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If YOU carry your comb in a hip pocket, you're like the majority of men we talked to in a recent informal survey. Also, you've probably broken more than one comb by sitting down on it hard. Even if you carry your comb in an inside coat pocket, as three men in ten did, you've probably bought some that lost their teeth in a short while.
The point is, why not try a Du Pont nylon comb next time. It's exceptionally tough and long lasting, because the plastic of which it is molded is the strongest used in comb manufacture today. The teeth of a Du Pont nylon comb are unaffected by water or hair oil, and have no sharp edges to scratch the scalp. A nylon comb is easily cleaned, too--if can even be boiled in water without damage.
If you'd like to establish these things for yourself, buy an inexpensive Du Pont nylon comb today in a drug, department or chain variety store.
Du Pont manufactures nylon combs in a variety of styles to serve the needs of every member of the family, and in natural (cream color) or pastel colors to suit everyone's fancy. Nylon combs are made by Du Pont in its plant at Leominster, Mass.
3W Pend Nyk*
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BEm t h in g s f o r b e t t e r l iv in g , . . THROUGH Cl
DU PONT MAGAZINE
vi. 48 n o . 3
JAMES 11. McCORMICK, Editor
Associate Editors, GORDON H. K ESTER MARY ELLEN EVANS
Published and copyrighted 1954 by E. I. du Pont de Nemours & Co. (Inc.), Wilmington, Delaware. All rights reserved. This magazine or parts thereof may not be reproduced in any form without permission in writing from the publisher. Printed in U.S.A.
'Ti 'il'lil%so QotiUii iinn tai csca ii'iiaccs n01f ddtr'fuir'ul^ea-sc aciOnrul cover illustrations highlights Com pany research on production in struments, its,..
smember seeing pictures--like the one below of Du Font's Sabine, Tex, methanol plant--that show operators facing rows of instruments recording the status of chemical reactions in remote operating areas?
Back of them ties one of industry's most far-reaching sucoesi stories. Only two or three decades ago thermometers, pressure gauges, hydrometers and the like were all the instruments chemical industry operators had to help them turn out more and better products. As you'd expect, things have changed, Du Pont and its competitors, working with instrument makers, have moved one chemical process after another from the area of art and rule-ofthumb to scientific control, ruled by man but without the variations inherent in human judgment. Where there's enough demand for a chemical, they are switching manufacture from 19th century batch methods to the more efficient and cost-cutting continuous processes.
This is a condensed and highlighted report of how production instrumentation research is improving quality, efficiency and work* tag conditions at Du Pont.
You can't put your finger on an exact date Do Pont began looking beyond thermometers and their ilk for instruments to aid
in production. It happened piecemeal; an idea here, an application there. The first goal, actually, was greater safety rather than higher quality. The process for making acetate yarn calls for the recovery of dilute acetic acid by extraction with ethyl ether, as combustible a solvent as you'd ever want to keep in the next county. In time accidents happened, and top management issued a mandate. It was rough. "Recover acid safely or dose up,'* it said in effect.
This was in the early '40s, mind you, when the expression "production instrumentation" was almost exclusively for the experts. But an order was just that, and engineers decided they must put the acetic acid recovery equipment outdoors and put the operators in a control house not even directly connected with the equipment they were to operate, The specification left no leeway, there could be no direct line from the recovery system to the control room.
Available equipment wasn't enough. It was revised, or even scrapped and rebuilt from scratch with new compo nents. The pressures, temperatures, liquid flows and oilier critical information from the recovery unit the operator needed at Ms fingertips were carried to transmitters. These were located near the operating equipment and looked and worked much like the radiator thermostat on your ear. The transmitters in turn activated calibrated recording devices which gave a picture of what was happening in the recovery unit. Then operators, without leaving the safety of their control room, were quickly and easily able to make remote-control adjustments on their new 53,000,000 re covery system.
World War II gave instrumentation at Du Pont, as in industry generally, a tremendous jolt. Du Pout's need for a central research group was realized acutely during the days of the Hanford atomic energy project when men faced control and measuring problems never dreamed of. Com pany men returning to Du Pont plants brought back a deep-seated respect--even a reverence--for what instru-
Thls calorimeter lias helped reduce by half ihe shadings re. t| Hired lo put a hutch of finish within color specifications.
meats could do. The early birth of an instrumentation research program was a natural outgrowth.
For close to ten years now, the Du Pont Engineering Dept. lias had a research group charged with applying physical techniques to plant processes. Today the group spends 60,000 man-hours yearly on instrumentation re search. Research activities very conveniently have fallen into three basic categories; continuous inspection of products, automatic control of processes, and continuous chemical analysis. Manufacturing departments with special process or control problems usually call on the Engineering Dept, group to get their experts to chew on them. When the researchers come up with a new tool, they go out to the plants to see where they can apply it.
These engineers strive to make their instruments work automatically, continuously and instantaneously. These are the usual earmarks of successful production instru mentation--and they're near enough to reality to cause one Du Pont plant manager to tell us he'll be happy when he can look at a couple of dials in his office and tell how each of his units and operations is doing.
Let's look at some of the specific tools and devices developed by this group and see how Du Pont lias capital ized on them.
Du Pont physicists are broadening the use of ultra violet gas analyzers, or detectors, for both safety and pro duction control. In the Company's manufacture of sulfuric acid by the chamber process, for example, a Do Fontadapted. ultraviolet analyzer measures the inked nitrous and sulfur dioxide gases in the exit gas. The device works automatically, continuously and almost instantaneously, giving operators the feel and pulse of the operation they need for best results.
