, different sizes weighed, and the percentage of each computed.”
This test, in a measure represents one of the conditions of handling The following
data on drop tests indicates the relative strength of the three types of briquettes made
at Hebron, N.D. An average of the results of eleven drop tests on briquettes from
North Dakota lignite at the Mining Sub-Station, Hebron, in 1921, as shown in Bureau
of Mines Bulletin No. 221, is included by way of comparison.
Lot No. 1 represents briquettes made with 2% flour and 10% of pitch having a
volatile content between 10 and 20%.
Lot No. 2 represents briquettes made from similar char using the same quantity
of binder but in which 20% of lignite pitch has been mixed with the coal tar pitch.
Lot No. 3 represents char with a somewhat higher volatile content, i.e. 20 to 30%
made with 2% flour and 10% coal tar pitch as binder.
Lot No. 4 is an average of eleven drop tests of briquettes made from N. D. lignite
at the Mining Sub-Station, Hebron, in 1921.
Results of Drop Test.
Screen Sizes
LotNo. On 144”, .On 14” .° On1” On 34” On 1%” On 14” Through 14”
Pie7. 2719218 1.25 47 .63 94 94 3:09
Fatih! 86.88 1.87 1.56 94 94 1.56 6.25
ere 90:93 1.56 1.56 63 94 63 ato
Ae as 95.29 45 LL 34 40 45 296
From the above table it is seen that degradation is chiefly from abrasion. While
the percentage of breakage in briquettes from the Canadian char is higher than that
shown for the average of eleven samples of briquettes from N. D. lignite, the briquettes
are amply strong to withstand all reasonable handling.
236 APPENDIX No. 30
The briquettes made with a mixed binder of lignite pitch and coal tar pitch are
somewhat weaker than those made with coal tar pitch alone. Because of its more oily
nature the lignite pitch apparently tends to keep down the fine dust from handling,
possibly a little lower even than that from the briquettes made with standard coal
tar pitch.
The high volatile briquettes stood handling reasonably well but showed a greater
tendency to abrasion and surface pitting than the others. This roughening of the
surface permits more rapid deterioration in weathering.
The briquettes were tested rather early after being made and have not reached
their maximum of hardness. They show up very favourably for the length of time
they have had to harden and can be considered as sufficiently strong to withstand the
normal handling required.
(7) Stove Test on Briquettes.
The following table gives the results of the stove tests from the three varieties of
briquettes made during the December test. A description of the method used for
making this test is taken from U.S. Bureau of Mines Bulletin No. 221 (Babcock and
Odell) pages 69 and 70.
“The tests were made in a room specially built for the purpose in a basement and partitioned off within a much
larger room that was kept at a uniform temperature. This testing room was connected by an ordinary stove
pipe with a chimney having adequate draft. Provision was made for the inlet of air through ordinary registers
near the floor. Self recording thermometers were used to take the temperature of the room at the beginning and
throughout the test and to determine the temperature of the flue gas. The temperature outside of the room was
kept normal and the drafts were regulated so as to permit the same flow of air in each test. 60 pounds of briquettes
were used in each trial and uniform conditions were maintained in all the tests. The amount of normal ash,
percentage of unburned carbon in the ash, and the percentage of briquettes unburned were determined in each
test.”’
The room temperature curves as shown on the attached diagrams, Fig. 45, a@ to h
inclusive, have the characteristic form for carbonized lignite briquettes. The enclosed
areas being approximately proportional to the heat value of the materials burned.
The briquettes held their shape and maintained a reasonable strength in the fire although
no coking coal was used. While the volatile content in all of the briquettes was rather
high, the combustion rate, except in the high volatile briquettes, was no higher than
in some of the low volatile briquettes previously made at the Mining Sub-Station at
Hebron. This was due probably to the higher moisture content and finer grinding
of this softer char.
The high volatile briquettes gave a longer flame and showed a tendency to burn
faster than the lower volatile product, a more rapid falling off of temperature after the
maximum was reached, and a greater duration of the effective fire. The contributing
factor in the higher combustion rate was the coarser particles in the briquettes due to
the inability to crush the uncarbonized material uniformly. Some sparking in the
fire was also observed during the burning. The percentage of combustible in the ash
was relatively low except in stove test No. 6 which was closed at the end of 1214 hours.
If the test had been continued until the material in the grate had burned out, the
combustible in the ash, would also have burned out much more completely.
In stove test No. 13 (see Fig. 46) on a larger quantity of similar material (except
for a higher moisture content) the combustible in the ash was low. The high per-
centage of combustible in the ash from the stove test No. 6 shows the tendency for
this particular lot of briquettes to disintegrate somewhat in the fire. This probably
can be charged to the relatively high volatile content rather than to the use of lignite
pitch’ as a part of the binder in this particular test. In a later test, briquettes made
from lower volatile content with all lignite pitch binder and no coking coal stood up
well in the fire.
As a matter of comparison, a table taken from U.S. Bureau of Mines Bulletin
No. 221 (Babcock and Odell) is included showing the results of similar stove tests
using anthracite coal. The analysis of the anthracite used in these tests is as follows:—
Moistures0 25 et). eae eee 3%
Vol. matterx ay ela ees sie 5.4
Fixed ‘carbone fa a oe nee oF eee 81.6
Ash :¢+2 i. Cb 2, rae eas We sees 127
APPENDIX No. 30 237
Results of Stove tests showing available heat for Anthracite Coal
and Lignite Briquettes.
Available
Ash from Combustile
heat per Ib. of .
Kind of coal coal consumed. Miibe: tak aay
In degree hours Ae i.
Arthracite.c4-hcte wee. tle oe 14.87 OS. 66h ue free tS
Me rs oe os. 7 et ap ee 15.65 17-57 wae
Se 0 Ree ates Beller Ok. 11.90 21.06 30.81
Tas okt padi ih ORDERS basa. T3.52 -20.10 31.09
ha) SPAS Sea 0 Penn 14.71 20 .54 23 .62
A, ee ae STOREY Metab, 17.44 21 15s ieee Lhe
Oy |W ) Eater eee gees cde 14.81 20 .63
PNTETACC Sate Mega ee aa, 14.36 19 .84 26 .54
(5) Lignite briquettes .
(normal char)..... 17 .00 BO? s EP
(6) “(lignite pitch
experiment)..... 16.41 10.45 Tae
(13) -. * 14.97 9.58 sa)
(7) Pee ue VOU Chater a 15568 9.22 OU)
PBVCTARO se. Corts ea ies ee 16.00 10.07 4.46
It will be noted that the lignite briquettes give decidedly more available heat per
pound than the anthracite. One of the most notable differences between the two
fuels is the relatively low amount of unburned matter left in the ash from the briquettes.
It is a characteristic of carbonized lignite briquettes to burn almost completely to
ash whereas anthracite always leaves much unburned carbon in the center lumps with
pieces of ash and cinder. From the above tests it will be noted that the briquettes
as made during this test give every evidence of being a very satisfactory fuel as judged
by commercial requirements. The diagrams (see Figs. 45 and 46) show in greater detail
the results of these tests.
SUMMARY.
(1) 125 tons of char containing volatiles between 10 and 20% have been briquetted
at the Hebron station.
(2) 25 tons of char containing between 20 and 30% volatiles have been briquetted.
(3) No mechanical difficulties were encountered during entire run.
(4) Binder necessary was found to be 10% pitch and 2% flour. (This is 11 and 2
in terms of mixing ratios.)
(5) No difference was noted between straight C.T.P. briquettes and those containing
20% lignite pitch mixed with C.T.P.
(6) No great difference was noted in mechanical operation between different chars-
(7) Close regulation of temperatures is necessary as well as control of feeds for
uniform product and minimum of trouble.
(8) High volatile briquettes show weakness in fire also rapid ignition and com-
bustion.
(9) In order to get best results char should not be stored before briquetting, for any
length of time.
(10) Deterioration of char is rapid.
(11) Char from internally fired oven not as hard and does not produce quite as good
a briquette as that from the inclined setting as used at Hebron.
(12) Lignite pitch seems to eliminate any tendency for sticking in rolls.
(13) Screen analyses shows higher percentage of fines. This makes a smoother
surface but requires more binder.
(14) Power requirements for grinding were lower than with the harder char.
(15) Briquettes produced can be considered of commercial quality.
(16) Fines did not show any increase over previous operation.
238 APPENDIX No. 31
CONCLUSION.
The test has demonstrated that the char made in the vertical shaft carbonizer installed
at Bienfait offers no new problems in briquetting. The char has several points of
difference from that produced in the Stansfield carbonizer also from that produced in
the Hebron retort but these differences do not present any obstacle in briquetting it.
It has also been shown that good briquettes can be made from a high volatile char and
while these briquettes do not show up as well in the physical tests as those made from
a lower volatile char, it has demonstrated that the operating range in the production
of char is wide, which is a decided advantage in commercial plant operation. The
range of operation is solely dependent on the quality of briquettes desired.
The briquettes produced while not being of the best quality obtainable owing to the
selection of the material to be briquetted, are a remarkably good product as judged
by commercial standards. The stove or burning tests show them to be superior in
some respects to anthracite coal.
Grateful acknowledgement is made to Dean E. J. Babcock and to Mr. R. L. Suther-
land for the carrying out of this test, and for their kindly assistance in collecting the
data desired by the Board.
S$
APPENDIX No. 31
Report on Briquetting Tests at Grand Forks, N.D., December 1923
By R. A. STRONG.
In order to supplement the tests made at Hebron, the results of which have been
given in a previous report, three lots of char were sent to Grand Forks to be briquetted.
It was considered that a great deal of information could be gained by a small scale
test of this nature where accurate control of all possible variables is more readily
attainable than in a larger plant.
SUMMARY OF RESULTS.
In the accompanying tables will be found the results of this test in tabulated form
together with data covering stove tests, B.T.U. values, and analyses of the small lots
of special briquettes made. A study of the tabulated results shows that the lower
volatile char produces a superior briquette both physically and chemically and requires
considerably less binder. It would therefore be better in commercial operation to
work for this type of char in order to reduce the binder costs as well as raise the quality
of the product.
Lignite pitch can be utilized as a binder but when it is used alone the briquettes are
not as strong as when it is mixed with coal tar pitch. The mixture of 20% of lignite
pitch with coal tar pitch does not materially weaken the briquette. The use of lignite
pitch is beneficial in reducing the tendency of the ‘‘mix’”’ to stick in the rolls, and also
in eliminating the dust in briquette handling.
The high volatile briquettes in this test did not show up as well as in the Hebron
test. This is due partially to the crushing system, which only includes one roll, and
partially to the press which makes a larger briquette but does not give the same uniform-
ity of pressure as does the press at Hebron. These high volatile briquettes are softer
in the fire, and tend to break up, as will be noted by the high percent of combustible
in the ash in the stove tests. The results of the entire test are not as favourable as
those obtained during the Hebron test, due to the difference in the two installations,
but they are, however, very instructive and may be summarized as follows:—
(1) A two ounce briquette is superior to a four ounce briquette, as greater pressure
is given to the smaller size during fabrication. (This applies to the product
of roll presses only.)
(2) ‘Two sets of rolls are preferable in crushing as a more uniform screen analysis
is obtainable and this results in a better briquette.
APPENDIX No. 31 239
(3) Binder requirements are dependent on volatile content of char. The higher
the volatile the more binder required.
(4) High volatile briquettes are not as strong in the fire as those made from a low
volatile char.
(5) Lignite pitch can be mixed with coal tar pitch and thus utilized as a binder.
(6) Briquettes made with lignite pitch alone are not as strong as those made with
the mixture of coal tar pitch and lignite pitch.
(7) The use of lignite pitch tends to eliminate dust in handling briquettes also
decreases tendency for the mix to stick in the press rolls.
(8) The char as produced in the vertical retort installed at Bienfait does not offer
any new problems in briquetting.
DISCUSSION OF RESULTS.
The tests were made at the School of Mines, University of North Dakota, Grand
Forks, where a plant has been erected for demonstration purposes and small scale
testing. The following is a description of the installation, a flow sheet of which is
shown in Fig. 50.
The general principles of the layout are the same as those which have given success
at the Hebron station. A small bin equipped with a Gauntt feeder is used for the
storage of the char, while a smaller bin similarly equipped is used for flour. In the
event of using coking coal in the briquette, the flour and coking coal are mixed by
hand and fed in together.
The crushing equipment consists of a small gyratory crusher and one set of smooth
rolls. The discharge from the rolls is to a crushed char bin.
The mixing apparatus consists of one long steam jacketed Gedge Gray mixer. The
first half of the mixer is used for heating up the mix and “‘cooking’’ the flour, — live
steam being injected in order to obtain the required temperatures. The binder is added
midway in the length of the mixer. The feed is controlled by a Gauntt feeder and
the discharge is controlled by a gate. By means of this latter regulation, the depth
of material in the mixer can be regulated, which allows of more or less mixing as desired.
The discharge from the mixer is to a bucket elevator which discharges into a Gauntt
feeder. The purpose of this last feeder was for tempering but as it was not found
to be satisfactory it has since been eliminated.
The briquette press is of special design and makes a four ounce briquette. These
are discharged on a perforated belt which allows the fines to pass through to be later
removed by hand.
cE pes A of char were shipped from Bienfait which weighed approximately two
tons each.
Lot No. 1 represented normal char having a volatile content between 10 and 20%.
30%. No. 2 represented a high volatile char having a volatile content between 20 and
O-
Lot No. 3 represented char having a volatile content below 10%.
As in the test made at Hebron the char had deteriorated by having been _ stored
before being briquetted. Analysis of the char and briquettes for each lot with the
average composition of the briquettes made is shown in the table Fig. 47.
Lot No. 1. This char was rather high in volatile and carried a considerable propor-
tion of uncarbonized or only partly carbonized lignite. As a result, the crushing,
through only one set of rolls, was not uniform. The briquettes produced were not
properly pressed, due in part to the lack of uniformity in size of the material, and in
part, to the large size and the shape of the briquettes made by the press used.* These
smaller tests, for several reasons, did not give as good results as those made in the
larger experimental plant of the School of Mines Sub-Station at Hebron, and did not
demonstrate as accurately as the larger test, the suitability of the material for briquet-
ting. However, in both the tests at the University and at the Sub-Station (Hebron),
the binder requirement was rather high, as would be expected with a high volatile char.
*Similar material was later made into strong briquettes of good surface at the Hebron Station.
240 APPENDIX No. 31
On November 30 and December 1, the briquettes in these tests had the following
mixture by weight:—
mCONALT(INOISL) ./. 3 3 1 tere cee ee meee 3,105 Ibs. 80.52%
eae COal «oa ee ee ne ee shade
WG td 8 re as ener hs Oh Or toga OES She 4 Ss. . /O
Flour) 3). 2.60 he Ree eee 68 Ibs. 1,76%
3,855 Ibs. 100.00%
On December 5, a test was made on similar char using as binder, in addition to the
flour, a mixture of 25 per cent lignite pitch and 75 per cent of coal tar pitch. Ina
second test the proportions were approximately 8 per cent lignite pitch and 92 per cent
coal tar pitch. No noticeable difference in plant operation or binder requirement
was found. A car load of similar char was later briquetted at the Sub-Station at
Hebron using 20 per cent lignite pitch and 80 per cent coal tar pitch as already described
in appendix 30. The only difference in plant operation noted was a reduced tendency
for the mixture to stick in small lumps in the pockets of the press, probably due to the
more oily nature of the lignite pitch or lower melting point, or both. The briquettes were
a little weaker than those made with all coal tar pitch, as shown by drop tests of the
briquettes made at the Mining Sub-Station at Hebron, but seemed strong enough to
be considered a satisfactory commercial product.
Lot No. 2. The char as received contained a large percentage of raw or dried lignite,
some of which was in lumps too large to pass the small crusher in the plant. Of a
total weight of 4,286 pounds in this lot, 658 pounds over one inch, mostly of uncarbon-
ized lignite, was screened out and discarded as unfit for crushing and briquetting.
In the crushing of the raw or imperfectly carbonized material, there is a tendency
to break into relatively large thin plates to which the binder does not adhere properly.
These plates, in the pressing of the mix, tend to arrange themselves with their long
axes in planes parallel to the common tangent of the press rolls; and the result is a
corresponding tendency for the briquettes to split when leaving the press. Raw or
partly dried coal crushed in smooth rolls is compacted into plates of finely divided
material weakly bound together by pressure. Although these plates break up in
part in the mixers, relatively large lumps hold together throughout and form weak
spots in the briquettes. When these spots are at or near the surface of the briquette,
they break down on weathering leaving a rough surface much less resistant to abrasion
and weathering.
On December 3 and 4, briquettes were made from a mixture having the following
proportions by weight :—
*Char (MOISt) eek ce pee ees ee ae eee 3,618 lbs. 79.33%
me COalA Shae ceee ey ns eee te es ee
OUT Fe ON. oe ee ee S. :
Géalttar pitchaiie se ai ea 534 Ibs. 11.67%
4,570 Ibs. 100.00%
No particular difficulty was found in the briquetting of the material, except that of
crushing, so long as sufficient pitch was used to prevent splitting in the briquettes.
There was some sticking of the material in the press, due to the tendency to split.
Lot No. 3. This lower volatile char was much harder than the high volatile char
of the previous lots. Being free from raw coal, and harder, the crushing rolls produced
a more uniform product. The briquettes made had better surfaces, were stronger
and required less binder.
On December 24 two lots were made up, one containing coking coal and one with
no coking coal. No change in binder was made. On December 25 one lot was made
up using all lignite pitch in place of the coal tar pitch. No coking coal was used, the
aim being to determine the relative strengths of the coke formed from lignite pitch,
and from coal tar pitch, in the briquette, when in the fire.
The briquettes made on the 24th were the strongest made during the series of tests,
having fairly smooth surfaces, and being pressed harder. The briquettes made with
*Analysis of this char is given in the tables Fig. 47.
APPENDIX No. 3l 2Al
the lignite pitch binder had smoother surfaces but were not so strong as those made
with coal tar pitch, though more binder was used. It was not the intention to use
more of the lignite pitch than of coal tar pitch in the runs of the 24th, but with the
same setting of the pitch pump, more lignite pitch was fed, probably because of its
greater fluidity at the temperature used.
Briquettes containing lignite pitch have less tendency to throw off dust in handling
than those made with coal tar pitch alone probably due to the presence of oil in the
lignite pitch.
No drop tests were made on these small lots of briquettes produced at the School
of Mines, Grand Forks, on account of the lack of uniformity in the product, differences
in plant conditions, and further because the results of drop tests with the much larger
briquettes used in these tests could not be compared with those of the smaller briquettes
made at the Sub-Station at Hebron, North Dakota.
BURNING TESTS.
The details of the burning tests are shown in the table Fig. 48. With the exception
of the high volatile briquettes burned in stove test No. 9, all the briquettes held their
shape and maintained a fair strength in the fire, although those containing a small per
cent of coking coal were, as would be expected, slightly stronger than the briquettes
without the coking coal. On account of the coarser material in, and insufficient pressure
on the briquettes there was a greater surface disintegration in the fire than from the
smaller, denser briquettes, made at Hebron from the same material (even though the
large briquettes contained coking coal and the smaller ones did not). Those made
from the low volatile char were better physically and stronger in the fire than the
higher volatile briquettes.
The high volatile briquettes broke down badly on heating, the breakage being
especially noticeable at the lower or discharge end of the magazine where the relatively
low heat, acting on the briquettes in the magazine softened the pitch without obtaining
the benefit of the coking qualities of the briquette and allowed the expanding particles
of the partly carbonized lignite, high in gas, to loosen and weaken the briquettes.
Briquettes charged into the firepot below the magazine at the start held together fairly
well so long as they were not disturbed but broke as soon as touched.
The briquettes made with all lignite pitch and flour binder were denser than any
of the other lots, apparently due to a higher content of a more fluid pitch. In the
stove test ignition was slower but a high maximum temperature was reached with a
falling off in temperature more rapid than in the tests of the other briquettes. The
briquettes held their shape and maintained a good strength throughout, though no
soft coal was used. On account of the decreased strength of briquettes made with
an all lignite pitch binder, it is probable that the best results will be obtained by mixing
with coal tar pitch.
Results of the burning tests are not altogether comparable with those previously
reported for briquettes made from similar material at Hebron, largely because of
differences in size and structure of the briquettes. The coarser material in the larger
briquettes tends to increase the combustion rate: the larger size of briquette reduces
the weight of fuel in the firepot and as the briquettes do not spread out properly from
the magazine discharge, there is a reduction in the total amount of heat given off per
unit of time. With the larger size briquette the ash drops through the fuel bed and
grate more readily, tending to maintain the combustion rate more uniformly throughout
the burning period. With the smaller briquettes the tendency is to produce a high
temperature during the earlier period due to the presence of a larger body of relatively
high volatile fuel in which the ash concentration is low. After the volatile is burned
off from the fuel in the firepot the ash concentration increases, slowing down the com-
bustion rate. For fuels of approximately the same composition and heat value there
is a tendency for the smaller briquettes to cause a higher temperature during the early
part of the test followed by a more rapid drop after the maximum has been reached.
While the single stove test of the high volatile briquettes, under the conditions as
explained above, appeared to indicate a high heat production it is not probable that
more extended tests would show this. Furthermore other conditions affecting cost
of production, physical condition, weathering qualities, actual sustained heat value,
and ability to stand up under severe firing conditions, make it evident that the very
high volatile briquettes will not prove as satisfactory as the lower volatile briquettes,
and it seems very doubtful if the production of very high volatile briquettes would
prove advantageous to either producer or cohsumer.
242 APPENDIX No. 32
Diagrams of the curves of available heat, room temperatures, and flue gas tem-.
peratures for each of the various stove or heating tests are shown in Fig. 49, @ to l
inclusive.
In conclusion the Board wishes to express its indebtedness to Dean E. J. Babcock
and Mr. R. L. Sutherland, under whose supervision these tests were carried out.
—__§———
APPENDIX 32
Report on Low Temperature Projects in America
CHarRLES V. McInTIRE
Engineer
66 Broadway, New York.
January 11, 1924.
Mr. Lessuiz R. THomson, Secretary,
Lignite Utilization Board,
288 St. James Street,
Montreal, Canada.
Dear Sir:—
Complying with the request in your letter of the 21st of December, 1923, I have compiled from data
in my possession and from my own personal knowledge the following list enumerating the many projects
and industries of the United States which have during the last fifteen years been engaged in the develop-
ment of processes intended for the distillation of coal at low temperatures or for the improvement of certain
low grade fuels by distillation methods. This does not take into consideration those processes, such as
the high temperature coke oven, the gas retort, or the internally heated complete gasification processes,
which have as their objects the manufacture of metallurgical coke from high grade coal or the manufacture
of gas.
These projects are listed below:—
Carbocoal process.
Piron process.
Greene-Laucks process.
University of North Dakota development.
Wallace process.
Bussey process.
Summers oven.
Sterling Midland Coal Company.
Jones and Laughlin process.
Pritchard process.
Bostoph process.
Traer process.
Pennsylvania Coal & Coke Company experiments.
Brown process.
Frank process.
Parr research.
Johns process.
International Combustion Engineering Corporation.
Consolidation Coal Products Company.
THE CarRBocoaL PROCESS
The Carbocoal process, the invention of Mr. Charles Howard Smith, was developed during the years
1914 to 1918 by a group of foreigners headed by Blair & Company of 24 Broad Street, New York. A
company known as the International Coal Products Corporation with offices in New York was organized to
carry on the development program; a subsidiary company, the Clinchfield Carbocoal Corporation, was
organized to operate the first (and only) commercial plant of the process, at South Clinchfield, Virginia.
This widely known development has been carried out on a most extensive scale and is by far the largest
of its kind on the American continent, comparing in magnitude with the Coalite development in England.
The process consists of a method of improving the physical properties of coal by three stages of treat-
ment, first, distilling the coal at low temperatures in a stationary retort with internal agitation and reco-
vering the by-products; second, cooling, grinding and briquetting the semi-coke residue with a pitch binder;
third, distilling the briquettes at high temperatures in a stationary retort with recovery of by-products.
The product, known as carbocoal, is an excellent domestic fuel, comparing favorably with anthracite, and
during the development period at Irvington, N. J., and the commercial operation period at Clinchfield, it
was well received by the purchasing public.
The primary purpose of the interests who backed the carbocoal project was to find a process for making
low grade coals desirable for domestic fuel and fit for any use where high grade fuel is required: They
hoped to widen the markets for bituminous coal and thereby create a greater market for certain coals owned
by them in large coal bearing areas of western Virginia.
