0): Io ae © ’ Lae © > BOs °. ) ) 9 ) ) ) ) conomy. ty oe ) ) » © »-) Cea 50 09 5) ) ’ ’ ) ee es ) ee J. 4 Se ) fh Je) a) ee) +) s) » 4 Yo ) a ) 3m. ony ) ) é v 5 MST es 5 5 Dy B) ‘ ’ are i) a . ) ay 2 ) ? ” 5) ) » ISSUED BY The Department of Smoke Abatement Geclaridt Ohio > SMOKE PREVENTION. > AND ECONOMY. £ = +3 © ts 4 In all industrial centers, except where water power in large amounts' is av ailable, ttie> ques- tion of fuel, its economical handling ‘ants torn- bustion is of prime importance. By “fuel” is meant carbon, hydrocarbons or a combination of the two, either in the solid, liquid, or gaseous state. The “Smoke Nuisance” is a problem whose determining factors are geography, freight rates, public sentiment and economy. The geography of Cleveland and prevailing freight rates are such, with respect to the an- thracite coal fields, the natural gas and oil supply, and the bituminous coal deposits, that for most industrial operations bituminous coal is the only fuel which is commercially feasible, and this is, above all other fuels, the smoky fuel. Public sentiment in Cleveland and consid- erations of economy both demand that. the “smoke nuisance’ be eliminated as a civic problem. It is to the method of handling bituminous coal in order to produce, as near as may be, perfect combustion, that one’s attention must be directed in any discussion on the subject of “smoke” and “smoke prevention.” e&6 CDG At the outset one naturally asks “What is smoke? How is it produced? Can it be pre- vented? Is it worth while to prevent it?” To the, first avety the answer is often made, BEE i suitbirndd carbon.” © But’ this: is anly * mae part “truth, for, the, same thing may be said of agthragits coat sow diamond, or an in- definite” jmsnber® rot Siher substances. Smoke fs ‘carbgn i wl a Gnely davided state escaping with thesptaqutts ¢ on *cpfitsw’stion from a place where céinfsitstion is more or less incomplete. By combustion is understood the chemical union of oxygen with the fuel. The source of oxygen supply is the atmosphere. To secure perfect combustion several conditions must ob- tain: (1) The air supply must be sufficient; (2) the intermingling of air and fuel must be complete and thorough so that every minute particle of each comes into direct and intimate contact with the other; (3) a temperature at which combustion takes place must be main- tained until combustion is complete. The ab- sence of any of these conditions results in imperfect combustion and is likely to result in the production of black smoke. In the burning of fuels rich in hydrocarbons, these three principles are fundamental. Take the ordinary gas burner. The gas issues from the tip in a thin flat sheet, offering a broad surface on two sides to the attack of the oxy- gen particles. Put a cold plate into the yel- low part of the flame and a deposit of soot is at once apparent, for the temperature.at the cool surface is below the temperature of com- bustion and carbon in a finely. divided state is 4 deposited out. In the bunsen burner if the slide be moved back and forth, which regulates the admission of air, the flame burns blue, or yellow and smoky, depending on whether the air supply is sufficient and the mixture com- plete. But bituminous coal is the smoke producing fuel and it is the methods for burning bitum- inous coal and the devices used to attain a maximum of economy and smokelessness that now claim attention. Chemical analysis of bi- tuminous coals show them to be a mixture of fixed carbon and volatile hydro-carbons in varying relative amounts, with volatile matter ranging all the way from 15% to 50%, the smokiness increasing in direct ratio with the volatile matter. Coal differs widely in heat values and other properties, such as percentage of ash, mois- ture, sulphur, iron, tendency to “cake” or “run on the grates,” etc. The bituminous coals from Ohio and Pennsylvania, from which fields Cleveland draws its principal supplies, range in heat value from 12,000 to 14,000 B. T. U., and in volatile matter from 30% to 40%. A perfect furnace is one in which the com- bustion is complete and the maximum heating value secured from the fuel. It is entirely pos- sible to construct a furnace in such a way that the volatile gases will all escape without burn- ing, and with such an arrangement we have the ordinary coke oven, with an efficiency as a heating or steam boiler furnace of zero, and a maximum as a smoke producer. Between this and the furnace of maximum efficiency 5 and minimum of smokiness there are an in- definite number of intermediate stages due to the fact that one or more of the conditions | enumerated above is not properly observed. The present discussion is