Edison, His Life and Inventions [358]
the law of gravitation. With its assistance, which cost nothing, these operations were performed perfectly. It was only necessary to deliver the material at the top of the chambers, and during its natural descent it was screened or dried as the case might be.
All these inventions and devices, as well as those described in detail above (except magnetic separators and mixing and briquetting machines), are being used by him to-day in the manufacture of Portland cement, as that industry presents many of the identical problems which presented themselves in relation to the concentration of iron ore.
XVII
THE LONG CEMENT KILN
IN this remarkable invention, which has brought about a striking innovation in a long-established business, we see another characteristic instance of Edison's incisive reasoning and boldness of conception carried into practical effect in face of universal opinions to the contrary.
For the information of those unacquainted with the process of manufacturing Portland cement, it may be stated that the material consists preliminarily of an intimate mixture of cement rock and limestone, ground to a very fine powder. This powder is technically known in the trade as "chalk," and is fed into rotary kilns and "burned"; that is to say, it is subjected to a high degree of heat obtained by the combustion of pulverized coal, which is injected into the interior of the kiln. This combustion effects a chemical decomposition of the chalk, and causes it to assume a plastic consistency and to collect together in the form of small spherical balls. which are known as "clinker." Kilns are usually arranged with a slight incline, at the upper end of which the chalk is fed in and gradually works its way down to the interior flame of burning fuel at the other end. When it arrives at the lower end, the material has been "burned," and the clinker drops out into a receiving chamber below. The operation is continuous, a constant supply of chalk passing in at one end of the kiln and a continuous dribble of clinker-balls dropping out at the other. After cooling, the clinker is ground into very fine powder, which is the Portland cement of commerce.
It is self-evident that an ideal kiln would be one that produced the maximum quantity of thoroughly clinkered material with a minimum amount of fuel, labor, and investment. When Edison was preparing to go into the cement business, he looked the ground over thoroughly, and, after considerable investigation and experiment, came to the conclusion that prevailing conditions as to kilns were far from ideal.
The standard kilns then in use were about sixty feet in length, with an internal diameter of about five feet. In all rotary kilns for burning cement, the true clinkering operation takes place only within a limited portion of their total length, where the heat is greatest; hence the interior of the kiln may be considered as being divided longitudinally into two parts or zones--namely, the combustion, or clinkering, zone, and the zone of oncoming raw material. In the sixty- foot kiln the length of the combustion zone was about ten feet, extending from a point six or eight feet from the lower, or discharge, end to a point about eighteen feet from that end. Consequently, beyond that point there was a zone of only about forty feet, through which the heated gases passed and came in contact with the oncoming material, which was in movement down toward the clinkering zone. Since the bulk of oncoming material was small, the gases were not called upon to part with much of their heat, and therefore passed on up the stack at very high temperatures, ranging from 1500 degrees to 1800 degrees Fahr. Obviously, this heat was entirely lost.
An additional loss of efficiency arose from the fact that the material moved so rapidly toward the combustion zone that it had not given up all its carbon dioxide on reaching there; and by the giving off of large quantities of that gas within the combustion zone, perfect and economical combustion of coal could not be effected.
The comparatively short
All these inventions and devices, as well as those described in detail above (except magnetic separators and mixing and briquetting machines), are being used by him to-day in the manufacture of Portland cement, as that industry presents many of the identical problems which presented themselves in relation to the concentration of iron ore.
XVII
THE LONG CEMENT KILN
IN this remarkable invention, which has brought about a striking innovation in a long-established business, we see another characteristic instance of Edison's incisive reasoning and boldness of conception carried into practical effect in face of universal opinions to the contrary.
For the information of those unacquainted with the process of manufacturing Portland cement, it may be stated that the material consists preliminarily of an intimate mixture of cement rock and limestone, ground to a very fine powder. This powder is technically known in the trade as "chalk," and is fed into rotary kilns and "burned"; that is to say, it is subjected to a high degree of heat obtained by the combustion of pulverized coal, which is injected into the interior of the kiln. This combustion effects a chemical decomposition of the chalk, and causes it to assume a plastic consistency and to collect together in the form of small spherical balls. which are known as "clinker." Kilns are usually arranged with a slight incline, at the upper end of which the chalk is fed in and gradually works its way down to the interior flame of burning fuel at the other end. When it arrives at the lower end, the material has been "burned," and the clinker drops out into a receiving chamber below. The operation is continuous, a constant supply of chalk passing in at one end of the kiln and a continuous dribble of clinker-balls dropping out at the other. After cooling, the clinker is ground into very fine powder, which is the Portland cement of commerce.
It is self-evident that an ideal kiln would be one that produced the maximum quantity of thoroughly clinkered material with a minimum amount of fuel, labor, and investment. When Edison was preparing to go into the cement business, he looked the ground over thoroughly, and, after considerable investigation and experiment, came to the conclusion that prevailing conditions as to kilns were far from ideal.
The standard kilns then in use were about sixty feet in length, with an internal diameter of about five feet. In all rotary kilns for burning cement, the true clinkering operation takes place only within a limited portion of their total length, where the heat is greatest; hence the interior of the kiln may be considered as being divided longitudinally into two parts or zones--namely, the combustion, or clinkering, zone, and the zone of oncoming raw material. In the sixty- foot kiln the length of the combustion zone was about ten feet, extending from a point six or eight feet from the lower, or discharge, end to a point about eighteen feet from that end. Consequently, beyond that point there was a zone of only about forty feet, through which the heated gases passed and came in contact with the oncoming material, which was in movement down toward the clinkering zone. Since the bulk of oncoming material was small, the gases were not called upon to part with much of their heat, and therefore passed on up the stack at very high temperatures, ranging from 1500 degrees to 1800 degrees Fahr. Obviously, this heat was entirely lost.
An additional loss of efficiency arose from the fact that the material moved so rapidly toward the combustion zone that it had not given up all its carbon dioxide on reaching there; and by the giving off of large quantities of that gas within the combustion zone, perfect and economical combustion of coal could not be effected.
The comparatively short