Practically all the development was carried out at Irvington, N. J. in a small semi-commercial plant
built chiefly for experimental purposes, at a cost of over one million dollars. Each stage of the process was
studied and experimented with over a period of four or five years. Low temperature carbonization retorts
of various types and sizes were built and operated, one after another, in an effort to find one which would
produce the desired results. Briquetting systems, at least three types of secondary carbonization systems,
various systems of conveying and crushing coke adh by-product recovery plants were built.
APPENDIX No. 32 243
Consulting engineers and designers were retained to assist with the development, among them the well-
known consultants: Ford, Bacon and Davis of New York and the engineering firm of Didier-March; the
latter were engaged in the design of fire brick settings and other furnace work.
As a war measure, to insure a large production of toluol and other coal by-products needed in warfare,
eae oras States government assisted financially in the building of a commercial carbocoal plant at South
inchfield.
The plant was finished in 1920 and was operated over a period of about two years. It was rated at a
capacity of 500 tons of coal but in operation never exceeded 300 tons of coal and, in my opinion, the average
output should be taken at 200 to 250 tons of coal per day. The reason for this disappointingly low capacity
was faulty design of apparatus and lack of knowledge on the part of the designers of the actual problems
which needed to be solved. Many attempts involving large expenditures were made to improve the Clinch-
field plant and to increase its output and reduce its cost of operation but without success and in 1922 the
plant was closed down. It still remains idle.
While the plant was in operation the experimental work was kept up at Irvington; a new retort was built
which promised to outperform those which had been installed at Clinchfield but whether this promise can
be realized has not been demonstrated commercially.
The entire program of the International Coal Products Corporation, in the development of the Carbocoal
process and the attempt at commercializing it, is said to have cost upwards of $6,000,000.
THE Prron — CARACRISTI PROCESS
This low temperature distillation system, recently taken up by the Ford Motor Company, has just
enjoyed a great deal of nation wide newspaper publicity under the caption ‘‘Ford to burn coal twice.”
It is the invention of Emil Piron and was first built by him under the financial backing of a local coal
operator at Huntingdon, W. Va. This plant consisted of one retort, of relatively small dimensions;
in which coal is distilled in a thin layer on the upper strand of a metal conveyor as the conveyor passes or
floats over the surface of a molten lead bath. The product is a soft friable semi-coke suitable for domestic
purposes only after briquetting or for steam purposes after pulverizing (or briquetting).
The Ford Motor Company, through V. Z. Caracristi has obtained rights to build a plant rated at 400 tons
of coal per day at the factory in Ford, Ontario. The plant is said to be under construction and it is said
Shae the cost will be about $400,000. In my: opinion the cost of the development plant at Huntington was
at least $75,000.
Data derived from my own experiments with apparatus similar to that used by Piron in his original
research differs widely from Piron’s data as to time required for distillation and the quantity of by-products
to be derived from coal. This leads me to believe that the fundamental principle of the Piron design is
unsound. I do not believe the process will prove a commercial success.
ba
THE GREENE-LAUCKS PROCESS
This process, developed in Denver, Colorado, by the Denver Coal By-Products Company with offices in
New York and Denver, comprises a method of manufacturing a smokeless high volatile domestic coke from
bituminous coal in one stage of distillation.
The distillation is carried on in a vertical metal tube which has an internal screw for propelling the coa
upward continuously while it is under treatment; both the tube and screw are heated by the gas. By-
products are recovered in the usual manner.
The plant at Denver which was first built in 1917 is of commercial proportions. It has been operated
from time to time since the start but has never been successful from a financial standpoint. Various
interests have investigated the plant with the view of taking over the process, among them the Combustion
Engineering Corporation of New York.
I have not seen the Denver plant, but from the information at hand I have formed the opinion it will
not be a success, and that the process is not fully developed. Judging from reports and illustrations of
the plant I should estimate the total cost of development and building at $500,000.
THE UNIVERSITY OF NortH Dakota DEVELOPMENT
The state of North Dakota through its University has been engaged for the last 12 years in an effort to
find a successful method of improving the physical and thermal qualities of North Dakota lignite. Ex-
periments have been carried out at the University laboratories and at a large scale experimental plant at
Hebron under the direction of Dean Babcock and much data of value to the scientific world but no process
of commercial value has been developed.
The Hebron plant consists of several large substantial buildings for housing the retorting and briquetting
apparatus and the laboratories. Many types and sizes of retorts have been tried during the course of the
experiments, including a large unit comprising 12 inclined continuous ovens which has been operated over
several periods of one to four months each. The system for manufacturing briquettes from the lignite
char has functioned satisfactorily.
In addition to the large scale experiments at Hebron, Dean Babcock has continued his research work
at the Grand Forks laboratories. A special type of internally heated retort, designed by Mr. Hood of the
United States Bureau of Mines, has been built at the joint expense of the University and the Bureau. It
has been operated with some degree of success but has not as yet been commercialized. :
I have seen the experimental plant at Hebron and I should estimate the cost of construction of this unit,
together with the cost of this and other research work, at about $100,000.
Ture WALLACE PROCESS
The Wallace process consists of a method of manufacturing coke from bituminous coal in a vertical
retort. Coalis distilled between the retort walls and the walls of an inner core of metal by heat transmitted
through the former. The coke residue is said to resemble the product of a high temperature furnace while
the liquid by-products are of the same high quality as those obtained from ow temperature distillation
processes.
The first development work was done by Mr. Wallace in a small plant in East St. Louis. In 1921 a
plant consisting of six ovens was built at Petersburg, Va., by the American Gas Company and the Gas
Machinery Company at Cleveland, and operated by them in connection with a town gas plant. It has been
‘reported that the original installation was not successful; that numerous changes have been made in the
244 APPENDIX No. 32
ovens and that an entirely new oven, known as the Petersburg process, has been developed. _ It is said that
the oven is to be built at Petersburg and that it will be operated on a commercial scale by the Economical
Carbonization Company. : ‘
I have seen the Petersburg plant and I should estimate that the expenditures for development of the
process (which is not yet a commercial success) have exceeded $250,000.
Tue Bussey PRocESS
The Bussey process, the invention of Charles C. Bussey, has been built at two experimental plants, one
a small scale test unit erected in Brooklyn, N. Y., the other unit at Louisville, Kentucky is a larger one.
The Louisville plant consists of one Bussey furnace, which is somewhat similar in design to a gas pro-
ducer; a coal handling system, and the usual by-products recovery equipment. It was intended to operate
on a commercial scale in the processing of Kentucky cannel coal; the gas was to have been sold to a large
user in the neighbourhood; and the coke residue was to have been sold on the open market.
Through some lack of capital or other reason, the plant’s operating period was brief. It was closed
down in 1920 and has remained closed since, with the exception of several short periods when it was put
into commission for the purpose of making demonstrations to prospective purchasers of the process.
It is said that the Bussey Process Company, which owns the process, has received financial assistance
from time to time from a number of interests and that the total expenditures for construction of the Brook-
lyn demonstration unit, the construction and operating of the Louisville plant, and the promotion of the
process has amounted to at least $200,000.
THE SuMMERS COKE OVEN
The Summers process consists of a long, narrow oven chamber heated from the sides and top by combus-
tion of gases. It is equipped with a moving floor which traverses the entire length of the oven and moves
alternately forward and backward by the action of aliquid motor. Coal charged into the oven at one end
travels continuously through the heated chamber upon the reciprocating floor and is there converted into
coke while being heated and compressed. Three ovens of this type with a total capacity of about 10 tons
of coal per day were erected in Harrisburg, Illinois, in 1910, and have operated over several periods, but not
continuously and are idle at the present time. The installation is not considered a commercial success.
In my opinion, its cost for construction and operating was at least $75,000.
THE STERLING-MIDLAND CoAaL COMPANY
In 1921 the Sterling Midland Coal Company of Chicago, Illinois, owners and operators of Indiana coal,
built a one unit experimental or demonstration plant for distillation of coal at low temperatures at Hammond
Ind. The process, known as the Richards and Pringle process, was one previously designed and built
in England. The plant consisted of one retort with coal handling system, a by-product house and a la-
boratory. The retort was a long, narrow oven in which coal travelled through a distilling zone on the upper
strand of a continuous metal conveyor and the product was a soft semi-coke of high volatile content which
was intended for sale as domestic fuel without further processing.
A short period of operation showed that the plant would not function as intended without being re-
modeled. It was closed down.
I have seen the plant at Hammond and from my own experience with such construction and operation, I
should estimate the capital expenditure to have been about $120,000.
JONES AND LAUGHLIN EXPERIMENTS
Since the year 1920 the blast furnace department of the Jones and Laughlin Steel Company of Pittsburgh
has been engaged in more or less continuous experiments in low temperature carbonization of Pittsburgh
coal. The primary object of this research is to improve the physical structure of the metallurgical coke
manufactured in the steel works coke ovens by the admixture, with the high volatile gas coal, of a certain
percentage of pulverized soft coke of 15 to 18 percent volatile content. Of course the main difficulty in
this program lay in the development of a suitable piece of apparatus for producing the semi-coke at low
temperatures; and at least two types of retorts have been built and tested. One of them, which was in
operation in 1921, consisted of a revolving drum heated externally after the manner of the Thyssen process.
I have seen this experimental plant and should estimate the cost of construction, maintainance and
operation at from $50,000 to $75,000.
PRITCHARD PROCESS
The Pritchard process, developed by Thomas W. Pritchard is owned by the Acme Coal Products Corpo-
ration of New York, a corporation capitalized at $1,000,000.
The process consists of a method of retorting coal within a metal muffle by means of heat transmitted
through the walls and also by heat carried into the retort by hot gases recirculated from the bottom. Small
scale test units were built at Hoboken and operated intermittently but not on a commercial scale. Tests
have also been conducted in a bone distillation plant at Allentown, Pa. No commercial units have been
installed although the owning company has made efforts to promote the process as a system for man-
ufacturing gas for city use.
I have seen the Hoboken plant and have formed the opinion that the process is not yet in commercial
shape and that the expenditures for construction and development work amounted to an least $30,000.
Tue Bostrorpw Process
The Bostoph process was one of the early attempts at low temperature carbonization for the purpose of
manufacturing a smokeless domestic fuel from bituminous coal. It was built in an experimental plant at
Warsaw, Indiana, and operated for a short time but was finally abandoned as impractical. I have no
information as to the size or cost of this installation.
APPENDIX No. 32 245
Tue TRABER PROCESS
This system consisted of a method of manufacturing domestic coke from bituminous coalin which coal
was loaded into small vertical metal containers and passed through a long horizontal tunnel heated extern-
ally by gas. An experimental or demonstration plant is said to have been built in Chicago in 1917 and
abandoned after a abort series of tests. It is not considered a feasible commercial process.
PENNSYLVANIA CoaL AND CoKE CoMPANY
Pennsylvania Coal and Coke Company, 17 Battery Place, New York, operators of Pennsylvania coal,
financed an experimental undertaking in low temperature carbonization several years ago. A small plant
was built at Cresson, Pa. which plant consisted of one retort unit of the revolving drum type. It was
operated for a very short period and then abandoned because it did not appear to possess commercial pos-
sibilities. Judging from reports at hand, I should say the total expenditures for this unit were at least
$50,000.
Tue Brown PrRocEss
This system is owned by the Shale Oil Machinery and Supply Company, 342 Madison Avenue, New York.
The retort consists of three units of the revolving drum type set end to end heated externally. The material
to be heated passes through the three drums in series.
The process has been developed primarily for the distillation of shale but is said by the owners to be
suitable also for coal and lignite. No commercial plants have as yet been built so the process must be con-
sidered as still in the experimental stage. It is claimed that the development expenses amounted to
$50,000 to $100,000.
Ture FRANK PROCESS
The Frank process, owned by Thermo-Catalysis Inc. of San Francisco, is a system of distilling coal in a
retort which is heated internally by direct combustion of gases therein. A small experimental plant,
probably of laboratory size, has been built and operated in California, but no reports are available to indi-
cate the probable cost or success attained.
THE ParR PROCESS
Professor Parr of the University of Illinois has interested himself in the matter of low temperature dis-
tillation of coal for many years. He has conducted numerous experiments on a laboratory scale at the
University and has produced much of interest to scientists and investigators although his efforts have not
resulted in a process which could be applied commercially.
JOHNS PROCESS
This process is now owned by the Industrial By-Products Company, 25 Broadway, New York, and is
offered by them as a method of distilling coal, lignite or oil shale. It is said to have been developed in an
experimental plant at Denver, Colorado. The retort consists of a long, narrow chamber set at a slight
incline with the horizontal, the floor of which is heated by gas flames; lignite enters the upper end of the
floor and is propelled along it by the action of a series of metal paddles which swing backward and forward.
According to a prospectus issued to investors, a new company, The Empire Fuel Products Corporation,
has been organized for the purpose of building and operating an experimental and a commercial plant of
this system at Rockdale, Texas with the object of perfecting and commercializing the process. It is my
opinion that the process is still in the experimental stage and that, if the new company carries out its deve-
lopment program, it will be obliged to spend at least $150,000 before it can learn whether the process is or
is not of commercial value.
INTERNATIONAL COMBUSTION ENGINEERING CORPORATION
The International Combustion Engineering Corporation, 43 Broad Street, New York, have during the
last four or five years investigated many low temperature distillation processes, among them the Greene-
Laucks process of Denver. Recently the corporation has retained a consulting chemist of New York to
investigate a German process with the view of conducting experiments in this country. This is mentioned
to show the general interest in the subject; but, since no plants have been built and all of the expenditures
by this organization have been for investigations, I have no means of judging their total outlay.
CONSOLIDATION CoAL PrRopuctTs CoMPANY
The Consolidation Coal Products Company, financed by the Consolidation Coal Company of 67 Wall
Street, New York, has recently been organized to conduct experiments in low temperature carbonization
of coal with the object of producing a smokeless domestic fuel from high volatile bituminous coal. An
experimental plant costing over $100,000.00 has been built at Fairmont, West Virginia, and tests have
been made; but as yet the results of the experiments have not been published. I have been retained by
Messrs. Coverdale and Colpitts, the Consulting Engineers who represent the Consolidation Coal Com-
pany, in active charge of this experimental work.
The projects briefly described in the foregoing paragraphs may be summarized as follows ;
Investigation or research work, no plant...............
Experimental plants — no commercial undertaking.................. 13
Experimental and commercial, or semi-commercial plants which were
Unsuccessful COMMeErCcially es aeee ere ely Men ss ea bol. Sera
BUICCESALIIL COMMMercialplalite. qkorat a roses cae tee oe conan none
246 APPENDIX No. 34
:
I have no means of determining the amounts of capital expended to carry on these various experiments
and enterprises, but for the purpose of this report I have set down a rough estimate, or opinion, as to the
probable cost of some of the important ones. These figures are based on my knowledge of costs for similar
enterprises but aside from that they have no value. The various projects may be summarized as to cost
as follows: .
ATO COAL ewe ee oo kaos eRe ee rrate FTO aaa deto tangle ematte ie Nat -ver eee ip $6,000,000.
| os ne Pe ENE RET, Aa ioe Ataris > cm OF Sn eit OO Ow 475,000.
@reene-Laucks bcs opto te ele on lea taboho cyanea et eae deer ein tees 500,000.
University of North Dakota.........5.2.-.6 2. sere snnneee 100,000.
Wallace 224. oo a er ra tetera tes ene toten elon ci Wenrenn ste 250,000.
Bussey}. oe Soa we ah see eee ails! Oat ee cate ote eee 200,000.
Sum mers 1.55 So Pe eh Sie ee Sh cea ee ee 75,000.
Sterling-Midland Coal / £2: 2.20205 2.35 Soa. sae aes ea pe ate 120,000.
Jones ‘and ‘Laughlin Steels, oi, ov. See ee ee eran 75,000.
Pritchard’; StL ea a i Seo a eer tee ie ed ete 30,000.
Pennsylvania Coal and Coke............+-s seer eee eeeeees 50,000.
PE ET reer h 5 SGA Sm PaO OSG SRLS Gea A 50,000.
Afri tbet Se ED eae si rh 5) Sete ts sc o wade ds'o.O ba 100,000.
Consolidation CoaliProducts Company... sites et erie els 100,000.
Total cost —= my. estimate. s2n sein isieieere rete =e te $8,125,000.
Any error that may be in the above summary is probably on the small side. Total expenditures for the
development of low temperature distillation in the United States has probably cost a great deal more than
the figure set down in the preceding, and yet all this money and time has not accomplished the desired
result — a commercially successful plant: It has produced a vast amount of infinitely valuable information
concerning the art of distillation of coal which may be and undoubtedly will be applied to advantage by
those who still continue in the business.
Very truly yours,
(Sgd.) C. V. McIntire.
APPENDIX No. 33
Appendix No. 33 will be found after p. 263.
-——-. §—__-
APPENDIX No. 34
Professional Records of Members of Staff.
LESSLIE R. THOMSON
EDUCATION AND TECHNICAL QUALIFICATIONS.
Educated Upper Canada College, Toronto, 1900-02, and the University of Toronto, as follows:—
Graduated Mechanical and Elect. Engineering.................e++0- 1905
Degree of B.A. Sc., (Hydraulics and Strength of Materials.)......... 1906
Graduated in Ctvil Emgimeecrings eee: cele ete eas eee 1907
TRAINING AND EXPERIENCE
Seasons of 1905, 1906 and 1907 acted as assistant engineer to the late Joseph Rielle, Montreal, on general
office work, administration, field work, and construction. Lecturer in Civil Engineering, University of
Manitoba, Winnipeg, 1910 to 1912. 1912 to April, 1918, continuously with the Dominion Bridge Company
Limited, in the following capacities: detailer, checker, designer and resident engineer. During this period
prepared designs for all types of buildings, power houses, highway bridges, railway bridges, viaducts,
abutments, etc. In addition was given responsible charge of certain special work, involving combinations
of hydraulic, mechanical and structural engineering, as for example, the large caissons of the new dry
dock at Levis, P. Q. and the design of the Stoney Sluice Gates at LaSalle Street, Montreal.
_ During 1917 and 1918, was in responsible charge of the installation of all the steel work for the new Par-
liament Buildings, Ottawa, under the direction of John A. Pearson, Architect.
April, 1918 to October, 1918, was Secretary of the Honorary Advisorary Council for Scientific and Indus-
trial Research, Ottawa.
October, 1918, to date, Secretary of the Lignite Utilization Board, Montreal.
1920 to date, Special Lecturer in Structural Engineering, McGill University, Montreal.
TECHNICAL SOCIETIES AND PAPERS
Member, Engineering Institute of Canada.
Member of the American Society of ‘Civil Engineers.
“The Rolling and Floating Caissons of the Levis Dry Dock’’ Pres’t.
- to Eng.-Inst. Canada... .i5.<:..5410 ie Lidalanc gn alot a I ek See 1915
Transmission Lines, Poles, and Towers’”’ Presented to the Engineering
Institute of Canada. 2)2 00" cot oe eee 1916
ave Briquetting of Lignites’’ Presented to Society of Chemical Indus-
ry
0 @ Bl 6 A166) 6 6 vere) eh ao, ae) p06
@ 6 \0, 0, ©) a) a 6.6/0) Je, 6) 0g 0) 0. 6.16 's Ses) wn a) Weer phe 60) 66) ares, ale:
APPENDIX No. 34 247
EDGAR STANSFIELD
EDUCATION AND TECHNICAL QUALIFICATIONS.
Honor School of Chemistry, Victoria University, Manchester, B. Se.... 1900
Honor School of Chemistry, Victoria University, Manchester, M.Sec.. 1903
TRAINING AND EXPERIENCE
Assistant Lecturer and Demonstrator in Chemistry at the Sunderland Technical College 1901 — 1906.
Assistant Chemist at the Dominion Iron and Steel Company, Sydney N. 8. 1906 — 1907. Chief Chemist
for aninvestigation of Canadian coals conducted at McGill University, Montreal for the Dominion Govern-
ment, 1907-1910. Chief Engineering Chemist, Fuel Testing Division of the Mines Branch, Department
of Mines of Canada, Ottawa, Ont. 1910-1918. Chemical Engineer to the Lignite Utilization Board, 1918-
1921.
Fuel Engineer, Scientific and Industrial Research Council Province of Alberta, 1921 to date.
PROFESSIONAL CONNECTIONS AND PAPERS.
Fellow of the Chemical Society, (London).
Member of the Faraday Society.
Member of the Canadian Mining Institute.
Member of the Engineering Institute of Canada.
Author or part author of the following papers:—
‘Preliminary Note on the Preparation of Barium’’, Memoirs and Proceedings of the Manchester Literary
& Philosophical Society, Vol. XLVI (1901), No. 4. ‘“‘Spontaneous Combustion of Coal’, Canadian Mining
Institute, 1910. ‘‘Two Simple Forms of Gas Pressure Regulator’? Faraday Society, 1911. ‘‘An Inves-
tigation of the Coals of Canada’’ Mines Branch Report No. 83, Vol. 1, Parts III & VI, Vol. II, Part [IX and
Vol. VI, 1912. ‘‘Products and By-Products of Coal’’, Mines Branch Report No. 323, 1916. ‘‘The Car-
bonization of Lignites’’, Royal Society of Canada, 1917. ‘‘The Carbonization of Lignites’”’ Part II, Royal
Society of Canada, 1918. ‘‘Analyses of Canadian Fuels’’, a compilation in five volumes, Mines Branch
Reports No. 479 — 483, 1918. “Low Temperature Carbonization of Fuels’’, Canadian Society of Civil
Engineers, 1918. Also the following from Mines Branch Summary report: ‘Report on Tests on
Blaugas’, 1910. ‘‘The Determination of Moisture in Fuels’, 1911. ‘‘Report of Tests on Pyrene”’,
1911. ‘‘An Electrically Heated Tube Furnace’’, 1911. ‘‘An Electrically Heated Tar Still’’, 1912.
“Specifications for the Purchase of Oil’, 1911. “‘Lignite Carbonization’’, 1919. ‘‘Carbonization of
Canadian Lignite’’ Journal Industrial and Engineering Chemistry, Jan. 1921.
R. DeL. FRENCH
EpUCATION AND TECHNICAL QUALIFICATIONS
Graduated Worcester Polytechnic Institute, Worcester, Mass., B.Sc... 1905
Graduated Worcester Polytechnic Institute, Worcester, Mass., in Civil
HAIG ITICET IN Gee ener ey. 2 ety ts EELS SOM say ah Rie aN Ate ante Mn OR re 1906
TRAINING AND EXPERIENCE
Draftsman, Assistant Engineer, Division engineer and principal assistant-engineer in charge of design
of sewage system, City of Louisville, Ky. 1908-1910. Assistant and Acting Chief Engineer, National
Concrete Construction Co. Louisville, Ky., on design and construction of re-inforced concrete buildings,
bridges, reservoirs, etc., and concrete pile driving (Simplex system) 1910-1911. Principal Assistant En-
gineer, R.S. & W.S. Lea, ‘Consulting Engineers, Montreal on municipal work, including sewers and
water systems, filtration plants, sewage disposal] plants, pumping and power stations, hydraulic develop-
ment and legal work, 1911-1918. Partner, Arthur Surveyer & Co., Consulting Engineers, Montreal,
1918-1919. Engineer, Lignite Utilization Board, 1918-1921. Instructor in Sanitary and Municipal
Engineering in Faculty of Applied Science, McGill University, 1911-1921. Professor of Municipal and
Highway Engineering, McGill University, 1921 to present date.
PROFESSIONAL CONNECTIONS AND PAPERS
Member, Engineering Institute of Canada, Associate member, American Society of Civil Engineers.
Member, Board of Examiners, Engineering Institute of Canada. Awarded Gzowski Medal by Eng. Inst.
of Can. for paper entitled:
‘““Covered Suction Reservoirs” presented to Engineering Institute of Canada 1918.
H. JOHNSON
EpUCATION AND TECHNICAL QUALIFICATIONS
Graduated McGill University, B. Sc., in Civil Engineering .......... - 1915
TRAINING AND EXPERIENCE
Construction work steel and reinforced concrete buildings and highway bridges, McKinnon-Holmes,
Sherbrooke, Que., summers of 1913 and 1914. Lieutenant, C. E. F. Field Artillery, 1916-1918. _Promo-
ted to Captain 1918. Transferred to Royal Air Force in 1918 —3 years’ service in France — Demobi-
lized 1919. Assistant Engineer, Lignite Utilization Board, Montreal 1919-1921. Transferred to
Lignite Utilization Board’s plant at Bienfait 1921-1922. Severed connections with Board in 1922.
PROFESSIONAL CONNECTIONS
Associate Member, Engineering Institute of Canada, 1921.