... "Infrared even more important"
Applying the principles of infrared absorption is even more important In Db Font's instrumentation research scheme. Infrared absorption bands, unlike those in the ultraviolet, are quite narrow and selective. They can pick out and measure one individual chemical or compound in a complex mixture--like the gases being synthesized into methanol or polymerized into polyethylene, for instance. "Such automatic chemical analysis methods," an expert summed up for us, "are paying off in an impressive amount of dollars and cents."
In making moistureproof cellophane, infrared devices are credited both with improving safety and saving con siderable cash. When cellophane is given its moisture proofing bath of organic solvents, vapors are drawn off to recovery units. It's possible, unfortunately, for the vapor to mix with air to proportions that can let go with a deadly bang. To play safe, a great excess of air was used-cheap enough in Itself but costly when you figure that the air tad to be heated and the vapors had to be salvaged from all that air by the recovery system. At one time, cellophane production was actually limited by the capacity of Ihe recovery system to handle the necessary flow of air. The engineers, we were told, could buy more recovery equip ment, or increase the efficiency of the recovery operation, bearing in mind the need for safety.
Filin and Engineering Dept, engineers put their heads together and developed an infrared-absorption control system that accurately controls the vapor-air mixture. It safely cut back on the air needed and removed a bottleneck at very nominal cost.
To fit their needs. Dm Pont scientists have increased the sensitivity of infrared devices by a hundred to a thousandfold over early commercial models, and some SO or 60 are in use at Company plants around the country. One such improved model records as few as three parts of water to a million of "Freon" fiuotinated hydrocarbon refrigerant.
"With tie equipment available in 1946 we could handle maybe 15 per cent of Du Font's continuous gas analysis problems. Now, 90 per cent can he handled with today's equipment and techniques," the leader of the instrumentation research group explained.
Liquids brew their own peculiar type of hell for instru mentation specialists. They resist the continuous, simul taneous and automatic soul-searching that production superintendents want, Refractometers, x-ray absorption
electro-magnetic are all weapons
At one plant, a refractometer continuously and auto matically compares a sample piped from the production stream against a known standard. The liquid being cheeked is as complex as a doctor's prescription, but sensitive changes in the refractive index reflect even minute varia tions in the mixture. .........Instrumentation, research is. saving ..time,...money ...and nerves in the realm of color. On one hand, Du Pont-clevised colorimeters cast their critical eye over products such as polyethylene plastic to make sure they're not off-color. On the other hand, they tell whether or not a dye, pigment, paint or colored fiber meets color specifications. Visiblelight photoelectric analyzers, for example, check the color of pigmented cellulose acetate solution to make sure both the hue and intensity are correct before it is spun into yarn.
The making of finishes is a good illustration of how Du Pout-devised differential colorimeters have replaced art with science. Historically, a highly trained operator called a shader added varying amounts of pigment and vehicle to get paint the color he wanted. He sometimes needed to make literally dozens of shadings to get just the desired hue, adding first a bit of this pigment, followed by some'of another.'" Then the batch of paint' might passiiir inspection but not sit right with another shader.
This Company, in gradually moving from the shadowy realm of art to the solid ground of science, first learned to judge color by instrument--to measure a color exactly and to reproduce it exactly time after time at one and all Du Font finishes plants. Soon they were able to re duce the number of shadings needed to get the desired
Rebuilding recorder for plant use. In 2 ....Minutes* it" records' '
hue. Tie record today shows that the colorimeter plus scientific calculation have reduced by half the shadings required to put a batch of finish within color specifications.
A new type of liquid measurement saves headaches where corrosive mixtures chewed up one measuring instru ment after another. Yet for proper operation you needed to know how much chemical was in the tank. A. radioactive liquid level indicator took care ofthis one, doing all its work without exposing any part of the measuring device to the .corrosive.chemicals..Rays-from "radium are-continuously beamed through the tank and its contents to an ion chamber on the other side. As the level of the liquid rises, fewer of the rays reach the measuring chamber. The minute change in the electrical output of the ion chamber activated by the radiation is measured electronically and translated into data for the operator.
The Company has a variety of such devices that meas ure the configuration or dimension of its products. One is a dielectric capacitance gauge for measuring denier variations in yarn, used by Du Pont textile fibers plants, that works on a tuned radio circuit principle. The instrument is tuned for the proper size yarn. Any off-standard product instantly puts the circuit out of tune, and the fiber is rejected, marked or recorded in some other way. "Once we are able to measure any quantity or materia!," we are told, "it's duck soup to do the "necessary controlling,"......................
So for, this picture of Instrumentation research has been painted in terms of devices and applications. For better focus let's see how one typical Du Pont department benefits from this in addition to providing safer working conditions. The Electrochemicals Dept, puts instruments to work on the process line in five ways.
First, they detect impurities in raw materials. Second, they automatically regulate low of such material into process, such as the flow of molten sodium metal into equipment for making the powerful bleach, sodium per oxide. Third, instruments regulate the conditions of re action--temperature, pressure, pH, flow and the like. Fourth, instruments analogous to those on the dash of your car give a complete and to-the-second picture of the progress of the operation. Fifth, devices determine..the. purity of the end product.
Elchem's instrumentation specialists also work closely with scientists developing new processes and products. They want to make those processes as automatic and self controlling as possible through the best use of instruments. Then when a full-scale plant is built, there'll be no guess work about what instruments can work where.
What of Du Font's broad aims in the next decade? They are many. Simplification. Standardization. Improve ment of existing tools. A search for other techniques and devices leading to more automatic, uniform operation.
