Document ZnKE5p0v4rO1ddzEmMY4qe7QO
FILE NAME: Reynolds Metals (RM)
DATE: 1943 Jan DOC#: RM101
DOCUMENT DESCRIPTION: Journal Article - Safety in Handling Aluminum Powders
& M T A L t U R C I C AL 'V-
S. D. KIRKPATRICK . . . . Edi t or JAMES A. L E E ....................... M a n a g in g Editor THEODORE H. O LIV E......... A s s o c i a t e Editor HENRY M. B A T T E R S ................ M ark et Editor JOHN R. CALLAHAM. . . . .A ssistant Editor NORMAN G. FABQUHAR .Assistant Editor LESTER B. POPE ................... A ssist a n t Editor
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Volume 50
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JANUARY. 1943
Number I
Our Year II of World War II....................................................... 75 EDITORIAL FOREWORD
Waste Disposal Problems in Wartime...................................... 78
By F. W, MOHLMAN
Safety in Handling Aluminum Powders................................... 82 By G. M. BABCOCK and F. B. BETHWISCH
Progress Report of the Rubber Director. .. .............................. 85
Selection of Pumps for Oleum and Strong Sulphuric A cid. . . . 86
By WARD E. PRATT
Effect of the Kinetic Energy Term in G as Flow Calculations. . 90
By BENJAMIN MILLER
Nylon Research Wins its War W ings....................................... 92 EDITORIAL STAFF REPORT
Manufacture of Butadiene From Ethyl Alcohol--II.................. 94 B y J, A. GAMMA a n d T. 1NOUYE
Labor Relations and Collective Bargaining in Chemical Industry ..................................................................................... 99
A CHEM. & MET. REPORT
Chrome Tanning Leather................................. ............................. 112 A CHEM. d MET. PICTURED FLOWSHEET
Chem. & Met. Plant Notebook Process Equipment News . Chemical Engineering News News From Washington . . Interpreting Washington . . New Products and Materials From the Log of Experience
. . S8 . .107 . .113 . . 121 . . 124 * . 129 . . 133
Personalities . . . . . . . . 137 Meetings and Conventions * . . 145 News From Abroad . . . . . 156 Chem. & Mel. Bookshelf . . . . 167 Chemical Economics and Markets 175 Current B r i c e s ............................187 New C o n stru c tio n .......................190
An index to adv ertisers will b e found on p a g e 286
McGRAW-HILL PUBLISHING COMPANY 330 Weal 42nd Street, New York, N. Y.
Director of Circulation: P l e a s e c h a n g e my a d d r e s s on C h e m ic a l Si M e ta llu rg ica l
Engineering
From
Safety in H andling Aluminum Pow ders
G. M. BABCOCK and F. B. RETHWISCH Reynolds Metals Co., Louisville, Ky,
........... - -------- Cftem, & Mef. I N T E R P R E T A T I O N
-- ........... ......
Except for those people who work constantly with aluminum powders, sufficient respect ior the explosibility of this material does not appear to exist. With the present widespread use oi aluminum powders ior the manufacture of military pyrotechnics, need has developed ior the more widespread dissemination oi information on safe practices in their handling and in manufacturing pyrotechnics. The article which follows is based on the experience gained by the Reynolds Metals Co. in many years of producing and handling metallic powders and is offered as a starting point in the develop ment of safety programs for concerns engaged in or beginning opera tions in pyrotechnic work. Certain fundamental precautions are dis cussed by the authors a s a service to the industry, but neither they nor their company assume liability oi any kind in presenting this information. --Editors.
F l a k e a l u m in u m po w d ek , some should he stored unopened in a sep what similar to the material arate area wherever possible, since commonly used in aluminum paintif they are stored along with such
under the rather misleading name of chemicals as sulphur, nitrates and
" aluminum bronze powder," is a valuable component of pyrotechnic mixtures used for flares and signals. The- high surface area of a given weight of aluminum flake powder
makes it easily ignitible when in the presence of oxygen or air.- Burning, it evolves a tremendous amount of heat and light. Owing to its low apparent density, .fine particles of the material tend to float in air with the attendant danger of violent ex plosion upon ignition, when n proper ratio' of aluminum to oxygen is
reached. A somewhat different aluminum
powder, the grained variety, consists o f spheres, sausage shapes or irre
others of similar character, a fire from any cause would present a most serious problem. Whenever a drum of aluminum powder is opened for loading or inspection, it should be closed and re-sealed as soon as pos sible. This not only insures greater safety against fire from external
causes but also limits the likelihood of tramp material getting into the powder, ot of the powder absorbing water from the air. In one instance a sealed drum of flake aluminum withstood an aluminum dust explo sion and subsequent fire without ignition of the drum contents.