248 APPENDIX No. 35
R. A. STRONG
EpucATIONAL AND TECHNICAL QUALIFICATIONS
Graduated University of Illinois, Urbana, Ill., B. A., 1915, BeasSesrre seL015
TRAINING AND EXPERIENCE
Fiel k, Illinois coal mines, 1915. Assistant Chemist and Metallurgist for Dominion Bridge Company,
Tiehine ©. @). "1915-1918. Lieutenant Canadian Engineers C.E.F. 1918-1919. Assistant foreman of
Copper Refinery Dominion Copper Products, Lachine, P. Q. six months in 1919. Assistant Chemist,
Lignite Utilization Board, 1919-1920, Acting Chemical Engineer, Lignite Utilization Board 1920-1921,
Chemical Engineer, Lignite Utilization Board at Bienfait, Sask. 1921 to date.
PROFESSIONAL CONNECTIONS
Associate Member, Engineering Institute of Canada — Member of Canadian Institute of Mining and
Metallurgy — 1921.
I. F. ROCHE
EpucATION AND TECHNICAL QUALIFICATIONS
Graduated McGill University, B Sc.,in Civil Engineering............. 1913
TRAINING AND EXPERIENCE
Assistant to Superintendent of Construction, John 8. Metcalf Co. Trenton, Ont. 1913-1914. Resident
Engineer, Canadian Light & Power Co. St. Timothee, Que. 1914-1916. Test_Engineer, Imperial Muni-
tions Board, Montreal, Que. 1916-1917, Assistant Engineer, Fraser Brace & Co. Montreal, Que. Cons-
truction of wooden ships and LaSalle Bridge, 1917-1919. Assistant Engineer, Lignite Utilization Board,
Montreal, Que. 1919. Resident Engineer on construction of plant at Bienfait, Sask., Lignite Utilization
Board 1920-1921. Resident Manager, Lignite Utilization Board, Bienfait, Sask. 1921 to date.
TECHNICAL SOCIETIES
Associate Member, Engineering Institute of Canada, 1920. Member, Canadian Institute of Mining and
Metallurgy.
W. G. HEPTINSTALL
EDUCATION AND TECHNICAL QUALIFICATIONS
Norton: Grammar: Schoolon vc (sca aie cia oe levetel oeklatcltinetov ah atone acre taftelisite) ats tate 1901
Two years University of London. i.5).0% «ws «ele bie s.5 oe ee see ete se 1903
TRAINING AND EXPERIENCE
British Admiralty 2 years in charge of engine room 1915-1917. In charge of repair shop, British Admi-
ralty 1917-1919. Operated electric light plant, Town of Minnedosa, Man. 1919. Operated light and
power plant, Town of Yorkton, Sask. 1920. Mechanical Superintendent at Bienfait, Sask., for Lignite
Utilization Board plant from 1920 to date.
TECHNICAL SOCIETIES
Member of American Society of Mechanical Engineers............... 1921
Member of Canadian Institute of Mining and Metallurgy
APPENDIX No. 35
Lignite Utilization Board of Canada
To those who may become interested in a business way in the activities of the Lignite Utilization Board
of Canada the following information is addressed:
Constitution — The Board is created by an Order-in-Council of the Dominion of Canada supple-
mented by an agreement, as to finances with the Provincial Governments of Manitoba and Saskatchewan,
by which the three governments have appropriated $400,000 for the use of the Board.
Business Status — In its relation towards business interests, the Board has the powers of an incorpor-
ated company to buy, sell, make contracts, hold property, etc. In its relation to the Government, it is
a poet holding and expending funds provided by the governments, and having power to hold property
in trust.
REASON FOR CREATION OF Boarp — The citation of part of the Order-in-Council will give clearly
the reasons for the creation of the Board: . = i
“That there are large deposits of lignite underlying various districts of the Provinces of Saskatchewan
and Alberta, some of which, in the raw state can only be utilized when freshly mined, and are, more-
over, unsuited in such state to household use;”’
APPENDIX No. 36 249
.
“That by carbonizing this lignite, a coke or charcoal is obtained which briquettes readily and, without
consideration of the by-products such as oil, pitch, ammonia sulphate, gas, etc., the result is to turn
two tons of inferior fuel into one ton of briquettes approximating, in heating value, anthracite coal
with practically the same heating value in the domestic furnace as the two tons from which it was made;”’
IMMEDIATE OBJECTIVE — The immediate objective of the Board is the carbonizing and briquetting
of the lignites of southern Saskatchewan for domestic use.
PROGRAMME — To reach this objective the following will be the steps undertaken:
(a) -More'softicoal.will becused)... . fac a. a. eeba ene 47% 29% 35%
2. Proportion of anthracite sold will be the same as
DIS VIOUSLLONUNOSWHT ret at sco tcn. eos oe beeerons 47 67 61
3. Soft coal will replace wood, but not anthracite,.. 4. 0 1
44 No reply, inGgenmitesecc.s. see. ee ee ee ee 2 4 3
QUESTION V.
i Pricelisithe dominant factor,... 46 2 ose 31% 17% 21%
2. Quality, convenience, etc., are the dominant
FACLOTS capaelts «(eee RN ok haan Roe 45 67 61
3. Both price and quality, etc., will be considered.. 20 10 13
45 NO reply, AMaenniterelG.anccaicche oes be. Ua ane 4 6 am
252 APPENDIX No. 37
It seems to me that certain broad conclusions may be drawn from the figures of the above table
although it must be admitted that these data are unrefined.
Considering the replies to Questions I and Il, apparently the people of Manitoba were more successful
in adapting their existing heating apparatus to the use of Alberta soft coals than were those of Saskatchewan,
and possibly more adept in its operation with these fuels. A partial explanation of this difference may be
found, perhaps, in the differences between the populations of the two provinces. 56% of Manitoba's popu-
lation is rural, while nearly 75% of Saskatchewan’s population lives outside the cities and towns. Thus,
there are undoubtedly proportionately more furnaces, steam boilers, hot water heaters, etc., in Manitoba
than in Saskatchewan, where the old fashioned base burner is still the standard heating apparatus for the
greater part of the population. Individual replies to this question have ranged from the highest eulogies
of soft coal to its absolute condemnation. The majority, however, have apparently been well considered,
and I believe that they represent fairly the general opinion of the coal dealers and reflect fairly the opinions
of the coal users.
In the replies to Question III, it is apparent that, practically speaking, there are no special devices for
the combustion of soft coal which have proved entirely satisfactory. One firm offers a hopper feed attach-
ment for the ordinary furnace or heater, but the few reports as to its use indicate that it is not completely
successful. Another firm has developed a magazine feed stove which seems to work well. The genera!
introduction of this device has been hampered by its price, which is referred to as ‘‘unreasonably high’’
The replies to Question IV are noteworthy, as they indicate a substantial difference in opinion as to the
future of soft coal. The dealers in the cities and larger towns are about evenly divided as to whether or
not soft coal will be able to hold any substantial portion of the market into which it has been forced during
the past season. In the rural districts, on the other hand, the majority of coal users prefer anthracite, and
will insist on having it regardless of price, if it is at all procurable. In this connection, it may be noted
that there have been numerous complaints against the preparation of Alberta soft coals, one dealer going
so far as to state categorically that one-third of his shipments consisted of slate, bone, clay, dirt, etc.
Turning to Question V, it is surprising to see how little weight the price of coal is given. Briefly expres-
sed, the general attitude is that the objections to the use of soft coal, such as its dirtiness, inability to hold
fire, excessive attention required, etc., are so great that the majority of users would gladly pay a much
higher price for a more uniform, cleaner, and more easily handled fuel.
Although the dealers were not asked to express any opinion regarding briquettes, nevertheless, a number
did so. Referring to the ‘‘Bankhead”’ or ‘‘Banff” briquettes, the opinions expressed were generally favour-
able. One dealer emphasized the favourable condition of the market, which led him to believe that pre-
pared lignite briquettes would meet with a warm welcome from the consumer.
I believe that the results obtained from the circulation of this questionnaire bear out the opinions I
expressed in my report to you of February 8th, namely, that although soft coal has become a much more
important factor in the domestic fuel situation in Manitoba and Saskatchewan during the past season, yet
the demand for high-grade fuel is such that this market would easily absorb all the prepared lignite bri-
quettes which are likely to be manufactured during the next few years.
All of which is respectfully submitted.
R. De L. FRENCH,
Engineer.
COPY OF QUESTIONNAIRE CIRCULATED IN MANITOBA AND SASKATCHEWAN
1. Is soft coal being generally burned in the same appliances as were formerly used for anthracite?
Has the burning of soft coal in these appliances been a success ? What has been the general experience
of your customers with soft coal as compared with anthracite?
3. Are any special or patented devices for burning soft coal in use among your customers, such as special
furnaces, underfeed hopper feeders, etc.? What are they? Have they given satisfaction? If not, how
have they failed?
4. Assuming that conditions as to prices and supply of all kinds of coal return approximately to where
they were before the war, do you look for soft coal to retain any considerable part of the trade in future ?
Or do you think consumers will go back to the use of the same proportion of hard coal as previously ?
5. What do you consider is the governing condition that would influence consumers to use hard or soft
coal? Is it the price or is it the actual burning and heating qualities of the coal?
to
APPENDIX 37
Laboratory Experiments on Lignite
Agreed Upon at 3rd Meeting of Lignite Board — Feb. 10th, 1919.
StoraGE, Etc.
1. — Investigation of the relative weathering and storing qualities of raw, air dried, oven dried and
carbonized lignite.
Experiments at Ottawa on absorption and evolution of water; probably completed by March 1.
Experiments at Toronto University on Physical and Chemical absorption of oxygen; probably
completed 1920.
Important results may be obtained and interim reports may guide commercial development;
but latter could safely proceed without waiting for these results.
CARBONIZATION.
2. — Heat of carbonization. Determination of the quantity of heat required to complete carbonization
at any temperature. Now in progress, probably completed by March 15.
APPENDIX No. 38 253
Results essential to good design of retort, also will indicate necessity (or otherwise) for supple-
mentary gas supply. Results will be ready in time for commercial development.
3.— Rate of carbonization. Determination of the rate of carbonization of lignite under such varied
conditions as in high or low temperature retorts with stationary or moving charges. Work now
in progress, and some results already available. Experiments preliminary to erection of shaft
retort (see 5) completed by March 1; if the Board decides to proceed with the design of a commercial
size of rotary retort, the necessary further work might be completed by June 1.
An bel trier 2 rotary retort, complete except as to its heating furnace, is available for the work
of 3 and 4 and for ecarbonizing lignite for briquetting tests.
4.— Atmosphere during Carbonization. Investigation of the effect of the presence of steam, lignite
gas, furnace gasses, etc., in the retort during carbonization on the product of carbonization. Not
now in progress, might be completed by September 1
ker of this work has its main importance in the provision of data for the scientific “laying of
gzhosts’’.
5. — Stansfield’s retort. Test of small model of suggested high temperature shaft retort. This to
be Fee on oak at doors with rough shed cover. Delay start to obtain preliminary patent protection
and results of 3
Probable completion April 1.
BRIQUETTING.
6.— (a) Investigation of the relative suitability for briquetting of lignite carbonized at different
temperatures.
(b) Investigation to determine the best fineness of material to be briquetted.
(c) Investigation of the available binders. Eight or nine types of binders have been suggested,
but this list could now, or very shortly, be reduced to three or four. It will be necessary, however,
to test samples of varying hardness of such binders as oil or coal tar pitch.
(d) Investigation as to mixers, principally testing grinders versus paddle mixers.
Amongst the essential facts to be determined before finally embarking on commercial development
are the quantity of binder necessary, and the possible rate of operation of a press, to make satisfactory
briquettes. As soon as it is established that these fall within the limits of economic possibility
determined by a revised estimate of fixed and operating charges the Board could commence commer-
cial operations.
Preliminary work on briquetting problems have been in progress for months and will be carried
on. No dependable results can be obtained on many points until a power mixer and roll press are
in operation. This cannot be before April 1. The time taken then to establish economic possiblity
will depend entirely on the difficulties encountered.
After the above is successfully completed, further experiments should be carried on, possibly
continuously until the work is transferred West, in order to reduce to the minimum the experimental
and adjustment work to be done in the commercial plant.
7. — Heat Treatment of Briquettes. Investigation as to the feasibility of, and best method for rendering
briquettes smokeless by heat treatment.
This work will be carried on simultaneously with 8. If the Board decides to make a smokeless
fuel the results obtained will be as essential as those of 6, and the two problems will be inseparable.
Proof that the briquettes made can be carbonized should be available without further delay. Design
of a satisfactory retort for heat treatment may require further experimental work, and time, but
this need not delay the preliminary work in the West.
8.— Tests on Briquettes. Investigations on the commercial value of the briquettes made, by such
test as determinations of the fines made by handling, of the water absorbed and deterioration ob-
servable on storing in the open, and of their behavior in a furnace. This work will be carried on
simultaneously with 6 and 7 and will cause no further delay.
APPENDIX 38
Short description of Ottawa Experimental Plant
By R. A. Strona.
In order to carry out the experimental research which was found to be necessary before a plant could be
erected to demonstrate commercially the process of carbonizing and briquetting the Saskatchewan lignites,
the Lignite Utilization Board made an agreement with the Mines Branch, Department of Mines, Ottawa,
whereby this work was to be carried out in their laboratories located at the Fuel Testing Station. A small
experimental plant was built adjoining the station, and the necessary. machinery acquired and installed
for briquetting investigations. This plant was designed for batch mixing only, in order that all possible
binders could be tested, and such variables as enter into a briquetting process thoroughly investigated.
The specific objectives of this investigational work are given in appendix 37 and the experimental plant
layout is shown in Figure No. 3.
The crushing equipment consisted of a small roll crusher with corrugated rolls, and a ball mill. With
this equipment any desired screen analysis was obtainable, and experiments were "made to determine that
which gave the best briquette.
The mixing ppparakiy consisted of asmall Werner and Pfleiderer steam jacketed kneading machine, and
a large horizontal mixer of original design. The former machine was used for small batch mixing in exper-
imenting with various binders. By reason of its small capacity, which was eight pounds, a nunber of tests
254 APPENDIX No. 39
could be made under different conditions of temperature and time of mixing. Steam for this mixer was
supplied by a small boiler and connections were so arranged that steam could be blown into the mix as well
as circulated in the jacket. The larger mixer was a single shell machine with two ribbon conveyors which
served to mix the material and move it toward the center where it was discharged. The heating was
accomplished by a series of gas burners directly beneath the mixer. This machine was used for larger
batches as its capacity was approximately 50 pounds.
The press purchased was a Mashek, type Y-1, roll press which contained three rows of pockets on each
roll. The capacity of the press was 31% tons per hour and the briquettes produced were pillow shaped,
weighing 114 ounces. This type of press was selected on account of it being the smallest commercial
machine possible to secure, and because the results obtained with such a press would be applicable to com-
mercial operations with larger apparatus. A removable division in the press hopper was made in order
to eliminate two rows of pockets on the rolls for use when experimenting with small batches.
In addition to the above equipment a small dryer was installed which was operated for the production
of dried lignite used in the carbonization experiments. A drying plate, gas meter, and work bench com-
pleted the installation.
The work conducted in the Ottawa laboratories and experimental plant extended over a period of nineteen
months. The carbonization researches had been started prior to the creation of the Board, and from its
inception until the completion of the demonstration plant at Bienfait these experiments together with
briquetting investigations, were continued. The results of the carbonization experiments are given in
appendix 18 and the results of the briquetting investigations are fully described in Section VIII of the
Secretary’s report.
——— § ---——
APY EAN Tee
Minutes of a meeting of the mine managers and operators of the Estevan Bienfait area with
the Lignite Utilization Board, held at Estevan, Saskatchewan on Wednesday October 8, 1919.
Present:—R. A. Ross, Esq., Chairman, Lignite Utilization Board.
Hon. J. A. SHEPPARD, Member, Lignite Utilization Board.
J. M. Leamy, Esq., Member, Lignite Utilization Board.
W. AppiEz, Esq., Resident Manager, Manitoba & Saskatchewan Coal Co. Bienfait.
A. Miuuar, Esq., Resident Manager, Western Dominion Collieries Ltd. Taylorton.
R. Hazarv, Esq., Bienfait Mine (Hosmer) Bienfait.
M. Hawkxrnson, Esq., Bienfait Commercial Bienfait.
H. Peterson, Esq., Coal Brick & Power Co., Shand.
Couin A. MANLOVE, Sec’y, Estevan Board of Trade.
F. W. Newcomse, Estevan Coal & Brick Co. Estevan.
Lxressitie R. THomson, Esq., Sec’y Lignite Utilization Board.
MINUTE 1
The meeting was called to order at 10 A. M. the chair being taken by Mr. Ross, who outlined, in opening,
the history and present position of the Lignite Board. Mr. Ross further stated that the Board were
taking this opportunity to consult the mine managers with the object of asking for certain information
and advice on a number of points which would be discussed in order.
A. — Location and site
The Chairman called the attention of the meeting to the importance of the question of site, owing to the
fact, among others, of the variation of the ash content of the different mines. It was planned to produce
roughly 100 tons of finished briquettes per day, and this would require from 250 — 275 tons of raw lignite.
The capacity of the existing mines to supply this demand was discussed. The other important factors
affecting the choice of location, would be freight charges in bringing raw material to the plant; freight
charges in delivery of finished product to railway; water supply drainage; and housing.
B. — Raw Material
W. Addie, of the Manitoba and Saskatchewan Coal Co. Ltd., stated that, from their mine there would
be no difficulty in getting during the winter, all the small sizes needed, say 30,000 tons, but during the
summer it would be only possible to obtain run-of-mine. The price for the three small sizes would be from
$1.50 to $1.60 F. O. B. mine. Run-of-mine coal would cost $2.60 F.O.B. Mine. Mr. Millar of the
Western Dominion Collieries, Ltd., agreed that the summer demand for small sizes was large. The fol-
lowing is a tabulated list of the commercial sizes used by the Western Dominion Collieries Ltd., and the
Manitoba and Saskatchewan Coal Co., Ltd.
From 2-14” up...... earitiarees Lump
In the Hosmer mine they use only three commercial sizes, as Pea and Cobble sizes are mixed.
C. — Storage
Mr. Addie stated that if lignite were stored in the open in any quantity, fire would be certain to start
sooner or later by spontaneous combustion. H. Peterson disa d with thi i
that fire was most likely to start in April and May. Be ee ee eae
APPENDIX No. 39 255
Regarding the desirability of using air-dried lignite, Mr. Addie stated that his experience with air-dried
lignite was not as satisfactory for boiler purposes as freshly-mined lignite. He quoted, as an example, the
experience one of his firemen had had with one of the boilers. While using air-dried lignite, on chain
grate stokers, it was impossible to keep up a certain pressure, but immediately after the firemen had soaked
the lignite with water by means of a hose, no difficulty was encountered. Mr. Hawkinson’s experience
agreed with Mr. Addie’s in this regard.
In closing this point, the Chairman agreed that storage should be avoided, if possible.
D. — Water Supply
The Chairman pointed out that the possible requirements of the Lignite Board, would be about 100,000
gallons per day. All present agreed that wells are not a feasible source of supply for this amount of water.
Newcombe stated that in Estevan, the C. P. R. in addition to having access to the municipal supply,
has installed a pumping unit and a 6” pipeline from the Souris River.
Mr. Addie stated that they only found it necessary to use their pump from two to three hours per day,
and also (speaking from memory) that the capacity was about 300 gallons per minute.
Mr. Millar stated that they got their water from the Manitoba and Saskatchewan Coal Co. and the
price (speaking from memory) was not more than 10 cents per 1000 gallons.
Mr. Addie stated that two miles of 6”” pipeline had cost in 1912 — 1913 about $12,000 — $13,000.
KE. — Housing
The population of Bienfait is three to four hundred persons. Mr. Addie’s company owns sixty to seventy
cottages. The population of Roche Percee is seventy to eighty. The population of Shand is about one
hundred, while from Pinto, all have departed.
The Western Dominion Collieries mine has a population of about two hundred.
At the Manitoba and Saskatchewan Coal Co. there are twenty-five to thirty houses costing on the
average about one thousand dollars, ($1000.00). These cottages possess concrete foundation and are
finished with clapboard and plaster. There are also better class houses costing about two thousand dollars
($2000.00), details of which are to follow. Mr. Addie charges for the cheaper cottages, four dollars per
month plus one dollar for coal supply and 50 cents for delivery. For the better class cottages, eight dol-
lars per month plus one dollar plus 50 cents. Mr. Addie called our attention to the fact that their company
had placed no restrictive regulations on the keeping of live stock etc., etc., by the employees. In this
way, most of the employees keep themselves supplied with meat, eggs, etc. In addition they have the
privilege of raising all their own vegetables in garden plots plowed at the expense of the company. Some
years ago, Mr. Peterson built some brick cottages for six hundred dollars but reeommended that the Board
should expend about two thousand dollars on each house, otherwise employees would be apt to become
discontented. Mr. Peterson rents his cottages at from seven to ten dollars per month.
F. — Labour
All labour in the Estevan — Bienfait area is on a ten hour shift basis, Pay is usually fixed by the rates
paid by the C. P. R., who at present are paying forty cents per hour. The Manitoba and Saskatchewan
Coal Co. however are paying at present 32-14—35 cents for surface work and 35—37-\% for underground
rer There are no miners’ unions whatever in the district, nor are there any general unions for other
trades.
G. — Shipping
The shipping charge between the mines and Bienfait on either of the spurs is three dollars per car (equi-
valent to 10 cents per ton).
H. — Market
Mr. Addie’s opinion is that the ordinary farmer will not buy lignite briquettes in any event, and the cities
Mehta aaa the real markets. On the other hand, Newcombe feels that the farmers will constitute a fairly
good market.
I. — Board’s property
The Chairman, in closing the meeting, called attention to the desire of the Lignite Board to locate their
plant over as good a quality coal seam as possible, so that in the event of any combination being arranged
of competing interests to refuse raw material, the Board would be in an independent position so far as raw
material is concerned.
The meeting adjourned at 12:10.
APPENDIX No. 40
256
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APPENDIX No. 41 257
APPENDIX No. 41
Journal of Thomson’s Visit to Mr. O. P. Hood, Washington
Montreat, November 10th, 1922.
Left Montreal, Rutland, 8.00 p. m. Tuesday, November 7th, to interview O. P. Hood, Chief Mechan-
ical Engineer, Bureau of Mines, Washington, D. C.
Picked up Mr. C. V. McIntire at New York, Pennsylvania Station on Wednesday the 8th, and arrived
Washington about 1.45. Proceeded at once to Bureau of Mines.
Opening interview, Mr. Hood outlined the history of lignite development in the Bureau that led to
his recent trip to Germany. Sketched briefly this outline is as follows.—
Work at Hebron, Grand Forks and Philadelphia had convinced Bureau that carbonization of lignite
and briquetting the char was a process that had now become possible and workable. While further
research might be necessary, no further doubt existed as to ultimate success if work be prosecuted
with vigor. Large capital is needed, however, for necessary plant. It is difficult to go to a man
with paren $50,000 invested in a mine, and say to him that by an investment of $1,000,000 he could
save his slack and fine sizes. Bureau kept constantly looking for other and alternative solutions in
order that they might serve the public. Briquetting is one solution, but there should be others with
different objectives, available. Bureau had read naturally great deal of success of German methods,
German apparatus, etc., etc. Hence decided to make personal investigation.
As a result of research work by Bureau they are now convinced that they can burn lignite char without
briquetting it by means of a special base burner. In brief the details are:—
Carbonized lignite is used in this burner in the sizes between split rice and split wheat. About 20%
of it should go through a 16 mesh seive. The success of the burner was due to previous researches
on zones that occur in a 6” or 12” bed of burning fuel. The important fact to grasp in connection
with this research is that in a bed thicker than 3” the oxygen in the air coming through the fire is
absolutely used up. The upper zone in fire bed in a burner with a deeper bed than 3” is practically
a producer, hence a glowing lignite fire can only be obtained by a thin fire. This bed must not be
thicker than about 214”.
European psychology in regard to heating and burning of fuel in houses is vastly different from Amer-
ican psychology. In many cases either due to poverty or to want of personal experience with other
methods, Germans are content with a small amount of heat in their houses — quite insufficient to
warm a whole house, and often insufficient to warm a part of any givenroom. This distinction must
be clearly grasped. None of the German stoves burning either briquettes or lignite char would
satisfy an American householder for one instant. The American demands a radiant fire and
pea of heat, something that he can see as well as feel! He wants his house thoroughly heated but
e also wants to sce some radiancy in his fire. Hence the following notes on German practice, etc.
are of interest from the point of view of general information rather than from the point of view of
their applicability to our conditions.
