For me to attempt, with the time at my disposal, to do full justice to
many important points which have cropped up since our last meeting, and
which will, no doubt, have been engaging your individual attention,
would be impossible. But I think there can be no doubt that, although at
our last meeting we had a very full and interesting discussion on the
different systems of regenerative retort settings, still we might very
profitably spend a little time to-day in hearing the experience of those
who have had some of the systems introduced into their works since then,
or who may have gained further experience with the system they were then
working, or have introduced improvements or modifications thereon.
For the purpose of inducing a discussion on this subject, I will give
you the result of the working of the bench of retorts which I erected
three years ago on the Siemens system. As I stated last year, my
experience up to that time had not been altogether a happy one, but one
of sunshine and cloud alternately. I am glad to be able to say, however,
that since then I have had nothing but the utmost satisfaction in the
working of the regenerative settings. The chief difficulties I have
before experienced were of a mixed nature--choked ascension pipes,
entailing considerable loss of gas; the choking of the orifices from
which the secondary heated air issued to join the producer gas; and the
eating away, in a "scooped-out" sort of fashion, of the brick lining of
the producers at the points where the primary air entered. These, I am
pleased to be able to say, I am now completely clear of; and this has
had the effect of converting what was before a considerable source of
annoyance and anxiety into as perfect a working bench of retorts as any
one could desire.
The results I have obtained have caused me much surprise, being far in
excess of anything I ever anticipated; and the saving effected will
materially assist in compensating for the greatly reduced value of
residuals. I may state that I have used 30 per cent. of fuel on an
average, saved from 25 to 30 per cent. on stokers' wages, and increased
my production of gas per ton of coal; while the regularity of the heats
was a pleasure to look upon.
As showing what I have been able to accomplish, I will give you a few
details. I was able regularly to produce 10,000 cubic feet of gas per
mouthpiece in 24 hours--the size of my retorts being 18 by 13 inches by
9 feet long, inside measure; and on a sudden dullness coming on, with an
increase of first class cannel I produced from 33 retorts 357,000 cubic
feet, or at the rate of 11,500 feet per mouthpiece in 24 hours. With 32
retorts I made as much gas as would have required 42 retorts to produce
on the old system. But I know that even this can be excelled; and I am
aware that there are works where, by the introduction of retorts
measuring 21 by 15 inches, instead of 18 by 13 inches--and which, I may
say, can be put quite easily into the same arch--a production of 12,000
cubic feet per mouthpiece can be obtained. This will, of course, still
further reduce the cost of production.
With such an experience, gentlemen, I think it is almost needless for me
to add that I am a strong advocate of the regenerative system. I have
often heard it asked, "But can the system be profitably adapted to small
works?" In answer to this, I will say I have proved that it can. During
last summer the manager of a small gas works in my neighborhood called
on me regarding the working of this system, and expressed a desire, if
it was at all possible to adapt it to his present settings without much
expense, to try it. I must say I admired his progressive spirit and
pluck; and, after a somewhat lengthy conversation with him, during which
I gathered the full details of his working and his requirements, I
determined to encourage him in his desire to prove if it could be
successfully applied to a works of the size mentioned. The present
setting consisted of three [semicircle] retorts in one arch; and one of
his stipulations to me was: "You must so contrive the setting that if it
should prove a failure I can reconvert it into the old system in a few
hours." I at once saw that the stipulation was reasonable, or he might
be caught in a fix in midwinter. But, with true "Scotch caution" and
forethought, he was, while anxious to experiment, determined not to be
"caught napping." After some consideration, I prepared a sketch for him
of how I thought it could be done, and at the same time comply with his
stipulation; and having received full explanations, he set about it, and
has had it working now for something like six months. His experience has
been somewhat similar to that of most of those who have gone in for the
new system. It did not answer very well at first. But after a little
manipulation and experience in the proper working and management, it is
now acting in first rate style, and is saving fuel, with better and more
regular heats; and this although it is not constructed in such a way as
to yield the best possible results, owing to the before mentioned
stipulation having to be considered and allowed for in construction.
In answer to an inquiry I made the other day, the gentleman referred to
informed me that he has now had this setting in operation for six
months. He has three retorts, 14 by 16 inches, and 8 feet long, in an
oven carbonizing 2 cwt. of coal every four hours; the heats are higher
and more regular; and the retorts easier kept clear of carbon. The coke
drawn from the top retort is sufficient for fuel. My oven would hold
four retorts; and the same fuel would heat this number just as well as
the three. I used only the coke from Cowdenheath parrot coal for this
setting; but had to mix it with Burghlee coke for the old system of
setting.
No doubt most of you will have noticed the satisfactory results obtained
by Mr. Hack, of the Saltley Gas Works, Birmingham, and by Mr. McMinn, of
Kensal Green, with the furnaces employed by them for gaseous firing
without recuperation, whereby they are enabled to save fuel and
carbonize more coal per mouthpiece than with the old system. Still they
admit that the saving by this setting is only in fuel, with increased
production, but without any economy of labor--one of the points in favor
of regenerative setting being a saving of at least 25 per cent. in the
latter respect. Even where regenerative settings cannot be had, I think
the system of using gaseous fuel is well worthy the attention of
managers; the expense of altering the existing settings to this method
being very small.