There ave few practical means of extinguishing fires involving alumi
gular grains of aluminum, which are num powder or mixtures containing
relatively hard to ignite. When mixed with oxygen-producing compounds, the grained powder will bum with
this powder. Anything which tends to disturb the burning mass may throw the aluminum into the air and
the evolution of much heat and light.
This material, however, has a high apparent density and low surface area which tends to keep it from suspension in air so that the danger
result in a violent explosion of tre mendous destructive power. I t i s 1 true that dry sand, carefully placed over a pile of burning aluminum, will smother the flame, but in the
of explosion or lire from aluminum " fog" is almost nil.
Both flake and grained aluminum are shipped in sealed drums with
excitement attending such a fire, there is danger that the sand will be thrown or shoveled on to the mass, and that the powder will be
fully removable heads. These drums thrown into the air. There have been
several cases where relatively harm
less fires have been changed to seri ous and fatal explosions from this
cause. Consequently, the safer and more
prudent rule is to instruct employees to walk out of the building in the ease of an aluminum fire, shutting the door securely but as gently as possible to avoid disturbing the burning mass.
All employees should he instructed
in procedures to avoid. They should understand thoroughly that water, carbon tetrachloride, fire foam, car bon dioxide and similar extinguish ing agents should not be used on aluminum fires. Use of such materi als will cause explosions. Night watchmen should be instructed to convey this information to any regu lar or volunteer group which at tempts to extinguish an aluminum fire. Furthermore, the use of a fine spray of water from a stirrup pump, such as is used by civilian defense workers on incendiary bombs, should never he used on aluminum powder fires.
It is of utmost importance that local fire departments he informed of these precautions. The depart ment should be provided with com plete information and charts regard ing those warehouses which contain aluminum, as well as those contain ing other chemicals. These charts should also be readily available to the watchmen and to the plant's own protection division at all times.
AVOIDING HAZARDS
A source of great danger in the handling of aluminum powder is the presence of foreign substances, par ticularly hard or metallic materials.
Care should be taken to see that closing bolts, nails and similar bits of metal cannot contaminate alumi num powder or pyrotechnic mixtures.
..Good plant housekeeping is one of the most effective methods in achieving plant safety and care must bo taken particularly in the weigh ing, mixing and pressing rooms. As little material as is practical should be kept in one place at one time. Scoops for handling powders should be of non-sparking material and the handling should he slow and deli-
&
JAMABY 19*8 CHEMICAL & METALLURGICAL ENGINEERING
berate to reduce dusting: to a mini lights, electric lighting and power Particularly hi the ease of flake alu
mum. Rooms in which powder is equipment carrying Underwriters' minum powder, considerable time is
Ii
handled should be cleaned at fre approval fo f use in explosive areas required to dissipate this charge.
quent intervals, but never during and where explosive vapors are en
Several types of non-sparking,
1 weighing, mixing or pressing opera i tions. All material should be kept
countered should be used. Wherever possible, both the shoes
conductive floors have been employed successfully.* Three types may be
in closed containers while cleaning of workers and the floors should be described briefly here, including (1)
is in progress. I f oil is used in the of a conductive but non-sparking Magnesite flooring installed over a
pyrotechnic mixture, special care type. Electrical discharges produced wood or concrete base, with conduc
must be taken to insure that all by static or lightning are the most tive metal grids placed beneath the
oily rags or waste are deposited in difficult safety hazards to control. surface of the floor and properly
closed safety cans away from the The danger from static charges pro grounded; (2) emulsified asphalt
storage or loading areas. These rags duced by friction is greatest in cold, composition flooring with a conduc
must be disposed of daily. In clean dry weather. Even walking on con tive aggregate which also is laid over
ing, care must be taken particularly crete or composition flooring in non grounded metal grids; and (3) in
to keep all corners, window ledges conducting shoes may produce dustrial graphite tile made o f a
beams, building steel and other rest ing places free from dust.