Last year Germany produced about 400,000 tons of lignite char for domestic consumption. This, in
the main, was burned in porcelain stoves or in the new type of stove looking not unlike an American
refrigerator. In this stove, the burning is done in a drawer — hence the nickname of — ‘‘bureau
drawer’. In this drawer the lignite char burns slowly or perhaps smoulders. So far as Mr. Hood
is aware no lignite char was briquetted in Germany. The brown coal briquetting industry is an
industry for briquetting raw lignite entirely.
The German brown coals are very different from our own lignitic coals. Mr. Hood believes they possess
distinct structural difference in which opinion the Lignite Board concurs. Mr. Hood stated from
his experience in Germany, that no German brown coa!, containing less than 244% bitumen, was
considered to be applicable for briquetting raw. Assuming for the moment that German and American
nomenclatures are the same, the tar in our lignites does not run over 14%%.
Mr. Hood next touched lightly on the mining methods used. He emphasized the fact that owing
to the difference in the characteristics of German brown coals and American lignites, there was an
absolute divergence between German and American practice in the mining, handling, storing, car-
bonizing and briquetting. Many of the lignite beds are deposited in streaks or layers, alternately
a dark brown layer and a light colored layer. In cases where deposits of this nature occur, the method
practised is to briquette raw the coal from the dark colored layer and to carbonize the light colored
coals. These light colored coals contain about 13% of bitumen paraffin compounds, and the resulting
recovery of these furnishes materials for a considerable percentage of the world’s supply of paraffin.
It is said that about 2/3 of the candles of the world are made from this paraffin. The char resulting
from haa a ee ble at is the material that is supplied for burning in the ‘‘bureau drawer” stoves above
mentioned.
The ovens used for making this light colored coal are standard, and resemble large tall chimneys,
diameter of each 114 meters, and are about 10’ centre to centre of chimneys. Surrounding the central
space of these chimneys are spiral flues heated by gas. Each chimney contains about 500 sq. ft. of
heating surface and has a capacity of about 5 tons of raw lignite per day. The passage of the lignite
through the retort is accomplished and controlled much as in the Rolle process.
In summing up the general impression of his visit, Mr. Hood was quite emphatic in stating that it
was his opinion that no imported solution was going to be successful for our problem here. We would
Beg > work it out along our own lines by methods suitable for and appropriate to American
conditions.
Mr. W. W. Odell was next called in and we had a pleasant conversation with him during course of
which he outlined to us the work of the Hood-Odell carbonizing kiln at Grand Forks, which had been
successfully tested by several long runs (as for example — 50 hours and 100 hoursruns). The retort
is an internally heated affair and the carbonizing is accomplished by the heat generated by the burning
of the gas and of a portion of the charge. The general features of the oven are shown on sketch
No. 1 preparedby Mr.C.V. McIntire. Consumption of lignite necessary to carbonize remaining
charge is about 5%, and not morethan10%. Capacity is 16 tons per day of raw lignite. I regar
this retort if successful as a very age bake contribution to the development of the lignite industry.
Mr. Hood stated that he is having chemists look into the question as to whether the German terms
“paraffin,” “bitumen,” etc. mean the same thing as they do when used by ourselves. Mr. Hood
stated that he would let us know the answer in due course.
258 APPENDIX No. 41
CEVA TUF
STRcK
G'- be
< Zz \o'- 6" High
aE ae Lis ob Ct
CARSOMZING Kiiw
Ce NS ON NEw Yor«
Nov. . 92
SKETCH No. 1. . (922,
APPENDIX No. 42 259
\
13. I mentioned to Mr. Hood that we were getting a complete line of German and Australian lignite
samples, and would be glad to furnish him with some on its arrival. I told him that the Australian
lignite samples would be here at any time now, but that the German samples might take some little
while yet owing to the fact that the matter was being arranged for us by the Canadian High Com-
missioner in London.
14. I told Mr. Hood that L. U. B. was in thorough accord with his idea that carbonizing and briquetting
was only one of other possible solutions.
15. Left Washington at midnight, reaching N. Y. on Thursday morning and Montreal on Friday a. m.
the 10th.
Nore:—A copy of this journal was sent to Dr. Charles Camsell, Deputy Minister of Mines, Nov. 13, 1922.
rams!
APPENDIX No. 42
Course of Action Recommended by L. U. B. in December 1922,
with Analysis and Digest of various Alternatives Facing the Board at that date.
RECOMMENDATIONS.
In view of the present position and of the accomplishments of the Board, and in view of the ultimate:
necessity of providing domestic fuel from the lignite deposits of the Canadian West, the national importance
of which demands a solution at some time, somehow, by some body, the Board reeommends:—
(a) That a period of 4 to 6 months of plant operation be entered upon practically immediately, even
though said operation cannot be undertaken on a purely commercial basis.
(b) That the Board procee tdo requisition the three Governments for the balance of the money they
asked for in February 1922.
The reasons that led the Board to make the above recommendations are developed in the balance of
this report. In order to make it brief, everything has been condensed to the smallest space.
ARGUMENT.
The proper procedure to undertake at the present time will be ascertained most easily :—
(a) By making a brief digest of the real present position of plant and of the affairs of the Board.
(b) By stating afresh the objectives the Board set out to reach.
(ec) By comparing how closely the results obtained have approximated the original objectives.
(d) By determining what courses of action will most rapidly fill in any gaps that may be discovered
between accomplishments and objectives.
PRESENT PosiTION OF BoarD.
PLANT
DEPARTMENT CONDITIONS
Raw Lignite Handling Satisfactory.
Carbonizers Not yet successful, but on other hand not a proven failure. So far our
faith has been pinned to one retort only. Other possible retorts have
been developed during past few months, however.
Briquetting Mechanical layout not entirely satisfactory but machinery can be made
to go if determination be shown. Good briquettes have been produced
now.
Cooling Satisfactory. 5
Storing 1Oe ALES i bi
Paekr ee j Satisfactory. ¥e pr:
Matar Supply and Sewage. Satisfactory.
Above represents situation of Plant. : :
Present situation of business end of Board’s project is:—
Staff and Organization Satisfactory and economical
Marketing Not yet attempted but no great difficulties anticipated.
Costs Present costs worthless
OpsEecTIvES OF BoarD.
(a) The Board’s objectives are to demonstrate a process of producing a carbonized lignite briquette
for domestic consumption.
(b) To determine commercial costs during such demonstration.
260 APPENDIX No. 42
RELATION OF ACCOMPLISHMENTS TO OBJECTIVES.
(a) The Board has not yet demonstrated a process.
plant on continuous operation.
Not one pound of lignite has gone through the
(b) The Board has not yet been completely successful in carbonizing. On the other hand it has made
very large strides towards success.
(c) The present costs are of but little value.
PossIBLE CourRsES or ACTION
There are apparently four and four only courses of action open to the Board.
1. Yo shut down the plant completely and immediately, wind up the Board’s affairs, and report to
the governments concerned.
. Tostop temporarily and revise the plant to suit the ideas and opinions developed within the last
few months, and thereatter make another attempt to operate.
to have some studies made of alternative retorts in case success should not attend our present efforts.
2
3. To concentrate on one part only of the plant, — say carbonizing — and solve it. At the same time
a
. To embark almost immediately on a continuous operating period, irrespective of cost, and to con-
centrate all efforts at producing maximum quantity of briquettes. At the same time gather inform-
ation on the possibility of other retorts.
This operating period should be from 4 to 6 months’
duration — depending on life of our 3 retorts under service.
DISCUSSION OF ABOVE CoursEs OF ACTION.
(a) Discussion of Course 1.
The Board believes the first course of action to be untenable because the Board can only state that it
regards the work to date as fairly successful though distinctly unfinished.
(b) Discussion of Course 2.
Present information would enable Board to make certain changes of which we are sure — for example —
in the briquette building. The Board believes it to be an open question whether enough fresh knowledge
has been gained to justify the Board in attempting immediate changes on the carbonizers. To sum up
the discussion, the reasons pro and con are tabulated below.—
For Course 2.
You obtain certain improvements in plant and
thereby increase chances of ultimate smooth run-
ning.
Economical.
AGAINST COURSE 2,
Changes of which we are sure are not absolutely
essential.
Lack of knowledge to make more far reaching
changes.
Delay — involving a large increase of public cri-
ticisms. Hence more difficult for obtaining
balance of money.
Delay might run to a whole year.
No briquettes produced.
The Board believes the balance of argument is in favor of rejection of Course 2.
Discussion of Course 8.
Course 3 presents many attractive features. The complete discussion of it can be summed up in tabular
p
form:—
For CourseE 3.
AGAINST COURSE 3.
Kconomy :
Almost sure solution of carbonizer problem because
on full seale, and efforts concentrated.
Alternative carbonizer available at end of period.
No briquettes produced.
No continuous process.
No costs of value. Public not encouraged. In
fact sure increase of public criticism.
The Board believes the balance of argument is in favor of rejection of Course 3.
Discussion of Course 4.
We next consider Course 4. Again the reasons are tabulated.
For Cours 4.
Continuity of process. Briquettes are produced.
Data on real life of retorts. We determine whe-
ther plant is an articulated whole. Public ap-
proval on sale of briquettes with resulting improve-
ment in chances of getting further financial sup-
port, hence complete objective of Board. If our
retorts a failure, then we have an alternative ready
if possible.
AGAINST COURSE 4.
Costs will be very much higher than they should
be, in fact operation will not be commercial.
The Board believes that balance of argument is in favor of the adoption of Course 4, provided financial
conditions permit.
APPENDIX No. 43 261
APPENDIX 43
Data SHEETS.
No
I Diagram showing relation of mixing ratio to ‘‘Percent Binder’’.
IT Western Freight Rates on Coal (J. G. 8S. Hudson).
Itt Binders (3 sheets).
IV Effect of Heat on Concrete.
V Coal brought into Winnipeg, May 1918 to Jan. 22, 1919,—P. Brereton (2 sheets).
VI Provincial Fuel Controllers.
VII Weight of Gases.
VIII Description of samples and analysis — McLean’s samples from Estevan Field (4 sheets)
IX Color and Temperature.
ON Analysis of Canadian Coals — Bulletins 22-26 Mines Branch, Stansfield & Nicolls.
XI Composition of coals — Tech. paper 76, U.S. Bureau of Mines.
XII Summary of Binder Experiments — E. Stansfield (2 sheets).
XIII Survey of Briquetting plants visited on Investigatory trip.
SY Bibliography of briquetting (3 sheets).
XV Map showing producing coal fields of Canada.
XVI Products of Carbonizing one ton of lignite from Sask. Coal, Brick and Power Company’s
mine, Shand, Sask.
XVII Balance sheet — carbonization of raw lignite from Sask. Coal Brick and Power Company’s
Mine, Shand, Sask. (2 sheets).
XVIII Composition of lignites, Bulletin 22, U.S. Bureau of Mines.
XIX Loss of heat through furnace, walls — J. Bied.
xX Boiler tests — Regina Municipal Power Plant — Feb. 18, Mar. 15, 1917.
XXI Physical properties of refractories (2 sheets).
XXII Heat transfer through walls (Alfred Stansfield).
XXIII Notes on carborundum refractories (2 sheets).
XXIV Effect of heat on Iron and Steel (prepared by H. W. Craver).
XXV Radiation of Heat (3 sheets).
XXVI Useful Equivalents.
XXVII Rapid lignite carbonization (in muffle at 1472° F.).
XXVIII Drying and Absorbtion curves for pulverized lignite in 60% Humidity air.
EEX Carbonization curves (3 sheets).
XXX Analysis of Shand lignite, Raw, Dried and Carbonization.
XXXI Carbonized residue, lignite carbonization.
XXL Gas results, lignite carbonization.
XXXIII Tar results, lignite carbonization.
XXXIV Products per short ton of different lignites from Estevan field.
DOO Form for screen analyses.
XXXVI Water Analysis from Bienfait.
XXXVII_ Records of briquetting experiments — series 96-147.
XXXVIII Nozzle discharge curves.
1 COO.4b. Screen analysis of coal briquettes.
XL Analyses of briquettes.
SOE Sereen analyses of Crushed lignite.
XLII Screen analyses of Carbonized lignite.
XLIII wey Ber Sections of Taylorton Lignite Field to accompany notes by A. MacLean Dee. 2nd,
0
XLIV Notes on Water supply — Souris district — A. MacLean.
XLV Information on lignite areas in Taylorton Dist. A. MacLean (2 sheets).
XLVI Chart of screen analysis of raw lignite.
XLVII Briquetting results — carbonized Novy. 19th, 1919 (2 sheets).
AXLVIII Air drying of carbonized lignite briquettes.
ele Analysis of composite charge and discharge samples.
L Gas data — vapor pressure of water.
Il Gas results — Moist Shand lignite.
LII Gas results — Comparative series.
TALLY Perfect combustion in air.
LIV Results General Briquetting Co’s briquetting tests.
LV Chart kind of coal B.T.U. percent by weight.
LVI Tests on briqueetes.
TVuL Sereen analyses of carbonized residues (Lignite in batches used in table LVI).
LVIT] Chemica! analyses of carbonized lignite (Lignite in batches used in table LVI)
LIX Minimum angles of slip.
LX Tests on firebrick — ‘‘Claybank”’ and ‘‘Clayburn’’.
LXI Comparative analyses of briquettes and coals.
LXII Classification of coals.
LXITI Physical charateristics of lignite tar.
LXIV Analyses of lignite ash.
LXV House heating test.
LXVI Freight rates on Western Canadian Coal.
262 APPENDIX
APPENDIX No. 44
General Ledger Trial Balance. December, 31st 1923,
General Expense Group
Engineering Administration
No. 44
Account A10 Office Supplies, Misc. Expenses. .
11 Rent, ight, Taxes & Insurance
. 12 Petty Cash 2033 22st rd aarti
of 13 ~Salaries}.5. 4% poe rch teen ha aie ere
si 14 Reports, Investigations, Legal Fees...
Travelling Expenses
Ac count B20 Members’of Board. 23.0.0 aa. ere oe
21 “Membersiof Stati... oe iee
Miscellaneous
Ace ount D40 Miscellaneous Expense..............
41. Interest and Exchange. jes eases
Cash
Bank‘ of Montreal... srt nice oe oie <0 eee ee ee
Liabilities to Governments
Appropriations
Dominion Government... .... 47s eee ee eres
ae
Saskatchewan
Manitoba
ee
Earnings
Interest and Discount
Inte rest. on Savings: Account: 16) 0 ab [co 0 6,0 6) 8 6 Cs el puss,
#616 @ e-iy ea) se) 0)
Los Jal.s) ogo wrens:
6) 2a tee. bee le letele
© ¢ 6.836 Pl ele ego's
a Wheon se \6! bie wie es
me ae 68 a) Scene ie
way ere PORE Cc et
@ 86 vu e016 6 8 8
Ce OMe Wecas Taran ya
ee eee
Dr:
$7,220.00
6,198.76
1,291.95
113,434.07
13,448.85
2,194.76
10,667.54
8,074.98
256.09
57,956.54
$1,948.04
216,866.36
117,749.77
27,900.29
53,487.95
64,995.48
47,395.06
2,735.72
40,516.99
13,623.27
36,751.99
67,755.90
7,567.06
5,527.94
1,827.15
2'374.12
855.69
681.40
2,931.04
3,986.22
5,448.48
30.25
8,916.43
1,907.12
1,732.90
29,275.02
5,485.14
1,745.56
124.19
2,733.63
12,202.19
7,853.60
$696,292.96
,000.00
170,000.00
13,261.13
332.82
376.09
APPENDIX No. 44
HOOD-ODELL OVEN SYSTEM
Capital
HOGSO Oy ememeaters deer aes oy on scale tee «
** 353 Raw Lignite Handling Equipment
** 356 Gas Handling Equipment
Operating
FI OVSB TO Vere rete tea ei ccri ct Ney toda chera as ok o's enge a hens
a oot haw lignite Handlings, 2c... si. ces bes
Ets (CAROLE ATICING fe Mey Bs cae kG a hick cieke «are
Repairs and Maintenance
TUQESDAMO VOTO Maite ota ate ner te ited dices ates
SL GoD Rn aWwartonite Landlnga. sss dc. vias «
MOU See CLOSPELANCLIINGD uy oti Nee Tae hk Aste cletene suds
Char Storage and Advertising Hxpense...........0006:
PENETUNENEAL ODENSE Waals ieee ecb oN a ele nik oe es.
ATA SCEHONEOUGLELUDOUAG Ma et kee US Paetiin oie ai trore seed Biate
INSU ONCE Soe iro ie ee inte Cokie ne te On eo ee
Y RE es a oye Puity Se Oe CUES DAR Ovo ICE CIEE Ow es OP Nod tie
Sundry Services
(PovHOousesses se sete ses ae ee CA Ue ee ae ae
RCL SELETS SO etic hie Sage Raeaniseia tiaras, oe era ne
IBientaiteviinetetrersit sects cocina oe oe ice
HeeVeECaMplonrae CO nee Trew te fine otis fe
CePA Laying te eros hak Oe ea & ohio ene.
Crescent ollieries Wt enn ae os tine ee ees
ins Grananiowern vee mie Grease otoai we ae oe
ihignite;Coaluviines Etats orien ciemeraeraein ala cute
TRIS StOWaAr bye Oolitic arate trier cra eatend nie ce
M. & S. Coal Co. Ltd.
(Accts Payable......... 887.75)
(Accts Receivable....... 443.34).........
INOn bes ocho Urusten,/ Case cena ciietessrcconscaaicene
Western Dominion Collieriess 4+." ues vec. fe
Ee PEE StANIG VA A rete ecko eerie ohiete elnlel niall ler ctehs
$3,874.24
621.92
350.33
10,941.86
639.86
160.82
301.05
65.15
126.73
332.43
477.93
758.62
14,004.51
3,534.80
1,309.43
98.10
1,934.05
$1,055,229.83
Note:—Gentral Revenue a/c; Balance in Bank December 31st 1923, $9,040.44.
234.33
348.55
$1,055,229.83
263
> aris” '* ~p*. ¢
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Name of Metal and
APPENDIX 33
Memorandum of Statements made in June 1923 by Manufacturers of High Temperature metals regarding their respective products.
Note. The information contained in this table is not guaranteed by the Lignite Utilization Board, nor is any responsibility for statements or accuracy accepted. The information is submitted entirely without prejudice.
PHYSICAL PROPERTIES
Tn nnn aU yIsES SSS
REMARKS
Driver Harris Max. casting capacity
is 3,000 lbs. per pour.
This alloy is non absorbing to C.
One of the Cimets containing Cr. is
non absorbing to carbon
Practically same as ‘‘Beckets Alloy”
Max. cap. is 5,000 Ibs. per pour
U. S. Patent No. 1378941 now
made about same as Cimets.
8,000 hours guaranteed at 2100°
for Atlas Powder.
Approx. Price Actually used in practice : : ~ HOW OBTAINED
Manufacturer Composition and where Extreme Working Can it be Can it be Canit be
temp. °F. temp. °F. Sp. Gr. forged | welded machined
as Nichrome Nee ao ene As EetOr a ae In ponneculen : with B1008 ; " ge “ y y
mH - r.-16% per lb.f.o0.b. Harrison} gas masks. — Yes. See Wheeler — 10 900 alg es es es a i
ae Fe-18% N. J. 20 cents scrap Woodruff Co., New York. Rolled Sheets & Casa nes
me a value.
ea eee
ae Becket’s Cr.-27-28 55 — .70 Yes. — Clinchfield, Va. See Curtis’ If C. is below Yes, if they are | If 0.50 of C. or _ Rolled Sheets,
BR Alloy, or ‘“‘Cimet’’ Fe-72-73 f. o. b. Harrison letter to C. V. M. 1800° 1750° 7.6 0.30 Yes. low C. Cimets, by | up, No. If 0.15 C,| (still experimenting).
Ain C — traces oxy-acetylene Yes. Castings commercial.
“ , zi ; A Sy Fs 6 h high and . A
Duraloy”’ Cr. — 29 .65 Bars and Sheets Yes. Gen. Oil Gas Corporation Niagara Yes if below .40C Yes, bot gf Yes if below 0.60 C, ‘
Cutler Stee! Co, _ Fe. — 70 60-65 Castings Falls. 2100° 1900° 7.60 low par aby. isher Sheets, bars, wires and
50 Church St., N. Y. f. o. b. Pittsburg Though grave troubles encountered, eet Not b y- castings. Tubes experim-
Cutler people claim alloy is O. K. bamanes y entally.
“Thermalloy’’ = Fe 75-85 .65 cents Not to be used in conjunction with
=| Cr. 10-20 scrap value carbonaccous material. Jones-Laughlin Yes
Electro-Alloys Co., ®)Si 2- 6 .12 cents Co., See. E.-A. Co. letter of 20-ii-23 2200° 1800° oxy-acet.
50 Church St., N. Y. Mes 15- 1 f. o. b. Elyria, O. :
°|Ti 5- 1
Fla. 12-2
F Ni. 3 50 cents lb. Yes. 15” 12) cyl. retorts Atlas Powder ,
Hybnickeloa a. Cr. 15 20 cents scrap Co. Wilmington, Del. See letter from 2t00° 2000° Yes. Yes Castings
Pusey & Jones Co., Wilmington Fe 50 value. Webster dated March 5th, 1923.
Calite Al. .80 a lb.
Colorizing Company of Pittsburg, Ni f.o.b. Lynn, 2200° 2000° 7.03 No. No. No Castings only
Pittsburg, Pa. Fe. Mass., plus patterns.
Hardite Ni. 80
Hardite Metals Inc. Zr. Non Yes
103 Park Ave. Mo. ferrous
New York.
Nichroloy—
Hiram Walker & Sons
Metal Products Ltd,
Walkerville.
Cr.
$ .80-1.00 lb.
f. o. b. Walkerville,
Castings only 300 lbs. limit of pour
Name of Metal and
Manufacturer
ans Nichrome
ies
ak
me.
a
Be ol oer
Pas Becket’s :
mE Alloy, or ‘‘Cimet’”’
Am
“Duraloy”’
Cutler Stee! Co.,
50 Church St., N. Y.
“Thermalloy”’
Electro-Alloys Co.,
50 Church St., N.Y.
Hybnickel
Pusey & Jones Co., Wilmington
Calite
Colorizing Company of Pittsburg,
Pittsburg, Pa.
Hardite
Hardite Metals Inc.
103 Park Ave.
New York.
Nichroloy—
Hiram Walker & Sons
Metal Products Ltd,
Walkerviile.
Approx. Price
Composition
Ni.-66% $. 90 — 1.20
Cr.-16% per lb. f. o. b. Harrison
Fe-18% N. J. 20 cents scrap
value.
Cr.-27-28 .55 — .70
Fe-72-73 f. o. b. Harrison
C — traces
Cr. — 29 .65 Bars and Sheets
Fe. — 70 .60-65 Castings
f. o. b. Pittsburg
Fe 75-85 .65 cents
= Cr. 10-20 scrap value
© |Si 2- 6 .12 cents
&)Meg. 15-1 f. o. b. Elyria, O.
uid by 5- 1
(Ca. 2229
Ni. 345) 50 cents lb.
Cr. Ld 20 cents scrap
Fe 50 value.
Al. .80 a lb.
Ni f.o.b. Lynn,
Fe. Mass., plus patterns.
Ni. 80
Zr. Non
Mo. ferrous
Cr.
Ni $ .80-1.00 lb.
oe f. o. b. Walkerville,
e.
Memorandum of Statements!
Note. The information contained in this table is not gu
Co., See.
Wess 15,
Co. Wil
Webster
PLATE 1
Products of Briquette plants in North America
For text reference see page 145
Plate 2
ee » -
(Aan \s Wiihithis .
Komarek Press
Rutledge Press
PLATE 2
For text reference see page 149
a
e.
-_
5 .
_
’
| . ws
ys &
. u
Seer o>
7
a.
hy $ os : i : " '
>'\ ae oo
7 Ae 7 ar 7
iv) See A aa
dt eee ‘
- 2 ory kh
a
wax
;
=e 7 _-
a :
aT. =
ie , oe _ a
eae
fs ie
= a
ra
ui
‘ :
vy
:
® -
,
‘
:
_-
Plate 3
Roll Press Shell
Roll Press
PLATE 3
For text reference see page 149
ia cat
err)
Ss
oe
ne ree or
' oe sa
oa on ost >>
is
a Paes
Plate 4
P2ys buipp
“sy
wh
r
pas See
7
7
LA
eulpying 2214/0 -
cf
2 dupis ie feos
ebeue >
PLATE 4
Construction of Bienfait Plant June llth, 1920
For text reference see page 183
atupsf fey ¢
eurpy ing a?
iffo>.
lant June 11th, 1920
ee page 183
}
Plate 5
PLATE 5
Construction of Bienfait Plant July 20th, 1920
For text reference see page 183
Plant July 20th, 1920
see page 183
ss
sis gta
PLATE 6
Construction of Bienfait Plant Nov. 8th, 1920
For text reference see page 183
{
i
:
6
Plant Nov. 8th, 1920
see page 183
Plates 7-8 |
PLATE 7 |
View of Completed Bienfait Plant
For text reference see page 183
PLATE 8
View of Bienfait Plant and Dwellings
For text reference see page 183
So Mice
coe
nfait Plant
age 183
ind Dwellings
page 183
PLATE 9
View of Interior of Dryer Shells and Brickwork setting
eset taba
ileirg:
)
s and Brickwork setting
Q
y)
o page 18.