"Within ten years, we even expect to measure molecu lar weights of chemicals in process streams," an authority said. "Ten years ago that wasn't even at the dream stage. This shows you how fast instrumentation is moving."
Checking radium source of liquid level measuring device, recent development of research to aid chemical production.
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By WILLIAM S. DUTTON
Some few men of every generation leave footprints that
ff, with the resolve that if he ever returned
time does not erase. John D. Rockefeller and Henry Pori
and had the power, one-man rule would be banished
forever from the Du Pont business.
industry. So was Pierre Samuel du Pont
He did return, and with Alfred and Coleman du Pont,
The genius of Rockefeller organized the men and marketing facilities of our petroleum industry. Ford blazed
took over the old company in 1902. The three cousins' first major move was to open the ownership to the public.
a like trail in manufacturing by organizing men and
machines in the phenomenon, of mass production. Pierre
In the front row of management. Governed by majority
du Pont organized men and chemistry.
decisions, that front line became the management. It com
rII1
He went beyond the factory to the basic source of waste* the failings inherent in age-old raw materials. On a
bined many talents,
_
wider front than any other, he dared to devise new raw
feature of the new structure, to the end that able men,
materials and improve old ones as a routine function of
together might be rewarded for achievement as
I our chemical industry.
well as they would be if
Ford and Rockefeller dealt with oil and motors, but
own
du Pont, the chemist-trained industrialist, planned in
or unborn. When singleness of purpose was
^^
* y . counsels of many view-
. as the ideal of production, he led his Company
and much of industry into a maze of diversification.
When he died tills April, the Du Pont Company, once solely a manufacturer of explosives, was producing 1,200 products and product lines. They included materials as old aa sulfuric acid and as new as titanium metal.
mon interest coordinated the
like the branches of a tree from
bole of ' '
The point is
conception, the id
,.
.
company, that money and plants and products and sales
However, diversification was not Pierre du Pout's
facilities are secondary assets, which become valueless If
chief contribution to free enterprise in America. The way
the right men are lacking. Possibly others preceded Pierre
to diversification had to come first in the form of a new
du Pont to this discovery, but nobody exceeded him and
kind of Company management, one that could Inject order
Ills associates in giving it wholesale recognition and
l
into what otherwise would have meant confusion, and
demonstration.
also disprove the adage that the Jaok-of-all-trades rarely
The vision reached down the line to the humblest
' * * ' any.
janitor. Plans for pensions and kindred aids to employes
agement plan, the pattern of which has been adopted by many large businesses. By virtue of it, the opportunities
Du Pont plants became among the safest in which to work, both as a matter of good business and as a responsi bility to those who maimed them. Medical services were
"One of the architects" is the way he would have
its roots went deep. As a young man, fresh from college, Pierre went to work for the old family-owned firm on the banks of the Brandywine, near Wilmington. It was a day
instinctive "Yes, Sir!" '
''* '
'
By instinct and training alike, the young chemist
businesses around the century's end. In the Du Pont firm, he saw the senior partner overburdened by a load that had outgrown any one man's capacity. He listened to men fret at being seen but never heard, he watched potential leadera-
Pierre
Pierre never had cause to regret or to revise Ms faith in the dominance of human values. In World War I, the organization that lie headed was credited with a major share In saving the Allies. It furnished 40 per cent of the propellent powders fired by our own and Allied guns. At the same time, the foundation of today's Company was laid.
Later, during a financial crisis at General Motors, du Pont reorganized that corporation after the pattern of Ms faith. Then he stepped aside. The men of General Motors went on to build the world's largest manufaetur-
Outsiders who study the Du Pont Company invari ably comment on what they call its remarkable faculty to
the resolve of a discouraged young chemist seeking else where the opportunity that he believed should begin at
10
By MARY ELLEN EVANS
Hit Perot's "Teflon" tetrafluoroethylene resin, unlike most products of research, was discovered accidentally. During research on nuormated hydrocarbons, tetrafluoroethylene gas, stored in a cylinder, changed into a gray-white, waxy solid. It had polymerized, and the result was the most inert organic resin scientists had ever run up against. But what is happening to "Teflon" today is far from accidental.
Its outstanding properties give "Teflon" more roles
mi the workine its applications range
and engineers have tried without success to d "Teflon" with the most violent of corrosive chemicals. It lMriMu*jpnSa iUi'So &gOnfO%UA. 'pnrfoApTkSOT.W'^l'oloSial jmvoesnil &oiuh iw'je3k0Y*nPrtenrc*cltiU4>UtrmeSe Upu t i Wf-n 60CTF. or as low as -4flOP, Bars of
has no effect on it. zero and it is one of the best
'"T1WMlIcIItInI" JUS witjill.liilnueg
and guided missiles have created a need for a hose that is flexible yet hard, strong yet lightweight and impermeable to all fuels, lubricants and other highly reactive fluids.
Resistoflex Corp. of Belleville, N. J., with wide ex perience in manufacturing aircraft hose assemblies, looked at "Teflon" with one eye and visualized the answer to the difficult fluid conveying problem with the other. In about three years, their chemists and engineers developed the
techniques. Result: this spring Resistoflex introduced a high-temperature hose made up of a seamless extruded tube of "Fluoroflex"-T, trade name for their compound containing Du Pont "Teflon", reinforced with a braided jacket of stainless Med wire.
T O^LPKtr*riUTlIttliK*s T*lJfCLi3V1,C*3 T* iilllllIiT. FI
Pressure, vibration, fluid Immersion and circulation tests at 4fl(PF. were carried out for more than a year.
