Document v1d9dqj06xZyDOqzz4bkLqo2Y

.Cf ; U,, February 12, 1935. () TO; EXSOOTITK COMMimS 4 I FilOJl: GI15JUCAL DSPARTSUfl? - DIRKWOR'- lu accordance with your suggestion recently passed on to me "that the Chemical Department he advised that the Executive Committee mould like to have an annual report frost them along the lines indicated in the third paragraph" Of the Chemical Depart ment's transmitting letter of aaioh 10th `but in much more con densed form", 1. sua attaching hereto & brief report of the activi ties of the Chemical Department during the year 1934. 1 have omit ted from this report, in so far as possible, chemical, terminology, si.fa a view to making-the report more readable without any sacri fice in olaxity. ha effort has been made to show the monetary returns resulting from the work, where it has been possible to make some sort of an estimate of these returns, but in numerous cases such an estimate is impossible. For example, how shell we set a figure on the value of an important Ingredient of Buoo? 3uch ingredients have bean synthesized by tbe Chemical Department, but it may be argued that if the Chemical Department had not found these mater ials,, some other materials might have been found which would serve the same purpose. Such an argument does not alter the fact that in many cases the work of the Chemical Department has resulted in important contributions to the list of.the Company's products,, but such contributions have taken the direction of alterations of exist ing formulae or the diicoyery of products, or processes for pro ducing products, which are essential ingredients in the finished articles offered for sale. I have in mind particularly results obtained in oonneotion with finishes of various types. It should b pointed out that the classification of some of these pieces of-work, eueb, for example, as the activities of the Chemical Department in oonneotion with the Sulphuric Acid(Committee; or those involving general sulphuric acid studies; or vise and audit work; or chemical control work, do not fall entirely under any one of the headings, "Direct Savings", "Indirect Savings", or "'.Quality Improvement*, sinoe the results of the work sometimes bring about improvement in quality and again result in indirect savings. In faot, nt timsa the work results in very direct savings, as, for example, the improvement of the purification train in our sulphuric aoid plants, with a view to deereasing the number of regenerations of our contact mass which may be necessary, as well as with a view to improving the general average conversion. These are exactly the results whioh have been aimed at in connection with some of our sul phuric aoid work during 1934, and there is every prospeot that success will be realized. 1 I am by no means ineensible of the fact that by far tbe larger proportion of the work carried out by tbe central Chemical , Department for the various industrial departments, not only along i consulting lines but along research lines as well, has not resultsf in striking advances in the art nor baa it led to the development bC, a product or process likely to yisld a net profit, of hundreds of N50787 DUP150089407 * thousand* of dollar* a yssr. It has often bean argued that tha central Chemical Department ought to devote a great deal . of attention to the development oi radically new things, and it has been suggested that It is perhaps* a aistate to have thia department do so much work of the present nature. It should he horn* in mind, however, that pretty complete familiarity Pith the processes and products of an industrial line is necessary in order that intelligent and really productive consideration may be given to question* involving radical improvements or departure* from the products comprised in the present linee of Industry. I do not believe that it would he possible for a central Chemioal Department to produce the desired results if the department were mutually divoroed from the great mass of work which it now carries out fox the various industrial depart ments, set of# to one side, ond-, in a manner of speaking, directed to "Invent acme good,, big. pxafita'ol* things". The intimate touch with the various industrial lines oi th* Company is, t my mind, absolutely indispensable for your central Chemical Department. On th* other*hand, I recognise that we axe. Just now, so completely tied up with work for the various departments, that there is available neither personnel nor tine*to undertake work along any very radionllv new lines. I plan, as conditions make it possible, to provide the necessary alack in th* depart ment to enable the department to give consideration to some radioally new things, .1.*., new so lar as the Gompaiiy's present manufacturing line* are oonoeraed. In order to do this econom ically, however, it must be done carefully, and, especially, the man delegated to the work mustbe carefully seleoted. I have In mind attention to snob problems.ae synthetic .resins ta serve as substitutes-for Pyralln window sheeting. I cite this particular example because I wish to make another point in this connection. Should work of this nature be successful, (either within the dnPont Company ox outside of the Company), immediate consideration of the effect upon Arlington's busmss* is involved. It, therefore, seems logical, at tha same time to-give considerable attention to the question of eo altering Arlington'* product* that wider fields of usefulness maybe found for them because of improved properties, and vet confining the alteration* to euoh developments ns may net preoiude continuation of the manufacture in the pretent equipment. It should be recognised that the question of the development of any new prowess or pxoduot has. many angle*. I should- like to add. that when on* of our research-staff is oall ad upon to develop something radically new, we do not hedge him about and weigh him down with th# consideration of all the various angles of' th# problem.. Otherwise, he might never get for ward with th* work. It is desirable, however, that within the de-jt partment the necessary perspective be available; In an attempt to clarify this question of the value in dollars and cent* of th# Chemical Department's work, I have classi fied all the subjects to which no gave any considerable attention during 1924 on th* following basis:- Croup 1 - dork undertaken with oroaneota of direot savings; research work wholly or practically complete/ Group 3 - as group 1, exoept research work ia incomplete. Grouo 3 - indirect savings, not estimated in dollars and cent*. This group includes also new processes involving potential profits rather than savings. Group 4 - Investigations aimed at improvement In quality. A brief and rather sketohy suawaxy of the work of the central Chemical Department during 1934 follows, arranged ia accord ance with the foregoing captions. --2-- DUP150089408 GROUP 1 Alum Manufacture Congo Eater Manufacture High Silica Barytas as Source of Black Ash liquid SO2 Manufacture Solvent Recovery - Newburgh Solvent Recovery - Tetxa Ethyl Lead Strontium Nitrate Process Revision Study of Paulshore as separate unit Zinc Liquor Purification White Lead - Continuous Reel QRPOP 2 Alumina Hydrate Manufacture Base Varnish Dry Colors (Yellows) Ester Gum Oxidation of Ammonia ProuB 3 Cryptox Core Oil Butyl Alcohol Southern Electro-Chemical Company's Suit Glycerine by Fermentation Llthopone Patent Situation Pratt Process Sodium Cyanide Slow-burning Pyroxylin Plasties Synthetic Ammonia Sulphuric Acid Committee General Sulphuric Add Studies Calvert Process Tribremanilia GROUP 4 Basie Alum Basio Oil Study Ethyl Celluleec Gold Seal Llthopone Improvement Fliatflex Green Beal Llthopone Deterioration of Fabrikoid Improvement of Automobile Finish Prsolar Bill softeners for Pyroxylin Rubber fop Varnish Spar Vanish Nitrocellulose in Varnishes Sew Explosives Vise and Audit Work It has been our habit, year by year, to point out that In those cases where an effort has been made te estimate the actual value of the work of the Chemical Department in tens of dollars saved or earned, the central Chemical Department disclaims any de sire -to claim all the credit for these savings. It must bs per fectly obvious that the results that have been obtained are realised only through the joint effort and complete cooperation of all the interested departments. Certainly the reduction to manufacturing praotiee by the interested Industrial department is as essential as the suggestion of the idea and the preliminary laboratory and nemlnoxks development which may be carried out in the Chemical Department. GROG? 1 Alum Baaufaoturei- 1334 Expenditure - 63,540.84. Savings - 14,000 per annumCongo Ester Manufacture?-- 1924 Expenditure - $8,048.83. Indicated possible yearly saving aa result of this work now coaplat* - ;?19,000. See Exhibit Ho. High Silica Barytas as Souroe of Black Ash:- 1934 Expenditure - 33,801.60. Probable savings, total of Newark and Philadelphia possibilities - 388,000 per annum. 839 Exhibit No. 3. -3- DUP150089409 1934 Expenditure - 344.56. this plant continued to be operated throughout 1934, having a total production of 7C3,000 15b. Production in 1933 v 466,SCO lbs., dating a total nreduc tion from February 1933 to flat* of 1,136,500 lbs. curing Vais same meriod there Tms purchased outalda 340,000 lbs. at an average price, delivered, of 4.914 per lb. when th* sulphur dioxide plant was first built, th* Company wa* paying 6.10^ per lb., delivered. It seems reasonable to conclude that the average price was lover over the period of the operation of the plant du* to the fact that our suppliers knew well of th* existence" of our plant and that we would not stand for exorbitant price*, this is boxne out by the tendency of the price of purchased ga to fall still lower. Savings (last three months of 1934 only axe included) - 5.0,305 total. 39 Exhibit So. 3. gol.v ynt, Jis.cyr.tiy. flgbqafe- 1834 Expenditure - $853.47. Saving* - $100,000 per annua, see Exhibit So. 4. ' Sqllgft*. ..Bg&oym t.3try$tfryl ^4:- 1934 Expenditure - $3,376.58. (Recovery eyete* put into operation in Hovember or December, 1934.) Savings indicated >300 to $500 per day. It should he added that the measurement of ethyl bromide lossee indioates the escape of a quantity equivalent to sore than $1,000 a day. Only partial recovery possible. Per annum saving may be anywhere between $75,000 and $100,000. Strontium Hltrate - Propose Reviaiotti1934 Expenditure - 3,780.51. Indicated savings - 18,000 to 8o,C00 per annum. See Exhibit Ho. 5. study of Pauisboro a Separate Uoittr. 1934 Expenditure - 1,188.37. 71*6 and audit work was concerned with the economies of chamber sulphuric manufacture at Paulcboro, end incidentally Involved a study of the manufacture of 3trontlua nitrate wad hydxcohlorie acid at Psnleboro. Ehile Eost of the recommendation* involved were tabled for further inves tigation, I am informed that, as a result of this investigation, Paulscore wae made a BUb-dlvision of the Philadelphia Works, which Hr. "`.eaash tells me is oaring them 3,000 per month, or >-36,COO per year. Zinc liquor Puriflcationi- 1934 Expenditure - $3,530.41. Indioated savings (sioo at ,0S5*J par pound) *49,000 per annual. Sea Exhibit Ho. 8. Shite Lead - Continuous Reeli- 1934 Expenditure - $5,613.15. indicated savings - 35$ on investment of $130,000. Value in conneotion with negotiations with -4-- DUP150089410 national Load Company certain but indeterminate. Sea Exhibit I/o. 7. GROUP 3 Alumina Hydrate MVMfeature,-- 1934 Expenditure -- $2,501.84. Study mad* of manufacture of color makers' alumina hydrate suoeeseful In determining factors essential to production of transparent product, and must result in very considerable improvement in manufacturing process. Too early to estimate amount. .y.MBJL&A.1934 Expenditure - $3,433.63. Goal of study; replace ment of duPont Company's varnish formulae, 5,000 in number, by about 35 formulae. Remit; reduction of stock, ua* of larger manufacturing unite (varnish kettles), greater ease of control, improvement in Quality of finished product, correlation of work of the different plant*. 7elue of work* Certain but Indeterminate in amount until vfd have result* on reduction of stocks. Pry Colors (Yalloweli- 1984 3E*p*nditur* - $10,020.44. possible yearly saving* indioated - $78,690. Sea Exhibit Ho. 11. 