confined chiefly to steam boiler furnaces, both for the reason that it is easy to determine the efficiency and econ- omy of such a furnace by suitable tests, and because in the larger cities where the “smoke nuisance” is a live and important problem the great majority of smoke producing stacks are in connection with steam boiler plants. When fresh coal is fed to the fire either by hand or by mechanical means, the first process which takes place is one of distillation. The volatile matter is given off at a temperature much lower than that at which combustion takes place, and in a very short time com- - pared to the time required to burn the fixed carbon or coke. This means that the air sup- ply must be considerably increased at the time coal is put into the furnace if stoking is done by hand, or that both the supply of air and of fuel must be regular and uniform if the stok- ing is done by mechanical means. In a hand- fired furnace if the air supply at all times is sufficient for the combustion of the volatile gases at the time when the fuel is supplied to the furnace, then it is too great for good economy, or, if arranged for conditions -of best economy it is not sufficient for smoke- less condition of the stack at the time of firing. The logical solution of the smoke ques- tion then, in connection with steam boiler plants, would seem to be an arrangement 6 whereby the supply of fuel and of air is uni- » form and continuous with some means of in- creasing or decreasing such supply with the change in demand on a steam plant. The mechanical stoker in various forms ac- complishes such uniformity of fuel supply, and proper furnace construction and damper ar- rangement governs in a very satisfactory way the air supply. Three quite distinct types of mechanical stokers are in very general use. One is the traveling or link grate in the form of an endless chain, a number of makes of which are in successful operation, as the Babcock & Wilcox, the Aultman-Taylor, the Greene, the McKenzie, the Victor, the Duluth. Onto this traveling grate the fuel is delivered from a hopper at the front, the coking or dis- tilling process occurring well to the front of the grate and the gases passing over the hot bed of coals before coming into contact with the surface of the boiler. The burning of the coke occurs throughout the central part of the grate, and at the extreme back the cinder and ash begin to cool off before being dropped into the ashpit, or as in the McKenzie, and the Victor, onto a dumping grate at the rear. For plants where the load is uniform and there is no occasion for severe forcing of the boiler, this is a very satisfactory type of stoker, and on account of the fact that it is self-cleaning it gives at all times, when the air supply is right, an almost perfectly smokeless stack and a high > economy in evaporation. A second type of stoker haswnclined grates "7 ‘ placed either in front, as the Roney, Wilkin- son and Brightman stokers, or at the sides, as the Murphy and -Detroit. These inclined grates are movable, the coal is fed onto them from a hopper at the top and is gradually worked downward. Some of them are pro- vided with clinker bars which work automatic- ally and keep the furnace practically free from ash, although they do not take care of the larger clinkers completely, making it necessary to clean fires one or more times during the day, depending on the amount and quality of coal which is being used. In the Murphy and Detroit stokers, in addition to the automatic feeding of the coal, great care is taken in the furnace construction to provide just the right supply of air and at the right place to secure complete combustion. This type of stoker gives excellent results as a smoke preventer, and shows high economy in fuel consumption. The oldest stoker equipments in the city are of that kind. The third type is the underfeed stoker, either the American or Jones. In this type the coal is fed into the furnace from underneath through a retort by means of a ram or screw and is forced upward into the centre of the firebox, the coking process taking place from below, the volatile matter passing up through the intensely heated coke at the top. With this tvpe of stoker it is necessary to use a forced draft, the ash-pit being closed up tight and kept under a pressure of several ounces. The fire is very similar to that in a black- smith’s forge. This type of furnace is not gen- 8 erally made self-cleaning, but very little ash is formed, the refuse being in the shape of large masses of clinker which can be easily pulled out through the door by a hook, the process of cleaning taking but a very short time. This type of stoker shows the same