Plate 10
PLATE 10
View showing dryer feeding mechanism and furnace
For text reference see page 153
0
echanism and furnace
e page 183
LOL PRLLLLLA LLANE aii
ae di
Plate 11
pV? iy
PLATE 1
View of Hood-Odell shaft carbonizer, Bienfait
For text reference see page 219
:
;
rbonizer, Bienfait
page 219
Plate 12
PLATE 12
View of Hood-Odell shaft; carbonizer, Bienfait
Circular structure in background is raw lignite storage bin.
For text reference
re page 219
a
)
12
carbonizer, Bienfait
is raw lignite storage bin.
so
»
page 219
Viewed by Minin iad d Pheee
ngineers. at ANNUAL METTING CLM. M4.
ESTEVAN, SASK. Oclober. 3-5:2923.,
PLATE 13
View of Hood-Odell shaft carbonizer, Bienfait
For text refeence see page 219
7 | Plate 14
PLATE 14
Section of a pile of about 200 tons of North Dakota Lignite Briquettes made at the Mining Sub-
Station, University of North Dakota. Notice perfect condition after standing weathering tests for
several months.
Courtesy of Dr. E. J. Babcock, Dean of the College of Engineering, University of North Dakota,
14
ta Lignite Briquettes made at the Mining Sub-
ct condition after standing weathering tests for
- of Engineering, University of North Dakota.
WERSITY OF |
mii
Fig. 2
e oe re a
DIAGRAM OF ‘THREE POSSIBLE FLOW SHEETS For PROCESSING
LIGNITE TO PRODUCE A CARBONIZED LIGNITE BRIQUETTE.
Presented at the 3% meeting of the Lignite Board held im Montreal Feb, loh 19/9.
STORAGE
BIN
Hor
BINDER
@ Raw uenire — [| foto
STORAGE
ff
BINDER
| || MIxER &
PULVERIZER| wee yas
APPARATUS OR PROCESSES SHOWN WITH ASTERISK THUS % ARE SUCH THAT FURTHER EXPERIMENTATION
IS NECESSARY, ANDO THOSE SHOWN OTHERWISE ARE EITHER COMMERCIAL OR ENOUGH INFORMATION
(3) RAW LIGNITE
IS IN HAND TO DESIGN THEM COMPLETELY.
FIGURE 2
Three typical flow sheets of Carbonizing and Briquetting Processes
For text reference see page 28
COARSE
CRUSHER
Fig. 3
Small Boller |
aah Roll Crusher
SS
1
Rolary Dryer
mall mixer
Lage Nixer?
Drying Plale“ |
SECTION - H-H
PLAN OF LIGNITE
SHED - OTTAWA.
10
45 Keel
FIGURE 3
Layout of L. U. B. Experimental Plant, Ottawa
For text reference see pages 31 and 258
2 a eee /6- On Neer ee,
oe H
i Work Bench Le)
| Drying Bal!
. Puale Smal
Briquelling ress
| Rotary Oryer
ican
(ail i
PLAN OF LIGNITE
SHED - OTTAWA.
{
aaa
|
nell
H000 gpd.
Jl is
ot 434 4200gpd]| By and. INIT BAT < an, ’ i, GH Y Mog
| g pi alc ; emg y
(ee cad DS RIL WU YU Yi
b Coal & Brick Co, Md | » 7 24000 apd ] Lease - 7 IS
IM 3 17
ie Hope Mine. Y
=|
‘Y
35.8% De B Haig-L pase
18 Lr he igs
al, BPrs iy y Aho, Lid, Lepse,--
R imo % :
woe al> See
~
\E 220% 4200gp.
27. a
ape
361% & 86% R 2B
WB
eS
I Excelsior Coal
355% 8 85%
/
Hid Boop
LEGEND.
Lands presumably available to LUB are shown
/5p tinted, if still in Government hands. Lands shown cross-
hatched have been leased or the mining rights otherwise
disposed of Sections marked 'R and 'H.B’ (untinted) are
respectively the property of the railways and the Hud-
son's Bay Ce. Sections marked 'S’are school lands, and
are not subject to tree entry
Figures following mine titles thus "36.1% 4 86% = in-
dicate, first the percentage of moisture in the sample of
! lignite. trom thal mine as received, and. second the percert-
A= 1800 age of ash in the same sample, on a dry basis
Wells shown thus: @ with figures gving depth and
yield in US gals per day
Figures underlined thus -75 : give approximate
Contour elevations are fH above sea level.
TE
Site selected for plart
a
I7 IS
4 R
| Re "||
7 8 7)
eat) ue : |
ar Ak ee |
5 4 3
SASKATCHEWAN,
NORTH DAKOTA
FIGURE 4
Data map of Estevan and Bienfait area showing site
For text reference see pages 37 and 182
WT
Recommended sile added in Red Deci91923
DaTA Map
Rance 7, AND 1&2, RANGE 8
: Mer
Appreved
Chairman
TownsuHiPs 1&2, RANGE 6, 1&2
O 13.1
vos GEE 1) Seal
S|
ie Pee lgatee A
¥ frre, on H 144%
H
Fig. 5
a
Sanderson & Porter,
D6. Loomis $ Sons,
Kaymond Con. Pile Co, Ltd
Tenderer Address. Estimate,
5
Smith Bras. & Wilson, Lt| Regina, Sask.
PW. Graham
Poole Const Lo, Lid
Standard Const Co, Ltd. | Weyburn, Sask
Moose Jaw, Sask.
160,019.00
/¢8997.90
162,239.50
189,998.15
190,680.00
256,672.00
#150 24325
Unit price.
Group total.
“ | 195 | AlSo0)
" | 0.15 |3525.00
7050.00
» | [$0 |7050.00
" | 265 |/2455.00
ENGINEERS ESTIMATE.
Averages /-b/incl)
949.00| | 4036.00)
1:2:4 Concrete. | :23:5 Concrete.
Unit price.
Unif price.
Unit price.
42,00
40.00
35.00
ny — Hw
Group 3.
Brick.
18,960.00)
15,200.00)
/3,300.
LIGNITE UTILIZATION Board oF CANADA. SUMMARY oF TENDERS, Contract No. Five, BUILDINGS, ETC.
Group 4.
Group total.
Unif price.
Tol.
Group 5.
steel roofing.
—— =
a.
ean
rs
AS}
Sis
Group folal,
Squares
Unil price
Tofal
Corrugated Tar and gravel
oup fofal
Lathing and
8
4
it price.
SS
Ss
Unit price.
Group total.
Un,
-s | Thousand.
I=| " |15.00 | (35.00 B=|489500| » 20 |4600.00/2} « |/400 |/,330 00)3
B=)" B00 | M200 |\2\l09700) " | 30 |6,900.004=| » | 15.50 |/472.50
Bo} * | 5.00 | 135.00 31/500) " | 22 |506000|3} » | iao |/045.00
42.50 |¥12.50 | 1 Pasresolrsoeolo 37 Vesinool7| a5 Moo M4zz5.a0
it
£15936 00| /050 |”
uw
8.43000 " {200.00|(800.00 |7|20710.00| " | 35 |8a50.00\6| » | 8.00 | 760.00
4 \50.00 | /9,.000.00) 5] % | 20.00) [8a00 |5|/2,38000| » 30 |6.90000|4+) " | 20.00 ||, 900.00 “
u 60,00 | 72,800.00 6} * | 5200} 45000 |6|/Soaco] * | I |2.53000\1| » | 18.00 | 170.00 ”
i
4250
N
15,385.00
|
~—
U5CA0| 35 | 547400
I | 1125 | 190.00} 12,700} 2028] 28¢| 58200| | 97 | i225 | 167300
772300 | 022
Ranting & tinting, | Finishing con-
ex, structural steel
Unit price.
Group total.
Lump Sums.
fal wk
o*
5 16,800.00 |3,220.00]
3 |6460.00|3.000.00
7 |/3.200.00|8500.00
2 | 708000|3500.00
6 \/0.875 00V//, 600.00
W510" thz9 tha2
FIGURE 5
Summary of Tenders Received for Construction of Bienfait Plant.
For text reference see page 43
1.500.00\4.000.00\4 [00.00
3580. 00} 2 800,00
Sheet mei
ee
Group total
2 z
243 00 |3./36.00 |Z 94.00 | 682.00 |" !2,480.00
| |5,905.00)3 500.00} | 500.00 }44.00,00|5.200.00\2,300.00| 500.00 | |7 400.00
4 00.00 )3 136.00 |2.9/4.90 | |500.00 | 17570, 90
/5,600.00
200.00 |4.000, 00 |3 500.00}2,500.00 | 76,200.00
4,000.00 |3500.00 |3.650.00 | /,000.00 |/7.50.00
8400.00 \7500.00 | 7,790.00 | 38,360.00
Fi
Also offers fo do work for cast plus 4p 000.00.
| Aiso oer to do work for cost plus lo%
2 5 +
‘orms, 6,050.00: tank erection 2250 a0: camp. ete, 4,500.00.
Also offers to do work for cost plus’ 0,000.00
Included in estimate
4loo | 8305.00
7 = 4
M3scel iron work,"1/Z2.00
uiing 15% allowance over all items. Tolals to dollars only.
4
Hove
4
23640 [616.82
|
Note:-
.
’
.
4
Not quoted in tender.
First item. hand excay.: Second, mechanical
First ifem, plain forms: second, circular
First item, 24-gauge: second, 20-qauge
: Average of Sanly anu Vance crnitied
V ipe
This eshmate prepared by distrib
lenderer Estimate.
Smith Bros. & Wilson, Ltd| Kegina, Sask ¥ 150 24325
PW. Graham Moose Jaw Sask. | 160,019.00
foole Const Co, lid | Kegina, Sask. 10849,7.90
Standard Const Co, Ltd, | Weyburn, Sask 162,233.50
Sanderson & Porter.
DG. Loomis § Sons,
Kaymond Con, Pile Co,Ltd
Chicago, Me
Montreal Que.
n” ”
183,998.15
19, C80. 00
250,077. 00
ENGINEERS ESTIMATE. 63386 00
Averages /- bic!)
TRACK HOPPER
Lume LIGNITE CONVEYOR
PULVERIZED RAW LIGNITE ELEVATOR
RAW LIGNITE BINS
DISCHARGE CONVEYOR
CRUSHER
NA as
_RAW LIGNITE HANDLING _
va ORYER FEED ELEVATOR
DRYERS
— DRY LIGNITE ELEVAT
OISTRIBUTING CONVEYOR A
RESIDUE ELEVATOR
DRY LIGNITE BIN
DISCHARGES a ee
CARBONIZING _
A
BY- PRODUCT RECOVERY,.-.....------.F
YAROS & SWITCHES,
WATER SUPPLY & DRAINAGE,
POWER £& POWER HOUSE,..---___-_.J
OFFICE & LABORATORY BUILDING, --_.C
MISCELLANEOUS), Seta ean maa.
MACHINE SHOR Se Sats. ener eG)
SMALL TOOLS & EQUIPMENT___--.-.-.P
EIRP OVEE SOLS = ae
EECEIVING SPUR
UNLOADING PUMP
BINDER FEEO TANK >
BINDER STORAGE TANK,
RESIOWUE BIN
BINOGR FEEO PUMP.
Ze APRON FEEDER
i
S
is
BS
Ty
= \
ly
is
2
=
vg
z
o
a
=
ty
K
"
4
w
a
y
z
a)
Q
=)
Uu
1
2 SL EeESE 8
3
w
,
3
ees.
MUSING & BRIQUETTING ~
e)
‘
<
uw
st
ly
wu
iS
yu
= |
9g
&
Q
[> DISTRIBUTING CONVEYOR
TRACK
0
BRIQUETTE BIN
tt SHIPPING ©
STORAGE & LOADING
Es
Note :-
LETTERS REFERRED TO ARE FOR ACCOUNTANCY
PURPOSES ONLY.
LIGNITE UTILIZATIAN BOAKO
OF CANADA
FLOW SHEET
APPROVED
FIGURE 6
Flow Sheet of Board’s Process
For text reference sce pages 67 and 183
TRACK HOPPER
Lume LIGNITE CONVEYOR
CRUSHER
PULVERIZED RAW LIGNITE ELEVATOR
ee te RAW EIGN ES NCC ae
A
BY- PRODUCT RECOVERY,..-...- cee a
YAROS & SWITCHES,
WATER SUPPLY & DRAINAGE, -_______-.
POWER & POWER HOUSE,-_---- ----.
OFFICE & LABORATORY BLSILDING, -- --
MISCELLANEOUS, | _._ _.2 2522 eee
MACHINE ‘SHOP. __..).. Al. See
SMALL TOOLS & EQUIPMENT_____.-._-F
EMPLOYEES WOUSES_.._.._.. Jee
SURVEY OF BRIQUETTING PLANTS
Visited on Investigatory Trip for Lignite Utilization Board Between November 11, 1918 and January 11, 1919.
Company,
Fuel Briquet Co.
Products Corp.
*Am. Briquet Co.
Nay. Co.
Briquet Co.
Briquet Co.
Plant reference Number appearing 12 10 13 8 il 4 3 1
on briquettes shewn in Plate 1.
i i Del Std. Briquet Pacific Coast Bankhead
eeriductstione Ny Coa Banat Goes Sinaeer Gos Va. Nay. Coal Co. rset Coe Fuel Co. Coal Co. Col., Ltd. Stott Briquet Co., Berwind Fuel Co.
Location,
1
2
3 BuiLpers,
4
5
MATERIAL HANDLED,
6 | Dryine By, Direct heat. None. Direct heat. Direct heat. Direct heat. Steam. Direct heat. Steam. Drect heat. Direct heat. Direct heat. Direct heat. Direct heat.
7 Tyre OF BRIQUETTE, Egg. Barrel. Pillow. Egg. Egg. Pillow. Cylindrical. Pillow. Cylindrical. Cylindrical. Pillow. Pillow. Cylindrical
8 | WEIGHT OF BRIQUETTE, 0ZS., 1. 134 2. 2. 244. 14. 16. ge lite 10. 2%. 214 13. 2%
9 | BriypeR vsED, Sulphite pitch. Coal tar pitch. “Hite”. Oil pitch. Coal tar pitch. Sulph. and oil pitch Coal tar pitch. Oil pitch. Oil pitch. Oil pitch. Coal tar pitch. Coal tar pitch. C. T. and oil pitch.
10 ConDITION OF BINDER, Liquid. Hard or melted. Emulsion. Melted. Melted. Melted. Hard. Hard. Melted. Melted. Melted. Hard, Melted.
¢ 11 | Mrxine ratio, 11.0 9.0-11.0 Si7ce 5.3 10.0 75k 6.4-7.5. 11.0+ 7.5 7.5 8.7+ 75k 7.6+
c 12 | Srpam ADDED TO MIXTURE? Yes. Yes. No. Yes Yes. Yes. Yes. Yes. Wee. Yes.
13 TYPE OF PRESS, Belgian roll. Komarek. Roll. Roll. Roll. Roll. Rutledge. Roll. Rutledge. Rutledge. Roll. Rutledge. Komarek,
14 Heat TREATMENT, In preparation. Recarbonization. Drying. None. None. None. None. None. None. None. None. None.
15 | Cootine, Air. Air, Air. Sprays. Immersion. Air, Air, Air. Air. Sprays. Air, Air.
Trenton, N. J.
Anthracite.
*Commercial plant building.
tNew 1,000-ton plant building.
Fae rey ee —
Irvington, N. J.
“Semi-coke,”’
Philadelphia, Pa.
Anthracite.
Lansford, Pa,
Anthracite.
Dickson City, Pa.
Anthracite,
Harrisburg, Pa.
Anthracite.
Norfolk, Va.
FIGURE 7
For text reference see page 145
Parrott., Va.
Kansas City, Mo.
es)
=e
oe
NJ
=e a ea ema erie rasta im NA Sta ye i Sl
Renton. Wash.
Bankhead, Alta.
Malcolmson, Malcolmson, Various. Mashek. Malcolmson. Mashek. Malcolmson. Malcolmson. Zwoyer. Mashek. Malcolmson.
APPROX. CAPACITY, TONS PER 24 uKs., 200-250 Experimental. Experimental. 500. 1,000. Part experimental. 1,000. 250-400. 700. 600. 1,000. 500. 600
Bituminous. Semi-anth. Semi-anth. Lig. and bitumin. Semi-anth. Anth. and bitumin. Bituminous.
Superior, Wis. Superior, Wis.
Plant reference Number appearing
on briquettes shewn in Plate 1.
ComPANY,
LOCATION,
BUILDERS,
APPROX. CAPACITY, TONS PER 24 HRs.,
MATERIAL HANDLED,
DRYING BY,
TYPE OF BRIQUETTE,
WEIGHT OF BRIQUETTE, 0O2ZS.,
BINDER USED,
CONDITION OF BINDER,
MIxING RATIO,
STEAM ADDED TO MIXTURE?
TYPE OF PRESS,
HEAT TREATMENT,
Coo.Lina,
*Commercial plant building.
{New 1,000-ton plant building.
12 10
Internation
Fuel Briquet Co. Products
Trenton, N. J. Irvington,
Malcolmson. Malcolmson
200-250 Experiment
Anthracite. ‘“‘Semi-coke.
Direct heat. None.
Egg. Barrel.
i. 134
Sulphite pitch. Coal tar pit
Liquid. Hard or me
11.0+ 9.0-11.0
Yes. Yes.
Belgian roll. Komarek.
In preparation. Recarbonizg
Air. Air.
Fig. 8-a
3
a
9
S)
ra
Date
elas)
The Tyler Standard Screen Scale
thmic Diagram of Screen Analysis on Sample of Gar
i
Cumulative Logar
~
rr
Qia0a8
,£000°
SURAREEE TLE
omen LH ow
eee L000"
SEESEEEE tet 8000°
HH HH : 000°
HNN os
OAR RO GR RRUEI
CUAUUUR RRL ARERI ,200°
SERAHNAUOAEERIND
CELLET Ae
ERGNTERITS TRAE
HEREC EEE CEE CEE EHEC EEE CEES ECO os
ae SASREARED
aa REBROR |
suuesdeett cates
PREECE
Coo
rh o
oO
aS o
p>
a
i
i]
Le)
co —
SCALE
LHOISM ASG SSDVLNSOYSd SAILVINNND
(HS3W 002)
6000"
(HS3W 09T)
6 #00"
(HS3W OOT)
8500"
(HS3W 99)
0800"
(HS3W GP)
9b 40°
(HS3W SE)
940"
sHSIW 82)
eee"
(HS3W OZ)
,82E0"
(HS3W WT)
y9v0"
(HS3W OT)
890°
(Hs3aw ®@)
,£ 60"
(HS3W 9)
uel
{HS3M ¥)
“sei
(HS3W €)
u£92"
Ay:
cag.
vevl'
y0S0't
OPENING
FIGURE 8a
Screen Curve of Carbonized Residue in Ottawa
For text reference see page 70
The Tylel °
Cumulative Logarithmic Diagram of S«
RR, &
oa I a:
©} ac @, of
Cave
Name
°
7
s
Se ee ee ee eeeret ne epee -
fe San es Ss ae ee ee ee Oe eo TD foe oer Soe SED WEY ST EY EE Soe es ee oe eee
L v Sah as Coad a
iifltiVlMifliiltiiiilie tuo SOERTRSUUECRRERERERAREREREE LS
POO ee
AUSEAGRGE SERS RRS PAs Re Es Re Ee Ree Re RR Re Bee eee
i
et ed TTT TTT TTT
(=)
i=]
“so
So i=] QoQ i=]
a> [<=] = oo ~N
LHSOISM AG SSDVLNSOYSd ZSAILVINNND
7H
“ U
(HS3W OT)
890"
(HS3W @)
£60"
(Hs3W 9)
ata
(HS3M ¥)
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(Hs3aW €)
yt 9e°
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OPENING
Screen Curve o}
=.
For
Fig.8-b
Screen Scale
The Tyler Standard
a a a ee ee ee ee) en oe i ee eee
at ee ee Se eee eee fee Sea ae a eee fat ONY cae Se YN
Cla ee ee Pace) TO eo. TR as ae a) ae
CO Le ea a a a eee ee eee te
$000" ’ ' ‘ ‘ ‘ ’ ‘ ' ‘ . ‘ ‘ ' ‘ ‘ ‘ . ‘ H
TOOT ¢ Se S3 oo Shee oe Pe ar ee re
eo ee ee at ow Oe oy bah. mien WNL ele te Rd a) Pe Ly
a eR cee tl ama Wee oT a Dee Vea eA) ee eet tc
RS Re, Oe IR ee eee eee Pe eae
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Coot -2000
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ee ees ie Ay ee eee te ee ee me ed Te ee
Ce eee a eee eee ee eet Bede A he ete Le ee RY
oe a nk) Ce ae eo ro week Ve a ea ew ee on mr fen fmoee fees a.
eae ee ie PA Ce ie i ee ee hee A Re ee et ek
es ee eT ea ee ome Vou eek YO eI Ls Tie THOR 7 Cmte
CP a eR Ae ee ee eee ee ee we
Ox SS tech a ee Oe ee CLL 8) ee eis mee. Liste ee
A, Oe a ONS ON Tae ema Ne, Re ee ane Seteg
Oe) fees Se Pe ee Ge Oe ee een vee Ree oe
Li Secs a a RR atl EO ie | ei Seta died i ee ee ae Oh es ey Wa,
Peete 46000"
TTT
Sa
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2. ECE a0" any | Wun terints iain ea
g pees seeae sense seaceaeess ae 200" 7800" Seis: SSeS Rosy
Bf ARSE TTT St SU BURL
= N (usaW ay a er ae reer ree ee ee
af ia apy si HH i aM | | gga | LEEE Ride idoimdeld | |
oa i ~ ‘a
2 ie’ | |B, | | SRGelacasass
= in NOT CS OYE Ot aera ey TPES RE PE
3 soon (EL le tt heptogeninghnicenienie: § 1]
EEE Popa Nag ae aes
= oH ‘8ze0" > a. Re a tae ete TEN yer Om Pa 3
£9 ae soe aie
a . 5 EECA HHAHTSOTTSATNOTTSGGUGGGGUIOGGISOAEGGHOOLUGGINGS=*CUL 60 9%0
=o COCO 190" tan 01)
TTT NTI TT - 890
SESSK50 NOG REREES 10
& | ee
Ss) EN oa ro
Sy pa *: ' “ S
4 A TTITTTTT Teoosaa 27» Ge ROS ier °
oS CUT ea TT =
oe PTT HT a PS
Bees C satsaeaussseutasssttitsiiainaiantaisatsatattainnss "setae ease
7 BE" 19
—— ,bL€" )e
© W RIS
i ee
& ; e Wes
La >
E F PPR Vee Pe Peete
ur. F eH 6" Saee | fi iii iiiiii:i: wy:
eeeesSoaee ool sssag] iii Mebiiii:a:i id
Hii i EEE 2 seis GRC Oam cee ticks eS
i 3 4 e 3. ox oye a 5 lees eed ht) fee told
4 So Ls RAE... TNE SAR oe teams Oe Co me aa ee A
FIGURE 8-b
Sereen Curve of Crushing results at Hebron, N. D., Feb. 19, 1923
For text reference see page 231
~ *
AuvuaT Rif: i782 nth 2 ALUSHIAIN?