T10F, and, while at this temperature, synthetic oil at 460 was suddenly introduced into the lines. Unlike previous materials used, its life span seems practically unlimited.
occurred before in a hose or assembly development pro gram," says Irving D. Press, chief engineer at Resistoflex,
the hose can be used equally well for heavy duty service
A companion product made by Resiatoflex is a lamin ated pipe which has an internal layer of "Fluoroflex"-T combined with a high strength reinforcement of glass fabric impregnated with "Teflon", This pipe has all the properties of the high-temperature hose, and in addition, it can be readily cut and fitted on the job. It has successfully endured operating temperatures of 600F. and wide, sudden tem perature changes. Developed specifically for the chemical processing industries, this laminated pipe looks likely as a prospect for foods, beverages and other industries.
.... lions of'IHreided, rigid polyvinylcMiorlle" pipe" aSIttmgs'" is a new pipe dope based on "Teflon''. Pipe dope on pipe
tions were set up in chemical, electroplating, pulp and paper, photograph, pickling and similar Mis, Strap wrenches were used to make all joints very tight before pressure tests were run. The fittings were then backed off one and one-half turns and pressure applied. Even then the seal was so effective no leakage occurred. The pipes and fittings can be assembled and disassembled easily because of the extremely low coefficient of friction of "Teflon". Reports indicate that the pipe dope works equally well with special formula steels and other metals used for chemical pipe systems.
The use of "Teflon" in chemical process equipment, for gaskets, pump packing, valves, pistons and agitators, mechanical seals and ping valve liners, means less main tenanee and less-replacement costs." It also' means'Stepped-.. -up production through less down time, reduced wear on pistons and shafts, and simplified design. Quality of the products is improved because contamination is eliminated.
These advantages aid up to substantial savings. For example, one manufacturer using chlorinated benzol was replacing centrifugal pump packing every three days. In 30 months he had spent $1,488 for replacements and labor. He installed packing of "Teflon" which lasted 30 months and cost 134.20.
A considerable number of fabricators are custom making products of "Teflon" to specifications of manufac turers. For example, Dixon Corp. of Bristol, R. I. makes a diaphragm of "Teflon" for use in valves. This diaphragm
presented special fabricating problems since a stud must be molded in the center. Dixon licked the problems, sat up lex and porosity teste, and the valve maker lilies the product because it withstands acids and solvents which attacked previous diaphragm materials.
Dixon has developed a hearing material of filled "Teflon", trade-marked "Rtikrn", which Is being used by Anco, Inc. of Providence, R. I. as a self-lubricating seal In their line of rotary pressure joints. "Rulon" is used because of Its low coefficient of friction and its resistance to abrasion and chemicals,.....................................................
Dn Pont*foresee a complete chemical system of "Teflon"
--pipes, tubing, wives, pumps, lined tanks, heat Inter changers uni distillation equipment.
MECHANICAL JOBS, TOO
For centuries bakers have been plagued with sticky raw dough. Even in modem bakeries, knives peel dough from steel rollers which must be dusted continually with flour. Now rollers may be made of "Teflon" or covered with "Teflon" coated glass fabric made by the Du Pont Fabrics Division. The dough drops off cleanly without a dust of flour. Savings on flour alone may mean the difference in profit and loss in a year, if the bakery has dozens of machines.
In packaging products in film, a big problem has been " 'coveringti*"heat-sealing' unite' so" Hie film will not atieS "to the machine itself. Now the plates may be covered with "Teflon" coated glass fabric for continuous operation of the sealing unit. Similarly, in the production of decorative laminates on tables and equipment, the coated glass fabric prevents sticking of laminates to plates. For printing and bookbinding, it has a future in covering ink, glue pots, and glue rollers to prevent absorption by the roller. In the food processing industry, another sticky problem is con quered by using conveyor belts covered with "Teflon" coated glass fabric so that candies or syrups leave the belt without a nudge from a knife.
The tough jobs of industry seem to suit the tough guy of plastics. "Teton" looks forward to full employment.
ResUloflex'a "Flnorolkud'-T Hue includes pipe,lulling, machined purls, valves and flexible hose made from Du Pont "Teflon",nil resistant to chemicals and oils.
Dii Pont starts a new venture--a search for
Convair-built F>102, llie Air Force's first supersonic fillerceptor, checks out for flight tost.
automotive industry was grinding along in second gear.
Engines were turning up 26 horsepower or maybe a
little better. Efforts to increase compression, anti, there
fore, engine efficiency, were tied to the capacity of
...............
.................. ' Auto
and turned to Du Pont to produce it. The introduction of tetraethyl lead as a fuel additive was one of the historic moments of the motorcar age. Automotive engineers were at once able to bring out the higher compression engines they were capable of making.
The parallel between 1923 and 1953--when the jet fuel research project was launched by Du Pont-- was just as clear cut and just as challenging. For better jet fuel means better, more efficient jet power plants. Better planes are the end product
The problems are in some ways as confined, and in others as limitless, as those of sound, speed, metal lurgy, and weight, which engineers, designers, and meteorologists are currently probing in their efforts to fling planes through the air at supersonic speeds. ......... The..ideal.,jet fuel" exists"Somewhere, possibly-only. in minute quantities. It burns clean and hot in the presence of the gales of air fed to it. It doesn't leave carbon deposits on the shining steel burners, or clog the pinpoint holes of the fuel nozzles, or corrode the blades of the whirling turbines, or leave black smoke efo+UwUflaiWrrvIlrlnilga? aftocbfitSsri rUt.
the objective is to increase the over-all efficiency of fuel use and to reduce critical flight problems. Who knows, maybe the day of the flameout--the pilot's nightmare--may soon be behind us. .........There is... much. .at ....stake., in...this. ..improved-fuels search. Just last March Congressional hearings on the defense budget brought to light the fact that the
cent more jet fuel during the fiscal year starting in July than in the previous 12 months. Industry spokesmen, without blinking an eyelash, said, sure they'd have it handy, whenever the Air Force and Navy called for it.
there won't be enough of it around once military and civilian "potential demand" becomes "actual need." It is necessary to adopt fuels which can be suppled in greater volumes.
