"Your favour of the 15th February, with a sketch of your brewery, I have received; and from which I find the head of water is 30 feet above the brewery, which makes it difficult to erect the chain and buckets so as to take advantage of the whole height of water; and as the stream is so very small, it will not admit of losing any part of the power.
"To erect a machine so high, to engage the whole fall, would be, I fear, more expense than the power you would get would warrant; therefore I would recommend it to be made use of in a cylinder, in the same way as we use falls of water of 200 feet in our Cornish copper mines. We allow one-third loss for friction and leakage in those machines; but your machine being so very small, the loss will exceed that proportion; therefore I cannot promise you above one-half of the real weight and fall to be performed on your machinery, and that must be by a well-executed machine, for a small defect would destroy the value of so trifling a power.
"As there is no expansion in water, it will be somewhat difficult to make the machine turn the centres with a fly-wheel, for if the valve shuts a little too early or too late for the turn of the crank over the centre, the fly-wheel's velocity must break something by confining the water between the piston and the bottom of the cylinder, which, after the valve is shut, cannot make its escape, and not having an elastic principle, the piston will strike as dead on the water as on a piece of iron, because, unless the valve is shut by the engine before the stroke is finished, it cannot shut at all.
"I know persons who have attempted to put fly-wheels on pressure-engines of this kind, but never yet has one been made to work rotative. I do not see much difficulty in making an engine of this kind to work a crank and fly-wheel, by connecting an air-vessel with the cylinder to receive the pressure and contract and expand and shut the valves, the same as in steam-engines.
"A machine on this plan ought to be placed as near the low level as possible. If I furnish you with drawings and directions for the executing of the work yourselves, I shall charge you fifteen guineas for them. If I send the machine finished, the charge will be 50l.
"Your objections respecting steam-engines I do not doubt are correct, when executed by persons who do not understand the construction of them. In England some persons privately erected my engine to evade the patent premium, but have severely paid for their saving knowledge by accidents and defects in their engineering ability. I have erected above 100 steam-engines on this principle, but never met with one accident or complaint against them. To prevent mischief from bad castings, or from the fire injuring the surface of cast iron, I make the boilers of wrought iron, and always prove them with a pressure of water, forced in equal to four times the strength of steam intended to be worked with.
"Some persons have worked those engines under a pressure above 100 lbs. on the square inch, but in general practice I do not exceed 20 lbs., finding under this pressure the piston will stand six or eight weeks, and the joints remain perfect, and no risk of bursting the boiler, it being made of wrought iron, and proved by pressure before sent off; but cast-iron boilers may, by defects not discernible, and are very apt to break by the water being left low in the boiler, and if heated red hot, exploding without the smallest notice; but wrought-iron boilers, when defective, give way only partially, without injury to anyone. With respect to the erecting and management of the engine, you need not have an engineer, for any common tradesman can do this from the drawings and directions sent with the engine; for, as I before informed you, farmers and their labourers set up and keep in order the thrashing-machine engines without my going on the spot or sending any person to assist them. I never saw a steam-engine rolling malt, therefore cannot judge the quantity the engine would roll, only by a comparison with horse labour, against the consumption of coal, which will be in some cases as about 42 lbs. to one horse; but where great speed is required in the machine, the coal will be less, as steam-engines make more revolutions in a minute than horse mills, therefore the work is done with less friction.
"I have several times applied the steam, after it has worked the engine, to boil water and other purposes, with as good effect as if the engine had not been there, therefore the work of the engine will be a clear profit.
"You say about a 1-horse engine. The boiler would be so small that it would not be worth applying that steam to any other purpose, as any large quantity of water would be but slowly heated.
"I find that it does not answer either the purpose of the vendor or the user of an engine, to make less than a 2-horse power, as the expense on a very small engine is nearly as much as one of the power I use for thrashing, those being only 80l., and a 2-horse is 60l. Respecting the mashing with steam, I never before heard of it, but from the theory of the plan I think it cannot fail to answer a far better purpose than any other that can possibly be applied for extracting the essence of the malt. However, should it not answer your purpose, it is only the loss of the expense of a few yards of 1-inch lead pipe.