TOO
SUGEURSGHG CRSQURSGUS SERURGEREERUCHCUEGDOEESEGSOL SURGR EEOC RORRSHUREE DOOR
IINGRAE VAR RREEREREERREEEREE jt
Cc
Fis. 8
The Tyler Standard Screen Scale
Cumulative Logarithmic Diagram of Screen Analysis on Sample of
TH
Date
a
DEDEDE ERE URR EUR ERER EER EROEL
Ce HN
Name
Mater Stl) HAT HTT
FENG OHARA DTT ED GRLORRRAAR ARR Oenoo aA
SRSREs Beene Sees ee
e 3 2 2 8
JHSISM AG SSDVLNEAONSd ZAILVINWNS
47 GOES PS FeE BARA ROP Se SORIA EER OTRAS
i ; TTT Th BEES eaeee TTT TT anes
COO NUT
LAC
ECCS Ra
Eu Un EH nH
TENA
TA tH PT
29 See eee ee
PNT
(482 002)
46200"
(HS83M OST)
+ 900"
(H33W 00T)
8$00'
(Hsaw 69)
©800°
(HOM O68)
910"
(Hs3M 82)
2&0"
(Hs3W 0Z)
,8ZE0°
(HSH Pt)
u9b0'
(HS34 Ot)
4890"
(Hsa" 8)
,£60°
(Ht3N 9)
wth’
(HSaW ¥)
sai"
(H93N 6)
af 92"
AW AS
omer
-
: tuhei i afl
er ANY ow Gy Saar ais ec daw id
ity
aU eee meng:
ce PPC 1 Tt it tt ert meena
pec, ttettyete leh ame ea
oe
Gia te ee SY
SO PEE sage sade |
wn ’ ' ‘ ‘ uJ ' ’ ' . uJ ’ . J ‘ ‘ ’: ’ ’ ‘
‘ ' ' . ‘ ‘ + oe NE OF ’ ' . ‘ . ' ‘
a Pid is : i i Ni ae SVS gigi gf ei gg! i
Saeco oe Seige oacere eee
ze bob Pe ee PS ee ee
S af PLETE Lisivieataial civil al | |
v PEELE EE IRS SRS |
Pee Es tos a gap oa |:
& pees SPIKS HUI xs |:
eae a Ue SS SE |
er Ol gio eg aie atonal
Pi: esa SRas Ise | |
PA INS Se
SEE PEM ot Oi lod si ai oft | |
VLEET ES&S aga deeiasl | |
: Ba De EM Eg ee STEN ing cote TD
2 He eat ae ates Pre aoe 1 med
Soares (‘SETS ae RG Geass | |
9 ioe trerdinane 1 et Sia! Bt mi get el FO! | |
See te tae PEC AAR ARRAS S| |
ota ieee tl Bie uO Moree Pot ee aa is PL ae Ar ae
Per Cent
WEIGHTS
pS
: r
3
HP HEEL
3° Qo
iE FLETELELEE
Onn er NDNA YM 0
ornroodnad
OmRoOnHNAHROOD
-
Retaining
Screen
and also First
Indicate the Screen
Crushed through
FIGURE 8-c
Screen Curve of Bienfait char briquetted at Hebron, Dec. 8th, 1923
For text reference see page 234
The Tyler Standard Screen Scale
Cumulative Logarithmic Diagram of Screen Analysis on Sample of
TH
cos
Name
te a4
SEBS. an
5
|
a 2 =
2 P
UORRGRTRORD DRBRRORENE
=H
Ht
4a
v,
2
ee
%000°
(HS3nR 002)
6200"
(HSI OS\)
+ ¥00"
(HS3W O01)
8500"
(HS3hW 59)
e800"
(483m GE)
$910"
“
tHS3W B82
yee"
(HSIW 02)
8260"
(HS3H wt)
4.960"
(S34 OL)
890°
(S36 8)
,£60°
(HS3H 9)
Awe
(H33W ¥)
,S8h"
(433% ©)
ne 9e°
% of Total Contents
cum
ae
A:T econeee
Big a a tees
RE ee ese
' SECOND
ROLLS
o
2b
04.| 12:80}...
M00. |45-46.| 2.0.
ARQG | 25226)........
8:20.
8:94 |. 89-42) __.
- 7:02. | 3.
-4:8b.|.JOAB!
CONTENTS
THRU $
Wr
A.
cunt
e FIRST | CHAR!
Vere hs
ASSAYS
THR!
Rou
#94623...
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|. 88:52). 55-0.
|
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38. | 89:20) 55-4 | H:08. | 56:24) 000.
2:20. |.9U.40). 38:9.
100 :0Q)_ 32:9. |. 10:58. |/00:20' |.
|. 96:96). 34-7.
J 0%. |.92-42.1.0:4.|..2:08.| 08-92)...
.- Jb, |. 23-08). 20:8.
3:23
9204.
ma)
Wr
40-0
-Ab2.
O..
O33
1.624. 1..3:
18:2
Per Cent
Cumulative
Weights
f=)
34..36...29:0.| 5:60
|
792.7. .\/16:2.|.38-24
91: 34 26:7. |.28-34
-94:08..).8 sate
SS:&.
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97. 1b...
(97:50: 1... Sil..
“97.-€2..|_.0:3..
98,96..
1.00.99. stRedes
WEIGHTS
RECEIV
Per Cent
|
CHAR A
Sample
Weights
ASB:4D..|...
SISKR..|..
~2:14...|..
au Ley Sin
3k
Ts
34
“ES ee lees
OSes
Of...
eo
ABT. |...33:52.|..
227. Q
fe
7
4
Wire
Diameter
Inches
Mesh
18.85
13.33
9.423
6.680
2.362
SCREEN SCALE RATIO 1.414
-742
-5625
371
-263
093
Of
Soe
=
| 78
A)
a
au
a
o| 3
a
Y
a
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523
A O.5 we
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ot 2ty
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an
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shea
3°
%.
.
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.
.
.
.
.
.
* .
. '
. '
‘ .
. . .
' . .
. . .
‘ . .
’ . .
. .
. .
.
.
.
.
Totals,
FIGURE 8-d
Screen Curve of Bienfait char briquetted at Hebron, Dec., 12th, 1923
For text reference see page 23
at
at
Lie a
>
fs
a
Fig. 8-e
The Tyler Standard Screen Scale
Cumulative Logarithmic Diagram of
Sample of
“
Sereen Analysis on
—
Name
° cause
Sess} hecee cee
Serer EH
{
Ree e t Tf |
PEPPER EEEH
Se ea 4}. a a
TTT CT
Ss =
#¥000'
TTT TTT TT)
COO
TTT
5
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y
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at
Pt
5
ane
HEE
Me
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ater ea
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= A
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=
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any
10
60
50
40
0
0
0
0
LHSOISAM AG SAOVLNEDYad SAILVINWNS
(HS3W 002)
6200"
(HSIW OG1)
— 1700"
(US3W 001)
8500"
“
(HSaW S9)
“_ 2800’
(HS3W GE)
(P9 10"
‘H59W Bz)
,0&C0"
(453 02)
,82E0"
(HS3W 91)
990°
(HS9W OT)
890°
(HS3W 8)
.£60'
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stl
(HS3H ¥)
'
$8!
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ut 92"
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wool’
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OPENIN
of Total Contents
%o
SS)
CONTENT:
ASSAYS
EIGHTS
Ww
RECEIV
CHAR
Per Cent
Sample
Weights
| Rasa at feat att Mee aneensed er allot
bacpees. ty eee cen eee on aie a teak
De bobo db Sree eer
| wa : wy oo. ee ' H
| ppb ‘in ale epieeteeaneimmeaied
ete aae eras
[des ' Pee ea A ee SO ey te
eae ‘ eet OO SS Se oy H
ae rae Sale Si Maye ee or
‘ ’ ‘ it a be ee ‘ee . u a v3! J
ay iil TYEBIR SS SHS |
4 re Be aled alka oi-sielord |
= es (ogee Spt eat et Me A! 3: Si RS Bia) 3:9: a: |
See) Ree ie See
w eae cose on en ee ee ee
Se gts ee ae es BIB cul cs OF PLN Viuiial of ofa! | |
SF : eo! Sug: PFI Gai sy! | ‘
at ees Pare Ee har a eee wae
lege rat = t! Fi oF si OF os 0; a) sl 9! 08 |
& Be im doi 2: TE et FS ae GES EF
= 7 ‘ ‘ a: U ‘ . ‘oo ‘ ‘ : :
ai al pel GS) ty eek wer SER, RE AiR! St
4 7 Pai ot hatigs St Ga tia
hae (SiS Ho a H Biwi gi gk |
¥4 cage MMH ANA SSH |
reais aie Ale ct, fe tgania Mathias a at
; PE On irc et. Oke
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us = Baragaon
ny Be ctr: te nao eae
> ’ ‘ ‘
e223
ars)
Os
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0 (UM
i
SCREEN SCALE RATIO 1.414
Indicate the Screen
Crushed through
Diameter
Wire
Openings
Mesb
Milli-
Inches
meters
Inches
1.050
and also First
Retainio
g
Screen
. ' . .
’ ‘ . '
' ’ . '
' ‘ . '
. . ' ’
. . ' .
. ' ' .
' ’ ' 1
’ ’ . .
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Passi. 2.2.
FIGURE 8-e
Screen Curve of Bienfait char briquetted at Hebron, Dec. 14th, 1923
For text reference see page 234
Fig. 8f-
The Tyler Standard Screen Scale
Cumulative Logarithmic Diagram of Screen Analysis on Sample of Lrye
@ “By D-s
ky seh
ee
29-6921
Date %ep7 A2¥-
FREESE STH A
PEE == H Gar t
Be
+ =
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poppe pf to
HH =H sci F = Billi
gee
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BES
fae
:
4]
F
=e
:
=
=
desea
a4
Bab
i
GEEen SERGRREHEE CARRS RRs oes SEGGHGGRREREOGE GSGGR Sans
Ste rate eae et eae eee ee eee ae eae
at
=
i
cH
i
ca
L
a
Hi EEEEEEEE
=
Ear
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alec
o So So J
“
G4ANIVL3Y LHOISM LN3DY43ad JAILVINWND
chosen oom
iseaeegs oases
ciety
EGSRSanEeEoe nn Eeeus sues 8000" -
BS RSP RRs OBES ARTES CAM CASe Ve
(H8DM 008)
6200"
(483m O98)
74 ¥00°
(HEE OO!)
=} 900" 8500
(HOam Ge)
v0"
450"
790"
7,09 10°
(HS3m" ef)
E20!
(HSIN Or)
—,,8Z€0'
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~ 990°
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a OU,
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(Ha3M 8)
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(HS9m ¥)
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(H93m ©)
n£ 9S"
hv -'_0O0OC OC
| : Pala
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j | ' ’ ' ' BP eats Hi
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= SS SSS SSS SSS SSS
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Pd a Be ee Mar er ma Ee ee i Ce a aes |
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% ;
Sc bobai seit boa egy ae t a
533 POR Ce. GA ist Ss a aes
HT Petes fate ae ire Die shabaB eS 6
coi et Mal Dae es te ees Me oh eT
£2830 Ne Mie BAe det ee re eee eo be ae ea is al
te. TSE hk Ones eA, Ee ae va
2° popes Oe ee ees eae oe ee ;
Ue oe ey ate: oe ee eee keer ©
FIGURE 8-f
Screen Curve of Dryer Discharge Sept. 28th, 1921 Bienfait
For text reference see page 189
ae
~~ thay
Arora
fa?
rs
ie.
he
ai
s
QHETD GORE REGTE DEEED RREROSREOE
OED SEGEE RORRA SERRE DORERORE
oo BRERERSGERRSEEE a
Fig. 8-¢
The Tyler Standard Screen Scale
ot eae Logarithmic Diagram of Screen Analysis on Sample of Crusher- (Fre
fam Gc, 1°22
EBs BUSES Sanee sane.
SEDSOCRSSUGHOD° US
SUSSSCRSRE SEEDS NE
TTT PRET HAMEL HHL
1 et a
itn ws il MMMM TT ,
i]
nagitiaa! LHOIaM IN30ua4 3AlLVINWAD
/¥000"
cama” 8
Lo A 200
PT
CT
Coo (ieee Ses
Ce Tt egg2—6200"
GRE CRSRDEISCTURRRORATEHORAe HSS
5ST PT SAGRERTERHRAR BOREL
SE EEE png eon
—t ah tt et carer OO -. 1900"
Mrttiititititt tt a
rT TTT coo:
HUSUERAREE REDEGRORED SEREORRSSERRROROOER CORRE RREES prenioen
Pg oO" +,8500°
00°
5 » (HSan 99)
rang 2800
0°
(HSIN er)
49440
(HS3W SC)
——- +4910°
you:
(HS3W e2)
= ZEN
£0" _ Greg
v0"
(HS3H Ft)
co ~,9%0"
TT 90: ga"
(Hs3H @)
£60"
HN ETE”
GNTAIAAIIN PTT ea
QLBIiaI SASAS SSAA e AORTA DTBBTAGeh. aon ATT — bE Ye
TTT TTA TT
l (isan ¢)
—,$81
(Hs3K ©)
yt9e'
one =Ale
CEP eet gz"
ROR GRReeees pe nenpeg pp ay
Ll
= 8 — cvl
Por} £6
Ut oo!
oO
wy z
S <= =
BS
es ees ee rd ee
ed eee eee ee ee ee eg ee
Weights
> Toren 2
v.
&e E.
2:7
2-0.
Gl-%
oS
4-%&
PA Ye aes poe ao pee RRR
2S.
E-S-. :
LOO. Oe oe onlee neem a =
&
Per Cent
LG:
Cumulative
Z
ae
x
vA
&£
7
fe 4
EE
bal iy
72.0
2
4
&
(4)
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Sas
Z.
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ji
c
—
ra
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7:
Per Cent
ee
We
S-
enol
FIGURE 8-2
Screen Curve of Crusher Discharge Oct. 6th, 1922, Bienfait
oD
mA
ok CP tse
yd
Aid
BF aK oy 8 0
Sample
Weights
gm
and
# f
ccesewem sec cl a swena na nena) SS Seems moawa| =a seene|nocsees
44.
Layee)
eyed Seas 2m
For text reference see page 188
Diameter
.0125
.0122
Totals,
'.149
-135
-106
092
035
0092
0072
0042
-0026
-0021
0021
-025
8
10
14
2
2
Oo
8
35
48
65
100
200
200
Mesh
-104 |on160
9.423
2.362
1.651
1.168
-833
-589
-417
-147
O74
O74
meters
Milli-
18.85
13.33
Openings
SCREEN SCALE RATIO 1.414
Inches
.525
371
.263
.185
131
.0328
.0232
0164
046
Crushed through
and also First
Retaining
Screen
Indicate the Screen
tea ee Ah eee,
a tt pe + Gg ame whe ; : o2
aS et ee ee 7 “ : e ' ¥
~s ae ee eae : ae nally ‘ : .
CE ee eine Site ae ‘ a
2s
ky
eke et He cael: no
Ss He 3 pipe ee
SER 8 POT AS qe 2 >
Srey ee Crys Ss
Scat re ay
Fig. 8-h
The Tyler Standard Screen Scale
Cumulative Logarithmic Diagram of Screen Analysis on Sample of Anthracite Coal
Name Crushing resu/; f Nukol. Plant
:
Sac:
tee
Ht
HT
TUAOAAOGESGONAAONSUUSHNOCUOOOLSUUSUSGENUSEAUAOASOUSNOOUNSOON GOULNGUESOOHNNOENDORECOOENOGENOSSNOUEG | PEE | iWGNe & oe ae
Peemr te HOR tet xb cr + ER Ss Kas Se
Nae a eee eee eee ee eeee eee eee eee eee ee UT TATITanAanl Hh - REE SOEs INV ENR SEVGS SY :
HONEUAUENEEUSHORINEY SI ELEESETSRESAHGLERE | Pi dd PEN Sid Ss MaighG yes
Ra ee eee ee eeccuseaeseens seesn seuss sesseceseaeancesce! CsEeNsGEEGL PoP bd P PMU GIASIN HONIOIN AS:
Seepareees steed sense boszanoses S2CezsE524 Seapeest: beveroece: a RE RERTOREET. Ky PeIn Csi
ieceesecereesccecee! peescecese cotter i eat ss Sh ae ea S35 NO! STUY Si! ‘
coo Suaueeuni - Corry 8000
BSS eaweseres~ es CI gon0
op
BN OI TT TS re PE Pa DO ee A Re a Cit
ee ee Oey SSS SH PSraa SLAPS LS SST SS SSSSLSSSCS Ses SSeS Lees
TET PUPS SAS SOCK RIT TAS SST Kh SeSeeSCURsSaSse Se. ee RII ON Bees
2scue 00 a i a as Be Tt chee. SeSee .
HHUHLVOGO ARORA AOA AHA UUAOOOOHES TEE SH:
& Py =
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SCREEN SCALE RATIO 1.414 Raw Coo/ A Dried Undersize | Aver nrostcofer — ow Coal B=
&
£
2
5
4
-
$
Openings
OSUSREDETS EERITEERI i 3 CUNO enh SOR hen eae
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—$—$——————————————————————
Sean
sr NaRREREETE
|
SEE
Atthpact/e
t fn| Pilea, Fex
Figs. 9-10
aCe
hy
Anthracite \ (arbor Ligpile Carbon Lighite| Anthr
Fol/s ‘4 Mb/s
Trenton, NL | Offawea Ont \ Ottawa Ont Wicksor
Cimt | % mh 2%
p24 oe
Lum %
Fol/ _ Fress
00 |
mb
Aathracie
Forrolt Va
to
127
MIF
9} ‘8 DIS
Sees:
lo,
%
/19-\| 9
O1 BS
2
Screen Arolyses on Coals ashrguelred
L4,Ma
Kg
15.8 =
40
Sen-Anrh
/
7E 5
am] %
270
54
EE:
8 | 974 |
73 [acs] 5
2 |975|3
| 9B3| 2
| 290] /3
| 995| 42
/20.0| 0
Be
27 \ 667) 17 \ FR!
torr, Wash\hansas
a 560
%
270
270
ys
WB
BE Ligne
fenton,
+ a N Q stele 8/8 X 8 Q
SNIPES slala/a|*
PSSSI8)8]8 8/818
+4
: Gre
Saeer
Sze
= RIS
aie
50 | 0.5 |
00| 2 5 |
Pe
Loss
19
Q|d
BES
\
FUN of 8/12/
a gists
FIGURE 9
Screen Analyses of various coals as briquetted
For text reference see page 70
AUN oF ——
SCREEN ANALYSES oF KAW & CARBOMIZED LIGNITE
ee
|
INI STN
SIS IN
iS Ss
UHL y eis
ANOGDES
INS
N
NS t, Ss
ISS) HQ) IRS
a
g
ES)
=
Corbonizing done by LB. experimental car-
SEE 1/88
ele
NINI& XLS
Avralys1s by A121 Nicol/s.
borizer. ow lignile wos aried ond crushed wilh rol! corn "mill eter lo Sfanstields
jerter of Aug. 29% 1/19
ORS
WRNSS
FIGURE 10
Screen Analyses of Raw and Carbonized Lignite (Ottawa results)
For text reference see page 70
a
UTILIZATION OF CANADA.
oes ee
LARGE MIXER.
I
7
TESTS ON BRIQUETTES.
Oct 23,25, Nov./,3. 1920.
Nov. 20" 1419. 2 minute discharge.
Car bonized
lignite,
Nov 19% 19194. 3 min disch.
Binder used. M.P. dermined by ring & ball
Coal Tar Pitch. 130°F
M.P by ring & ball.
Amount of coal. Ibs
Amount of binder Ibs.
REMARKS.
All batches were briquetted in a Mashek Roll Press.
Batches /-8 were mixed in a small bread mixer, blades of 28 &60 rpm. resp.
Batches 5-8
The idea thot a variable time factor in mixing has an impor tant
bearing on the strength of briquette ts not borne out.
Botches 9-14. were mixed in a /arger gos heoted cylindrical paddle MIXES.
Time in mixer before binder added.
58 6I 56 56 |
SS | ee | TE |
/3.2 /2.8 /4-0 | 14.9
17 /o /o 10
a L
Temp of coal when binder added.
180°
/80°
Temp. of binder deqs Fob.
Steam pressure in boiler
Gas consumption
Time for lo cf.
220
Temp. of mixing. degs. Fa
Time of MIxINg
‘Time cooled mins
Method of cooling
floor.
Briquetting temp. degs Fah
Time in press
Depth in press. ins
Speed of rolls before briquetting
it | ir rt
Speed of rolls during briquettng
/0
Method of catching discharge caught on a shovel to break the f
by a shovel.
PRELIMINARY __ OBSERVATIONS.
Nye? I Stonds drop Not crumbly Good briquette
Ne 2 Not so strong as N°!. Some stand drop Clean break not crumbly. Good.
N23 Same as N22, but slightly crumbly.
N24 will not stand drop. Slightly. crumbly.
Ne S. = f= - do- Crumbly. Only fair
N26 Some stand drop All fractures clean. Good.
N2 7. Stands drop. Good strong briquette.
N28 Will not stand drop, but break 1s clean and not crumbly.
N29. Failed in drop test’ Crumbly.
N2 10. - do- - do - Not crumbly. Good average briquette.
Nye 1. -~do- — do- -do- - do- ~do-.
N2 12 Stands drop. Fracture clean ‘Not crumbly. Very fair.
N2 13. Some stand drop. Crumbly. Not so good as N® /2.
Ne2 (4. - do- - do - Fracture clean. Not crumbly.
Note- These observations are more or less borne ovt by the densities.
Wt of screened briquettes Ibs |
Drop TEsT ~ & Briquettes dropped fo’ fo concrete floor.
Batch Ne n 2
Wt of briquettes, gms. 285 286
Wt. of screenings.
Total recovery. %
G+ lo- | l0-
Fall broken
47 | 54 | 475
WZ 14 12
900 | 99.0 | 93-0
Wt refoined on £ screen, gms. [ 280 280
Fines, % of recovery.
206 | 20.2
Density of briquettes.
155 Ibs. screenings
— ee
FIGURE 12
Briquetting Results (From L. U. B. Data sheet LVI)
For text reference see page 71
47
ite
90 |
19-7
1255
Number of brigueHes broken. 2 /
Number of briquettes cracked.
Number of briquettes chipped.
: : in
Loss.
%o
The addition of screenings doss not help toward harder briqueHes.
SMAL
we
Material _briquetted. Car bonized
Binder used. Coal Tar Pit
Ow
}
|
Amount of coal. Ibs. 6-625 b
Amount of binder Ibs.
Mixing ratio
N
Cy
mA
“IR
N
lS
WR
N
S
Time in mixer before binder added. 10 min.
S
®
nN
9
Temp of coal when binder added.
Temp. of binder deqs Fab. 34.0° F
Steam pressure in boiler
N
S
oN
S
oO
Temp. of mixing. degs. Fa
g
a
by
OF
Ww
Lo)
Time of mixing mins.
Time cooled mins
Method of cooling
| Briquetting femp. degs Fah
2)
lot lot
Briquettes ca
Time in press secs
Speed of rolls
ise of rolls during briquetting
Method of catching discharge
Wt of screened briquettes Ibs
WE of screenings Ibs,
before briquetting
Total recovery. %
8 | eos |
Note - To batches Nos. 5.6.7 &
Fines, % of recovery.
Den sity of briquettes.
ere |
Fig. 13
BRIQUETTING RESULTS - LIGNITE UTILIZATION BoarD.
A.D.SL = air dried sulph ite Squor tines: C-lst = coarse firste CMe passed through coffee mill once: CM-2=
assed through coHce mill twice. CT P-i40 = coal far pitch, 140°F, mp. F Ist = tines first F-!22,ehc = fines from
Series No I?2cte.: GT = gas tar: HWP-I30- hard wood pitch 130°F.mp; HWT= hard wood tar: LT-50%°
hianite tar, 50% water: LT. 35% = Ignite far, 67% water : Met rabio: OP-172= ol pic, '72°F, ma: Paste
3/73 = Sour paste ,3 nm 73: R-/ = passed through rolls once: R-2= passed through rolls twice: 5.L- 50% =
commercial sulphite /quor , 50% sohds: SL- 14 ete = commercial sulphite hguor diluted 30 as to con-
/ pert salids fo 3 parts water, efc
Series No.loo is dried Ngnite_,
Quality grading 13 up from P through P+ F- F,F+ &- toG
= a © a — 2 Goa T Atos tanya
E (ae Se Se a eG eee}
on . :
pes Secono| THiro |e) 8 |.2 | & a
a eed ee Ene ay e8{_— (3 General, summanz
SIR 14 els Kind |S] Kind Kind ERIS |B le
lids o
urn
Anth | R-1 |4-5 | 7 |CTP-190" Tce F-G smoky
n 7 G “ “
G P
P JING
P |N.G
122 ie
p | P
ae pee
taaie
6 |6 G but not waterproof
F | F F; quile smoky
GainG fe very-
Feo F F, smok
FIG F-G, smoky
F F, very smoky
G F+ “ n
G 0 ” »
Pp n u
Baa]
'
~quie -
123 | 8/nhg
G, litle smoke
F+ ” °
P, smok
F. somé smoke
Vwwvang PV PaAwHVAGH
F. poor mixing
F-G when dry
G not waterproot
F, little smoke
G, smoke burns
a
‘
AWHs4
Be NSCS Den te eae bares on 9 ht aa 3S =9
a]
'
222 Qa-0
un ®
fs ; not waterproof
FIGURE 13
Briquetting Results (From L. U. B. data .sheet XLVI)
For text reference see page 71
|
—s nth
~
ry
HS CIRRARY
%
Pe rer |
we
CaLVERSITY
jer ~~
a
Att
eo
he eh od
ie tae orate, 1e
5
A Dance Rx
Fig. 14
BR/IQULTTING RESULTS A LIGMWTE UTILIZATION BQARD
Jobles f 10 with Corbonized Lignite Smo/! mixer & rel! press CARBON/ZEOD NOV 19% 19/9
More Nef -Briguettes mode with notable amounts of soft Jor have good surface and stond drop test but can be
broken in the ringers, they harder wilh a.
