Edison, His Life and Inventions [359]
length of the sixty-foot kiln not only limited the amount of material that could be fed into it, but the limitation in length of the combustion zone militated against a thorough clinkering of the material, this operation being one in which the elements of time and proper heat are prime considerations. Thus the quantity of good clinker obtainable was unfavorably affected. By reason of these and other limitations and losses, it had been possible, in practice, to obtain only about two hundred and fifty barrels of clinker per day of twenty-four hours; and that with an expenditure for coal proportionately equal to about 29 to 33 per cent. of the quantity of clinker produced, even assuming that all the clinker was of good quality.
Edison realized that the secret of greater commercial efficiency and improvement of quality lay in the ability to handle larger quantities of material within a given time, and to produce a more perfect product without increasing cost or investment in proportion. His reasoning led him to the conclusion that this result could only be obtained through the use of a kiln of comparatively great length, and his investigations and experiments enabled him to decide upon a length of one hundred and fifty feet, but with an increase in diameter of only six inches to a foot over that of the sixty- foot kiln.
The principal considerations that influenced Edison in making this radical innovation may be briefly stated as follows:
First. The ability to maintain in the kiln a load from five to seven times greater than ordinarily employed, thereby tending to a more economical output.
Second. The combustion of a vastly increased bulk of pulverized coal and a greatly enlarged combustion zone, extending about forty feet longitudinally into the kiln--thus providing an area within which the material might be maintained in a clinkering temperature for a sufficiently long period to insure its being thoroughly clinkered from periphery to centre.
Third. By reason of such a greatly extended length of the zone of oncoming material (and consequently much greater bulk), the gases and other products of combustion would be cooled sufficiently between the combustion zone and the stack so as to leave the kiln at a comparatively low temperature. Besides, the oncoming material would thus be gradually raised in temperature instead of being heated abruptly, as in the shorter kilns.
Fourth. The material having thus been greatly raised in temperature before reaching the combustion zone would have parted with substantially all its carbon dioxide, and therefore would not introduce into the combustion zone sufficient of that gas to disturb the perfect character of the combustion.
Fifth. On account of the great weight of the heavy load in a long kiln, there would result the formation of a continuous plastic coating on that portion of the inner surface of the kiln where temperatures are highest. This would effectively protect the fire-brick lining from the destructive effects of the heat.
Such, in brief, were the essential principles upon which Edison based his conception and invention of the long kiln, which has since become so well known in the cement business.
Many other considerations of a minor and mechanical nature, but which were important factors in his solution of this difficult problem, are worthy of study by those intimately associated with or interested in the art. Not the least of the mechanical questions was settled by Edison's decision to make this tremendously long kiln in sections of cast-iron, with flanges, bolted together, and supported on rollers rotated by electric motors. Longitudinal expansion and thrust were also important factors to be provided for, as well as special devices to prevent the packing of the mass of material as it passed in and out of the kiln. Special provision was also made for injecting streams of pulverized coal in such manner as to create the largely extended zone of combustion. As to the details of these and many other in- genious devices, we must refer the curious reader to the
Edison realized that the secret of greater commercial efficiency and improvement of quality lay in the ability to handle larger quantities of material within a given time, and to produce a more perfect product without increasing cost or investment in proportion. His reasoning led him to the conclusion that this result could only be obtained through the use of a kiln of comparatively great length, and his investigations and experiments enabled him to decide upon a length of one hundred and fifty feet, but with an increase in diameter of only six inches to a foot over that of the sixty- foot kiln.
The principal considerations that influenced Edison in making this radical innovation may be briefly stated as follows:
First. The ability to maintain in the kiln a load from five to seven times greater than ordinarily employed, thereby tending to a more economical output.
Second. The combustion of a vastly increased bulk of pulverized coal and a greatly enlarged combustion zone, extending about forty feet longitudinally into the kiln--thus providing an area within which the material might be maintained in a clinkering temperature for a sufficiently long period to insure its being thoroughly clinkered from periphery to centre.
Third. By reason of such a greatly extended length of the zone of oncoming material (and consequently much greater bulk), the gases and other products of combustion would be cooled sufficiently between the combustion zone and the stack so as to leave the kiln at a comparatively low temperature. Besides, the oncoming material would thus be gradually raised in temperature instead of being heated abruptly, as in the shorter kilns.
Fourth. The material having thus been greatly raised in temperature before reaching the combustion zone would have parted with substantially all its carbon dioxide, and therefore would not introduce into the combustion zone sufficient of that gas to disturb the perfect character of the combustion.
Fifth. On account of the great weight of the heavy load in a long kiln, there would result the formation of a continuous plastic coating on that portion of the inner surface of the kiln where temperatures are highest. This would effectively protect the fire-brick lining from the destructive effects of the heat.
Such, in brief, were the essential principles upon which Edison based his conception and invention of the long kiln, which has since become so well known in the cement business.
Many other considerations of a minor and mechanical nature, but which were important factors in his solution of this difficult problem, are worthy of study by those intimately associated with or interested in the art. Not the least of the mechanical questions was settled by Edison's decision to make this tremendously long kiln in sections of cast-iron, with flanges, bolted together, and supported on rollers rotated by electric motors. Longitudinal expansion and thrust were also important factors to be provided for, as well as special devices to prevent the packing of the mass of material as it passed in and out of the kiln. Special provision was also made for injecting streams of pulverized coal in such manner as to create the largely extended zone of combustion. As to the details of these and many other in- genious devices, we must refer the curious reader to the