sparks capable o f igniting pyrotech nic mixtures or fine aluminum p ar
conductive mastic, the edges of the tile being melted together with a
BUILDING PROTECTION
ticles suspended in the air. Even the friction caused by aluminum
hot iron on installation to provide a continuous surface. With this last
The buildings used for weighing, powder poured from scoop to a mentioned type no metal grid is
mixing and loading operations container can create high static necessary, the tile itself being
should, wherever possible, be so charges on the aluminum particles. grounded at various points.
spaced and protected that fires or
explosions in one unit cannot be com
municated to other units. Construc T h ese v ie w s, from ph otos b y the U. S. A rm y S ig n a l C orp s, sh o w a thermite hom b
tion should be adapted to the vent dem on stration at the A rm y W ar C o llege , W ash in gton , D. C .; the u p p e r v ie w sh o w s
ing oC explosions, using either a
ihe bom b b egin n in g to exp lod e, w hile the low er sh ow s the clim ax of Ihe exp losion
"so ft" wall or roof, or a blow-out
w here the bom b, h avin g reach ed a tem perature of about 4.000 d eg. F ,, is m elting
panel. All equipment should be
through the s la b of ste e l on w hich it rests
located so that the operator has n
free path to an outside door, with
out a mixing bench, press or mixer
between him and the door.
All metal in the buildings should
be grounded. This not only includes
the equipment itself, but also metnl
window and door frames and other
building elements. Clips connected to
flexible grounded leads should be
placed on all metal drums or other
movable equipment. Only explosion -
proof motors should be permitted,
and for these the controls should bo
fully inclosed and non-arcing, located
outside the workroom so that no
worker need be in the mixing or
pressing room from the time of
starting these, operations until they
are completed.
All lights should be of a type
approved for explosive operations
and conditions. Particular care
must be taken when automatic or
manual tools are to be used in build
ings for repairs or changes. When
such work is to be carried out, the
rooms must first be emptied o f all
ignitible material and thoroughly
cleaned. F atal explosions have been
caused in dust-filled rooms by an
are from the switch of an ordinary
flashlight. Therefore, only flash
* F u rth er inform ation on these floors can be wocurod fr o m A rm s tro n g 1 C o rk Co., B uild hip P ro d u cts DIv.. L an caste r. P a .; the Flint bote. Co.. I n d u s t r i a l E m u l s i o n s D i v . , SO llockefeller P laza. N ew York, N. T . : and ihe Kom polltft Co.. I l l C lay St.. Brooklyn, N. Y.
CHEMICAL & METALLURGICAL ENGINEERING J A N U A R Y UU,3
S3
The. causes of static should be ex plained to employees, using simple
illustrations such as the rubbing of silk in cold weather, o r the combing
o f .hair. Belt drives should not be used on machines in the mixing, pressing or loading rooms. Special care should be taken in screen rooms, since the friction of the particles p assin g over the screens and their tem porary suspension and separa
tion in air can build up high static
charges. All metal in processing an d storage rooms should be ground ed nnd every possibility o f a sp ark from machinery, from broken electide light bulbs, or from the drop
ping o f steel tools should be guard ed against. Properly grounded metal containers on spark-proof con
ductive flooring will permit more rapid dissipation of static charges than wooden containers. Mixers should be allowed to remain at rest fo r a short time before the mixture is removed, thus permitting any sta tic charge induced in the metal par-
tides in the mix to be conducted to ground. Simple electroscopes can be made to determine when a mixture is free of static charge.
Adequate lightning protection is an important requirement fo r the plant handling aluminum powders. The grounding of all metal window and door fram es and approved light ning protection of all wiring will largely eliminate, the possibility of
high charges collecting before or during a thunderstorm and perhaps discharging to the ground with nn accompanying flash or spark. P ro tect ion against actual lightning strokes is best left to authorities on this subject.3'4 Many concerns shut down all mixing and loading opera tions during severe, nearby lightning
storms, the employees leaving the processing rooms during that, period. Radio sets are good indicators of approaching electrical storms, but if they are used, they should not he installed in the loading area owing to the hazard they introduce.
