The process of manufacture as it is carried on at Niagara is
interesting. The visitor is first taken into the rooms where are stored
the crude material, the sand, coke, sawdust and salt. The sand is of the
finest quality and very white. The coke is first crushed and screened,
the part which is reduced to sufficient fineness is mixed by machinery
with the right proportion of sand, salt and sawdust. The coarser pieces
of coke are used for what is called the core of the furnace, which will
be described later on.
This mixture is carried to the furnace-room, which has a capacity for
ten furnaces, but not all of these will be found in operation at one
time. Here the workmen will be taking the manufactured material from a
furnace that has been completed, and there another furnace is in process
of construction, while a third is under full heat, so that one sees the
whole process at a glance. These furnaces are built of brick, about
sixteen feet in length and about five feet in width and depth. The ends
and bed of the furnace are built of brick, and might be called
stationary structures. The sides are also built of brick laid up loosely
without mortar; each time the material is placed in the furnace, and
each time the furnace is emptied, the side-walls are taken down.
A furnace is made ready for firing by placing a mass of the mixture on
the bottom, and building the sides up about four feet high (or half the
height when it shall be completed). A trough, about twenty or twenty-one
inches wide and half as deep, is scooped out the whole length of the
pulverized stuff, and in this is placed what has before been referred to
as the core of the furnace, namely, pure coke broken into small pieces,
but not pulverized, as in the case of the other mixture. The amount used
is carefully weighed, so as to have the core the proper size that
experiment has proved to give the best results. The core is filled in
and rounded over till it is in circular form, being about twenty-one
inches in diameter. At each end of the furnace the core connects with a
number of carbon rods--about sixty in all--that are thirty inches long
and three inches in diameter. These carbon rods are connected with a
solid iron frame that stands flush with the outer end of the furnace. On
the inside the spaces between the rods are packed full of graphite,
which is simply carbon or coke with all the impurities driven out, so as
to make good electrical connections with the core. This core
corresponds, electrically speaking, to the filament in an ordinary
incandescent lamp, only it is fourteen feet long and twenty-one inches
in diameter. The mixed material is now piled up over this core, and the
walls at the sides are built up until the whole structure stands about
eight feet from the floor--a mass of the fine pulverized mixture, with
a core of broken coke electrically connected at the ends. It is now
ready for the application of electricity, which completes the work.
Public-domain text, read in full here on John Shaqi.
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