1934 Expenditure -- $1,074.94. A laboratory study has been made demonstrating tbs possibility of producing our own ester gum from glycerin* and rosin. The study was so conducted as to- shoe the best condition* for production from the point of view of cheapness and ease of operation as veil as Quality of product. A.a a result, the process is now ready for aetui-plant scale development. The investigation showed the possibility of a considerable saving in cost oouplsd with an increase in Quality. Indicated cavings axe the difference between the market price, which is about l0<( per pound, and our cost of Manufacture, which will be 7-8<f per pound,- multiplied by the number of pounds which it may be found possible to use. Ester gum consumption figure# for four du?ent varnish plants for first half of 1934 were 81,265 pound a. On the basis of"122,SCO pounds a year, our saving would, therefore, be ^3300 a. year. See Exhibit #8. Oxidation of Anunonjai- 1934 Expenditure - $10,860.03. Savings;- in connection With email unit installed at Philadelphia for production of oxides of nitrogen for the chamber prooesa; also, single unit plant just -5- DUP150089411 started at Repauno, oapaoity 5,000 lbs. iQC<t HKO, par day (deli-raxed a# 5QJt sold, however) at a saving of close to l/3tf a pound* also, extension of proeese fox oxidation of ammonia to produce nitxie acid to take oaxe of Company's general requirements* also, development of improved equipment for resistance to dilute BSOa. The foregoing result# are tangible enough, but can scarcely be assigned a monetary value at this time. See Exhibit Ho. 9. 9STPl(bX>1924 Expenditure - 3,407.09. This pigment cam be made in Gold Seal lithopone equipment. It oan be regarded as a modified Cteld Seal lithopone, oving its inorsaeed hiding power to n considerable increase in Its aiaosulabide content. Single email lot made on seai-noxks soals gave satisfactory results as to coier and strength. Because of potential competition, of Titanox, the product is very interesting. If successful in putting it across, will be fine money-maker. See Exhibit go. 10. ft-Ui 1924 Expenditure - 3,069.47. flork auoeeesfni in develop ing about 50 raw material combinations from 200 raw materials avail able, any on* of the 50 being more efficient than linseed oil which is used at present. Ultimate value of work depends upon amount of product manufactured, and quality of material selected to market. ^t7l....ilP9h9lLr. . 1924 Expenditure - 13,741.46. tfork on this subject ceased in June, upon completion of satisfactory arrangements with commercial Solvent* Corporation. Expenditures were mostly in connec tion with patent situation, and this Information was useful in con nection with negotiation of contract with Commercial solvents. Some experimental work was oarrled out on our process for making butyl alcohol and acetone from molaeses. Commercial Solvents' process involves com as raw material. Southern Sltotra-Ofrenigal g<a8grl . 1924 Expenditure - $1,284.85. Rush time spent in assisting lawyers in connection with cuke Suit. Repauno experimental tower altered and very useful results obtained in conneotlon with ootual demonstration of prooast. Our lawyer*' brief in this cane thoroughly reviewed, certain inconsistencies removed, and certain points emphasised which had not, perhaps, been sufficiently brought out. itonetary value of Chemioal Department's work on thl* matter I believe to be very large. It should be borne in mind that, natu rally enough, both the lawyers and the expert* Whom we employed, were -6- V DUP150089412 completely Ignorant of the technical detail* involved and had to J *?rt dona h ** in thia coanertion. Also much of^ii^ork ttaRy fr ou* 8ide * th cs** ototeined as result glycerine by Fermentation , . _ 19?4 S*pnditure - $30,613.30. Eight large rune were made at Peoria. Thee* rune vex# all made with the same lot of hnadde*xpTMec+te.dP* * It v s j i 2fu*3y2thvcloxwSdrftjatohnaa?lJraaJt*e?dftStfcat *t*hebedloxwpcwchtcadt wt oe-- covexiee of gljroexine from the Bpray tower were not obtained even when a weighed amount of cure dilated glycerine waa put through the spray tower. Indication# that changes in design or material of construction in spray tower would be necessary. Further ex perimental work in the laboratory carried on in latter part of year. Reasons for Spray tower decompositions probably located. Seems likely that spray tower yields own be much improved by cer tain changes, improvement of yields obtained from molasses, nor mally giving low glycerine, still problematical. However, the process might be profitable on basis of improved spray tower yields if we obtained only the average yield of glycerine'and of alcohol wbioh our full works scale runs have shown to date. Llthopona Patent Situation 1924 Expenditure - $5,182.69. Proposed methods of defense against threatened suit by hew Jersey zinc Company have been devised and tested, end much data baa been obtained bearing on the validity of the claims of the Sew Jersey zlno patents. Prior art samoles of great potential value have been uncovered, and their authenticity eetacllshed. A number of statements made In Sew Jersey zinc Company's patents have been cheeked experimentally. As a whole, I am well satisfied with the results of the work, but it seems to me little on be said about the indirect savings. '<78 axe expecting to be involved in an infringement cult, and we are taking active steps to prepare ourselves for defense. Certainly, if we are successful, the savings will be large. Pratt Process 1924 Expenditure - $2,283.63. The expenditures in ques tion were not concerned solely with an investigation of the Pratt process, but were also concerned with an attempt to apply water dis persions of rubber at Fairfield in connection with themanufactuxe of rubber automobile top material. Hr. Pratt gave his personal assistance in some of these experiments. The experiments were dis continued because they gave little promise of definite savinga at that time. At present there is no immediate pxcBpeot of water dis persions of rubber proving useful in connection with the Company's products. / Sodium Cyanide;- 1924 Expenditure<- $2,879.00. By far the greater por tion of this expenditure was in connection with the determination of the value of the by-product eafbon produced from our cyanide Pro cess. It was indicated that thia by-product would probably be quits valuable. The process was published and elioiied exceedingly favor-- -7- DUP150089413 able coament in the technical journals, both in the United States and England. The general tenor of the cements was to the effect that the process reflected great credit upon the ingenuity and resourcefulness of the dupont Ooaroany. g^'Hforaiag Frroyriia .flatUsat-: 1934 Expenditure - @1,613.40. Radio panel material affords profitable outlet for Pyxalin. 5ou-?leja formula trieresyl phosphate and gypsum combination - covered by patent owned by Oelluloid Company. We have developed for Arlington satisfactory alternate formulae. Have also furnished Legal Department Information in connection with patent validity Inves tigation. Dork indispensable and itnovn to be of considerable valus. t-. 1934 Expenditure - $16,387.03. Prior to formation of L&zote, incorporated, experimental work was carried on at the Station on hydrogen production, as well as patent studies and cost studies, and certain experimental work on details connected with Claude process. Beginning with September, results of work covered direotly by Lasote reports and Experimental Station per sonnel transferred to Lnsote. This work is indispensable in con nection with the development of the manufacture of synthetic ammonia. Expenditures in this connection set definitely segregated. Fart of one nan's time. Much valuable work accomplished in coordin ating information and experience on contact sulphuric acid manufac ture among various departments of the duFcnt Company, as well as in applying valuable information obtained from visits to outside plant*. Result. Improvement in design and operation of duPont plant*, considerable improvements are being reelired in tbie connection. ffgnuai foavfoulq Expenditures In this connection not segregated. Part of two men's time. Result* Changes in design and arrangement of Company's sulohurio sold plants at Barksdale, duPont, Louviers, and suggestions in connection with the plant of the south American Explosives comnany. Cooperated with Engineering Department In connection with design of ooatact plant for the Tennessee Copper Coamany and for the Pennsylvania Salt Company. Small amount of fundamental work dona in laboratory. Perfeotly definite result* obtained of undoubted value. Calvert Process.:-. 1924 Expenditure - $958.86. Investigation (for the Development Denartruant) of an English pxooess dealing with manu facture of alcohols from carbon monoriide and hydrogen, and a second preoess for manufacture of molded rubber artioles by incor-- -8- DUP150089414 poratlon of natural rubber latex Pith fillers and vulcanizing agents. Demonstration of the alcohol proeese disappointingly inconclusive. Kubber process nob sufficiently attractive to warrant our further interest. ? rlbromanllln;-- 1324 Expenditure -,1*897.63. Chemical .Department asked to obtain certain chemical information in connection with a process suggested by the F.thyl Gas Corporation for which du?ont Engineering cepartment has been asked to' build a plant. Objeot:To relieve bromine shortage by recovering bromine from sea water bs tribromanllin. Yield# obtained In the laboratory roughly equivalent to between 0.85 and 1.0 pound of txlbromanilia from 1800 ; e lions of sea water. i*any elementa of uncertainty involved. GSiOOP 4 Baaie .iluau- 1324 Expenditure - 5395.38. Object:-?roduation of basic aluminum sulphate superior to ordinary aluminum sulphate for x?ter parification. Patent application prepared; product can be manufactured at lower cost than ordinary alum. At present this Company sella about 13,000.000 pounds of alum per year for water purif ication purpoeee at an average price of ^1.30 per hundred pound*. Daaia oil Otuav:- 1924 Expenditure - 2*093.30. Objects:- (1) develop ment of oil Intermediate* irhioh can be combined with varniah gum intermediates (to be developed in connection with another study) to produce finished varnish formulae; and (2) ths standardization of methods of oil treatment. An ideal paint oil will be one which combine* properties of cuick drying* maximum hardness and great durability. Sthyj cellulose;- 1934 Expenditure - 18*598.53. Object:- The develop ment of the possibilities of ethyl cellulose ae a filjn-foraing material for Hon-flaa film. Ethyl cellulose also of interest because of possibilities of usefulness in artificial silk, tuco* Fyralin substitute, and insulating material. 3aeia patents to Lillenfeld in bend* of Ghemloel Foundation. Exclusive license for use of material in photographic film owned by Eeataan Kodak Co., who have also taken out a number of other patents on celluloee ethers. Patent (situation io being investigated. h'uch valuable experimental information obtained. Because of the r.Vfcractlve properties of this ceiluloB* derivative, the investigation is being continued, in spite of the rcther complicated patent situation. Cold Seal llthosone Improvement:- 1934 Expenditure - 519,359.39. Attention devoted both to method of ssenui'aotura as carried on et Newark end to improvement of properties of finished pUment. Tangible results obtained:- -3- DUP150089415 Large saving In zinc consumption; better standardization of pro cess of manufacture; Improved texture; improved paint grinding properties. 3y--product of investigation:-- Application of methods for improving psint-mixing; properties of lithopon to general improvement of paint-nixing properties of ell our pixmente. Ke,suits in this connection perfectly definite end Quite promising. Fliatflox:- 1924 Expenditure - 449,795,18. Object:- To develop ?