Document zzqaq9VnddwrovJg4eKX6DxMz

ST * ` 00*42*2 O U i \ S- COKMN (. Fiberglas INTRA-COMPANY CORRESPONDENCE To R. M. Moyer - Berlin From 00 Wo Pfeifer - Toledo Subjsct KAYLO IMPROVEMENT PROGRAM o.t. June l4, 1962 ; R. Co Amos e Berlin Ho Eo Grimmie - Berlin J. A0 Pershing es Toledo R. F0 Shannon - Granville t^-Ws'C^Taylor - Toledo The OP Quality Control Department Monthly Hoport for May, 1962, lasued by H V0 Smith states on page 3 under General Comments regarding the Audit held at Berlin on May 25* 1962: "The results on Kaylo produets made with the new formulation were disappointing. Based on aaterial examined, there is no realistic basis for any announcement or promotion of a product improve ment." Everyone, whether actively engaged in the Kaylo Improvement Program or not, has been keenly disappointed at our inability to matoh the results of test trials, in day to day production. This is in relation to number of drops, impact results, which make for improvement in handlsabillty. Therefore it la imperative that we immediately search out any and all areas, where we might not be obtaining the best processing performance, lo PHT MILLING ASBESTOS One of these areas is the dry milling operation of asbestos fibers through the 36" Bauer Mill. If this operation is performed efficiently and if the equipment is correctly set up, the asbestos will be opened in a manner that gives test results of more than 2.9 drop average, using bateh amounts of 500 lbs. of W3 aaosits. This has already been done. We realise that 200 lbe. of AW ameslte has been used in the K-10 light density batch over the past several months. A few test runs did not indicate a notieabls reduction in impact resistance. The week after week production test checks showed that the W3 - AW combina tion did not give as high & drop tost average as straight W3o The W3 amosite or ita supposedly equivalent K3 amosite, is now available for use with the 4T3 chrysettle. This variable has now been eliminated. The tests which J. B. Rhoads has shown monthly indicate an increase in number of drops for complete breakage. These are listed as a matter of record and review. These drop values are on x 1 half sections takes from daily production and reflect all variables of course, sot just dry milling of asbestos. Date 7/61 8/6*1 10/61 11/61 12/61 1/62 3/62 4/62 5/62 No. of Crops Obtained Pieces Tested k> --iL. .4 1 6 20 - 12 5 3 - 2 55 150 7 113 30 a - 2cl5 125 9 98 13 - OS - 2 .00 80 2 67 10 1 - 2,125 105 3 74 27 1 me - 2.30 90 4 72 12 2 am 2.13 105 3 55 30 15 *S1b 1 2.6 135 3 30 75 25 2 2.9 * 125 3 29 77 15 1 - 2,9 * Contained l/23 Olass Fibers 300# W3 Amosite 200# AW Araosite 100# 4T3 Chryaotile 400# Dost - when available The last 90 days have indicated an improvement in the 3 drop - 4 drop range with less percentagewise in the 2 drop area. There are three areas to check in this operation! 1} The rate of feed, which is by an individual and by hand. This most be at as near a constant rate as possible and at the amount which gives the best fiber opening. This rate must be determined through trials. Jo A. Pershing and H. So Coiegrove are working on the design, a screw feed, or a combination of screw-variable speed conveyor feed, to constantly control this Bauer Mill input rate When the mill is fed too fast it is possible to secure attrition of the fiber length* Several months ago you and I went through this exercise and even clogged the mill at vdllo 2) The maximum opening of the W3 amosite, now the important asbestos fiber for imparting strength to the end product, also depends on the sharp ness of the revolving and stationary plate teeth. These mill plates are made of hard metal, but will experience some blunting, even when the mill is reversed daily and we presume it is. If not the-procedure should be set up to do so. The degree of bluntnesa will have to be determined by condition checks, correlated with examination of dry fibero We know the degree of wear on wet milling plates has an effect on the fiberizing of the asbestos, which has a definite negative action on processing and the physical properties of the end product. The same recognition of the state of wear of these plates must be established. There will be some relationship as to tonnage opened and time elapsed. These plates will have to be changed when each a negative con ditioning of the asbestos results, in order to maintain the peak opening of the asbestos fiber, on a dry basis. 01 041 0574 3) The tested opening of the devil tooth plates, indexed froe the Maxima ''in'* position, at Bauer's Lab in Springfield, wan 0,375**. Because Initially, dne to build up from within the asbestos tanks into the sill, this was increased to 0.575", It never has been definitely proved that the 0.375" opening did not give the best opened fiber. This point should be cleared and tests made at 0.375" plate opening. The expedient say have inadvertently beeoae the standard. We have given considerable thought as to how to establish these facts. Special test runs have been made several aontha ago and favorable results obtained. It is the production test checks day la and day out that aunt show the iaproreaent the special test checks indicate are possible to achieveo What ideas do you and Messrs, Aaos, Orinsis, Rhoads and others havs that might decrease this range and raise the production test cheeks? Iten 2, the condition of the sill plates can be an immediate starting point, Itea 5, can fellow almost immediately. Iten 1, using the present method of asbestos damping into Bauer Rill is going to be more difficult to uniformly control, until a acrel^ceneyor or other control device is available. The inacrtieei of some cross bars to make up a grill or grating prior to entrance to the feed chute, may tend to afford some semi-regulation of the feed rats by keeping large asbestos chunks from directly falling into the mill. These would havs to be reduced in sine by being forced through the grating openings. The plash may have a better method, R P. Shannon's report of 6/11 on trial remits of Proctor and Schwarts Dry Milled Asbestos, using W3 aaosite, run at Berlin with cores in, poured on #2 line, gave an average of 3.8 drops, Sams line, cores out, gave 5,8 drops. Poured #3 line cores out. Research nossle, 6.8 drops. Miring with email hydrapulper - bucket poured - cores out #3 line gave 10.6 drops* % 5* Total Glass Avg, Drop Formulation Arnetts Ghryaotlle Asbestos Fiber Cores Drops Banss Rosaries (1) 10L 1 x 5 (2) 10L 1 x 2 (3) 10L 1 x 2 (4) 10L 1 x 5 (5) 10L 1 x 7 17,79 15c28 15 c 28 17*79 18.12 2.96 3o06 3o06 2.96 20.75 None cut 6.2 5-9 Dry silled 36" 18.3* - in 5,5 5-7 ft tv 18.34 - out 5.5 4-8 I* ft M 20.75 m in 4,6 4-6 ft ft tt 18.12 0,51 in 4.6 4-6 tt ft w Bauer Mill dry opened W3 aaosita with "cores in" at 155* amoeite - 35* chrysotile gives an average of 5*5 drops, Proctor-Sohwarta test results for opened W3 with "corea in" produced 3.8 drops. The Bauer Mill "cores out"dron average ms 53 Proctor-Sohwarta was 5,8 drops. Daily production tests of similar formulation do not yeild the Proctor-Schvarts 3,8 drops, yet alas# the Bauer Mill 5*5 drops, with the "cores in" method, WO must discover what are the contributing variables that are present in the dry sill processing of asbestos, that makes regular production pipe insulation to have a lower drop 01 041 0575 test value than special test batches. We do not think rerunning special test batches is the answer. How do 70a think we should prooeed? What do you propose? This assignment is stated in Ites 2 on page 2 of Kaylo Process and Product Review niautea of nesting on June lt 19620 OWPssra 01 041 0576