Edison: His Life and Inventions

by Frank Lewis Dyer; Thomas Commerford Martin

Edison realized from the start that the true solution of this problem lay in the continuous treatment of the material, with the maximum employment of natural forces and the minimum of manual labor and generated power. Hence, all his conceptions followed this general principle so faithfully and completely that we find in the plant embodying his ideas the forces of momentum and gravity steadily in harness and keeping the traces taut; while there was no touch of the human hand upon the material from the beginning of the treatment to its finish—the staff being employed mainly to keep watch on the correct working of the various processes.

It is hardly necessary to devote space to the beginnings of the enterprise, although they are full of interest. They served, however, to convince Edison that if he ever expected to carry out his scheme on the extensive scale planned, he could not depend upon the market to supply suitable machinery for important operations, but would be obliged to devise and build it himself. Thus, outside the steam-shovel and such staple items as engines, boilers, dynamos, and motors, all of the diverse and complex machinery of the entire concentrating plant, as subsequently completed, was devised by him especially for the purpose. The necessity for this was due to the many radical variations made from accepted methods.

No such departure was as radical as that of the method of crushing the ore. Existing machinery for this purpose had been designed on the basis of mining methods then in vogue, by which the rock was thoroughly shattered by means of high explosives and reduced to pieces of one hundred pounds or less. These pieces were then crushed by power directly applied. If a concentrating mill, planned to treat five or six thousand tons per day, were to be operated on this basis the investment in crushers and the supply of power would be enormous, to say nothing of the risk of frequent breakdowns by reason of multiplicity of machinery and parts. From a consideration of these facts, and with his usual tendency to upset traditional observances, Edison conceived the bold idea of constructing gigantic rolls which, by the force of momentum, would be capable of crushing individual rocks of vastly greater size than ever before attempted. He reasoned that the advantages thus obtained would be fourfold: a minimum of machinery and parts; greater compactness; a saving of power; and greater economy in mining. As this last-named operation precedes the crushing, let us first consider it as it was projected and carried on by him.

Perhaps quarrying would be a better term than mining in this case, as Edison's plan was to approach the rock and tear it down bodily. The faith that "moves mountains" had a new opportunity. In work of this nature it had been customary, as above stated, to depend upon a high explosive, such as dynamite, to shatter and break the ore to lumps of one hundred pounds or less. This, however, he deemed to be a most uneconomical process, for energy stored as heat units in dynamite at $260 per ton was much more expensive than that of calories in a ton of coal at $3 per ton. Hence, he believed that only the minimum of work should be done with the costly explosive; and, therefore, planned to use dynamite merely to dislodge great masses of rock, and depended upon the steam-shovel, operated by coal under the boiler, to displace, handle, and remove the rock in detail. This was the plan that was subsequently put into practice in the great works at Edison, New Jersey. A series of three-inch holes twenty feet deep were drilled eight feet apart, about twelve feet back of the ore-bank, and into these were inserted dynamite cartridges. The blast would dislodge thirty to thirty-five thousand tons of rock, which was scooped up by great steam-shovels and loaded on to skips carried by a line of cars on a narrow-gauge railroad running to and from the crushing mill. Here the material was automatically delivered to the giant rolls. The problem included handling and crushing the "run of the mine," without selection. The steam-shovel did not discriminate, but picked up handily single pieces weighing five or six tons and loaded them on the skips with quantities of smaller lumps. When the skips arrived at the giant rolls, their contents were dumped automatically into a superimposed hopper. The rolls were well named, for with ear-splitting noise they broke up in a few seconds the great pieces of rock tossed in from the skips.

It is not easy to appreciate to the full the daring exemplified in these great crushing rolls, or rather "rock-crackers," without having watched them in operation delivering their "solar-plexus" blows. It was only as one might stand in their vicinity and hear the thunderous roar accompanying the smashing and rending of the massive rocks as they disappeared from view that the mind was overwhelmed with a sense of the magnificent proportions of this operation. The enormous force exerted during this process may be illustrated from the fact that during its development, in running one of the early forms of rolls, pieces of rock weighing more than half a ton would be shot up in the air to a height of twenty or twenty-five feet.