Highlights in Avoiding Aluminum Powder Explosions
1. All machinery and all metal door and window frames should be well grounded. 2. All mixing and conveying equipment should be constructed so a s to minimize the escape of dust into rooms. 3. Spatulas, scoops, conveyors and the like should be of non-sparking materials, 4. Motors, as far as possible, should be kept in separate rooms, outside the work rooms. Where it is necessary to have them in the workrooms, they should be of the explosion-proof, dust-proof, splash-proof and waterproof type of squirrel-cage construction. 5. Dust should not be permitted to collect in workrooms; they should be cleaned several times a day, if necessary, although no! while operations are going on. 6. Dust in the air should be kept at a minimum. Most people who do not work constantly with aluminum powder do not fully appreciate the explosibility of this material. Trosfel and Frerert1 state that the lower explosive limit for aluminum powder suspended in air varies with the method of ignition. With an electrically heated glowing wire, or with an arc, the lower explosive limit w as found to be at a concentration of 7.0 mg. A l per liter of air, and at a concentration of 13.7 mg. with an induction spark. 7. Lighting of rooms should be provided by dust-proof, explosion-proof bulbs. 8. If necessary to use flashlights, they should always be of an Underwriters'* approved type, for use in explosive atmospheres. 9. All bearings and gears should be kept well lubricated and protected from dust. 10. All employees should wear approved type clothing, without pockets or cuffs, if feasible. H . Operators engaged in mixing should wear respirators as a health precaution. 12. Safety shoes of a type which are both conductive and non-sparking should be worn by operators. 13. Conductive flooring should be employed if possible. 14. Operators should be instructed that, in case of fire, they should walk out and close the door of the room until someone in authority arrives to take charge. 15. Aluminum powders should be stored only in sealed drums and apart from other materials, especially oxidizing agents or easily oxidizable substances. 16. Only dry sand or Underwriters'-appraved extinguishers should be used on aluminum powder fires. 17. Care should be taken to prevent foreign substances from getting into aluminum powder. 18. Building construction should follow the recommendations of the National Fire Protection Association." 19. In general, it is advisable to follow most of the precautions usually observed 3n the handling of explosives.
MIXERS AND PRESSES
Machinery used in m ixing and pressing operations should he equipped with outboard dust-proof; bearings, which should he kept well lubricated. Excessive temperature rise in any p art should call fo r an immediate shutdown. I f a shaft or other p art should freeze on a beard ing surface, no attem pt should he made to loosen the p art by force, such a s by a hammer blow on the shaft, as long as any ignitihle m a terial is in the room. Exposed ring gears or bevel gears should be p ro tected from al riminnm-powder- contaming materials, liberal applications of a heavy grease minimizing this danger.
The clothing worn by plant em ployees should be kept clean and free from aluminum dust by fre quent washing. Many concerns sup ply shirts and slacks to both m ale and female employees, the slacks be ing made without cuffs. There is a possibility o f clanger when employees wear their work clothes to their homes before changing. F o r exam ple, a spark from a cigarette may easily cause fatal burns to a person whose clothing is filled with the dust of a pyrotechnic mixture. Owing to the possibility o f static charges, silk and si Ik-like m aterials should not be worn at work by employees.
The ideal arrangem ent in looker rooms for employees is to use a double looker system with an inter vening shower or washroom. W ith this method, a locker is provided fo r each employee at each side of the shower or washroom. The em ployee removes his work clothes and places them in the work clothes lock er, then takes his shower and con tinues to his second locker on the other side o f the shower room where he secures his street clothing. Thus his work clothes locker is always available for inspection by company officials or for the removal of soiled clothing fo r replacement with clean clothing. As previously mentioned, spark-proof and conductive shoes should always be worn by employees in the loading' and mixing areas.
REFERENCES
1. Trcstel and Prevert, The Lower
Lim its of Concentration for Explosion o f D u sts in A ir, Ghent. <C- M'et., 30, No. 4, p. 141, J a n . 28, 1924.