- bating automobile finish of improved durability. Sesult:as ' flexible, tough, very durable finish for automobiles, exhibiting superior anchorage to metal panels, Flintflex appeared to be a very 'promising development, but the popularity of air-drying spraying Oueo led to discontinuance of the work so far s tha us of Flintflar as a top coat material ia concerned, instead, the unique properties of Flintflex ere now tha object of study in connection with the development of improved under coating materials to be uaed with Buco. Flintflex &1bo under investigation aa an insulating varnish, as well as an ingredient of formulae containing nitro cellulose. Groan Leal Lithopone;- 1924 Sxpendltux* - 44,450.95. In March we wars requested by the faint Department to undertake a very considerable improvement in the quality of Green 53*1 lithopone, to be effected without impor tant changes in toe existing equipment, the quality goal being very definitely set up by the Sales Division. The first plant run indicated definitely that the desired quality could be obtained in the Green Seal equipment, end runs mad in August produced a large -mount of pigment equal to goal quality In every respect. Change in a&las policy deferred further development. Lete in 1924, however, the plant undertook further development, involving application ox tbs results we had obtained. Deterioration of S'ahrlitoid:- 1934 Expenditure - if?,474.38. In thin field we havs done pioneer work end obtained positive end valuable result*. We have die covered groups of substances which, when added in small amounts to the ingredients of the Fsbrikoid film, inhibit the oxidation of the vegetable oils used as aoftenera, retard the development of rancidity rod the deterioration of the film. fie expect to obtain valuable patents on these discoveries; one preservative is nos used by Newburg in all dark-colored goods except bieofc, end another in ell llyht-- colored good* including white. Sleek goods hove never been as bad a shite and colored goods. It is safe to h p.y that our Fabrikold is no practically free from rancidity, and that tha keeping quality of all colored good ha3 been very greatly improved. Improvement la espaoia noticeable in brown goods, onoe the worst offender. You will be interested, in the fact that sn arrangement has been made with ilobcla to use our preservatives on * royalty heals. -10- DUP150089416 Premier fUll:- 193* Expenditure - $668.78. This so-called "colloid mill", manufactured in England and designed for very fine disin tegration and formation of emulsion#, has been investigated by us, both as to its adaptability to the dye business and. the paint, varnish and lacquer business. Tangible and valuable results have bean obtained in connection with its use for a particular line of dyes, as well as In lithopone grinding. ' Softeners for Pyroxylln;- 1934 Expenditure - $6,003.83. We have oarriad out pioneer work during the past several years on solvent softeners for pyroxylin. Definite and valuable results have been obtained. Dibu tyl phthslate, an important ingredient of Duco, is one of the devel opments. I believe it is safe to say that Puco cannot be satisfac torily manufactured without solvent softeners, and our study of this field ha* been most useful to the company, and baa given it a con siderable advantage in developing a superior product. Another softener which we hare developed is aoetyl laurin, regularly used at Newburgh ae & small percentage ingredient of certain jellies. Certain new softeners have been developed during the year, such as glycol tolyl ether lauxate, which is one of the most Interesting, and several thousand pound* of synthetic, high-boiling softeners have been manufactured at the Station for uee in plant experiments at Hevburgh and Parlln. " ."uLiber Ton Varnlaha- 1934 Expenditure - 705.83. The problem of a durable finishing varnish for use over rubber automobile top material is of first importance in connection with the business of Fairfield. The trend to closed cars hae made Inroad* In the use of the material ordinarily used for open-oar tops, necessitating attention to the development of a type of finish for the closed-ear top which shall be very durable and retain the neeesaaxy gloss. This work was be gun December first, and no conclusions can be drawn as to the probability of successful results. Scar VarniSh;- 1934 Expenditure - 3,290-67. Qbjeot:- The development of a spar varnish ae good a* the beet of our competitors* products. Result:- The beet competitive products have been equalled in all properties except gloss, and considerably greater durability has been obtained. Results have been turned over to the plant for ap plication and the chemist trained in the work transferred to the plant. Improvement of Automobile Finish;- 1924 Expenditure - 10,535.89. This work, undertaken originally to improve Flint's paint and varnish lines for auto fin ish, chiefly by the formulation of long oil baking enamels of great / durability, led to much valuable information. For example, the devel / eient of a method of processing Chinawood oil, the design end study o -11- DUP150089417 sooelarated weathering test fox paint and varnish oanele, informa tion as to the effeot of oertain'driert and pigments on the rate of curing or drying of finishes, as well as upon durability, the effect of certain foesil resins on the physical properties of tbs finish in which they are incorporated, and other indispensable information of a similar character. Hitrogellulose in Vamlahes:1334 Expenditure - $5,531.54. Definite results hare been obtained from the investigation of methods for incorporating nitrocellulose and ethyl cellulose in varnishes. The results obtained in connmotion with nitrocellulose ere particularly interesting and are believed to be of great value. 1934 expenditure -- 7,585.98. About $4,500 of these' expenditures are directly chargeable to our vox* on the development of new ingredients for flashless, non-hygroscopic, smokeless powder. Very tangible end interesting-results hare been obtained. Hew products have been devised whieh appear adapted to the purposes in mind. Patents have been applied for. It is possible that come new stabilis ing agents may also result from this study. Vish and Audit florin- 1924 Expenditure - 14,738.18, The work comprised under this heading has been concerned with such matter* as contact sulphuric &Cid, ohamber sulphuric acid, aoetio acid manufacture, hydrochloric acid manufacture, strontium nitrate, and various other studies. Refer ence has already been made to some of the tangible results of this work. An inspection of the Arlington pleat was made late in the year. There is else some general consulting work, such as some attention which we have been giving to the Pibersilk and Cellophane operations, which hie been taken oat* of under this heading - 7ia4 and Audit. Certain studies in connection with the recovery of spent acid and with methods of yield accounting and operation, particularly in sulphuric adid manu facture, have been paid for out of this account. The total amount of money spent by the Ohemloal Department during the year 1934 was $360,851.83. Of this amount the expenditure of ^33,545.33 shows an indicated saving of $484,350 per annum on Group 1 work, alone. It should further be pointed out in this connec tion that while some of the savings indicated ere not yet in force, ir*e the continuous lead reel process, others which ere in force lndioate much larger returns during 1935 than the figures cited for 1934, because the 1934 figure covers only a few months* operation. The liquid SO* process is a notable examole in this connection, where the figure cited is $10,605, but the indicated 1935 saving ie 33,350. On the other hand, it should be pointed out that the expen ditures by the Chemical Department on euoh things as the continuous reel nxooeea do not give the whole story, because the Engineering Department has also been spending money on experimental work in this connection. Actually the only complete picture would be a complete report on the total expenditures involved, upon the completion of a given piece of work end the actual operation of a plant for a few yesre, together with the plant investment involved and the profits or savings realised, obviously our figures for savings realized, or expected, and research expenditures, mat only be taken as an Indication of the value of the work of the Chemical Department and not as a profit and loss sheet. The total of the individual accounts sited in this report is 283,181.5-4. This figure takes no Recount of expendi tures by the Oheaioal Department for a number of individual depart ments wher# the expenditures wer* made at the dizeot request of the department and the cost of the wort was billed out direotly to the interested department. For example, there was 1,089 north of analytical work on nitrate of soda for the Purchasing Department; $3,840 north of work for the Engineering Department; $3,889 for Cellulose Products Department; $l,85i for Explosives Department; $3,338 for Paint Department; Dyestuffs Department, 1,783; 9,179 of miscellaneous products; 15,574 for Lazot*; $1,353 billed against Gxasselll for lithepons patent situation investigation; general work for company not chargeable against a specific indus trial department, 19,849; end many small pieces of work costing two or thro* hundred, dollars apises. These go to make up the 75.000 difference between the total expenditures of the Chsmioal Department for 1934 and the expenditures itemised in this report. It is probably not worth while to go into the details of these expenditures in a report of this nature where so much interesting and essential informatien in connection with the most important research Work has already been omitted. Continually increasing amounts of work have been requested by the industrial departments, though the individual totals have fluctuated. Z believe It is fair to*, say that the past year has narked a further advance in the efficiency of the Department. It will be obvious from this report that the work which has been oarxisout has been very conoxete and very definitely aimed at results of value to the Company. CHA3. a. A. sm*, CHEMICAL DIHSCTOR. CilA3|K--11* DUP150089419  EXHIBIT SO. 1 C 91*00 83TER -- rQtiSltiL'Z 3J>V'IIiti. (Expended 1934, - $8,043.83). Consumption of Kauri Gum at Vernish Plants during first 8 months of 1924: Plant lb, price uentltyValue Chicago 180 3900 GO0 17000 Philadelphia 36-1/2* 7000 10* 1450 430 800 Everett 43ft 18a io 33--1/30 1800 150 350 2700 Total, all plants. for six monthsi. Yearly consumption on six aonthn basis Congo Ester 150 20900 9250 5000 35150 70300 70300 703. 10300. 1855. 145. 336. 756. 27. 35, 715. 10903. 2336. 1533. 14771. 29543. 10546. Possible yenrly saving by use of Congo Ester, approximately 19000. work with thiB pTobla* prior to January, 1934 established EOa of the fundamentals of the process. A. number of the diffi culties of preparing Congo Ester in email, open-kettle batches, together with the best means of meeting these difficulties, had. been fairly well worked out. Sore than half of the year wae therefore spent at the different plants introducing Congo Ester end further standardising the method of Its manufacture. This work very clearly established the value of Congo s'Bter os ts varnish gum. In quality It waa found to be unsurpassed, even by the much more expensive resins, especially in regard to durability and water resistance. Likewise, when properly prepared, it gives a very hard varnish, being in this respect practically tho e>mc ea the very expensive Kauri. Congo Ester can be used aa an intermediate,like rosin or ester gua, and hence Congo Ester varnishes are very assy to prepare as compared with Kauri, t'anila, ?'cntlanao, etc. The color of the Congo Seter varnish is much auoerio? to a similar herd pum varnish, which in turn will coat considerably more than the eBtsrified Congo. These varnlshee are, of course, practically neutral, end hence can be used with bselc pU;ment3 without danger of livering. The cost of Congo Ester will vary with the hardness, acid number sad color desired, but two very good grades can probably be prepared et approximately ten and fifteen cents per pound, respective ly, as comosred with Kauri of thirty-five end sixty cents. DUP150089420 EXHIBIT SO. 1 GoSGO ESTER -- ?OriSX2XS ShVIMOa. (Expended 1334, - $8,048.83). Consumption of Kauri Gum at Varnish Plants during first 8 months of 1324: Plant lb. price uantity Value Chicago 18* 3900 SOfJ 17000 20900 703. 10300- 10903. Philadelphia 36-1/2* 7000 10* 1450 43? 800 9350 1855. 