Today's standard jet fuel--the military calls it JF-4--combines a small amount of kerosene with gasoline fractions and cracked stocks. As such it is relatively cheap and plentiful, but It puts a limitation " on "the'"efficiency" of jets, "To tils" extent," jet" progress "is. dependent on progress in making better fuels.
At the Petroleum Laboratory at Deepwater, Du Pont maintains a jet burner which is purposely inefficient. In a 15-minute operating period, for ex ample, more carbon will collect on the dome and in the
operation aloft. An array of instruments constantly samples the way the fuel burns. One even takes running samples of the smoke.
CHEMICALS AFFECT FOIL
This is not a full-scale test of a jet engine In operation by any means, but the single burner is suf ficient to perform the necessary job; to test changes In the performance of the fuel brought about by various chemical additives,' Months' qf""testing" are required to investigate the effects of fuels on such bugbears as carbon, nozzle clogging, and the like. How chemicals
In jet. room at Petroleum Laboratory, operator chocks effect of fuel additives on carbon depo sition, nozzle clogging and smoke tit jet burner.
That's all well and good, but where there are some 11,000 thirsty jets to be fueled in the next year, there will be 20,000 or more by 1957. And it Is certain that the aircraft industry and our military planners won't be content with jet power plants of the same power and efficiency as today's.
What it means is that the "dream" fuels in research status today will have to be furnished in quantity tomorrow, with the same process repeating itself over and over again into the future. .......; Du Pont hopes that its addition ofjet fuel research
ing combustion will help solve this problem which, directly or indirectly, affects us all.
m can
saj m *
s make the man
LOUISE J, GEUBER
of the many ways chemistry contributes to
is even at work on men's fashions.
In appearantcrtert, man's
T-iaem*-!- /iVia-ncm/J
--di in the last 50-odd yes
..
sometimes vest. But the silhouette of men's apparel
has undergone a subtle, gradual transition toward
greater comfort and casualness. Fabrics have become
more porous; they are no longer stiff and tightly
woven. They look, feel and wear better, thanks in
many cases to the properties of chemical fibers,
mi i
,
chemistry is the concept of "wash 'n wear," which lihaass madewicirlii wmiAenn'e's ncIflto-fthhaeas aeaae-stry frt*o +taa1krAe <ciaairae rotff asties we***!! as easy to wear.
The first wash 'n wear suits, available in 1952, featured both Du Font's "Dacron" polyester fiber and "Orion" acrylic fiber. Since then, increasing numbers of owners of wash 5n wear suits and slacks have been praising their light weight and wrinkle resistance, and
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CRUSHED ICl CHIPPER tray made by Gits Molding Corp., Chicago, freezes 60 slim ice wafers, A twist of the tray and crushed ice tumbles oat for dozens of uses. The ice chipper is made from "Alathon" polyethylene resin. So is another new Gits product; a FLASHLIGHT whose case is made of iioiioorrosive, unbreakable "Alathon", a boon to outdoorsmen and men who work around chemicals.
BELTS of extruded Du Pont nylon plastic studded with diamonds are being used to polish ultra-hard carbide in tube and Tod""drawing "dies. Long-wearing 'nylon furnishes a cushioning effect to keep diamond grits from tearing out of their sockets. Belts are available from Hartford Special Machinery Co., Hartford 12, Conn.
DRESSES, so wrinkle-resistant they show scarcely a crease after being rolled and left in a 4- by 6-inch tube for hours, are being made in a Cavalcade sheer of "Dacron" polyester fiber. These washable Martha Manning dresses, made by Forest City Dress Co. of St. Louis, keep their fresh appearance even in humid weather.
A LEATHER REPRODUCTION in durable "Fabrilite" elastic supported vinyl plastic upholstery has been intro duced for office and home. Called Seville, the new material has a knitted support and adds the "soft look" to plastic. Seville Is available in a wide range of colors.
PHOTO CREDITS; Page 14, top: Courtesy Consolidated Vultee Air craft Carp,; Page 12-13: Courtesy Resistofl Corp.; Page 20-21, center:
for five minutes is activated by "Freon" fluoriiiatat
hydrocarbon. A temperature of 140F, causes the "Freon"
to expand, break a seal and set off the whistle. Price is
$9,5 from Fyr-Larm Co., 243 Broad St., Summit, N, J.
------------- --
..... ....... ................
Fur additional information on products or services mentioned in any issue of this Magazine, write to James II. McCormick, editor, Du Font Magazine, Wilmington 98, Del,
---- ...................-<< -- - -
--.......................................................-
Courtesy Swift Mf*. Co.; Page IS, tight; Courtesy Fyr-Lunn Co.*, Pl# 2; Courtsty U. S. Bureau of Reclamation.
25
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By 11. C. RICHARDS
Bernard De Voto, veteran chronicler of the American West, quotes this wry Westernism in a recent magazine article: "Sure, all this country needs is a little more water and a better class of society--but that's all Hell needs."