satisfactory re- sults in smoke prevention and economy as the others when properly handled, and admits of somewhat greater flexibility of operation. A mechanical stoker of any one of the several types above enumerated meets most of the re- quirements to be found in general stationary plants. Steam boiler furnaces on the down draft principle are quite extensively used. The one best known in Cleveland is the Hawley Down Draft. In a furnace of this type fresh coal is supplied at the top on a water grate with rather wide openings, the air passes down through this and over a lower grate onto which the coal drops as the coking process takes place. Furnaces of this type are prac- tically smokeless when properly operated. The Puddington furnace comprises a retort or gas generator in some suitable place, gen- erally in the bridge wall, through which a small supply of oil is driven by means of a fine jet of steam. The gas generated in this retort is projected out of small nozzles from the front of the bridge wall over the fire. Some little distance in front of the bridge wall is built a deflecting arch suitably supported. The gases as they are given off from the fresh coal are deflected downward by the suspended arch and must pass up through the intense 9 flame made by the burning gas before passing over the bridge wall. At this point is admitted an additional supply of air which is thoroughly mixed with the gases and a high temperature is maintained: This furnace’ isa) satistactory smoke preventer, effects considerable economy in fuel and meets very well the severe condi- tions imposed by a plant with extremely vari- able load. It is also of easy application to heating and annealing furnaces, to large stills, brick kilns, etc., where mechanical stokers are out of the question. Much experimenting has been done and some considerable success attained in the use of powdered coal during the past few years. The coal is thoroughly dried, ground into a fine powder and blown with an air blast into the firebox, where it burns with a clear white flame and intense heat, much as a jet of oil would burn. The stack is clear and the economy is said to be high. The conditions for combustion are ideal, but difficulties in the preparation and handling of the fuel in this form have delayed its application to small boiler plants. It has met with the greatest success in cement plants where no other fuel save oil or natural gas would serve the purpose, and is being success- fully applied to heating and annealing furnaces. The apparatus for handling fuel in this form is made by C. O. Bartlett in this city, and his boiler plant is operated with powdered coal. In the ordinary hand-fired furnace with plain flat grates, a steam jet projected over the top of the fire from the front or sides and fre- quently provided with an air attachment for Io regulating the steam and air supply at the time of firing is of frequent application. It does fairly well as a smoke preventer where the conditions are not too severe, and when pro- vided with an automatic means of controlling the steam and air supply. The steam projected in over the fire seems to play a double role, that of increasing the draft at the time it is needed, acting as a sort of injector to bring in additional air supply and also to mix the air thoroughly with the gases given off by the coal. A large number of devices of this kind of dif- ferent makes are in satisfactory use in Cleve- land. They are installed by W. F. Black, W. E. Cubben, T. W. McCue, E. F. Honness, of Cleveland, and G. H. Scharf, of Ypsilanti. Mich. There are plants where the load is so vari- able and the changes so sudden, the demands of steam so great at one time and so small at another, that an automatic mechanical stoker is not altogether satisfactory. There are some plants where the load is at all times so heavy that a mechanical stoker will not meet the demands. There are still other plants (these are, however, confined chiefly to heating plants in apartment houses and small office build- ings), consisting of one boiler, where the load is so light that the fire is never hot enough to maintain good combustion and secure smoke- less conditions. These several conditions need varying methods of treatment. The obvious solution of a plant with a greatly overloaded boiler, either from the standpoint of economy or any other point of LE view, is increased boiler capacity. About the only solution of the problem for the small heating plants is the use of fuel which has only a small per cent of volatile matter, such as hard coal, coke, or smokeless coal, or else the use of central heating plants and the elim- inating of the small nlant entirely from the