14,5. 338. 2336. Everett 42* 18* 10* 33-1/3? 1800 150 350 2700 5000 756. 27. 35* 715. 1533. Total, ell plants. for six monthsi. yearly consumption on six months basis 35150 70300 14771. 9543. Congo Ester 15 p 70300 10545. Possible ysnrly saving by use of Congo Ester, approximately 19000. *ork with this probl9 prior to January, 1934 established some of the fundamentals of the process. A. number of the diffi culties of preparing Congo Ester la email, open-kettle hatches, together with the best means of meeting these difficulties, had been fairly ^all worked out. Sore than half of the year was therefore spent at the different plants introducing Congo Ester end further standardising the method of Its manufacture. Tbia work very clearly established the value of Congo 5'eter &s a varnish gum. In Quality it waa found to be unsurpassed, even by the much more expensive reeins, especially in regard to durability and water resistance. Likewise, when properly prepared, it gives a very herd varnish, being in this respect practically the same *a the very expensive Kauri. Congo Ester can be used aa an Intermediate,like rosin or ester gum, and hence Congo Ester varnishes are very easy to prepare as compared with Kauri, '.'anila, Pontianao, etc. The color of the Congo .Ester vernish la much superior to a similar hard gum varnish, which in turn will cost considerably morn than the esterified Congo. These varnishes are, of course, practically neutral, end hence can be used with bseic pU;msnt3 without danger of llvering. The cost of Congo Ester will vary with the hardness, acid number and color desired, but two very good grades can probably be prepared at approximately ten end fifteen cents per pound, respective ly, as comcered with Kauri of thirty-five end sixty cents. DUP150089421 e x h ib it so. i. 0%>StiO SST2R -- rOBSlBX> 3/1. VUGS. (Expended 1934, - 8,043.83). Consumption of Kauri Qua at Vernisa riant* during first 3 months of 1924: Blunt lb. price uentlty Value Chicago 18ji 3900 sop 17000 20900 703. 10300. 10903 Philadelphia 36-1/24 7000 lOd 1450 43$j 300 9250 1855. 145. 336. 2336, Everett 43d 18a lOd 33--l/3j< 1600 150 350 2700 5000 756. 27. 35. 715. 1533, Total, oil plants. for six months. 35150 14771, Tesrly consumption on six months basis 70300 29543, Congo ister 15p 70300 10546. Possible yearly saving by use of Congo Ester, approximately 19000. *oxk with this problem prior to January, 1934 established some of the fundamentals of the process. A. number of the diffi culties of preparing Congo Ester in email, open-kettle hatches, together with the best means of meeting these difficulties, had been fairly pall worked out. Sore than half of the year was therefore spent at the different plants introducing Congo Ester and further standardising the method of its manufacture. Tbia work very clearly established the value of Congo ?8ter as n vsraish gum. In Quality It wsa found to be unsurpassed, even-by the much more expensive resins, especially in regard to durability and water resistance. Likewise, when properly prepared, it gives a very hard varnish, being in this respect practically the e'ae es the very expensive uri. Congo Ester can be used aa an Intermediate,like rosin or ester gum, and hence Congo Sster varnishes s t b very assy to prepare as compared with Kauri, t'anila, i-'ontlanao, etc. The color of the Congo Sober varnish is much auoerior to a similar herd gum varnish, which in turn will coat considerably more than tbs esterifled Congo. These varnishes are, of course, practically neutral, end hence can be used with bssic plmsnt3 without danger of livering. The cost of Congo Ester will vary with the hardness, acid number sad color desired, out two very good grades can probably be prepared at approximately ten and fifteen cents per pound, respective ly, as comosred with Kauri of thirty-five end sixty cents. DUP150089421 EXHIBIT WO.3 HIGH 3ILICA BARYTES - PROBABLE SAVIBOS Expended 1934 - g 3,801.80 Reduo* Ion of High Silica Barytes It Is gsilly rscegni*ed that silica is a vary detri mental impurity In barytea and Its presence In excess of 4# is undesirable la the ore used for the production of barium sulphide. A3 a result, only the better grade of ox* le being rained which, coupled with the faot that it undergoes a purification treataent, makes its ooet appreciable, while there is also the possibility of an increasing desand overtaxing ths supply. At the earns time there axe large deposits of bsrytss containing from 10 to 15# silica which are unfit for this purpose at present and can be obtained at a much cheaper price than the present ore. The util isation of such ore is ths objeot of this study. Our attention is particularly directed toward a large deposit in South Carolina containing approximately 1,000,000 tons owned by ths product Sales Corporation. Cur rather thorough study of ths blaok ash furnaciag operation in the plant, mads several years ago, which set up stand ards for operation and yields that are at present used, had shown that one pound of silica rendered unavailable 2.7 lbs. barium sul phate. Consequently, this high allies ore would give a yield of water-solubla barium sulphide of approximately 60# in plant oper ation as compared with an average of 804 for an average grade of ore used by the plants and it is therefore uneconomical. Our laboratory work using a briquetted Charge, made 1-1/3 years ago had shown that this method cut down ths deleter ious silica reaction to a great extent. This knowledge applied to high silica ore in the present work resulted in ths same in hibition of the silioa action and the obtainment of a conversion of 90# to water-soluble barium sulphide. Following this a con siderable amount of laboratory work successfully solved several problem* In connection with these briquets, such as hardness, binder, nature of coal, fineness of materials, temperature of furnacing, and leaching of resultant black ash. pleat teste consisting of five runs, baaed upon laboratory experience, shoved that briquets made from ox* containing 85# BaSOg and 14# SID3 gave successful operation in the present rotary furnace and particularly that a conversion of 90# can be obtained in the plant. This yield is comparable with 60# which would hare been obtained with this ore in the ordinary practice and with 80 to 83# obtained with present ore containing 93 to 95# Ba30* and 4 to 3.8# BlOg. Due to this high conversion, the weight of barium sulphide from one ton of ore is the same ae with present high grade ore. Another favor able result wae the absence of sticking of ths charge to the fur nace walla which, besides eliminating the barring required at present, would make possible the operation of a continuous kiln for this purpose since the sticking constitutes a serious obsta cle in this connection. fhe use of briquets applied to low grade and high silica ora will consequently result in a considerable saving. As listed below, this consists of several items, chief of which la the diff erence in the cost of ore. The present cost is $8,00 (1/28/35) pear ton plus $8.00 freight, while assurance of & price of $5.50 per ton for the low grade ore has been obtained and there la a possibility of a priee of $4.50 per ton. There is also a cheaper freight cost of $.35 to ft.40 per ton from the South Carolina deposit. The use of anthracite culm in briquets at a cost of approximately ft.SO to ft.90 per ton as cospared with $3.45 for coal, together with an ad vantage in freight cost, entails another appreciable saving. ';lth the culm ordinarily available, containing approximately 204 ash, this saving would be possible only in a briquetted charge but the very reeent availability upon the market of culm with 12$ ash at ft.90 net ton makes it possible to realise this saving with the present form of charge. (Inoidentally, this information applied to present charge was worked up about three years ago and now the market conditions make it possible to utilize thie knowledge.) In the nature of savings indirectly dependent upon a briquetted charge axe {1) continuous reduction of barytes, which is made possible by the avoidance of sticking of the charge, end (2) grinding by means of the Hardings mill at Newark, the fine grinding of which would he an advantage fox briquets but is ob jectionable at present. The list of savings is as followsj- Direct Savings Newark Philadelphia Ton--^flujL. ..Tons......vSue_ Crude baryte* at $8.00 per ton. fob mines'(1925 contract). ' 12000 $96000 8000 $64000 Crude barytes at $5.60 per ton, fob mines (conservatively estim ated price high silica material). 13000 66000 8000 44000 Savings on exude baxytee at $5.50 30000 20000 Reduction in freight rate on account of charter haul (nay be as much as 40)& per ton, but is conservatively estimated at 2Sj&). 12000 3000 8000 2000 Total savings on crude barytes 33000 22000 Coat of briquetting high silica barytes at $1.50 per ton. .12000 19000 8000 12000 Net savings on high silica barytes 15000 10000 Further probable savings through reduction of wine price of high silica material to $4.50. 13000 12000 8000 8000 / Probable net savings on high silica baryte*. (a) 27000 18000 DUP150089423 Coal at prevent pxloa* Bewari, per ton del'd. $5.33 Philadelphia, per ton field. 4.56 Bawark Ton* Value 3640 $13800 Culm at 9Q, fob nine* BewarIt freight, per toa 3.14 3640 Philadelphia freight,per ton 2,39 8000 Savings on use of Cola (*> 5800 Total direct saving* ( + b) (0) 33800 Indireot Savintra Continuous reduction baryta*, labor 11700 fuel 7500 Grinding in Harding* Hill, labor 4700 Total indireot caving* Total saving* (o + d) (4) 33900 56700 Total saving*, jiawark and Philadelphia 86000 Tons Value 1760 % 0000 1760 5600 3400 30400 3900 6000 3900 39300 DUP150089424 EXHIBIT TO.2 HIGH SILICA BARITS3 - PROBABUS SAVINGS Expended 1934 - $ 3,SOI.SO Reduction of High 3111ca Barytas It is generally recognized that aliion is a vary detri mental impurity in buryte* and it presence m excess of 4$ is undesirable in ths ora used for the production of barium sulphite. A3 a result, only tha better grate of or* la being mined which, coupled with the faot that it undergo** a purification treatment, make* ita ooat appleciable, while thar* is also the possibility of an increasing demand overtaxing the supply. At the sane tin* there ara large deposit* of barytes oontainlng fro* 10 to 15$ silica which are unfit for this purpose at present and can be obtained at a much cheaper pries than the present ora. The util isation of such ore is tha object of this study. Our attention is particularly directed toward a large deposit in South Carolina containing approximately 1,000,000 tonB owned by tho pxoduot Sales Corporation. Cur rather thorough study of tha blade ash furaaciag operation in the plant, n&ds several years ego, which sat up stand ards for operation and yields that ax* at present used, had shown that one pound of silica rendered unavailable 2.? lbs. barium sul phate. Consequently, this high eilioa ore would give a yield of waten-eolubi* barium sulphite of approximately 60$ in plant oper ation as compared with an average of 80$ for an average grade of ora used by tha plants sad It i* therefor* uneconomical. Our laboratory work using a briquetted charge, mad* 1-1/3 year* ago had shown that this method cut down the deleter ious eilioa reaction to a groat extent. This knowledge applied to high silica ore in the present work resulted in the same in hibition of tha eilioa action and the obtainment of a conversion of 90$ to water-soluble barium sulphide. Following this a con siderable amount of laboratory work successfully solved several problems in connection with these briquets, such as hardness, binder, nature of coal, fineness of materials, temperature of furnacing, and leaching of reaultant black ash. plant teat# consisting of five runs, baaed upon laboratory experience, showed that briquets made from ox# containing 85$ BaSOg and 14$ 8i0g gave successful operation in the present rotary furnace and particularly that a conversion of 90$ can be obtained in the plant. This yield is comparable with 60$ which would have been obtained with this or* In the ordinary praotioa end with 90 to 83$ obtained with present ore containing 93 to 95$ BaS04 and 4 to 2.8$ SiOg. Cue to this high conversion, the weight of barium sulphite from one ton of ore is the same ae with present high grade ore. Another favor able result wa* the absence of sticking of the charge to the fur nace walls which, besides eliminating the barring required at present, would make possible the operation of a continuous kiln for this purpose sinoe the sticking constitutes a serious obsta cle in this connection. The use of briquets applied to low grade and high silica ora -sill consequently result in a considerable saving. As Hated below, this con*late of several item*, chief of which la the diff erence in the cost of ore. the present cost is #8.00 (1/25/35) per ton plus #8.00 freight, while assurance of a price of #5.50 per ton for the low grade ore has been obtained and there is a possibility of a price of #4.50 per ton. There is also a cheaper freight cost of #.25 to $ .40 per ton fro* the South Carolina deposit. The use of anthracite culm in briquets at a cost of approximately $.60 to #.90 per ton as compared with #3.45 for coal, together with an ad vantage in freight cost, entails another appreciable saving. 