Like most good jokes, this one is grounded in truth--at least so far as water is concerned. Much of the West is a desert, too lacking in rainfall to be agriculturally or industrially productive. It is chiefly in the "Valleys, where the'runofffrom"mountain snowsnan"" be captured and put to use, that life and society thrive.
But even in the valleys nature does not surrender her bounty easily. Vast irrigation and power projects, some executed by state and Federal governments and others by private interests, have been needed to create the farms and factories. In the process, mighty rivers like the Columbia, the Colorado and the Rio Grande have been broken to harness for the first time.
This is the story of one valley--the so-called Magic Valley of the Snake River in south central Idaho --and of a farmer-owned irrigation company that helped transform a wasteland into one of the country's most prosperous agricultural regions. It's a story also of the self-reliance which the West's yawning distances and rigorous climate demand. .......The" Twin 'Falls"'Canal Co. had Its origin "in 1000," when settlers on the parched Snake River Plains banded together to tap the river for irrigation water. The plan was not a new one even then, but raising capital to finance the work had taken time. Construc tion finally began in 1902, and in 1905 the first river water was turned into the main canal of the project. It has flowed there almost continuously since.
PIONEER RECALLS EARLY DAYS
Before the land could be farmed, of course, it had to be cleared. Joe Marshall, one of the original settlers, recalls the period wall,
"I filed on 160 acres of land in November, 1903," he wrote me recently. "It was nothing but a lot of arid sagebrush land then. I cleared it with the aid of some, "hired "men" with' nothing hut a grubbing hoe, which according to present methods, you will agree, was rather an antiquated method.
"I have farmed in this Magic Valley of ours ever
since that time, and have lived to see Its development
in all its present glory."
Today, at 80, Marshal has turned over his land to
his son, although he still markets Idaho potatoes as a
farm manager. He has held the title of Idaho Potato
King for 30 years.
The Twin Falls tract in its "present glory" encom
passes more than 200,000 acres, a strip about nine
..
"miles wide and'48' miles'long Beside'"the "river.'"Where.........
sagebrush once collected dust there are rippling fields
of grain, symmetrical rows of potatoes, beans and
sugar beets stretching to the horizon, lush pastures and
the bleat of lambs in the spring. Towns, including the
county seat of Twin Falls with a population of 18,000,
have grown up within the tract. Power generating
stations have accompanied the growth of irrigation
dams along the river, making manufacture possible.
Some 3,000 stockholders, practically all of them
farmers who use the water directly on their land, own
the company that created the tract. They operate it
Sagebrush near Snake River in Mitli. With water, land like this could be as fruitful as that pictured on preceding . page....
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What do you know about grooming your
Whether your automobile is new, custom or antique, you may prefer Du Pont No. "7" polish, a favorite since 1928 when it was developed to maintain the successful "Duco" lacquer finishes. Whatever the polish, for best results wash your car first with Du Pont Car Wash to remove the..grime that-can damage the surface.................
Don't be alarmed if a little color comes off on the polishing cloth. All automobile finishes oxidize or chalk slightly and minute particles rub off, letting the original color show. Keep a protective coating on to avoid oxidation.
It pays to keep your automobile in what used car dealers call the "cream puff" class, "If you maintain good mechanical condition and appearance of your car, it will average 17 per cent more on a trade-in," says an executive of a large automobile credit corporation, reporting on a nationwide survey.
For beauty treatments that mean as much to your liny as lipstick to the American girl, you have a wide choice in No. "7" grooming products. For bumpers and trim, there's Du Pont Chrome Polish; for tires and rubber mats, Tire Black, and for upholstery. Dry Clean and Foam Cleaner.
There's normally nothing worse for your car's com plexion than hot sun, particularly if it also takes night dew, rain or salt air. Best preventive is a garage at night, shady parking by day, and a good protective coating. If you're buying a new car, ask your dealer to apply Du Pont Spray Glaze. Then repeat periodically, or follow up with "Seven-Ite" polish to maintain high gloss without fre quent cleaning.........................................
Find a shady nook for washing and polishing your car. If the surface is sun-baked and hot, rapid evaporation of suds, polish or water can cause streaking.
Cleaners and polishes are packaged for your conveni ence. There are three types. One, a single package of combined cleaner and polish, like No. "7" polish, for a quick, easy way to high luster. Another type is a twopackage combination of cleaner and liquid coating con taining wax and silicone, such as "Seven-ite", for those who have more time and want a more durable coating. And third, for those who prefer a wax, another combination offers Du Pont Speedy Cleaner and Du Pont Auto Wax.
As every woman knows, good grooming w not depend ent on expensive cosmetics but on regular beauty routines. Your car will respond to the same good care.
31
After eight years of research and three years of pilot-plant production
flew plant for making "Mylar" will open in July at Circleville, Ohio.
By MARIAN ELIOT
for commercial production of
Du Pont "Mylar'* polyester film will begin operations just
south ofCircleville, Ohio. Theopeningoftlienewf10,000,000
plant will mark the coming of age of a film which has
shown some phenomenal abilities even as an adolescent.
Eight years of research and development and three
years of semi-works production for test use by manufac
turers have proved that "Mylar" offers definite advantages
in the major property categories--electrical, physical,
chemical and thermal. It has what its creators call "bal
anced properties iincl affords design opportunities available
in no other single film. Result; it is firmly established in
certain industrial and consumer products barely hinted at
in our Magazine report a year ago, ^ ^
_
it would go far in the electrical field where its properties are excellent for insulation. Its dielectric strength, to say the least, is excellent. It keeps its dimensions and properties over extremes of heat, cold and humidity. As an insulator it can be used at temperatures as high as 150C. and as low as -60C.