Volatile matter about 6%, passed Wyice through sira/! rolls GOO2 commercial brguetles classed os A and
subdivided tA A-A. POOR commercia/ briguettes classed os B ond subdivided +E B-B.NON-commercal
briquettes classed as C ond subdivided +©C C-C FAILURES classed as D Drop lest series 150-/60 consis-
ted of a 104 ghop onh a wooden floor wilh the BrigueHte falling Hat Subseguent fo series 160 rest
wos 267 arop onlo o cement floor with the Briqette falling Hof TABLE Nol Series Nos [50 7o /$9.loa/
Tor Fitch MPE/90°F TABLE Noa LT Seres Nos 160 70169. lool Tar Fitch. 4 Pt /90°F TABLE No I Series
Nos /70 Jo (80 incluswe &/B2 Sun Coy. Hydrolene MPL 1e0°F Taledo Pith M Pt Z10°%% TABLE No IV Series Nos /81 183
10/87 prtluswe Imperial O11 la, Asphalts of different /elting Points. JAZLE NoX series £0/ Jo 212. pile Liner.
wilh variations The file Mixtures ip practically af! cases produced Briguetes havirg 2 stnoolh surface but
which could be broken ir the hands CTP + Cool Tar Pitch: W.b.=Worer Gloss: L T= Ligatlelar : C«Cement:
A-Aspta/}: [/7= Mydrolene * M.R.=/Uixing Ratio: LT 50% = Lignite Jar, 50% Wotrer: S.L-4aefc,= commercial
sulpiite liguot diluted $0.28 1o confoin port solids /o 3 parks worer, efC :S*Soap: f=Flour :W=Worer:
6.7 =GasVar ‘LA.< Lignile Asphalt: [P= Toledo fitch: F< fair; P* Poor’ G-G00d' N.G=NoGood
as
NaN BS |Aand-|Burr| Temp \ Drop j
7a ia Ee | ener summarised
Worer 15 - IS|F |\F | ~ |Aass\ +B 5 Slow Speed; See Note /
- |ass,|\-A 3 fost = a
*C, 10¢ RPM: :
-8; “”
/Z0°\ Pass.
40° | Fall.
140°" fail. \
150 °|\ Foil
{50° | Foil
170° Foil
200° \ Fai!
adr
+, “
-C, owed MO mir. of 200°F
Vee ” D
200°\ foss\-8; ~ ZOmnnZ1I2F
£00" fass\*B, “ * 3
200°\ Rail \-C, * “
00°| Fass\+C;
00° | fe]
200° | fass
200° \Fau/
200° | fass
00° | Fass
00° | Poss
200° | /ass
190° | fos/
200°| -
a0 | =
/60°| -
180" | Pass
/80°| fass
190° far.
[90° Vail
[90° \F
{80° " fail
/70° | Foss
190°\ Loss
Oa on i
+B; + pe ROR
af OP ‘ 2 AZO
Ci Wadeded just betere Briag
A, C.Eriguelte; litle smoky
18;6. +» rough surface
1G; G. # “ “
C;: Net suttitient binder
D, Mo briguetes
Bs " ”
dD. “ “
B, 99, surface; lille smoky |
+C; SA? breaks ip tire
#0; Poor surface
Cs eS -
8. Breaks 17 fire
2D;
1C; bh ssurhoce olberw. goed
4; d f
160 i Lass sek DSurk WeSEL mised, doges her
[90° | fa5s\C,9.Ssurk but Crammbly
160° \Fass| B;
150° Fail \-C, No ernulsior, Brigs NG
Ip/ekl = S\Were “ No Srigts
J2O" Voit NCI P Brigveres
120° \fai \ Cr ” ”
100° \Fai/ \ C; G.£rul: Brie, Sol1& crumbly
f00° | fass\t0:A.did ad emubity.b Tadd Crab
/75° | Pass\C. Cumbliy
175? Von |C
[75° \Far! \C. Surtece C breaks in band.
[60° \Fail \C: a “
180°\ Fail\C Med wih A 0° PRG
150° \F5)/ \-C° " -
of above mixturé
”
Flour
“
ZVa\GT &-CTP/¥0°
Bec rT Ryan
(0) GUEF,
q A
WWMM AMAWVYD | VHAGHHHYH WRG Ce WOHH AVAYVVOUMVINVVER a
VHHMRNVVOVDHT I YAUHHH VY VIG | AHHH RRA AMNARVAYDVWAW
FIGURE 14
Briquetting Results (from L. U. B. data sheet XLVI)
For text reference see page 71
Fig. 15
Col. 1 Col. 2 Col. 3 Col. 4
Estimate prepared by Research Council — 1917, Contract prices and estimated prices for present under- Estimated prices for exactly similar Remarks on col. No. 3. The below quoted,
rearranged to suit headings in Col. 2. taking of L. U. Prepared in May 1920. equipment had it been obtained average percentages were obtained from vari-
Figs. in parentheses, thus (8), are reference nos. to original in first quarter of 1917. ous engg. sources and are believed to be
Exact Copy of Estimate prepared in 1917 by Fuel Committee of Research Council estimate. conservative.
- BRIQUETTING PLANT, Ref. No. Item Cost Item Cost Buildings...............$115,000 Complete detailed estimate based on figures
; : : 5 or ona : Profit 10%......-..+++- 11,500 and prices from Dept. of Labour, Ottawa.
(1) (9) (6) Labor and Materials on bldgs including bins... $90,000 Yard switches, sidings, Buildings. ............ $195,000 Yard, Switches, ete....-.. 6,000
Carirat Costs YEARLY OvurpuT 5 7
Maleolmson letter of date May 21st, to Mr. Haanel. (2) Briquetting presse cepa aatsrachemitere aes 15,000 Press}and Mixers! a7. Jno ttep\orataast pte aiereiet caer 30,000 16,700 Based on 75% advance since 1917.
15,000 tons-30,000 tons’
$ $s (3) Waterprooliig ovens: sene- bcc. cee aemrelele 15,000 Not contemplated now.
o} Seated on a marie 73°00 75°000 D 36,0 ) D $32,000) ) Contract tati b) Estd 60%
¢ riquetting Press.... 5,000 5,000 1 . EV ONS Ae oe eros 3,000) a TYETS 1. « - i a) Contractor's quotation, std. on 0
(3) Waterproofing Oven... , 15,000 15,000 @) Dryersjand! Garhomzers iy: 2ic-nsr uaa AASAEE Carbonizer...... 40000): 0 oak tan sree tray otere 76,000 |b) Carbonizers 25,000)...... 57,000 advance since 1917.
= (4) Dryer and Carbonizing mstane 28,000 56,000 =
i (5) Power Plant, Motors and Wiring...........-....--++ 32,000 32,000 (5)(9) Power Plant Boilers and PowerPlant. <2. .n. + ams sleteleless 81,000 45,000 Based on everage advance of 75% since 1917.
(6) Conveyors, Mixers, Track Hoppers, Bins, Storage, etc. . ae 40,000 45,000 =
(7) Fuel Gas and Pitch Recovery Plant..............-.... 35 23,000 23,000 (6) @onveyors cs duet renee ce eae ere alii Track Hopper, Conveyors....... | Gorn ae 52,000 29,000 Based on average advance of 80% since 1917.
(8) Shop Tools, Laboratory, etc........ A 10,000 10,000 =
Cy eabounions alli SDOVE rer etetera: oleletrereiernintahastar state) atasale Pals (a\stme rede Bie 50,000 55,000 (7) By=proaguctibiante. cee cess crtaceertetameete 23,000 Binder storage and gas purifying ............-. 10,000 6,000 Based on average advance of 67% since 1917.
(10) Engineering and Travelling expenses, Freight and Insurance... . 27,000 30,000 =
(8) Shop: toolsrand ab ya. tis stately) tele ateap meters 10,000 Machine shop equipment. ...... prvsenesetees 8,000 4,500 Based on average advance of 70% since 1917.
ARC ye Bras 23,5 SA Gen ce LADO OOD SOO ED COG ROD SEATS 260,000 301,000
(11)15% for Engineering and Contracting...............+..0+055 39,000 45,150 (LOY Engineering). reas sais ane asesiersts oe eT aegis ee 30,000 Office administration and general engineering 68,500 33,000 Based on advance of 25% since 1917.
U Actual up to March 31st $41,000 — Estd for
Grand} Totalteenc se cacieccle averse: ois starrateptenter teres 299,000 346,150 (11)\(12) Contracting: and Int... 2... semen cae 55,000 next 11 months at 2,500, = $27,500 22,000 Based on advance of 30% since 1917.
: (12)Interest on above—6 months at 6%....-.. 2.2.6.0 cece eee ee 8,970 10,384
‘2 (13) Expenses of operation for 6 months of adjustment............ 10,000 10,000 (8) “Working capitals: Ssjcerretecetenaatee eiteretole 10,000 Working capital 8 months at 4,000............ 32,000 18,500 Based on advance of 70%
f ; : ETotalleencmaeeee nce seins cersistsesiea siete ene mareee 317,970 366,534 Totals. ....2uads be ee eee 552,500 364,200
Fixed Charges: Interest = 6%; Depreciation = 10%;
Repairs = 4%;—Total = 20%........-.ceeeeecseeues 63,594 73,307 Contingencies:8-4% «.. c++ «easels =e © alm alales = 47,500 Conting. 8-14%.......... 30,957
(Rear tonamouepiib emer -lastonieletstalseteleicissa) teie.«) \caisterciaYereielriatnietstals 4.24 2.44
Total $366,000 Final! Totals sco p-ro nie aio atts ene ent etn hat 600,000 $395,157
; FROUSIN Go osesi sehr atat cla stots shed see Pee een oe eels 75,000
Total $675,000
FIGURE 15
Digest of Estimates on Plant Expenditure
For lext reference see page 83
Exact Copy of Estimate prepared in 1917 by Fuel Committee of Research
BRIQUETTING PLANT.
CaPpiraL Costs YEAR
Maleolmson letter of date May 21st, to Mr. Haanel.
ee ton
(1) eMaterialsonlys-for buildings... eee oe oer meee ee are. es) cee 20,000
(2) eBriquettine: Press 4. foci. co . Ce ee isis oe ce 15,000
(3) Waterproofing/Ovens. 7.25) Sere nee 15,000
(4) 2Dryer'and:Carbonizing Kilns) Seep eee eters acess ee 28,000
(5) -Power, Plant Motors:anGavaningee ser eee See oe 32,000
(6) Conveyors, Mixers, Track Hoppers, Bins, Storage, etc........ » 40,000
(7) Fuel Gasiand Pitch; Recovery Plant... cee ee sone clo 23,000
(3) Shop) Tools; Laboratory sete sori s eee eet Gaels ia ale oor hoe 10,000
(9)..Labour/on all aboves sweeties eee nan ee oes ee 50,000
(10) Engineering and Travelling expenses, Freight and Insurance... . 27,000
rFotal 04x lerees tower. eee alt eiet ee eee ee ee, Bee 260,000
(11)15% for Hngmeeringsang (Contracting wiser eine aniate 39,000
Grand !Lotal 75 aces) eee Enh cine ea Lee 299,000
(12)Interest on above—6 months at 6%..............cccccccews 8,970
(13) Expenses of operation for 6 months of adjustment............ 10,000
fit hs AO eee er RA 317,970
Fixed Charges: Interest = 6%; Depreciation = 10%;
Repairsi=49,:—T otal =120 Geese oe ee eee 63,594
er: LON OfOULDUte ie ses ss Sela sk Ee ee 4.24
Isr}
1
th
=
om
i
4— — ols — -7‘0— aes
|
|
|
a
a
|
ND
oo
wa
t
ose
“A
Seoie = 1°O°
Engineer Date Apri/ (4 1922
Approved +
Cheeman
Lan i af a ee (NE oe SD te ea em ay 7 ;
yA Cross SECTION A-A
-— 7 Drown FW: Tieeed FON. Checked
FIGURE 17b
Revised layout of Gas System Bienfait Plant 1922
For text reference see page 190
q
! ' “&/", NY
ia, Be — — — — N
SS.
NY
| lire
: | 1%,
Ll ee 3 iz
Sa ee
: ee —
Soe hag ek eae
S i ys 1); 8
5] RTT 1) | i
Q eH
ety e eS
Beall : << Aes
ict oe ee =iS
| |
: |
iS
sa
i
!
: I
Qa | aly ‘1 i] BEY
ae 3 | * Q
/ es PS assy eet H &
/ SF) anal Ra, | }
O a
| es aml
Lo
2 .
—§ Hs
oO 4
S
S >
Ww
\ i
is
*
ox
£ Gas Holder
sg
(Qevralled by rise & fall of Ges Holder bel!)
8 Guick pening Gab Valve
Guy wires” { :
Delt
WGI FE _O BS
t)
J
t)
)
sim 5 See Dy
Fig. 18
So I
je @
re
‘ Canveyer | t ssss=)
Tunne/ to Briquette bin
SECTION B-B SECTION c-c SECTION D-D.
INDUSTRIAL PLANT
BIENFAIT, SASK.
Main MANUFACTURING BLDG.
Cross SECTIONS
oO ww 20 a0 Feet
FIGURE 18
Sections of Main Manufacturing Buildings Bienfait Plant
For text reference see pages 76 and 186
ISON AAAAA ET TH
al
SECTION B-B
\
\ |
wi
\ (Biel 2 oe ee
SAAAAAAAAAAAAA AANA TT Pee
AN SI
Dy
Cu
Fig. 19
,
Manhole fF : an, Sa
Sel
c Binder storage tank
———— 574
List oF EQUIPMENT
DESCRIPTION
Elevalor for Carbonized
Fan fer Dryer Furnace
Feeder
Molors for Oryer Drive
Mixer N°!
Molors for Oryer Exhaust Fans
Fluxer ae
Oryer Exhaust Fans
Edge Runner
Oryer Slacks
Spiral Conveyer
Elevalor for dred cal fo Slorage
Mixer N°2
Motor fer Pressure Blower
Elevalor fo Press
Pressure Blower tor Carbonizers
Press
Gas Exhausler
Shaking Screen
Gas DustTrap
Cooling Conveyer
Ges Scrubber
Main Driving Molor
Molor for Scrubber
Binder Pump
Separaling Tank
Pumps for Liguor, Tar & Waler
Woo/f¥e Cooler
Tar Tanks
Conveyers ter Carbonized Lignile
Plan
Sena
PLaN
FIGURE 19
view of Main Manufacturing Buildings Bienfait Plant
For text reference see pages 76, 184 and 186
Tunnel jo |
Briquette bin
NOTE :- NUMBERS DENOTING CARBONIZERS SHOWN
30 Feet
IN ROMAN FIGURES
[os ae. ea
Montreal P.@.
INDUSTRIAL PLANT
BIENFAIT, SASK.
MAIN MANUFACTURING BLOC.
FLooR PLAN
Scale 'g “10
Date Sept 20th 1971_
Rie oe CRP
[Orewn [Traces [checked |
w= sees Engineer
LS
— - +
NN
%
"tats
lisr oF EQUIPMENT
|____Desenerion «A DESCRIPTION
Fan fer Dryer furnace
Molors for Oryer Drive
Molors for Oryer Exhaust Fans
Oryer Exhaust Fans
(6 [Dryer Stocks | 2a | Spiral Conveyer
[7 lelevalor for died coal b Storage [es|oizer nr?
Molor for Pressure Slower |
| 9 | Pressure Blower for Car
Gas Exkausler
Gas Dust7rap Cooling Conveyer
Fie |Gas_ Scrubber | 30| Man Driving Motor
Woksrtaasabbes
Separating Tank
or Liguor, Tar & Waler
16
Tar Tanks
| 18 \Conveyers for Carbonized Lignile
JS Se
BESSOSSS8So
Fis. 20
Secon 10. Tip. 2 RE.
Section 3, TP. 2 RE.
Twp. 2 R6.
Twp.2 Ré6.
: Z __Sechon 4
Sechion 3,
3
SewsGe D/sPOSAL PLANT
660"
Sr
|
7 Boundary of L UB properly
To Manitoba & Saskatchewan Mine ‘
and Brenfo/t station.
7320"
ae cea
1 HED ae) a
L—.e-CLass A Houses
1
ela a ea
eS a
SS
a
Track HopPeR, CRUSHER Hovs—&->~>=~~~
& Raw LIGNITE BINS ae
QoS Speen eeh a ee ee SRSSES RSE ST SST SS SSR
HooD — ODELL CARBONIZER
5000 CUB. Fr GAS HoLOER
==
|
|
a
Hee ee TE)
om | a
| cry
To Weslern Dominion Colheries
& Taylorlon
Z ee
FUEL Olt TANK
| BINDER STORAGE TANK |
' H '
ft
i BINDER UNLOADING SHED
uy
1| 3
N |
4 |
‘ |
pene 2 Oa
ce) 50 100 150 200 Feel
ns
FIGURE 20
General Plot Plan Bienfait Plant
For text reference see page 62
Nores.
Sewer = -------
lp Ses
Manhole —--e----
Gale ——+-—
Hydrant age
Dotted lines show futures b/dqs.
ear ee)
LIGNITE UTILIZATION BOARD OF CANADA
Montreal P.Q
INDUSTRIAL PLANT.
BiENFAIT, SASK.
PLOT PLAN
Sere | = SO
Oate Rec. 10 P_ 1823,
:
z
b
Q
=
bo)
WN
: : x
lis q N
Ke . q
‘ig u
eS ct “a
Ria A =
QI} es) =
% S
§8 8
al 3
ahs
GY 2dML 'E WOYI2S | : 092
“SY 2 UML "py Uoyae ; a Sea aa a eae nd Saleen hares meer
Fig. 21
ole syeg
goes
Rea yey Yt ee
|
Vv-7 NOILO3S$
oS ee
NV1d
3
992 729 © $206 Sy seg, F
———_|
CXS A PE SPE A SE ECE SC I
NOILO3$
LIGNITE UTILIZATION BOARD OF CANADA
Montreal PQ
INDUSTRIAL PLANT
BIENFAIT, SASK.
RAW LIGNITE BINS
beg IKIG Of IQCAAF
seat 6 = "Oo"
Date OCIS T 1923
-- Engineer
CROSS SECTION.
Correct:
Approved
JIAO] pseog
- Chairman
FIGURE 21
Raw Lignite Bins
For text reference see page 183
‘Oorseo
Fig. 22
Inspection pipes
Feed hopper
a
Gas blowoff fo fi}
almosphere— 9 \K
RI Ge
Discharge mechanism
Carbonized hignile conveyor =
= re otis
S res rif | |
= Sain |
ir rd |
ix
Fire brick |_| Insulating brick
FIGURE 22
Sectional Perspective view of Stansfield Carbonizer Bienfait
For text reference see page 184
~
Inspection pipes
al. ie oe
\Nao
lly,
eL Down ake
‘es bee
eS \w
8 Paes gh SE
hone
—{f
it
uv
Main flue
rbonizer Bienfait
Fire clay Tile mii
Fig. 23
& 2| 3/0
al loti] ¢
3 O Pl =| Qs
g|2 2 2 Miz/Ol;
ta wv & wliz/O/°
Sol/j gS wives
2el1QnFE 0
i 4 oe
wig 5 SO! : |
9-9 NOILOaS -SsoUD S13 2@ma| : :|,
ez u < ole
BJS|EzZ42 “le
EI\S Has
wl/oam © al
Elz i a
2\— Ye 2
= ko 3
a et <= tere — — = — —— —-— -— - ---— — -} --_ _-_ 4 9o 2
Odi; :
4O"f {C. j}
20 Feet
a
|
ay
15
NV1q yOOT, LSULJ
N
N
l6N AvQLYyogY7 =
$
SFYOLE
TWINFHD)
7
|
=o
SSNS ———— meee
WOON FTAWYCS
8°8eo0
FIGURE 23
Office Building and Laboratories Bienfait Plant
For text reference see page 187
SAMPLE Foom
ie yy {Eas SSS SSS z :
Gugungumulammmaunya| EZ
AVS a1 Pas soe the
4
ae
GAS MACHINE
YACKET HEATER
STEAM HEATER
—— —9-6z7—-—- — —
— ee See
Fig. 24
DIAGRAM
OF
DRYER DAMPERS
RAS. 10-21-22
Fan Inlet
Liv ae SEAS nn oe wee Oe ered coco es model ene aes ae
7 ee Tee
; coe
Combustion Gases from Retorts.
FIGURE 24
Section of Dryer showing position of dampers Bienfait Plant
For text reference see pages 183 and 189
ha Pa
; Fy
—e » =
cae
aw
a “
> ’
7 - -
a
6.
ae
»~ 7
oe. a {
= a
= %~
,, ; She
" ie a Cs
/ * — +—
| tad a
| a8
> cone
“2
yo " — | aa 2
7 % a é — :
si ye * ; et
J F a - . ° f or
ee i " S Ae “ad |
BP a ae |
we 4 , vate
a - : a l
> Ws, f- ;
q ‘ fpf
‘ , <
, eS a |
“ ' ~~ ? é t .
‘ . ‘ > + )
2 2 ; 5 .
~ # :
d bi r :
“ , ae 5 %
- ? 4
P ¢ a ]
k 7 . = ‘ta ‘ '
“4 ; a ¢ 2
a » te ‘eo;
= vi ] * }
AEE ’ he a | be ;
+ - ‘S ' ‘ ’ 7
y / ie 5
‘ y » - % a ‘
e ‘ , '
we ) = q :
' ° :
wm \ a
t - a :
a ;
| :
* * ¥
« if
4
¥
k , i
‘
|
' f
"
i
5
;
7 :
‘
‘
4
‘ : :
y \
’ ‘
m >
2, % vtisethina delle il
= a ar
‘ é ( , } t L4
=
‘ ‘4 ’ ry) {
[ “
t ‘ t 1h five ' Whi ani fies
’ ‘
iti >? - eee
aids f Va ot Qa
. ye)
a Ra a Wigs sy si atk
Te 7 st ay se
Fig." 40
OT TAWA _ CARBOMZESY
IMOLDVTED CONSTAUYCTIOW.
SCALE /7-
oO
e 3 Pr 4
Concre/e |
Cas/ sror7 SG
Fire LBI1ck.
Carbhorunavm Zi
7. OCTOBER 9”
FIGURE 40
Modified Constructica of Ottawa Carbonizer
(Oct. 9th, 1919)
For text reference see page 172
qin
Wir a, hd
Ponti im fide One
we areca! NT ee
Fis. 41
CARBONIZER BUILDING AND CARBOMIZERS:
wots oF
ester! = ae ae #6 4a
oe ——— es —— se ee ee ee ee ee ee es ss
mein or a
ww
H [hiee.
| CONVEYOR | GALLERY.
Lxp/osion a
or
OOF |
a N pT CS Zee
Qrred Liginile Bir.
So
WLLL
tho
ZZ
SS N
NS NN
N NN
NS SN
NN WN
NN SS
NM N
X N
NN WN
N N
\ ‘
‘ ‘)
\
NN NN
: :
Ph aS
3
FIGURE 41 |
Carbonizer Building and Carbonizers — Sectional Elevation Bienfait Plant
For text reference see pages 175 and 184 |
ei
:
Lo a
Pahl i. ee BS
Fig. 42
STANSFIELD CARBON/IZEF
Scale fr t f
$0, LULA SLLMATEEO
. esa F-
_——
Y FIVE.
AAjes. | baa”
ae ULLZZ1N SPR
~~ Y ‘
y VATA Pre
Ba
vL
7) z
SN Ar
RS ZEA
IRIN OCA OTL LLL
#22, NNRAARNARSARQA
SECTION A-A.
SS
cee
4
10°6-0:6:
woteses
weteten
ore"
2
Ss
NZ
VY
NZ
‘iY
VY v (@ Bx
WY x x A
wile SN ZS &§ AR
Safely NZ NaZS:
kosve. BS Z 8 S Ns:
NZ Q Ns
BS Z ise
NZ =
et 'Z IN RRS
NG 33
SING V3
BRY SB
ggg
44,529 Z
WN
ve RAs isd
“oge" 50 e%
0.0.9,
7
Oo
A
5250
7
<*> SP rs 4
4
%2
orereren
Od
77 Ut 4, s
7 Peale t 3
Y, fai A FSI
(ae oe
LR ss
'o -~-
CX
tote
2s
v
o,
A) Gas 6urner.