31th the culm ordinarily available, containing approximately 204 ash, this saving would he possible only in 8 briquetted charge but the very recent availability upon the market of oulm with 124 ash at #.90 net ton makse it possible to realise this saving with the present form of charge. (Incidentally, this information applied to pres*nt charge wae worked up about three years ago and now the market conditions sake it possible to utilize this knowledge.) In the nature of earing* indirectly dependent upon a briquetted charge are (1) continuous reduction of barytes, which is made possible by the avoidance of sticking Of the charge, and (2) grinding by means of the Hardinge mill at Newark, the fine grinding of which would be an advantage for briquets but is ob jectionable at present. The list of savings is as follow* Direct Savings Crude barytes at #8.00 per ton, fob mins* (1925 contraot). Newark Philadelphia Tone Value Tons Value 12000 #96000 8000 $64000 Crude barytes at #5.50 per ton, fob mines (conservatively estim ated price high silica material). 13000 66000 8000 44000 Savings on crude barytee at $5.50 30000 20000 Reduction in freight rate on account of shorter haul (may be as much ae 40 per ton, but is conservatively estimated at 25j&). Total savings on crude barytes 12000 3000 33000 8000 3000 22000 Cost of briquetting high silica barytes at $1.50 per ton. 12000 13000 8000 13000 Net savings on high silica barytes 15000 10000 Further probable savings through reduction of mine price of high silica material to $4.50. 13000 13000 8000 8000 / Probable net savings on high silica barytee. (a) 27000 18000 DUP150089426 Coal at present prices Jfawark, per ton del'd. $5.33 Philadelphia, per ton deld. 4.56 Hgwadfk Tons Value 3640 $13800 Culm at 90j, fob nine* Newark freight, per ton 3.14 3640 Philadelphia freight,per ton 2,S9 8000 Savings on use of Culn (b) 5800 Total direct savings (a + b) (o) 33800 Indirect Savins* Continuous reduction baryte*, labor 11700 fuel 7500 Grinding in Harding* Hill, labor 4700 Total indirect saving* Total savings (o -f d) (4) 33900 B870O Total saving*, aevark and Philadelphia 86000 Philadelphia Tone Value 1780 $ 8000 1780 6600 3400 30400 3900 5000 8900 29300 DUP150089427 e x h ib it WO.2 HIGH 3II.XCA BARYTSa - PROBASU SAVISOS Expended 1924 - $ 3,801.80 Roduotlon of High Silica Barytas It is generally recognired. that silica is a very datrirasmial impurity la barytes and its presence la excess of 4 is undesirable la ths ore used fox ths production of barium sulphide. A3 a result, only the better grads of ora la being mined which, coupled with the faot that It undergoes a purification treatment, makes its ooat appreciable, while there la also the possibility of an increasing demand overtaxing the supply. At the saw* tine there are large deposits of bsrytss containing fro* 10 to 154 silica which are unfit for this purpose at present and can be obtained at a jsucb cheaper price than the present ore. The util-- i sation of such ore is the objeot of this study. Our attention is particularly directed toward a large deposit in South Carolina containing approximately 1,000,000 tonB owned by the product Bales Corporation. Our rather thorough study of the black ash fumaciag operation In the plant, made eersral years ago, which set up stand ards for operation and yields that are at present used, had shown that one pound of silica rendered unavailable 2.7 lbs. barium sul phate. Consequently, this high eilioa ore would give a yield of water-soluble barium sulphide of approximately 6Q4 in plant oper ation as compared wltb an average of 804 for an average grade of ore used by the plants and it is tbsrefore uneconomical. Our laboratory work using a briquetted charge, mads 1-1/2 years ago had shown that this method cut down the deleter ious silica reaction to a great extent. This knowledge applied to high silica ore in the present work resulted in the sane in hibition of the silica action and the obtainment of a conversion of 804 to watt insoluble barium sulphide. Following this a con siderable amount of laboratory work successfully solved several problems In connection with these briquets, such as hardness, binder, nature of coal, fineness of materials, tasperatuxe of fumacing, and leaching of resultant black ash. plant tests consisting of five runs, based upon laboratory experience, showed that briquets mads from ore containing 854 BaSOg and 144 SIO3 gave successful operation in the present rotary furnace and particularly that a conversion of 904 can be obtained in the plant. This yield is comparable with 604 which would have bees obtained with this ore in the ordinary practice and with 80 to 834 obtained with present ore containing 92 to 954 BaSO-f and 4 to 3.84 3iOs. Due to this high conversion, the weight of barium sulphide from one ton of ore is the same as with present high grade ore. Another favor able result was the absence of sticking of the Charge to the fur nace walla which, besides eliminating the barring required at present, would make possible the operation of a continuous kiln for this purpose since the sticking constitutes a serious obsta cle in this connection. The use of briquets applied to low grade and high silica ora will consequently result in a considerable sawing. As Hated below, this consists of several items, chief of which la the diff erence in the cost of ore. The present cost is 8,00 (l/ZS/25) per ton plus 8.00 freight, while assurance of & price of $5.50 per ton for the low grade ore has been obtained and there is a possibility of a priee of 4.50 per ton. There is also a cheaper freight cost of .35 to $.40 per ton fro* the South Carolina deposit. The use of anthracite culm in briquets at a cost of approximately $.60 to $.90 per ton as cospared with $3.45 for coal, together with an ad vantage in freight coat, entails another appreciable saving. 31th the culm ordinarily available, containing enproriaately 204 ash, this saving would be possible only In a briquetted charge but the very recent availability upon the market of culm with 134 ash at $.90 net ton makes it possible to realize this saving with the present fox* of charge. (Incidentally, this information applied to present charge we worked up about three years age and now the market conditions Bake it possible to utilize this knowledge.) In the nature of savings indirectly dependent upon a briquetted charge axe (1) continuous reduction of barytes, which is made possible by the avoidance of sticking Of the charge, and (3) grinding by means of the Harding# mill at Newark, the fine grinding of which would be an advantage for briquets but ie ob jectionable at present. Tbe list of savings is as follows:- Direct Savings erode baryte# at 8.00 per ton, fob mine# (1925 contract). Tons Value Tons Value 12000 $96000 8000 $64000 Crude basytea at $5.50 per ton, fob mine# (conservatively eeti*ated price high silica material). 13000 66000 8000 44000 Savings on crude barytes at $5.50 30000 20000 Reduction in freight rate on account of shorter haul (any be as much ae 40^ per ton, but ie conservatively estimated at 2S^). Total savings on crude barytes 12000 3000 33000 8000 3000 22000 Cost of briquetting high silica barytes at $1.50 per ton. Net savings on high silica barytes 12000 13000 15000 8000 12000 10000 Further probable savings through reduction of nine price of high silica material to $4.50. 13000 12000 8000 8000 / Probable net savings on high silica barytes. (a) 27000 18000 DUP150089426 Coal at present prions Newark, per ton del'd. $5.93 Philadelphia, pr ton deld. 4.56 Bsw&Tk Toni Value 3640 $13900 Cula at 3Qji, fob nine* nenark freight, per ton 3.14 3640 Philadelphia freight,per ton 3.39 8000 Savings on use of Cuba Total direct savings (a + b) (*) 5800 (o) 33800 Indirect Saving* Continuous reduction barytes , labor 11700 fuel 7500 Grinding in Hardings Hill, labor 4700 Total indirect saving* 33900 Total saving* (o + d) 66700 Total savings, 3awar! and Philadelphia 86000 Philadelphia Tons Value 1760 $ 8000 1760 6600 3400 30400 3900 5000 3900 99300 3s. DUP150089427 EXHIBIT SO. 3 Liama s u l ph u r pio x x d s _ -_c .^c u l a t io k or singoa Manufactured, 1934 (a*. price .0558) Purchased, 1934 (av. prioe .0435) Total manufactured and purchased, 1334 Cost of ssue at old purchase price (.QSi) having effected, assuming present purchase price (.0485) to t# due to fact that it * hays plant in operation, approximately - 703,000 .S15J&& 1,217,000 1,317,000 $38,981. ..%L2Tk. 83,938. 74,237. 10,300. Manufactured, Oot.-peo. 1834 (ar. .0399) Oott of same at old puxobase prioe (.081) Saving effected on three month* production 341,000 341,000 10,198. 20,801. 10,605. Estimated 3avinrsfii,T.S3$i Total requirement* if purchased at .0485 Total requirement* if produced at .0399 Estimated savings, 1935 1,250,000 1,350,000 Ibis estimate is mad* on a strictly competitive haela, triib no consideration given to thm effect that the operation of o u t plant ha* on the market price. 80,635. ..azawk $33,350. / / E-ll* DUP150089428 BX31B1T NO. 3 Lr-ma s u l ph u r sioxm - g mw l a t x o s or s a v ih o s Manufactured, 1934 (av. prioe .0558) Purchased, 1934 (ax. prio# .0485) Total manufactured and purchased, 1934 Cos* of same a* old parch*#* prio# (.031) Saving effected, assuming present purchase prio# (.0485) to he due to fact that it # have plant in operation, approximately - 703,000 B18.QQQ 1,217,000 1,317,000 $38,981. 34.977. 83,938, 74,237. 10,300, Manufactured, Oot.-peo. 1924 (ar. .0299 ) Cost of same at old purchase prioe (.081) Saving effected on three month# production 341,090 341,000 10,198. 20,801. 10,605. SaUaaiftl 3ay&gg. I335t total requirement* if purchased at .0485 Total requirement* if produced at ,0299 Estimated saving*, 1925 1,250,000 1,350,000 this estimate is made on a strictly ooapetitive h&sia, with no consideration given to the effeo* that the operation of our plant ha# on the market prioe. 80,63$. 37,375. $33,250. / / E-ll* DUP150089429 EXHIBIT SO. 3 U'-yuia s u l ph u r .pioxm.-.oaonLiHwi or sAYWa Manufactured, 1934 (av. prioe .0536) Purchased, 1934 (av. prioe .0483) Total manufactured and purchased, 1384 Cost of ease at old purchase price (.031) Saving effected, assuming present purchase prise (.0483) to he due to fact that we have plant in operation, approximately - 703,000 .glgJ&B. 1,217,000 1,217,000 $38,961. ..3a.$77*. 83,938. 74,237. 10,300. Manufactured, 0ot.-x>eo. 1934 (av. .0399) Oost of same at old purchase price (.061) Saving effected on three months production 341,000 341,000 10,196. 30,801. 10,606. SatlaftttftJfaTjggg... 1335.1Total requirement* if purchased at .0435 Total retirements If produced at ,0299 Estimated savings, 1935 1,250,000 1,350,000 This estimate is made on a strictly ooarpstltiT* hasla, with no consideration given to ths effect that the operation of our plant ha* on the market price. 30,625. 