"Mylar", in combination with asbestos paper, mica mat, or glass cloth, provides a wide range of insulation materials. Motors are being designed with slot and phase insulation of "Mylar" and laminates of "Mylar", much stronger than ordinary electrical insulation. The tensile strength of this film, about one-third that of high grade steel, permits its manufacture in gauges as thin as 1/4000 of an inch. Because of thinner insulation, the motor has more space for extra wire and thus more horsepower for its size, or the motor may be made smaller with equal power.
"Mylar", vacuum-metalked to itbitttfii foil, makes a bright thread for fahr
Capacitors, transformers and other electrical equip ment also can be made smaller and less costly. For example, "Mylar" is replacing impregnated paper to separate the metal foil electrodes in telephone systems. The voltageresistant film needs no impregnation.
erg at Du Font and other companies to look beyond elec trical insulation for jobs for this film. Laminated to aluminum foil or kraft paper, it makes a strong vapor barrier for hot or cold pipes. Thermal insulation--glass, fiber, magnesia, foam glass or cork--serves well if the surroundings are clean and dry. But chemical plants, for instance, abound In fumes and moisture that reduce the efficiency of these materials. Maintenance men have used impregnated tapes or asphaltic compounds as protection over the insulation. Both are messy to apply and often decompose rapidly when exposed to chemicals. Now a covering of "Mylar" film laminated to aluminum foil is adhered to pipe insulation as it is made. Installation is simple since the cover is built onto the insulation, "Mylar" resists solvents, moisture vapor, most adds and alkalis.
Sound recording tape for radio and television is a promising field for "Mylar", as reported in the April-May '54 issue of this Magazine. Also in the tape field are pressure sensitive tapes for carton strapping and control tapes for machines.
Acoustical tile need no longer be colorless and dustcatching. Printed "Mylar" film can be laminated to the tile
Acoustical life, covered with printed "Mylar", Is 11 colorful and very easy-to-clcan material for ceiling#.
for decorative as well as practical ceilings and walls. The
smooth tiles can be wiped clean with soap and water.
"Mylar" brings to the furniture industry a new idea
for low-cost surfacing. Wood grain can be exactly repro
duced, printed on "Mylar*', and laminated to plywood,
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With "Mylar", the textile industry has a new nontarnishable metallic yarn that withstands washing, pressing with a hot iron, and dry cleaning. The yam is manufactured by bonding a sheet of aluminum foil between two sheets of "Mylar" with a colored adhesive. The sheets are slit into strips of yarn aa narrow as l/64 of an inch and interwoven 'with other'textile'yarns "into "fabrics for "clothing and for automobile and furniture upholstery.
Possible new uses for "Mylar" are as kick panels and coverings for flexible dashboards in automobiles. It is the first film strong enough and sufficiently attractive for these jobs. Manufacturers are now exploring "Mylar" for wall paper, wall paneling and movie screens.
_ This new film, "Mylar", is already making its con tribution to bettor living--from electrical equipment to evening shoes.
Bruce Farquhar of our Textile Fibers mlm development team, answers questions about ike role of Dm Pontfibers in solving industry's filtration blues
Q. To begin with, what la filtration, and what industries use it?
A. Filtration is a fundamental process used to separate physically one form of matter from another, such as a solid from a liquid or solid particles from a gas. In some cases, the solid that won't go through the filter is what you're after; in others, the solid may be the material you're trying to get rid of. In any event, filtration is used in practically
pigments, plastics, fertilizers, minerals, drugs and anti biotics. That's a fair list, but it's by no means complete.
Q. Could you give us a specific example of liquid filtration?
A. A very common one is the filtration of dyes from the chemical liquor in which they are formed. This is often done by forcing the liquid through a filter press, a series of fabric-covered plates separated by frames held tightly together. The solid particles of dye are trapped within the frames by the fabric. Another example is the filtration of pulped fruit to recover juices.
Q. How about gas filtration?
A. Here we might mention the carbon black industry, which bums oil or natural gas with insufficient air, thus forming tiny carbon particles. These are then filtered from the combustion gases. Metal smelters, too, often recover their products by gas filtration. On the other hand, many noxious ingredients of stack gases are removed in this way to prevent air pollution.
Q. How much filter material does industry use in a year?
A, Something like 19,000,000 pounds of textile fibers, both natural and man-made.
Q. What filters am used in filter doth?
A, Many of them. Among the natural fibers represented are cotton, wool, jute, linen and sisal. Among the syn thetics, nylon, "Orion" acrylic fiber and "Dacron" poly ester fiber are doing a real job in applications where, for one reason or another, they excel. This is probably as good a place as any to point out that there is no more a uni versal fiber for filtration than there is for any other purpose. Each fiber has specific properties which fit it best for certain jobs.
Q. Could you go into a little more detail on that?
A. Well, take nylon, for instance, the first synthetic to be
used on a large scale in filter fabrics. It has high abrasion resistance and great strength, it can do its job in the pres ence of alkalis, and it resists heat. Nylon has been extremely successful as a dust filter in cement manufacture and in liquid filtration of caustics. Often its working life has been 10 to 16 times that of a natural fiber filter.
Farcjuliar, lei, at dye plant. Call* like this tell him where Du Pont fillers can best be used In fillers.
How about "Orion"?
A, Nylon and "Orion" complement each other pretty well.