question. The plant of the fluctuating load is the one which is hardest to handle. If a mechanical stoker is used at all in this kind of a plant a stoker of the underfeed type with means of varying automatically the fuel and air supply to meet the varying load gives best results. Whether the furnace be hand-fired or me- chanically stoked the fundamental conditions must be observed in order to attain smokeless- ness, namely, sufficient air supply properly mixed and temperature maintained at or above the combustion point until combusion is com- pleted. Generally speaking, it is not difficult to supply sufficient air. The problem of properly mixing this with the fuel and of maintaining the temperature at the right point until com- bustion is complete is somewhat more compli- cated, but not by any means an impossible one nor one presenting serious obstacles. In the last analysis the test of a smoke pre- venting device is the appearance of the top of the stack, and of this any man endowed with the sense of sight is a judge, and one man is as good a judge as another, though it is a fact frequently noted by the Supervising Engineer that the layman never sees a smoke stack ex- cept when it is smoking badly, and a bad 12 smoker once cured is speedily forgotten. The test of the economy of a device is in the size of the coal bill, and of this the man who has to pay the bill is the cne most capable of forming an accurate judgment. Before final judgment can be passed on the cost of operating a plant one must know how much coal is used, how much water is being evaporated, and also what per cent of the total output of the boiler is used to operate the smoke preventer or me- chanical stoker. This is, generally speaking, an easy matter to determine. The tendency in modern development is for mechanical or automatic handling of materials, and the mechanica! automatic handling of coal in a plant: of any size is in line with modern development, so that the installation of a me- chanical stoker equipment in a large plant is made with a view to economy in labor as well as economy in fuel consumption; but even in small plants where the cost of labor has not been changed by the mechanical stoker instal- lation, it is the almost universal testimony that the use of a stoker or smoke preventing de- vice effects a net economy when all additional expenses which can be properly charged to it are taken into account. A smokeless stack may be an evidence of an excess of air rather than an evidence of per- fect combustion and maximum economy. How- ever, the experience of this department is such as to warrant the statement that smoke prevention and fuel economy are synonymous terms, and this statement is borne out by the 13 records of tests and the letters of well known men included in this bulletin. ‘These are only a few selected at random from ‘material on file in the office of the Supervising Engineer to answer the queries: “Can smoke be prevented?” “Is it worth while to prevent it?” Test at Harmon Street School, March 23, 1900. Kind "o£ botlerc oa. amaaien tact neers horizontal tubular Sizeof: boiler. ==. =. 16 long by 60” diam. 82 3” tubes H. P. of boiler....basis of 10 sq. ft.'to aH. P:—108 Kindwof furnacernri. acts Murphy automatic smokeless Kind of fuel. Bituminous slack (said to be Massillon) Durations of “test one ere aie ae eee eight (8) hours Method of starting and stopping test...... alternate Size of grate surface...... 5—0” by 4—0”—20 sq. ft. Proportion of air space to whole grate......... 33% Water “heating ‘surfaces «mutter nee 1,080 sq. ft. Ratio of heating surface to grate area....... 54 to 1 Feed water entering boiler... ... 7-2 34 degrees Escaping gases leaving boiler........... 385 degrees Weight of: coal :usede.0 5 vs ia ene 3,775 lbs. Per cent: of ‘moisture: in coall/itsanate snateenatete 4.02% TLotalvidry” coal used xc <2 1s) ssics eter 3,624 lbs. Total ash and refuse. (<..7)... .nctabye eteneecer 557 lbs. Total combustible’ burned .;. .~... 32 eee 3,067 lbs. Per cent. of ash and refuse..........06 hoe 14.75% Smoke prevention 2’... 5 ici eu on oh tanene ene 100% Dry. coal consumed per: hour..<.4... tubes Murphy automatic furnace. ..2.3 2.2. 62-0”, dy > 5H—0” Durationsofatestasat st. .ts4 ios be 2. 709.92. >2,9 tours Weirbtaot coal as Dred. .ccceea css 0 be Ont 1 DS. Per mCentAnO Le Aasilamtiy svete ts sia lenace o\ srehelelsheranehenaiens 19 DrvercOdlepeteOUG cs sas cers a siare etefeteien «enone che 920 Ibs. Average. temp: “escaping gases........ 1 564.8 degrees AV CHAP COUT ALTER sexo Sib terre eee Osler ideas ae ele .5 inch Horse-power developed Pe SAE OFAL OO DRO OER 232 Horse-power builders’ rating... ..)f203.)03. 