37.375 $23,250. E-ll* DUP150089429 F&bxikoid Division Newbury, H.Y. February lo, 1985. soiaaBKtt PR. HAiatTOS BRADSHAW, ASST, caxuioju, DlRSOTOJl. YODR Utnsa FBBfiBARY 3. SfraSHiMU-... According to o at #1 forecast of the 1925 production, we will make approximately 7-1/3 Million stado thie year. Ou t not solvent oaring aa calculated by Mr. stinpeon i* l-X/3d pax Btad if w uso activated carbon for all o u t production. However, u o estimate that w will got only 90$t of our good* coated with this recovery, and therefore the oaring should bo 7-1/2 million timee 1-1/2# time# 9E#>, or approximately $100,000. Shile wo night oaloulat* some tawing on labor, it Is wioor for tho protect to leave thie out. A* to tho safety feature, however, w bar* already had a Tory good demonstration of tho real valne of activated carbon sol vent recovery. On February 3rd, w had a fire on 2i machine that a Tory similar to prtviou# fir*# which have caused the destruction of two coating machine# at a tiao. Tho fir* wae promptly pat out with an extinguither, and they were coating again within ten minute#. X am folly con vinced that with tho old typo coating maohinee wo would have loot them both, at a lo# of approximately $15,000. o. t . Bsiatoh - vim JlAAa2R. (3) 0. T. B. CTB|UH E--XI* EXHIBIT 30. 4 Rabrikoid Division Newburgh, N.Y. February 10, 1935. PR. HA^ItlOS BRAD3HA3, 4331. CHX3IICAL DXfcSWO*. y o u r isrrsa ysawiAHY 3. YOBB m3 23-370-30. AGeording to our #1 forecast of the 1935 production, w# will jack* approximately 7-1/3 Billion 3tad* this year. Ou t not solvent saving as calculated by Mr. stimpeon is 1-1/3d por Btad if we use activated carbon for all our production. However, wo estimate that wo will get my 9o of our geode coated with this recovery, and therefore the saving should he 7-1/3 million time 1-1/3# times Se, or approximately $100,000. $hile wo night Oisleulste some saving on labor. It la wiser for the present to leave this out. As to the safety feature, however, ire have already had a very good demonstration of tbo real value of activated oaxbon sol vent rooovery. On February 3rd, we bad & fire on #3i machine that was very similar to previous fires which have ceased the destruction of two costing machines at a time. The fire wae proaptly pat out with an extinguisher, and they were coating again within ten minutes. 1 sm fully con vinced that with the old type coating mao'nines wo would have lost thorn both, at a loss of approximately $15,000. 0. T. BRlSTOj, - RIANT NANAEfiSR. (3) 0. T. 3. GTBiiM B-ll* JPabrikoid Division Newburgh, S.Y. COmpmm, February 10, 1985. PH. HAMtlOS BRAB3HM, A33T. CEXMIOAL DIRSOIOR. v o d r isma mauAHY 3. VOBB m& E8--870-30. According to our #1 forecast of tk* 1925 production, we will oak* approximately 7-1/8 million Stada this ysur. Our not solvent saving as calculated by Mr. stinpeon la 1-1/20 par Stad if we uae activated carbon for all our production. However, wo estimate that wo will got only 90^1 of our good* ooatod with this recovery, and therefore the anting should bo 7-1/2 million tinea 1-1/2# tinea 9$>, or approximately $100,000. Shile wo sight oalouiat# pome saving on labor. It la wiser for the present to leave this out. Ae. to the safety feature, however, we have already had a very good demonstration of the real veina of activated oaxbon sol vent recovery. On February 3rd, we had & fire on #21 machine that wa* vary similar to previous fires which have caused the destruction of two coating aaohlnes at a time. The fire was promptly pat out with an extinguisher, and they were coating again within ten minute*. I m fully con vinced that with the old type coating eaohinee we would have loet then both, at a lose of anproxiaataly $15,000. o. t . Bsiatoi - vtm j *a*RR. (3) G. T. a. CTBjlfil E-U* DUP150089431 gxaiait so.s. SYROBTm HITRWB - ACOOUHT 3-80Q-A-3 Expended 1924 - $8760.61 TIbk i of study - February. March. Anrll a May. 1934 Th# study of til* fwujufaeture of strontium nitrate wa# undertaken primarily to prove the feasibility of using calalum nitrate as the nitrate radical source in the manufacture of strontium nitrate. Before completion, however, tbie study Included;- (1) Bee of calcium nitrate ae nitrate radical source. (8) A modemi ation of the present process. (3) Use of ammonia oxidation acid in the present process. Some experimental work was done for number* 1 and 3. Cost estim ate* with general plant design in conjunction with the Engineering department were made for all three. It was found that; (1) The use of caleium nitrate ns a nitrate radical source la possible, but involve# some difficulties. Essentially, the process consists of the direct addition of solid calcium nitrate to strontium black ash leach liquor of the highest possible con centration and followed by filtration and evaporation. Becrystal lization is neoessary to obtain a sufficiently pure product. Mod ifications to avoid this last step have proved impractical. It was found that on a 300 ton monthly production basis a yearly sav ing of $30,300 was indicated, but with a plant installation cost of $85,000, of which $55,000 would be net investment increase. (8) Modernization of the present process showed a consid erable saving. These changes ax* (a) Substitution of hot wet grinding of celestite and soda ash for the present dry grinding and subse quent digestion steps. Small scale hot grinds were mads at the Experimental station. One large scale unheatsd grind was made at the Philadelphia Plant. These grinds uniformly were successful. (b) Substitution of an Oliver Filter and Dorr Equipment for the present wash-tub system. The installation of this equipment shows an annual saving on the same 200 ton monthly production basis of $17,600, with a-new equipment cost of $38,000 end a net Investment increase of $1,000. (3) Ths general design of end cost estimate* for an ammonia oxidation pleat to produce nitric acid for strontium nitrate manu facture showed a caving in nitrio hold cost of $49,000 per annua, which, when combined with the probable profit on the sodium nitrite by-product increased these savings to $80,000 per annua. The estim ated Installation cost of this ammonia oxidation plant was $139,000* DUP150089432 Tbs installation of the now equipment was recommended, 'fh# ammonia oxidation plant would necessarily "be constructed primaxily a* an experimental unit, later to be used in regularr plant operation. The following tenia give* a summary of the estimated annual sawings, should the different processes studied he adopted. Sawing in Item Calcium Hitrate Hoderalaa- Ammonia Strontium-Slaok Ash tlon of pres- oxidation Process eat process process Ingredients Operating Labor Repair Labor Maintenance Materials Power Oil By-produot Credit $ 50,100 - 3,eeo - 1,333 - 1,093 + 340 - 9.4as - 3,840 Hons | 6673 1164 1020 8760 Hone Hone $ 49,000 ( 80,000 if l nitrite be sold al ( an expected profit Total Sawings ............... . 9 30,960 17,616 49,000 Plant Installation Cost . 9 65,000 28,000 129,000 Set investment Increase . 58,000 1,000 - Hate i~ It should be noted that should the ammonia oxidation plant be constructed, lie sawing would be added to that of the modernisa tion of the present process, should those changes be made. DUP150089433 EXHIBIT NO.5, STROUtm HITHAT'S - ACQOUHT 3-800-A-3 Expended 1934 - $3760.61 Tlaa of study - February. March. Aozll & May. 1934 The study of the nanufaetuxe of strontium nitrate was undertaken primarily to prore the feasibility of using calcium nitrate as the nitrate radical source in the manufacture of strontium nitrate. Before completion, however, tbi* study included;- (1) Use of calcium nitrate as nitrate radical source. (3) A modernisation of the present process. (3) Use of aasLonia oxidation acid In the present process. Sons experimental work was dose for numbers 1 end 3. Cost eatlavatas with general pleat design in conjunction with the Engineering Eep&ztmeni were made for all three. It was found that; (1) The use of oaldust nitrate as a nitrate radical source is possible, but involves some difficulties. Essentially, the process consists of the direct addition of solid calcium nitrate to strontium black ash leach liquor of the highest possible con centration end followed by filtration and evaporation. Eeoxystalllz&tion is necessary to obtain a sufficiently pure product. Mod ifications to avoid this last step have proved impractical, it was found that on a 200 ton monthly production basis a yearly sav ing of 30,900 was Indicated, but with a plant installation cost of 3S3,000, of which $66,000 would be net investment increase. (2) uoderalration of the present process showed a consid erable saving. These changes are- (a) Substitution of hot wet grinding of celestite and soda ash for the present dry grinding and subse quent digestion stops. Small scale hot grinds were made at the Experimental station. Cne large seals unheated grind wss made at the Philadelphia plant. These grinds uniformly were successful. (b) Substitution of an Oliver Filter and Dorr Equipment for the present wash-tub system. The installation of this equipment shows an annual saving on the same 200 ton monthly production basis of $17,600, with a-new equipment cost of $38,000 and a net investment Increase of $1,000. (3) The general design of and cost estimates for an ammonia oxidation plant to produce nitric acid for strontium nitrate manu facture showed a caving in nitrio add cost of $49,000 per annum, which, when combined with the probable profit on the sodium nitrite by-produot increased these savings to $80,000 per annum. The estim ated installation cost of this ammonia oxidation plant was $139,000. DUP150089434 The installation of the new equipment was recommended. Tba ammonia oxidation plant would necessarily be constructed primarily a an experimental unit, later to be used, in regular*plant operation. The following table givea a summary of the astiaated annual savings, should the different processes studied be adopted. Saying in item _______________ fiaioiua kiirate Modernism- ...Ammonia Strontium-Black hah tied of pres- oxidation Pro case eat process Process Ingredients Operating Labor Repair Labor Maintenance Materials Power Oil By-product Credit $ 50.100 - 3,660 - 1,333 - 1,093 + 340 - 9,458 - 3,340 Sons | 6673 1184 1030 8780 Sons Rone $ 49,000 | $ 80,000 if | nitrite be sold al . an expected profil Total Sating* ................... $ 30,960 $17,618 $ 49,000 Plant Installation Cost . $ 63,000 $28,000 $129,000 Hot Investment Increase . % 58,000 1,000 - Pate;- It should be noted that should the ammonia oxidation plant be constructed, its saying would be added to that of the modernisa tion of the present process, should those changes be mads. DUP150089435 EXHIBIT HO.6. KX1I0 tlQUOR RtjRlylCATICH - AOCOOHT S-80Q-A-23 ilxpended 1934 - $ 3530.41 Ik* fundamental study of the debtsrinu* effect of iwpurl-ti*a la the zina liquor op the properties of the finished lithopons pointed. very clearly to the need for improved method* for their removal. The net result of the experimental pork on zino liquor purification has been to diminish the amount of alac required, to spaed up the reaction, and to reader more complete -the removal of impurities. A by-product of the investigation was the developmeat of a method for recovering the aino value la the spent zlao dust sludge. The work may ha summarized in dollars and cents somewhat aa follows: During the first nine months of 1934, cine dust was used at the rate of 393,000 pounds for 13,000 tone of Cold Seal lithopona produced. Its value at $.0745 was $39,500; the new process requires not more than 135,000 pounds at $.0745 par pound, equals $10,058. Xf the coat of aino dust is taken at $.095 per pound, the saviags become the difference between $37,630 (instead of $39,500) and $13,835 (instead of $10,058). The savings, there fore, amount to somewhere between $19,500 per year and $34,795 at capacity production. This saving, however, might be regarded a* reduced by the fact that the experimental work resulted In develop ing a method requiring lg|| zinc dust than the amounts just quoted* The runeunis just quoted were the amounts required before the improve ment* were made; however, ainee not only the amount of sin dust has been reduced but methods developed for the recovery of the zinc value of the sludge end since the savings ars applicable not only to the Gold Seal hut to the Green Seal lithopons manufacture, the net result may beet be summarized a* follows,: 1934 at 1.0745 1/35/35 at 3.095 398,000# Zinc Dust- $ 39503.00 37620.00 Deduot 133,000# bin Dust 10058.00 12835,00 Met Saving on Gold Seal (12000 Tons) $ 19444.00 $ 34795.00 Be covery on Gold Seal -4740.00 $ 6000.00 Saving on Green Seal (7200 Tone) $ 11668.00 $ 14877.00 Recovery on Green Seal 6 3344.00 8 2600.00 Total Saving % 38634.00 % 49273.00 5XH13IT MO .6. quo l iq u o r mmcAtioH - a c c o p mt S-800-.