Where nylon resists alkalis, "Orion" is highly resistant to acids. In the carbon Hack industry I mentioned earlier, bag filters of "Orion" are doing very well indeed. There's an acid condition to contend with here--sulfur combines with oxygen and moisture in the combustion gases to form acids. "Orion" also withstands an operating temperature of up to 276F. As a matter of fact, because of its prop erties, "Orion" made possible the readoption of cloth filters ""by "'thi" carbon.Hack.Industry," which' "had..given them up some time before. With "Orion", tire carbon black recovery rate has been boosted from a former high of 70 per cent to more than 99 per cent.
Q* This high operating temperature. Is it desirable in carbon black production?
A, Yes, just as it is in many other processes. In fact,
they'd probably like to operate at even higher tempera tures. The point is that it costs money to cool the gases, besides lowering the efficiency of the process. I'd like to add that in primary and secondary smelting of metals.
filter bags of "Orion" are lasting from four to eight times longer than the natural fiber cloth they replaced. Despite the fact that they cost more initially, they are proving to be two to three times more economical. The producer not only saves money on filters, he also has less down time to change filters because of the new fiber's longer life.
Q-. We've heard talk about this new fiber Du Pont is making in development quantities, the one made from the same raw material as "Teflon" tetraflnoroethylene resin. What can you tell us about that as a filter cloth material?
A. As I said a little while ago, there is no such thing as a
universal fiber for filtration. This fiber, however, comes pretty dose to making me eat crow. It has the most out standing chemical resistance we've come across yet. You can boil it in aqua regia, a mixture of acids that will dis solve gold, without effect; alkalis don't affect it, either, and it can stand temperatures of 400 to 500F. I said some producers were interested In operating at higher tempera tures. We're in the process of testing this new material in carbon black collection and nonferrous metal smelting. Since the fiber Is in limited supply right now, and the process for making it is a new and difficult one, its price is much higher than that of our other fibers.
Q. But still you think its properties are enough to justify its use in filtration?
- A. We certainly do. Despite the high-initial cost we are convinced that in some applications it will save the user money and permit operations that would be impossible with other fibers.
Q. How about felts of the man-made fibers? Are they likely to be used in filtration?
A. Yes. It recently became possible to make felts with the Du Pont fibers--something that had never been done before with the synthetics. Felts of nylon have shown definite promise in oil filters for truck engines, for example, while felts of "Dacron" have been used to part emulsions of water In oil, making it possible to decant and thus separate the two liquids.
Q* Has the fact that synthetic fibers can lie made in con tinuous filament form meant anything to users of filter fabric?....................................................................................
A. Yes. In some cases the smoother surface of filament yam fabrics has made it easier to remove filter cake from the fabric. Now, of course, the man-made fibers are avail able in staple form, too. The spun yarn fabrics made from staple are preferred for certain jobs where maximum clarification of the filtrate is desired.
Q* Suppose a reader of the Magazine wants some advice on a filtration problem?
A, I want to emphasize that Du Pont makes only the fibers. The filter fabric suppliers are well equipped to answer just about every question that comes up, since they are familiar with the physical properties of our fibers and others. More than that, they are people who know filter fabric construction, and the best fiber in the world is worthless if It isn't woven into the proper fabric. If in quirers wife -the. Magazine, we will put them in touch"" with filter fabric suppliers, and any questions about the place of Du Pont fibers in this broad industrial field will be answered.
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SHE'S A BEAUTY,
MR. POPE!
It 'S appropriate that Junior should be showing off his new deluxe equipped Columbia bike to Albert Pope, for Pope has been called the father of the American bicycle industry. He built the original Columbia in 1 877--it was the country's first commercially produced bicycle--and founded what is now The Westfield Manufacturing Co., modern maker of the Columbia.
This balloon-tired beauty of 1954 would raise Mr. Pope's eyebrows with its built-in electric horn, electric headlight, electric stop and tail light, spring fork, built-in lock, built-in kick stand and crash rail saddle.
Not to mention its chrome trim and baked-on finish of lustrous "Dulux" enamel--the same durable finish that protects and beautifies modern cars, trucks and home appliances.
The Westfield people say: "As bicycle manufacturers for 77 years and pioneers in many of the industry's advances, we demand a finish capable of withstanding the punishment a bicycle gets. We're satisfied that 'Dulux' enamel meets the test."
Du Pont Industrial Finishes
Chemically engineered to do the job better!
HfG u s HAT Off
BETTER THINGS FOR BETTER LIVING ... THROUGH CHEMISTRY
I
Chemical helpers for your garden
This year, these "chemical protectors" can help you have a productive garden.
For best results, begin preventive dust ing or spraying with combinations of chemicals to keep bugs and diseases away from plants. But even if pests are al ready in your garden, you can fight them with chemical helpers.
Fruit trees, berries, vegetables and flowers can all be protected with these effective combinations of chemicals, pack aged for convenient use:
DU PONT FRUIT TREE SPRAY Follow the simple schedule on the package for best results. Spray several times to keep fruit enclosed in a protective coat as it grows.
DU PONT FLORAL DUST Outstanding for roses. Spray or dust, but keep ahead of the pests. The handy, ready-to-use dust gun package makes it easier.
VEGETABLE GARDEN DUST Ready for use on all your vegetables. Helps you harvest prize-winning vegetables.
Du Pont also offers products for weed control and plant feeding. Du Pont Sol uble Plant Food, for example, can be used throughout the season. It's clean, easy to dissolve in water. Spray or sprin kle on all your plants. It's excellent for lawn feeding, too.
There's a garden supply dealer near you who displays these products. See him about Du Pont Garden Chemicals.
Du Pont Garden Chemicals
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