The giant rolls were two solid cylinders, six feet in diameter and five feet long, made of cast iron. To the faces of these rolls were bolted a series of heavy, chilled-iron plates containing a number of projecting knobs two inches high. Each roll had also two rows of four-inch knobs, intended to strike a series of hammer-like blows. The rolls were set face to face fourteen inches apart, in a heavy frame, and the total weight was one hundred and thirty tons, of which seventy tons were in moving parts. The space between these two rolls allowed pieces of rock measuring less than fourteen inches to descend to other smaller rolls placed below. The giant rolls were belt-driven, in opposite directions, through friction clutches, although the belt was not depended upon for the actual crushing. Previous to the dumping of a skip, the rolls were speeded up to a circumferential velocity of nearly a mile a minute, thus imparting to them the terrific momentum that would break up easily in a few seconds boulders weighing five or six tons each. It was as though a rock of this size had got in the way of two express trains travelling in opposite directions at nearly sixty miles an hour. In other words, it was the kinetic energy of the rolls that crumbled up the rocks with pile-driver effect. This sudden strain might have tended to stop the engine driving the rolls; but by an ingenious clutch arrangement the belt was released at the moment of resistance in the rolls by reason of the rocks falling between them. The act of breaking and crushing would naturally decrease the tremendous momentum, but after the rock was reduced and the pieces had passed through, the belt would again come into play, and once more speed up the rolls for a repetition of their regular prize-fighter duty.

On leaving the giant rolls the rocks, having been reduced to pieces not larger than fourteen inches, passed into the series of "Intermediate Rolls" of similar construction and operation, by which they were still further reduced, and again passed on to three other sets of rolls of smaller dimensions. These latter rolls were also face-lined with chilled-iron plates; but, unlike the larger ones, were positively driven, reducing the rock to pieces of about one-half-inch size, or smaller. The whole crushing operation of reduction from massive boulders to small pebbly pieces having been done in less time than the telling has occupied, the product was conveyed to the "Dryer," a tower nine feet square and fifty feet high, heated from below by great open furnace fires. All down the inside walls of this tower were placed cast-iron plates, nine feet long and seven inches wide, arranged alternately in "fish-ladder" fashion. The crushed rock, being delivered at the top, would fall down from plate to plate, constantly exposing different surfaces to the heat, until it landed completely dried in the lower portion of the tower, where it fell into conveyors which took it up to the stock-house.

This method of drying was original with Edison. At the time this adjunct to the plant was required, the best dryer on the market was of a rotary type, which had a capacity of only twenty tons per hour, with the expenditure of considerable power. As Edison had determined upon treating two hundred and fifty tons or more per hour, he decided to devise an entirely new type of great capacity, requiring a minimum of power (for elevating the material), and depending upon the force of gravity for handling it during the drying process. A long series of experiments resulted in the invention of the tower dryer with a capacity of three hundred tons per hour.

The rock, broken up into pieces about the size of marbles, having been dried and conveyed to the stock-house, the surplusage was automatically carried out from the other end of the stock-house by conveyors, to pass through the next process, by which it was reduced to a powder. The machinery for accomplishing this result represents another interesting and radical departure of Edison from accepted usage. He had investigated all the crushing-machines on the market, and tried all he could get. He found them all greatly lacking in economy of operation; indeed, the highest results obtainable from the best were 18 per cent. of actual work, involving a loss of 82 per cent. by friction. His nature revolted at such an immense loss of power, especially as he proposed the crushing of vast quantities of ore. Thus, he was obliged to begin again at the foundation, and he devised a crushing-machine which was subsequently named the "Three-High Rolls," and which practically reversed the above figures, as it developed 84 per cent. of work done with only 16 per cent. loss in friction.

A brief description of this remarkable machine will probably interest the reader. In the two end pieces of a heavy iron frame were set three rolls, or cylinders—one in the centre, another below, and the other above—all three being in a vertical line. These rolls were of cast iron three feet in diameter, having chilled-iron smooth face-plates of considerable thickness. The lowest roll was set in a fixed bearing at the bottom of the frame, and, therefore, could only turn around on its axis. The middle and top rolls were free to move up or down from and toward the lower roll, and the shafts of the middle and upper rolls were set in a loose bearing which could slip up and down in the iron frame. It will be apparent, therefore, that any material which passed in between the top and the middle rolls, and the middle and bottom rolls, could be ground as fine as might be desired, depending entirely upon the amount of pressure applied to the loose rolls. In operation the material passed first through the upper and middle rolls, and then between the middle and lowest rolls.