&-23 Sweated 1934 - $ 3520.41 The fundamental aiudy of the dehtarleus effect of impurlti*B la the zlno liquor on the properties of the finished lithopono pointed very clearly to the need for improved methods for their removal. The net result of the experimental work on zinc liquor purification has been to diminish the amount of zinc required, to speed up the reaction, and to render more complete the removal of impurities. A by-prodnot of the iaTsatigaiion was the development of a method for recovering the sine value in the spent zlno dust sludge. The pork may he eummaxized in dollars and cents somewhat OB follows: During the first nine months of 1934, sine dust was used at the rate of 394,000 pounds for 12,000 tone of Gold Seal litbopona produced. Its value at $.0745 was 29,500; tbs new process requires not more than 135,000 pounds at .0745 per pound, equals $10,068. If the cost of sine dust is taken at .095 per pound, the cavings become the difference between 37,630 (instead of 39,500) and 12,835 (instead of 10,058). The savings, there fore, amount to somewhere between 19,500 per yea* and 34,795 at capacity production. This saving, however, might be regarded as reduced by ths fast that the experimental work resulted In develop ing a method requlrlmt lg| zlno dust than ths amounts just quoted. The amounts just quoted were the amounts required before the improve ments ware made; however, since not only the amount of sl&o dust has been reduced but methods developed for the recovery of the sine value of the sludge and since the savings are applicable not only to the cold Seal cut to the Green Seal litbopona manufacture, the net result may best be summarized as follow*: 1924 at .0745 1/35/35 at 3.095 398,000# Zinc Dusk 39503.00 37820.00 Deduot 135,000# Zlno Dust 10058.00 18835.00 Met Saving on Gold Seal (12000 Tons) Eecovery on Gold Seal 19444.00 47*0.00 34795.00 6000.00 Saving on Green Seal (7300 Tons) 11668.00 14877.00 Recovery on Green Seal 3344.00 g 2600.00 Total Saving 38894.00 % 49373.00 EXHIBIT HO. 7. w'rllTB L2AD - Accounts 8-800-C-l 4 9-901-A (H'.xpended, 1934 - f5,612.15) JAHOASJ, 1934 - JUNS-BSCSiSSS, 1924. This problem was taken up by tha Chemical Department to give the tseistanee necessary in developing a satisfactory unit for tha mamifaetttie of Carter Lead with proper operating conditions of th* same. This work is based on the results obtained with an autoclave operating at ataospherlo pressure (see anginaerlng Department Account MX-302). In 1933 end the early part of 1324 it was shown in a 4* d. x 13' reel taking a 4,000-pound charge that 72-hour corrosion producing a satis factory grad# of white lead wae possible. This lead we3 equal to the plant output in all respects except color. In color, it was superior. In 1934 a i'ull-slaed plant unit 8* d. x 12' was installed. The cepaoity of thia unit is 16,000 pounds of blue lead with an overload capacity of 30,000 pounds. Twenty-two runs wars mad# on this reel in 1924 end January, 1935, the last seven of whioh were satisfactory. It wee found that 73 to SO-hour corrosion was possible with everything pointing toward a. still lower figure. The grad# of white Lead produced was superior to that produced in the present plant, in hiding power (25$), tinting strength (10), end color (3 points Beokton standard), and the Oil (absorption wa* apparently controllable. The essential differences between this process and the ordinary Carter process are: (1) Larger and improved unite; Carter process - 6700-lb. charge; new process - 16,000-lb. charge. (2) Greater reel speed; Carter - 0.2 r.p.m.; new process 0.95 r.p.ra. (3) Veohanioal spraying - 3. & K. nosales on a fixed spray line with ceiai-autoswtic control--ef. coarse hand spray oi the Carter process. (4) lialf-hour spraying periods with acid used at intervale during the run --of. 8 to 10-hour spraying period acid concentrated at early part oi' run -- Carter process. (5) Close control of humidity and temperature. Optimum conditions found 70*C. for the enter ing gas with '7?>i relative humidity or 90 ~,r&m per cubic meter of water absorbable whatever the temperature--cf. no humidity control -- Carter process (6) Close COi control. average desired--6-1/3''. CQfc by volume--cf. very rough control--Carter process. (7) Gas tight apparatus resulting in no duet losses and Is very sanitary--cf. exit gases in Oerter process escape into the reel mom. (8) Single stags corrosion--no intermediate, unsanitary disintegration step--cf. two-stags operation with disintegration with the Carter process. DUP150089438 A sodem lead plant san designed by K. !. Holliday, of the Hnglnearing Department, with these units for the basic plont process. Other changes from the present method are: (1) Closed system throughout, eliminating any duet hazard; (2) Imnroved blowing similar to that used 'ey tbs National Lead Co.; (3) Closed recovery system, using a hydroseparator, br-11 Rill, bowl and table classifier and thickener, oil blue lead tailings being returned for further corrosion. these changes form sn essential part of the process developed in ibis study. The saving* embodying thie whole nyatem are computed by Sr. Holliday end r. lliff on 80.i present plant capacity; iCSTfUATir. 0? SAV15G3 1. Present Permanent Investment . . . *343,139.32 2. Addl. for taking over 73 31dg. complete. 53,913.00 399,053.22 3. credit carter lead Plant Inveetment 33 3ldg......................................... 33 *......................................... 41 ".......................................... 48 " . . . . . 37 "......................................... H!> 293.00 43.934.00 84.413.00 43.337.00 30.138.00 13,410.00 4. Cash Outlay .... <d o 3, ,\j O.OO 5. Set increase permanent investment 93,708.CO 6. Seeing* effected annually Labor . . . y.aint . . . Yield . . . Power (fuel only). $31,883.00 37.129.00 33.716.00 71,709.00 7. Depreciation on Mo. 5 at 3i4 . . Tftv.es at .30 par $.100 . .. Insurance (property) .40 per $100 . 2,300.00 370.00 337,00 4,157.00 3. Net Savings effected annually ;67,551.00 9. P.eturn on cash outlay . . . . . , 28. The reduction in labor la large, the crew being reduced from SO to 15 men. (bgd.) 2.L.Holliday (?-ng. rept.) " John w. lliff (them.bept.) DUP150089439 tVSIoIT so. 7. iVrUTS L2AD - Accounts 8-B00-C-1 & 3-901-A (Upended, 1924 - 15,612.15) JAWA-tf, 1934 - JUKE-2SCSU3IIR, 1924. This problem ass taken up by tha Chemical Department to give the ssaistanoe nscsssary In developing a satisfactory unit for the manufacture of Carter Lead with proper operating conditions of the same. This work is based on the results obtained with an autoclave operating at atmoapherio pressure (see Engineering Department Account MX-302). In 1933 and the eerly part of 1924 it a shown in a 4* d. x IS* reel taking a 4,000-pouad charge that 72-hour corrosion producing a satis factory grade of white lead wee possible. This lead was equal to the plant output In all respects except color. In color, it was superior. In 1924 a full-sized plant unit 8* d. % 12' was installed. The capacity of this unit is 16,000 pounds Of blue Lead with an overload capacity of 30,000 pounds. Twenty-two runs wars aiad* on this reel in 1924 and January, 1935, the lest savan of whioh were satisfactory. It was found that 72 to SO-bonr corrosion was possible with everything pointing toward a still lower figure. The grade of Shite Lead produced was (superior to that produced in the present plant, in hiding power (25), tinting strength (10), end color (3 points Beckton standard), and the oil absorption was apparently controllable. The essential differences between this process and the ordinary Carter process are: (1) Larger and improved unite; Carter process - 6700-lb. charge; new process -- 16,000-lb. charge. (2) Greater real speed; Carter - G.2 r.p.m.; new process 0.S5 r.p.m. (3) Veohanioal spraying - 3. & %. Resales on a fixed spray line with ceai-autoswtic control--of. coarse hand spray of the Carter prooeae. (4) half-hour spraying periods with acid used at intervals during the run --of. 3 to 10-hour spraying period acid uoncentratsd at early part of run -- Carter process. (5) Close control of humidity and temperature. Optimum conditions found 700. for the enter ing gas with 75fc relative humidity or 90 ~,r&m per cubic meter of we ter absorbable whatever the temperature--of. no humidity control -- Carter pi-ocean (S) Close COi control. average desired--8-1/3*. C04 by volume--cf. very rough control--Carter process. (7) uae tight apparatus resulting in no dust losses and Is very sanitary--cf. exit gaaea in Carter process escape into the reel room. (8) Single stags corrosion--no intermediate, unsanitary disintegration step--cf. two-stags operation with disintegration with tha Carter proessa. A Bodsrn load plant was destined by K. !. Holliday, of th* 'Engineering Department, with these units for t'ae basic plant process. Other changes from the present method are: (1) Closed syBtem throughout, eliminating uny dust harard; (3) Improved blowing similar to that usad by the National lead Co,; (3) Closed recovery system, using a hydroeeparator, br-11 will, bowl and table classifier and thickener, nil clue lead tailings being returned tor further corrosion. These changes form sn essential part of the process developed in this study. The saving* embodying this whole system axe computed by y.r. Holliday and -'p. Xliff on koi present plant capacity: E3TIUiiT?. QV SAVING'S 1. Present Permanent Investment..................................... *343,138.33 2, Addl. for taxing over 73 31dg. complete. 53,919,00 399,053.23 3. credit carter lead Plant Investment 33 31tig 33 11 41 " 4B " 37 " 41,293.00 43.934.00 64.413.00 43.837.00 50.138.00 213.410.00 4. Cash Outlay .... 253.300.00 5. Set increase permanent investment 95,708.CO 8. ravings effected annually Labor ..... y.atnt ..... Yield ......................................... Power (fuel only). . . $31,883.00 27.129.00 33.715.00 71,703,00 7. Depreciation on llo. 5 at 34 . Taxes at .90 per 100 . - Insurance (property) ,40 per 100 2,900.00 370.00 397.00 4,157.00 3. Net Saving* effected annually ;67,551.00 9. Saturn on cash outlay . . . 2S.? The reduction in labor la large, the crew being reduced from SO to 15 men. (bgd-) H.L.Holliday (Frig. rept.) " John e. Iliff (Chem.fept.) DUP150089441 SXHIBIT Ho. 8 33TER GUV - 2-3TIBAT12 0? SAVIKGS. (Expended, 1924 - *J1074.94). Rosin at 57.BO per bbl. of 380 1'oa. * ,03785 per lb. Glycerin - 1S-1/2{1 per lb. Freight not tafcen Into consideration, as it is thought the freight on purchased Set*? Oum would about offset freight on raw materials for manufacture of 3b tar Cum. Rosin - 100 lbs. at .03785 Glycerin - 12-1/3 Iba. at .195 Katerlala coat per 100 lba. Ro b in Yield at 9714 weight of Rosin 97 lbs. yateriala cost per lb. i'ster Gum Droduoed Other costs - estimated Total coat per lb. Ester Gum 2.785 3.3125 5.0975 .05355 .03000 .07355 1934 Consumption S-Bter Cum - First six months: Philadelphia Cverett Chicago 10039 lbs. 12275 33851 61265 lbs. Xear'a requirement* on basis of 6 months' consumption - 132530 lbs. Cost of purchased Ester Gu m - 123530 lbs. at .1035 12559. Cost of producing J'ster 3ua - 133530 * " .07355 8390. Possible yearly savings 3669. note: There has been an advance in the price of e. v;. RoBin, quotation in Oil, Paint a Prug Reporter January 36 showing *10.50 per bhl. It is felt, however, that the prloe of Ester Gum mill advanoe in sympathy with the Rosin market, end that the figures given ebovs represent the probable saving. Sfith Rosin at 10.50 the cost of producing Soter Qua would go up about 1/ per lb. aXHIBIT Ho. 8 33TER GUli - H.STIKATE 0T SAVIBGS. (Srpended, 1324 - <$1074.94). 3." 8. Rosin at S7.SO per bbl. of 330 lbs. = .03785 per lb. Glycerin - 18-1/2ft per lb. freight not tnicen Into coneideration, an it is thought the freight on purchased Seter Gum would about offset freight on raw materials for manufacture of Kb ter Gum. Rosin - 100 lbs. at .03785 Glycerin - 12-1/3 lbs. at .195 Kateriala coat per 100 lbs. Hosln Yield at 97,4 weight of Hoeln 97 lbs. materials coei per lb. Ester Gum Drotiuoed Other costs - estimated Total coat per lb. Ester Gum 3.785 3.3125 5.0375 .05355 .03000 .07355 1934 Consumption Sstsr Gum - First six months: Philadelphia Everett Chicago 10059 lb*. 