060s 175 Pemicent Wavovee TaAUIG shod s.¢ 5 si sires ds» a 5's Gs 26 Betampration per lo. cosl actuals. -.cs eee es: 8.79 Evap. per lb. dry coal from and at 212°..... 9.75 lbs. Evap. per lb. combustible from and at 212°...12 Ibs. Smoke prevention—Clear except trace twice of periods of minute each. (Signed.) The Van Dorn Iron Works Co., ies Bs. Vany Dorm: Vice Pres. Test on Cleveland Arcade Bldg., May 21, 1902. Nandgotecielonsas ste chien Massillon Slack Coal Ordinary Jones Under- Gain Grates. Feed Stoker with Stok. Duration of trial, 10 NOULSmerie were te 2: 10 10 Average stack draft in 5 Wa bet morta swctteve,c ctor avs 0.65” 0.5 Aiahe Force of blast in fur- Nacemin= water se cea 4.2 —- Mage eh of coal as fired, Reta s. wobre bilecashacs, 10,500 8,700 1,800 Percentage of ash and refuse in dry coal.... 13.7% 14.6% 0.9% Dry coal consumed per Houtrelpsiks ieee 995.4 822.2 173.2 Horse-Power— Horse-power developed 3414 lbs. of water evap. per hr. into dry - steam from and at Rize veqtials 1TeHs Pe 193.5 216.0 22.5 Boiler-H. P. based on 12 sq. ft. heating sur- faCen PArat Elbe aac 87.3 . 87.3 Percentage overload above) Tatinlieras v6 oe 121.8% 147.5% 25.7% 15 Economic Results— Water- apparently. evap. . péy. Ik. of, cpal under ; actual conditions <.. (6.11 8.21 Pa Percentage “incréase*c 3 72 34.4 Equivalent: evap, from: oat vand at 212 per db. © oovenee cof combust: bie , Siselay ase os CCE Se ope sO262 2.84 “Percentage increase’ *. ©‘ * 36.5 Rédlatiye to thé avove, it is noted that at the time‘ ae each +ést, tite boiler was run far above its rating, and undoubtedly also far above the output at which it would give greatest eff- ciency. The coal burned per sq. ft. of grate, and the water evaporated per lb. prove that the exceptionally great overload was obtained. During the first test the hand-firing was of the most careful character, and much better than possible for the average fireman, and also much better than it would be reasonable to expect of the best firemen for regular service. The results obtained proved that with the stoker the boiler could be forced to a greater overload than by hand-firing, and at the same time with greater efficiency, but as before stated better results would probably be ob- tained by operating the boilers nearer their rating. Respectfully submitted, (Signed. ) E. P. Roberts & Co. By E. P. Roberts. Test at Cleveland Woolen Mills. Paring 052 soe ee ees ee Hand. Stoker. Boiler,.internally tired te ce 5 -aa.- erect 2—42” furnaces Duration; hours) ive s.cee ceereree ereie een LORS 9 Kind of coal—Goshen run-of-mine; Salineville slack. Cost: “of::coal: "per tons acon eee $2.05 $1.35 Goals-pers-hour; lbs. eee eee 735.6 949.3 Refuse; .pér Vicente. lose eeeeae ce 14.31 8.67 Actual ‘evaporation per lb. coal...... 7.49 7.79 Evaporation F. & .A. .212° per Ib. COs ee tmy leet stern s salah cs late ctl My cre ae ot 7.994 8.425 EDO PACE Veloped Brees cicvatrss aie ie lst st oils altars 170.45 232 Gain in evaporation, per cent......... 5.39 Savinigsainerdel. percent... os... ss 37.5 Cost to evaporate 1,000 lbs. water i TO TUE AIT Laine babes UE Qukecet sacl ois. « et s,a.sl Swe es =! $0.128 $0.80 We hereby certify that the foregoing report is true and correct. (Signed. ) Phillip Elliott, For Cleveland Woolen Mills. (Signed. ) A. Malm. For the Underfeed Stoker Co. of America, Marquette Building, Chicago. Test at Cleveland Paper Co.’s Broadway Plant, Sept. 17, 1896. DD asALIONMMO LE CESL.tti tere esti hon ehoneie < 8 hours, 0 min. Coal consumed, bituminous. slack, Youghio- REGIA Go.2yhcy ASTER oo EES SESS CIES ie rane euro 6,270 Ibs I SEECETIN MOLMASIICS 0 ns Satan sc, ciel cl bes cle ene sere si as 12.4 Ibs. of water evap. per lb. of coal from and AIMEE sl oe MENA I Trop sectckep ela sia cre oetwe: eyehane ey eaeeee eet aneitete. Gite 9.77 Lbs. of water evap. per lb. of combustible from Ie teme Wea tel ail tyn vente: ater sane ebet tape tesa us ete re oe iltealel The above test was made during the usual operation of the mill and without any special preparation of the boilers, which were equipped with Brightman stokers. The chimney was smokeless during the en- tire run excepting four or five times when the air spaces in grates were cleaned, when there was a puff of light gray smoke. _A light gray smoke was emitted for about eight minutes when the fires were cleaned. This occurred twice only. The above test and report was made by Chas. Goffing, M. E. Cleveland Water Works. 17 ‘sIq 8 FOL ‘6 ounf T8S‘sL yorr “AT Bd PTS Yrs Sings ‘O- [eoD sings} I 01 FF 33 ‘bs 09 33 ‘DS 607 33 “bs 6g9°% OST Ul 7 OFT ra °¢@ GNV T ‘SON SUYH’IIOd ‘SAIYOIS JDIUDYIIPY IDA uwWYD) puw saayvaysadns . CMR Aelia! ee . 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