2. " N ation al F ir e Code for the P rev en tion o f D ust E xplosion s, 1940." N ation al Fire Protection A ssociation, Boston, M ass.
3. " Code fo r P rotection A g a in st L ig h t n ing," Bulletin H 21, U. S. B ureau o f Standards. O btainable from Supt. o f Documents. W ashington, D. C.
4. M cE ach ro n an d P a tric k , " P la y in g with Lightning," Random H ouse, New Y ork, N. Y.
84
J A N U A R Y 19J,3 CHEMICAL & METALLURGICAL ENGINEERING
Advertisers In This Issue
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Abb<s Inc., Paul 0 .................. 127 Acm e Coppersm fthlng & Wa*
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198, 244
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9
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178
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117
Debothezat Ventilating Equip ment Div, Am erican Mach. &
Metals, In c........................... 264
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24
Dougherty, James A ............... 284
Page
Dow Cham . C o ....................... 193
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179
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Electrical Engineers Equip. C o . . 70
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184
Fairbanks C o .............................238 Fairbanks, Morse & C o ........... 186 Fenwdll In c............................... 270 Filter Paper C o ........ . ............ 276 First Machy. C o rp .280, 282, 283, 284 Fletcher W orks ..................... 127 Foster W heeler C o r p ............... 219 Fluor C o rp . L td ........................ 237 Foote 8ros. G e a r & M ach. C orp. 227 Foxboro C o . ......................... 66 Frederick Iron & Steel C o . . . . . . . 150 Fuller C o ................................ 147
G arlock Packing C o ............... HO
G e lb & Son. R ........................ 280 General C e ram ics C o ................ 243
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General Elec. Co. A ir C on d i tioning & Refrigeration Dept. 22
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23
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Master Electric C o . ...... ,3rd Cover
M c G ra w -H ill Book C o ....... .... 220
Mercer Engrg. W orks, Inc.. .... 158
M errick Scale C o .............. .... 276
M etric Metal W o r k s ,,.,.,, , .... 64
M ich iga n Steel C a stin g C o .... 132
M id v a le C o . .................... .... 69
Midwest Piping A Supply Co. Inc....................... .......... .... 65
M illar, Inc., 1.................... .... 278
M ixin g Equip. C o . In c ....... .... 135
M onarch M fg . W orks, Inc. ... 165
M onsanto C hem ical C o . . . , . ... 123
M orris M ach. W o r k s .......... .... 167
Morse C h ain C o ............... .... G
Mount Vernon W oodberry Mills, inc........................ ......... .... 160
M urray M fg . Co-, D, J ...... .... 268
Nash Engrg. C o .............. . .... 251 National Box A Lum ber C o, .... 252 N ational Radiator C o ......... .... 261 N ational Technical Labs. ... .... 174 Neville C o ......................... .... 266 N ia g a ra A lka li C o .............. .241-242 N iag ara Filter C o r p .......... .... 233 North Am erican M fg . C o . . . .... 47 Nukem Pros. C o r p ............. .... 61
O liver United Filters Inc -- .... 213
Pangborn C orporation ...... .... 164 Partridge, Arthur S ............. ... . 283 Peerless Pump Div., Food Machy.
C orp . ............................ .... 165 Pennsylvania Crusher C o ___ .... 273 Pennsylvania Salt M fg . C o .. .... 57 Perez, M artyn ................... .... 280 Perkin-Elmer C o r p .............. .... 248
Perry Equip. & Supply C o , .... 2B2 Petro-Cham Development Co.