SIX,
ienece,
Wi :
QA We Sornace pla/e.
FZ ; Z) VR
kf Lxlosion BS)
BS NN YY | D0 S/idle Z S we =
RSS Gok ZN.
a . 2 ; G . KS ———
Be a fe \* PS]
A Yi ee :
BS N Yy H ae SRS
RAN Vlllaeatts oor sre. ‘ se a
N 1 8.
Oe
BS
: © Discharge SNS
Conveyor.
Z 77.90 ,97,°0,77,
ara ae ePP 2,8
OOOO
Fire brick. Ui Insvlating brick. Common Lrick. Sees
&
LIL
22S
"o%
2,
¢
x
ca .
4447
"2,
v,
o
CE
a
?
*
x
%
Grit A OF:
or
re
2,
a
2
5
e
O
\7
aS
wr,
SSS
sen q . Nis.
LONGITUDINAL SECTION OF ASSEMBLED CARBONIZER. BI Ve LAS
x0 Repetto area
Bassey ap
FIGURE 42 |
Longitudinal Section of Assembled Carbonizer Bienfait Plant
For text reference see page 175
—_ 2
te ee
—_
—
pe = ;
Fis. 43
WSs
Wee
ESS
==
ene
_In speciion oles
Ss!
MUL
RSS
RY
a
aaa
SON
LLL ALL
Shde gale
Section D-D
furnace plale
Nr door
weiner by Ja
A take
LONGITUDINAL SECTION OF ASSEMBLED CARBONIZER
Gas oO
Footing for bldg column
LIGNITE UTILIZATION, BOARD OF CANADA
72234 DousLe CARBONIZER
ASSEMBLY & SECTIONOF FLUE
& DOWNTAKE RECONSTRUCT-
1ON TyPe N°!
\Zoeyuor SIYf ul [out wu) Correct: Scale ‘¢ > 1-0"
JOKPAUOD 2 eYy2sig nore nee eeee sees seas Engineer Date Aus iS eoz2
fF Reese:
| ee Gree C27 Sik
Drown _JGH
°
Iron cock
3
Zz
PN3 Woaier inlet
\pischa rge_hogpe
Hot waler &
FIGURE 43
Stansfield Carbonizer after Reconstruction Aug. 15th, 1922
For text reference see page 190
,
-
Ye
a
a)
~&
S
S
ow
8
ne
<
;
wash Laesiale epee fae <é iy hs /
gee Gs = : Kot
Stansfield
Fig. 44
Aralysis of Caqadiar Materials Griquetted Ar Hebroz, NO.
Date- December 92a 8| 0 | uv | el 3 | 4] | © Wreragel zo | 2 rere
ava Pe ee a iio I
| pfoisture | tas2| «| saoal 172/| 14.06| 1ag2| 16.73| 1792| /5.60| /4.75| /6.00| 15.37
[ velgrile tes | sd a7] + 720| rs.4s| 171e| 17.67| 16.81| 37 27|_2795| 2¢.65|0 2825
Fixed Carbor | sésa\ 0 |S s5| s2.40| sso} ssc] _sa.o| sasel_saes| 4535/4665) #508
eis) me | rei7o| OS | 29 5\orsis Mes s|" 74a s0l0 7250
| lB. p203a[ sd 93. 05| ga ar| 9260! g914| g808| 3857| 9027| 8739| ¢767| 8753
| Dry Bzsis 8B7s/s -—_{ ff ff ft rT ott
Volatile pitas} | 20sa| 20.78} 2007 20.17] 24201 za2H 2046] 32671 26/2 33.40
Fixed Carbo 63.29| 64//| 63.04 63.g0| 65.20| 64.32| 53.20| 53./5| 53./7
As [14.96] | + 5.07| 15.93| 14421 16.79| 15.00] /4.35| /5.22| 1 4./3| /2.73| 13.43)
| KTM fo vol [0 1 5[ 106 8 ol 107701704 60|10578|10775| 106 92|/0 250|/04 30| 103 go
rox ard of Char ix | | a eee ee a
| eisture | 4 52| ra.20| 14ae8| to s2| 7394] 74.12] 15.08| 76.15| 14389] 1390] 16.85| 15,37
HE VeizFie [6 rt | 6.98] 64.97] -16.68| e507 7.76| 17. 26llege s|) ress |memsolmeenolmeges
BTL. |9203| 943¢| 9329] 9081| 928/| 9370| 2/62| 9374 9279] 9/26| 8755| #9 40
Volatile | 1¢.84| 19.75| 17.481 1990] 2/.09| 19.98| 2030] 27.771 1999] 3/.94| 3465) 7
(4.96| 14.63| (4.33| /460| ;4.22| »455| 1470] 13 53| 444] 13.46| 12.08!
( meistire" - | 7 4.28| 10.89] 10.:6| 1426] 9.5| foes] ye75|) aayle esl) Daolaso
| Kelarile | zs.90| 2/.¢7| 2/.95| 2282] 23.66] 22.78| 22 06| 2337] 22.66] 3340] 3430
| Fixed Garbog | 55.50| 5597| 56.88| 52/3 2} S628 5377| 53 67| 56 30| 5500| 4820| 47.45| 47.82
Sees 427 | 7783 2| 27 eor 10,9/| 10.57| (0 62| 1092] 140.93] 9.70] 9.75
10307
Pry 84s/' Pennies i im i |
| Yelgtile | 24.68| 24.53] 24.43] 2662| 26/9| 2675] 26301 2580] 2559] 36.58] 37.48
d Carboy | 62.56| 62.¢2| 63.321 60.80] 6/.74| 6 72| 6/.53| 62.201 62.09] 52 s0| 5/87
A. 12.76|9/2.65| 12.25) 72.58|4/ 200 7 nes |e 7 |eener ol ay
0.65| 10.64
/ 2
2.32
(1 475\/1 34011 5201/1 48 O|// 570l//) $56] (14.44) 1131 31/7462] 112 001// 350/72
FIGURE 44
Chemical analyses Hebron briquetting test, Dec. 1923
N
>|
BR
For lext reference see page 234
Araly sis of Canddiar Mater i
Date ~ December, /92 8 Mf (3
Prox. 4asl of Char |= |. Pee ae |
oishure i482) | sees her 1 4.
Volatile jerr| | 72 ee ae
Fixed Carbo -#6.e|___|_sa.85) 8200) $5.1
AS 12.79 1295) /(3./49|] 1/23
B.T. |2203| «||: 93:05| ggar| a2¢
Dry Bzsis pA a |
Volatile Liss | 20.82} 2028 21.4
Fixed Carbo b AL
Ash 14.96] | 15.07] 15.93| 14
B.T uf 10770| si | ro 81 S| 1068 ollo7:
ox. Aral. of Char ix | a |
vish; 3
Volatile 18.1
Fixed Carbor | 56.5$| 56.25| 58.05| 54.95| 55.6
As) 12.79| 12.53| 12.20| 12.25| /2.2
BTL. 9203| 943/| 9329] 9o0g1| ¢
Dyer | Se er :
Volatile 1.0
Fixed Carbo b 4.4
As | 14.90| 14.63| (4.33| (460 74.
IRAE '10770|11003|/09 601/0825|1073
ox, Agalof Brigte’s |) |. | a
Moisture 1426| 9.6
Yolapile 2/.95| 2282] 23-6
AC 55.97| 5688| 52.13] 557
A: 10,6
BT Ld. 10 4
Pry Bas/: Ma |
Olah ile ba
xed Carbon ere
A 12.76 12.65] 12.25| 42.58] /2.¢
. GEERT RGRIAG (1 &@75V/I340\11 S2O\// 48 Of // 57
Gua
Chemical analyses Hebron bri
For lext reference s
Figs. 45-b-45-a
Scnanene
=
y
5
=
\)
D
y
ape
AL GOM
216, b>, +
~
| Hoe
PY ees eee
/
FIGURE 45-b
Stove test curve briquetting experiments, Dec. 1923, Hebron, N. D.
For text reference see page 236
FIGURE 45-a
Stove test curve briquetting experiments, Dec. 1923, Hebron, N. D.
For text reference see page 236
oy RAVEQTT CME
*
Figs. 45-d-45-c
~
s: 38
x See
\
is
peg: ban
Temp ise
i
wa
MUO OG RAE Su
Teh
pi aBas
4S MOR ARAE
NEHER
rg Nt Ret eb leb at
O.
fey
SQ uw I <
LO
fe ie.
$913.95
1% of As
gues Leon Temp.
Teta dil iteg? ip Demers iy oo b\. bre \lens és\|l 927)
Avil. Heat per |b Surgzed deg. hrs 17.00| /6,4/
ist toile). 10674110649| soo 7/\/0/ 7/2 |
Shore Test WS was Madde o7 brigdets MXVS
Dec. 8-/0-1!-/2-13-/4 And represents the 7 body o 2
briguethi [esis .
Srove Tests 6 /3 Wer ade a7 the prodiuck
of Dec. 18 and 1/9 whieh differs from the earlier riguers
dlr ELLA 17 the binder, 20% of Lagite pit
Stove Test N77 covers the bi volgtile materi!
the lask car tregted. 6 birder nas cogl tzr_pite
And flour
FIGURE 46
Table showing results of stove tests briquetting experiments, Hebron, N. D.
For text reference see page 236
: ; Fe if
Anste |
Ce
a ee
.
‘
4
- .
b 4
| -
4
‘
:
b ‘
t
é i ,
’
"
s
q : > ™»
a
| af “
od -
;
r ra
= — » 2 ‘ ‘ e
] a
. -
e \AE h. ‘
> tgs i ¥
int
Fe = a:
5 Mpa
it ,
> t i 4 vet
I ; : S) ie
4 ; Most -ergfies
>, be sep if j
vee + by Pe ve Bia he
; Ae OW Bie be es
mt bier
© ASS
ESAS ORE Ba aa hae
Sh ny Ve atu gd eet
+ - . f
ete,
D oi
,
“Pi
eX
Fig. 47
| Basis |
Meier me se | 7 ee ee ee ee ee eee
Dare of Magufachire -1923| ror. 30| Dec. 1 | deo. 4 | dee 5 | dee. 5| Dec 24| Dec 24 | ee 26)
Sarena
Char + Moisture Yo 80.62 &3.04| 90.04] 852
grite Fit
Frox. Aridl. of Char
Morstusre ,
WG Voletile |
Kee'd | Fixed Carboq |
| Ory | Fixed Carboy
Rae Z
Ss.
3.94 15.16
L 5.62 0.3
/16 801//323|//430
S iy Lilia
FIGURE 47
Table of chemical analyses briquetting experiments, Grand Forks, N. D.
For text reference see page 239
aa imine
SE TTPNCO eS La
Se aoeihar lof Briowetre
Cher + Pleisture Yo | 80.62) 9) e753 ame
or pul 727 S725 ee
ee Four Yt th as ee
Cada! Tar (Fb
rite Fit | p90 | 2 bloom ee
Prox. Anil. of Char a
Moisture
4
fed | Fixed Carbo 5047| 46.20| 5908
Bit ee
ltt ke | z0ose | 37 70) 32/35) comme
Dr
Basis | As /0.25| /242| /2 bo
Fron Arnal of Char Mix. |.
amine 5.66
A; | Yokrrile 19.06| 27./9| 28.70] 20.98
Reed | Fixed Carbo 5 42| 46.96 46 22| 5505
As ‘ga | //.96l //.93| so43| 9.79] 7.83)
letile | 2740| 2/.56| 32./0| 3390] 23.95
Or [Eixed Garber | 46.bal 694) exeal Sea
Basis | As! | /2.98| /3.50| 12.32] // 56| 13.46
STM 43b| 621) / 7 475) ee
Fron Arpal. of Briguets || Oe
9)shel-e 9./2| 9.79] /5.20| /e7/8| 1442'
Al Yolahile 24.26| 23.43 29.56| 3/.32| 24.00
fec'd | Fixed Carbo 55.29| 55.45] 46.47| 42.00) 49 0S
.
Yolatile
~
0 j~
|>
ON |w
, AY
SS
SiN
‘ OW lw
5 >
Via)
w {SQ
~ IA
Q |
Ye)
aa Sah
CN 1H
N lo
ee i™~
© |
N
Oo
SO SET TR Se ST A A, I A SY MRE AAR
FIGURE 47
Table of chemical analyses briquetting experiments, Grand Fork
For text reference see page 239
Fig. 48
Cr. =< 9D
Store Test Oale. Tests
Ou
2)
Ns
®
:
o
toes
~ [
So NY
1067.5
ERE
Som ay al F, /0960
/04-/ OS
[g-25 17.45
/0633 |/0935
7
x.
+
eS
o
iN)
| xX
S
8
“
—
Oh
N
FIGURE 48 |
Table of results of stove tests briquetting experiments, Grand Fi
For text reference see page 24
La
Figs. 49-a-49-b
Taz. 3, /924 Stove TéesT NS Loo Temp. Curve
tetas | Aghilal Temp Curve
o—0——_0-——0 Te rve corrected to bo/lbs burved ig 23 Yrs
FIGURE 49-a
Stove test curve briquetting experiments, Grand Forks, N. D.
For text reference see page 242
Jaq 3,/924 S7ore Tesr N° 8. Flite Temp. Curve
Ls)
ne
~
~
-
é
z
N
ry)
ny
5
an
~
NX
bj
@
.)
8
N
rey
nN
o
Eo
paieehes|| | ley
HY
oie
FIGURE 49-b
Stove test briquetting experiments, Grand Forks, N. D.
For text reference see page 242
FY CF Hoe epaRy
~
_—
E
e
intiide) esac x
tS
2 ~
Figs. 49-c-49-d
Jaz 47 1924 Stove Tesr ng Keon Temp. Curve.
~———— a —_—— 4 ——— a
Bae
Cos
TRE Ty RT. 2 YS eae ee a Lee et ee
Time i'n hours
FIGURE 49-c
Stove test curve briquetting experiments, Grand Forks, N. D.
For text reference see page 242
T4zZ_4, 1924 Stove Jesr N29 Flue Temp. Curve
SWe4eEo Emel
22 a sa Raed
DO ees
ESV EP EES Ses a:
Biase ese ee
5 ol Fn
gc oe |b al a Sd
Lee ae
SA Aaaaeee
Time in hours
FIGURE 49-d
Stove test curve briquetting experiments, Grand Forks, N. D.
For text reference see page 242
4. ie = = 2% -
a. : =f eS
aa ‘ , wt: z aw
. _ =) :
a iy ‘ . , * t , 7 =
cy He ete RFE
“ he. : +7 1
: A. a
_ ad at
b
ia =
. L
4
~
Fal
:
—
¥
xv
+
E
~
r
3
z o
Pa ntl
ms
‘
: ‘ > 9
\ \ < vinden a ~
ish ESLER BEAS ae
ot onl
‘ ee ea?
f t g > Pat .
p —
» _ . vu, _
Figs. 49-e-49-f
Taz 5” 926 STrove Test N= /¢ Koom Teme. Curve |
Aetwa! Tegp. Curve
Gurve corrected % 0's burned 17 2372 brs
PLEtar ee
am a se = m
3 2 Ss 6 2 ? 9 fe) “4 Ur 43 a ‘§ 16 ‘7 / , to r] 22 3
Time in hours
FIGURE 49-e
Stove test curve briquetting experiments, Grand Forks, N. D.
For text reference see page 242
Fide Tempe. Curve
Jaz 5.1924 Srove Tesr V°/0
pee nud.
Time in hows
FIGURE 49-f
Stove test curve briquetting experiments, Grand Forks, N. D.
For text reference see page 242
“hig,
EAT
»
|
¥
ma
=
Ph
sires a eh .
Lot ew hl od ee aS pF
- °
- ' e)
So) OAV, Soe unrerrale
Me
Figs. 49-§-49-h
Jaz. b, 1924-. STOVE Test Lf? 1/ Koom Temp. Curve
el a Aelita / Te, . Curve
Gent Te, Curve corrected fo 60 /bs buried “@ 23 fours.
.
Seay san
ari If Lt
25> 8nee
See iss
pe bP dearged = ete ||
ET tL
Seer tlhe
na
i
eal
WA
id
a»
eh.
Pal
i
a
Corre ee
| sae
3 d
ae
Ny .
re d
nail
|
Rae
/
Weds
ele
Aa
FIGURE 49-¢
Stove test curve briquetting experiments, Grand Forks, N. D.
For text reference see page 242
Jan. 7 1924 Stove Test Na// Flue Temp. Curve.
SR RSERD = 22S eee
occ eee eee
JSRReS o" See eee
_| SBSRS = see eee
Sea (SSaeRR eee
__ / SS ees eee
ee) eee Ne ees
ev A= eee
40 ——
| er a = a
(Re See ee
7 3 x 3 f TE TEE.
6 3 9 Ot: /2 I
Time in hours
FIGURE 49-h
Stove test curve briquetting experiments, Grand Forks, N. D.
For text reference see page 242
Gq I5
ss
Hl
,
=
j
+
h—~ 0 eer ae a
aad rar ad
' - wh
~ _
' Yo d S ge ee
. Pe ‘
* i
}
» “
*, ~ a »
“
< f
~ 1 f
t
< “
Pr f
. -
'
‘
rd
b -
= 2
,
sot
A >
% . 5
. af
4
a F
:
~ j - ba ’
_ co — i - eo me me =
s aa 7 =
= Seino wee
* - -
" .
“j
L ib beets $
: ok ea =
ear ae. Xa ye
‘4: &
i, i. Bae
*]
bia
Figs. 49-i-49-j
Jaz Z_ 1924 Srove Tesr N2/2 Koon Temp. Curve |
eee rela Koon Terup-
TEeo Temp. Curve corrected % bolos. burned jo 23 br
ea
es
ie Zope Une
Fey anil ISOS alas
ee eee ee Ne
soe tates ede = Voth Ae be Lt buboey Node |
* Sie Tadeudes [iachede ae.e*| | [SAT |
on juaa aun aueeeenae=
i a ee i eh
FIGURE 49-i
Stove test curve briquetting experiments, Grand Forks, N. D.
For text reference see page 242
eee
rae Se
473 4% IS oat ‘7 4e 69
Stove Tesr N?2 /2 Flue Temp. Curve
Je eee see
| Bee
, | ee 2S eee
“ets NS
z 3 9 2
FIGURE 49-j
Stove test curve briquetting experiments, Grand Forks, N. D.
For text reference see page 242
; y % ~- i ol alin bodies
ty ‘eee
77 .) 5
i)
ws
n
4am
TY wi
wi
a
whed
ae
ad
nd
&
3
Figs. 49-k-49-1
JAZ 13, /924 STove Test N2IS
e Artin g | Tempe. Curve
FIGURE 49-k
Stove test curve briquetting experiments, Grand Forks, N. D.
For text reference see page 242
Taz 13" 1924 Stove Tesr N15
Flue 7e77p. Curve
FIGURE 49-1
Stove test curve briquetting experiments, Jan. 1924, Grand Forks, N. D
For text reference see page 242
a
Av
a
ue
gi: ?
i 20 ALISHSAINS -
\
Figs. 50-51
FLOW SHEET of EXPERIMENTAL BRIQUETTING INSTALLATION
at
UNIVERSITY of NORTH DAKOTA
GRAND FORKS N.D,
Gy rater
Ef Crushed
‘
; Goont Feedar
é Used as Cooler
ya ol) Press
x
Terforated
Belt tor
Ramoving
Fines
Gaunt Faeda
FIGURE 50
Flow sheet of briquetting installation, Grand Forks, N. D.
For text reference see page 239
DIAGKAM
f
HEBRON OVEN
2/26/23 — RAS
heoppae—— *
B8oe gut
Top bottle w of-toke Vico
desting Fides _
Intarmad ata
Betlle wOr theke
Flues
Stor thhag z Y a af
O+sehar
an ¥ ‘ @
ce)
Conveyors we
FIGURE 51
Diagrammatic elevation of Hebron retort
For text reference see page 229
_—_— ma»
nat y = — ey
ential: Se
on
-
eee a eee ee
=e oe a
é _ @ i. bas
< _~ 7.
“ ; 0 Pore
+): Vue ee ATS :
j Pear
~ )
1
r “ , : ; + /
' wPUWAG@ WMO. te”) Twa ey
= :
—)
ose ‘i
= — | ae
(™ ia
om
_ ~
a oie inn
+4
a
4 7 MeO
"t =
#24 3
ae ) 7
ma ? fe =!
hfe
aim | ° i
= "
oy }
ae
=>
i
a oe a
E a bs
i
3 é )
14
2 cas. c %
~ “ >
, oa
“a *
«
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'
_ ‘
aA
:
a: j
wae
- - re yet
ae od
]
— ee
. e@r ei
Fe fox
BI : f
Lase 5h rq
- -
Fig. 52
FIOW SHEET
of
BRIQUETTING PLANT
Mining Experiment Sub- Station
Hebron N.D
2/26/23 RAS
_.hive Steam
‘ gor
/0°%10'Staam Jackefead frehcatan
eos"
Cele = L | cs atomined
Bucket 22 “x/o “Rolls eon 12° /G/s0ar — Piteh- Sarey
Flavayor a divvarede
pw
o
~_—
Ww
Y
—
=
wy
+
om
S
oOo
&
iv)
~~ te “t+ ‘
ote a es re
te
it
purymary gv 20 ALISA
if me, , |
a | , a>
a a La ’ . 2 vt Be
oe) er : |
ede ae noire sleyt x eae Aw «© teh ' 4
} ; r . & ri
i>
as ? , |
Fig. 58
wee
ud
S|
ED |
OEQ7
=)
(aed
C\2
Vv)
.-<
LD)
>
oc
—
GS)
“al
FIGURE 58
For text reference see
/ Y /
a ip ane 3
(
LTT
a eb ae
TTT TTL ae
4
NN
>
va
—Z
+
so
=
S?)
a
3S
a)
—
)
=)
=
E
>
co
os
3
So
_2
+
Q
2
<
LY)
oc
a
8)
c
is]
9
i
8
=
lees pipet SALLI Tg
we - 2 wg P a
gt
as a
nae
?
i
.
t
RVD eT ALISHSAIED
Fig. 59
S71 26nd aas aouasafas 129} 10g
6S CANON
“buy ‘vopuoy ‘py]"0) s}anposy oqiey ¥ IQ
LINC) ONIZINODYW) JLIHA
BES SQ GC Prey
one oe Bees mei 2 erred al
Y
SSS) ASSGGH ASS IaH EEE ws S a} :
sokanuo? Le
o Knea
> hi
‘ on . ; 2m - ee Tan nae
! . ‘ a » Ties
ph A See aoe . 7 OA
Ber seed is a Se prema nit
f
Ae he ode
~~
2
sf ee hi ’ AS Oe ase 4
; fe id alee cidedacda
- juvuat 8. Pi sO AUS
oe Rais
ERT GAS ,
t _ ;
i
whe)
ntl athe ie TON a NE ek mn we ew
Fig. 60
urner
SECTION OF DR.BREDLIKS RETORT. |
Gas & Coke Oven Corpn. of America, New York. NY.
FIGURE 60
For text reference see page 145
F | alll
oe!
es,
~~
Bes TI
os. - ee
ag ry Ee - ;
~ ' ert ’ F w
‘ »
a 7 ee t 5 om ae «
“§ - ‘33 i - 4
j é Pa e '
fg ~ Stee teat 4k aay J ;
‘ , ea. Ai ae ae _
ae Bey é.\ os A
e : - meas * Meds fo 2? :
: | iy ees ee
i a he ae |
a y b Pe) { :
: . 3 '- <
e j =
| . 4 4 * ~
Fi “} *
ee 3 meme
: 7 ; é = PF
a a a
‘em :
,) > a ~ ne
rae
ht
hie
a
?. r
n :
> = P
< ~ i a
~ .
ae
TP oy ae ae
. iA Gy SU TARE FEE
qc) wot Joma Re acti |
r ——— - ares ee Se. cee - ~
- “1 a 2 ’
=
i ie eae
Fath of materials through hard pitch plant shown thus’
ERT Eafe IP eG a ee ee
Allernative routes through either plant with additional equipment sometimes
installed, shown thus ------------- .
Flow SHEET- TypicaL BRIQUETTING PLANTS.
FIGURE 62
For text reference see page 145
. d ‘) y J ¥
il liana nie GA ig A nc lalate tell
-
ob 5 oa @
, “ fe
a ee
>
7
tt lt mag
a ed
_-
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ati ae
»
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terse ee on ete Pe teal
“¢ '
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4
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