12275 " B88S1 " 61265 lbs. Year's requirements on basis of 6 months* consumption - 122520 lbs. Coat of purchased Ester Gu m - 123530 lbs. at .1035 12559. Cost of producing ;:'ster 3u -- 133530 * " .07355 8390. Possible yearly savings 3669. Uote: There has been an advance in the price of v. aosln, quotation in Oil, Paint a i'rug Reporter January 36 showing J10.50 per bbl. It is felt, however, that the price of Ester Gum sill ndvanoe in sympathy with the To sin market, and that the figures given above represent the probable saving. -Ylth Rosin at 10.50 the cost of producing Ester Gum would =o up about If! per lb. sxHiarr so. a 331'ER GUli - g-STIBATfi 0? SAVIBG3. (Expended, 1924 - $1074.9*). rV'Y'i. Rosin at 7.80 per bbl. of 330 lbs. a .03785 per lb. Glycerin - 18-l/2j< pa? lb. Freight not taken Into consideration, as it is thought the freight on purchased Sntsr Cum would about offset freight on raw materials for manufacture of Sater Cum. Rosin - 100 lbs. at .03785 Glycerin - 12-1/3 lbs. at .135 yaterlala cost per 100 lbs. Rosin Yield at 974 weight of Rosin s> 97 lbs. yateriala cost per lb. ister Gum produoed Other coats - estimated Total coat per lb. Ester Gum 3.785 3,3125 5.0975 .05355 .03000 .07355 1934 Consumption ,Sster Gum - First six months: Philadelphia Sverett Chicago 10039 lbs. 12375 " 38851 61265 lbs. Year's requirements on basis of 8 months* consumption - 122530 lbs. Coat of purchased Ester Gum - 123530 lbs. at .1035 {12559. Cost of producing J'step Gum - 133530 " H .07255 B390. Possible yearly savings 3689. Ilote: There has been an advance in the price of V?. Rosin, quotation in Oil, Paint & i'rug Reporter January 36 showing J10.50 par bbl. It is fait, however, that the price of Ester dura rill advance in sympathy with the Rosin market, slid that the figures given above represent tbs probable saving. -7ith Rosin at 10.50 the cost of producing Xoter Qua would go up about Ifi per lb. axaiBir so. 9. OXIJ3ATTOH o? VOSIA - ^TlVAtS ,y x k (Expended, 1934 - *.10880.03) f-'nginasring nop&rtment's summary of costa for the pressure oxidation system, ehoes operating cot*. per ton 100;? HUO3 equivalent 513.215 Summary shows coot of Ammonia, (consumed at 92C overall efficiency) at 10* per lb. - *59.85 at 11$* per lb. - 64.?4 Calculating from these figure*, with Ammonia k i: 10-l/4$< (present price) the cost per ton of 100y JllrOjj equivalent la 60.333 Coat of producing 70i tlSC3 ?ie equivalent 100? HSlO-j 72.54 Coat per pound .03637 Concentration to 96? PJ(03 - Coat per lb. 100? HH03 .00733 Total coat per lb. 100S KHO3 equivalent .04359 Cost 10O,i 5?;o 3 at Kepauno (supplied by Explosive* fcapt.-Chem. section) Difference in favor of Ammonia Oxidation, per lb. .049 .00541 Saving per ton ICOj? :i.50<g equivalent 10.83 Saving on 20000 tone (flepsuno's yearly output) 313,400.00 / DUP150089444 sxatsiT m. 9. 011.OAT TON 0? ,Vi!*081A - ?.":'T1'VA'"S ~ A ?/1 i'Go. (Sxcendad, 1934 - *.10860.03) Engiuaaring Department'a summary of coats for the pressure oxidation eysteiu, ehows operating coats, per ton 100* HHO3 equlvalant 513,215 Summary shows cost of /urronia (consumed at 92.5 overall efficiency) at lOp per lb. - 4-53.85 at 11^ per lb. - 64.74 Calculating fro* these figures, with Anueonia at lC-X/4p (present price) the coat per ton of 100.4 SIMOj j equivalent la 60.333 Coat of producing 705 H8O3 an equivalent 100$ HSOj 73.54 Cost oer pound .03637 Concentration to 98$ V8O3 - Uont per lb. 100$ H8O3 .00733 Total cost per lb. 100 S KHOg equivalent .04353 Cost 100$ at flepauno (supplied by Explosives Cept.-ckem. section) Difference la favor of Ammonia Oxidation, par lb. .049 .00541 Saving per ton ICO3& M0<j equivalent Saving on 20000 tons (depaum^s yearly cutout) 10.83 $313,400.00 / DUP150089445 mimT.jsg,..io.w 71i* rapidly increasing demand tot whit# pigment* possessing superior hiding power ha* prompted a detailed investigation of the production of oar proposed new pigment, named Cryptox. a preliminary laboratory study of the problem yielded vary favorable results. Latex, the pigment *as orepaxad la aemi-woxkt equipment, thereby a product slightly superior to that obtained In the laboratory we* produced with out difficulty, ftitfe the possible exception of a snail addi tional amount of fund**eatal study, the project la now ready for plant-seals trlsl. Bto serious difficulties si* antioipated for plant production of the material. The superior quality of Cryptox c&n best be observed by coopering the materiel with Titsaox, whioh la turn is rapidly gaining In popularity primarily due to the feet that it possesses the highest hiding power among all present commercial white pig ments. (The hiding power of Tltenox 1* 10ft greater than that of Cold 3sal ilthopone.) Cryptox, however, possesses a hiding power 254 greater than that of Titsnox, and Is likewise far {superior to the latter in oolex. In other respects, Cryptox equals the high quality of onr present Hold Seal litfcopona. it is our opinion that Cryptox represents the nearest approach to an ideal white pigment at present available. *ra believe that the production of this new pigment would be a very profitable undertaking for the Paint Department. Cur cost calculations show that if the by-prodnot of the process, i.e., olano fixe, be sold at 4.2# per pound (present market price 4.54 per pound at Philadelphia), the total cost of Cryptox would be not more them S.o4 per pound. In Other word*, the total cost per pound of Cryptox would be about 3/44 to 1* higher then that of cold deal llthopene. fitpoor now sells for 13-1/34 per poundVt 3t. Louie, or wore than twle* the estimated oost Of Cryptox, and its pro duction has rapidly increased to about 35 tone per day. Bearing in Bind the fact that cryptox possesses a hiding power 3&jt greater that that of Titanox, a very conservative estimate for a selling pria* of oar new pigment may be placed at Be per pound, thl* figure being based uoon the selling pxioe of Cold 2eel lithopon* and the relative hiding covers of the latter and Cryptox. The profit to bo gained by marketing the new pigment would therefore amount to at least 2# per pound. Hence, on the basis of a production of 35 tone of Cryptox per day, the profit* would approximate a minimum of $350,000 osr year. He ore of the opinion that this project presents an exoeptionably favorable outlook and should be given serious consideration toward further development. / ?(hite Gold kSaSL 2113301 39*1, Total cost per lb. probable selling prioe Relative hiding power Consumer's cost per unit biding purer 10-1/24 lie .50 194 ? 13-1/34 1.10 84 54 84 1.00 s4 6if is4 1.35 4-1/34 E-ll* DUP150089446 EXHIBIT KO. TO. mzm. lb* rapidly ineresBlng demand for whit# pigments possessing superior hiding power has prompted & dotsilsd investigation of the production of our pro90 tad new pigaent, named Cryptox. a preliminary laboratory study of the problem yielded very favorable results. Later, the pigment was pre pared la ssmi-woxks wjuipment, whereby a product slightly superior to that obtained in the laboratory was produced with out difficulty. 31th the possible exception of a small addi tional amount of fundamental study, the project is now xsafy for plant-seals trial. ETo serious difficulties are anticipated for plant production of the material. The superior Quality of Cryptox can bast be observed by oonpnring the material with Titanox, which in turn is rapidly gaining in popularity primarily due to the fact that it possesses the highest hiding power among ail present commercial white pig ments. (The biding power of Titanox is 10ft greater than that of Gold Seal lithesome.) Cryptox, however, possesses a hiding power 25t greater than that of Titsnox, and is likewise far superior to th* latter in ooler. In other respect*. Cryptox equals the high quality of our present Sold Seal lithopone. It is our opinion that Cryptox represents tbs nearest approach to an ideal white pigment at present available* $a believe that the production of this new pigment would bs a very profitable undertaking for th* faint Department. Cur coat cmediations show that if the by-prodnot of the process, i.e., blaao fixe, be sold at 4.8* per pound (present market pxioe 4.5a per pound at Philadelphia), the total cost of Cryptox would be not more than S.o4 par pound. In Other words, the total cost per pound of Cryptox would be about 3/4* to Is higher than that of Gold 3el lithopone. Titanox new sella for 13-1/34 per poundVt St. Louis, or mors than twiee the estimated cost of cryptox, and It* pro duction has rapidly increased to about 35 tons per day. Bearing in Bind the fact that cryptox possesses a hiding power greater that that of Titanox, a very conservative estimate for a selling price of our new pigment may be placed at 84 per pound, this figure being based noon the selling pxioe of Cold Seal lithopone and the relative hiding nowart of the latter end Cryptox. The profit to be gained by marketing the new pigment would therefore amount to at least 2d per pound. Hence, on the baels of a production of 35 ton# of cryptox per day, the profits would approximate a minimum of $350,000 nex year. *!e are of the opinion that this project prscents an xoeptionahly favorable outlook and should be given serious consideration toward further development. / white Gold lad X.UWftS. gqpl, &&C2&X Total cost per lb. Probable selling prioe Relative hiding power Consumer's oast per unit hiding power 10-1/34 ll4 .50 194 13-1/34 1.10 94 3 1.00 54 64 134 1.35 4-1/34 E-ll* DUP150089447 EXHIBIT NO. 11. BUT COLO 33 (TEtLOWSl -- P033IHL3 TSAP-LY HAVI3G3 (Expended 1934, - $10,030.44) The first step in this study sue a careful datermination of the yields and losses. Of the tribasle lead acetate used 84 to 10ft is lost, the major part remaining unpreolpltated from solution after addition of the chromate. Losses of chromate rare less, being about 3ft of the amount used. The 3cond step was to develop reliable laboratory methods for making yellows, by which suggestions for reducing the cost could be tested. This was done for the three most important yellows. survey of possible yearlT sawings to he made; (1) Recovery of Acetic Aoid by forma tion of lead sulphate or carbon ate as an Intermediate step* 5.37,100.00 (2) Substitution of commercial alum for Iron-free alum. 3,170.00 (3) Elimination of lead used in ex cess of formula requirements. 4,S80.0Q (4) Elimination of excess materials called for by present formulae. 13,960.00 (5) Having due to use of scrap lead or cheaper lead materials. IS, 700.00 (6) Labor saving by improved equip ment. 4,080.00 Total possible savings revealed by survey $78,690.00 The use of serap lead was shown by small scale and plant scale tests to be practicable and the effect of various metallic im purities on the quality of the yellows was determined. Altogether, the outlook is very promising for making sub stantial savings. EXHIBIT KO. 11. VPY 001033 (fELLOWS) -- ?Q3i3IBL5 TEAPLY i!AVI3G3 (Expended 1924, - $10,020.44) The first step in this stud/ ires a careful determination of the yields and losses. Of the tribasi lead acetate used 84 to 10'$ ie lost, the major park remaining unpTeoipitated from solution after addition of the chromate. Losses of chromate rare lees, being about 2'j of the amount used. The second step waa to develop reliable laboratory methods for making yellows, by which suggestions for reducing the cost could be tested. This sae done for the three most important yellows. lurvey of cos aibla yearly savings to be made: (1) Hecovery of Acetic Acid by forma tion of lead sulphate or carbon ate as an intermediate step. :>37,100.00 (2) Substitution of commercial alum for iron-free etltw. 3,170.00 (3) Elimination of lead used in exC93B of formula requirementa. 4,380.00 (4) Elimination of excess materials called for by present formulae. 12,960.00 (5) Saving due to uee of scrap lead or cheaper lead materials. 16,700.00 (6) Labor oaring by improved equip ment. 4,080.00 Tot al possible eavinge revealed by survey 178,690.00 The use of scrap lead was shown by small scale and plant scale testa to be practicable and the effect of various metallic im purities on the quality of the yellows was determined. Altogether, the outlook ie very promising for making sub stantial savings.