Inc.................................. .... 177 Pfaudler C o .................. Back C over Philadelphia G e a r W o rks.., ......222
Photoswitch In c................... . ... 63 Pittsburgh Lectrodryer C o rp .... 197 Pittsburgh Piping & Equip. C o. 221 Porter Co., Inc., H. K ....... ___ 144 Powell Co., W m ................. .172-173 Powers Regulator C o . . . . . . . .... 170 Premier M ill C o r p ....... ... .... 285 Prestfuel C o rp . ................ .....283 Pritchard & Co., J . F ....... ......247 Proctor i Schwartz, In c .... .... 274 Professional Services ....... . ..2 7 4 Pulverising Machy. C o . . . . . ........... 246
Q uaker O a fs C o . . . . , ............. 157
Raymond Pulverizer Div., C o m bustion Engrs. C o. In c ---- ... 12
Reading C hain & Block C o r p .... 160
Raading-Pratt & Caay (Div.) American Chain & Cable Co. 198, 244
Reeves Pulley C o , . . . ............... 183 Reiehold Chem icals, In c .... 32 Reilly Tar A Cham . C o r p ... 236
Republic Textile Equip. Co., In c......................................... 284
Rhoads & Sons, J. E . ............... 268
Pagn Richardson Scale C o .............2 5 0 Roberts Filter M fg. C o ....... . 33 Robins C onveying Belt C o ... 40 Robinson M fg . C o . . . . ........ 156 Roofs-Connersville Blower Corp. 126 Rowan C ontroller C o ................ 285 R-S Products C o r p .................. 130 Ryerson A Son, Inc., J. T .... 141
Sarco C o. In c .......... ...............254
Searchlight Section .............278-284 Sharpies C o r p ......................... 18
Shepard, Niles Crane & Hoist C o r p .......................................246
Shriver & Co., T ..................... 258 Solvay Sales C o r p ................. . 258 Sperry A Co., D. R . ............... 264 Sprout-W aldron M fg. C o ......... 275 Standard C onveyor C o ............. 210 Standard OH C o. ( In d ia n a ].... 55-56
Stebbins Engrg. & Mfg. C o ..... 134
Stein Equip. C a r p . . . . ....... Sfruthers W e lls C o r p ........... 141 Sturtevant M ill C o . . . , ........... 140 Sutton Steele A Steele, Inc.,
Separation Engrg. C o r p ........ 162
Taber Pump C o ........................ 270
Taylor Forge & Pipe W o r k s ....... 71
Taylor Inst. C o s ...............
30
Texas C o . .....................
14
Thermal Syndicate, Ltd............ 126
Tidewater Equip. & M ach. C o rp . 283
Timken Roller 8earing Co., Roller Bearing D iv ................. 217
Timken Roller Bearing Co.,
Steel & Tube D iv ........ . .
35
Titanium A llo y M fg . C o .............232
Tolhursf Centrifugal Div., Am erican M ach. & M etals, Inc. 67
Traylor Engrg. & M fg . C o ........ 139
Tube-Turns, In c.................
6
Turner Halsey C o ..................... 168
Union Bag & Paper C o ........... 54 Union Bay State C o ................. 26 Union Carbide A Carbon
C o r p ............................... 13. 191
Union Standard Equip. C o .......280
U. S. Ind. Alcohol C o ...............19-20 U. S. Stoneware C o ....... ..........37-38
Viking Pump C o ........................ 248 Virginia-Carolina Chemical
C o r p .......................................208
Vogt M ach. Co., H . . . , ...............240
W all-C olm o n oy C o rp . ............... 25G
W atson-Stillm an C o .................... 261
W arren Steam Pump C o . . . . . . . . . 151
W estern Precipitation C o r p ....... 125
W estinghouse Elec. & M fg . C o . 39
W eston Elec. Inst. C o ................270
W here to Buy............................ 276
W hitlock M fg. C o ..................... 252
W ickwire Spencer Steel C o .......256
W ilfley & Sons, Inc., A . R ........ 45
W illia m s Pat. Crush A Pulv. C o. 171
W illson Products In c .,,............. 138
W orthington Pump A Machy. C o r p ............................... ... 195
W righ t Mfg. Div. Am erican C hain A C a b le C o. In c,....... 244
W yckoff A Sons, A ...........
276
Professional Service........ .
274
SEARCHLIGHT SECTION CLASSIFIED ADVERTISING
Business Opportunities ............... 278
Employment S e rv ic e .............. . . .. 278
Patents ...............
2711
Positions Vacant ...................... 278
Positions W an ted ..........................
278
Selling Opportunities .................... 278
Wanted ta Purchase...........
278
Used S u rp lu s E q u ip m e n t ........... . , 278-284
286
J A N U A R Y m s CHEMICAL & METALLURGICAL ENGINEERING