marked advantages over the former method, which is now becoming extinct. In the regenerative system of firing, a mixture of carbon monoxide and nitrogen is produced by passing air through incandescent gas coke in a generator placed below the bench of retorts, and the heating value of the gases so produced is increased in most cases by the admixture of a small proportion of steam with the primary air supply, the steam being decomposed by contact with the red-hot coke in the generator into water gas, a mixture of carbon monoxide and hydrogen (see Fuel: Gaseous). The gases so formed vary in proportion with the temperature of the generator and the amount of steam, but generally contain 32 to 38% of combustible gas, the remainder being the residual nitrogen of the air and carbon dioxide. These gases enter the combustion chamber around the retorts at a high temperature, and are there supplied with sufficient air to complete their combustion, this secondary air supply being heated by the hot products of combustion on their way to the exit flue. This method of firing results in the saving of about one-third the weight of coke used in the old form of furnace per ton of coal carbonized, and enables higher temperatures to be obtained, the heat being also more equally distributed.
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| Fig. 6.—Regenerative Setting. |
There are a great number of methods of applying the regenerative principle which vary only in detail. Fig. 6 gives an idea of the general arrangement. The furnace A is built of fire-brick, coke is charged at the top through the iron door B, and near the bottom are placed fire bars C, upon which the fuel lies. The primary air necessary for the partial combustion of the coke to “producer” gas enters between these bars. The gases are conducted from the furnace to the combustion chamber E through the nostrils D D, and the secondary air is admitted at the inlet F a little above, this air having been already heated by traversing the setting. Complete combustion takes place at this point with the production of intense heat, the gases on rising are baffled in order to circulate them in every direction round the retorts, and upon arriving at the top of the setting they are conducted down a hollow chamber communicating with the main flue and shaft. The amount of draft which is necessary to carry out the circulation of the gases and to draw in the adequate amount of air is regulated by dampers placed in the main flue. By analysis of the “producer” and “spent” gases this amount can be readily gauged.
Retorts are set in either the horizontal, inclined or vertical position, and the advantages of the one over the other is a question upon which almost every gas engineer has his own views.
The introduction of labour-saving appliances into gas works has rendered the difficult work of charging and discharging horizontal retorts comparatively simple. Formerly it was the practice to carry out such operations entirely by hand, men charging the retorts Charging and drawing.either by means of shovel or hand-scoop, and the coke produced being withdrawn with hand rakes. Now, however, only the smaller gas works adhere to this system, and this work is done by machinery driven by either compressed air, hydraulic or electric power. In the first two cases a scoop, filled with coal from an overhead hopper carried by the travelling machine, is made to enter the retort and is turned over; the operation is then repeated, but this time the scoop is turned over in the opposite direction, the coal thus assuming such a position that as much of its under surface as possible is exposed to the heated side of the retort. With “through” retorts charging machines feed the retorts at both ends, the scoop, which has a capacity of about 112 cwt., entering and discharging its contents twice at each end, so that the total charge is about 6 cwt., which is allowed from four to six hours to distil off according to the quality of the gas required. The machines charge simultaneously at each end, so that the lids of the retorts may be shut immediately the coal enters. The charging machines travel on lines in front of the retort bench, and the power is transmitted by connexions made with flexible hose. A device of more recent introduction is an electrically-driven charging machine, in which the centrifugal force created by a fly-wheel revolving at high speed is applied to drive coal into the retort. If the velocity is sufficiently high the coal may be carried the whole length of a 20-ft. retort, the coal following banking up until an even layer is formed throughout the length of the retort.
For the purpose of discharging the coke from the retort either compressed air or hydraulic machinery is employed, a rake being made to enter the retort and withdraw the coke on returning. With this method it is necessary that the rake should enter and discharge several times before the retort is clear, and thus the use of a telescopic ram worked by hydraulic power, which pushes the coke before it and discharges it at the other end, is an advantage. As much as one-third on each ton of coal carbonized is saved by the use of machinery in the retort-house. Taking into account the original cost of such machines, and the unavoidable wear and tear upon the retorts brought about by using labour-saving appliances, and the fact that the coke-dust is very detrimental to the machinery, it is clear that the suggestion of setting the retorts at an incline in order to facilitate the work presented great inducements to the gas manager. The object aimed at in thus setting retorts is to allow gravity to play the part of charging and discharging the coal and coke, the retorts being inclined at an angle to suit the slip of the class of coal used; this angle is between 28° and 34°. The coal, previously elevated to hoppers, is dropped into the feeding chambers, which are so arranged that they can travel from end to end of the retort-house and feed the coal into the retorts. When the retort is to be charged, an iron stop or barrier is placed in the lower mouthpiece, and the door closed. The shoot is placed in the upper mouthpiece, and the stop or door, which retains the coal in the chamber, is released; the coal is then discharged into the retort, and rushing down the incline, is arrested by the barrier, and banks up, forming a continuous backing to the coal following. By experience with the class of coal used and the adjustment of the stops in the shoot, the charge can be run into the retort to form an even layer of any desired depth. For the withdrawal of the residual coke at the end of the carbonization, the lower mouthpiece door is opened, the barrier removed and the coke in the lower part of the retort is “tickled” or gently stirred with an iron rod to overcome a slight adhesion to the retort; the entire mass then readily discharges itself. Guides are placed in front of the retort to direct its course to the coke hoppers or conveyer below, and to prevent scattering of the hot material. This system shows a greater economy in the cost of carbonizing the coal, but the large outlay and the wear and tear of the mechanical appliances involved have so far prevented its very general adoption.
The vertical retort was one of the first forms experimented with by Murdoch, but owing to the difficulty of withdrawing the coke, the low illuminating power of the gas made in it, and the damage to the retort itself, due to the swelling of the charge during distillation, it was quickly abandoned. About the beginning of the 20th century, however, the experiments of Messrs Settle and Padfield at Exeter, Messrs Woodall and Duckham at Bournemouth, and Dr Bueb in Germany showed such encouraging results that the idea of the vertical retort again came to the front, and several systems were proposed and tried. The cause of the failure of Murdoch’s original vertical retort was undoubtedly that it was completely filled with coal during charging, with the result that the gas liberated from the lower portions of the retort had to pass through a deep bed of red-hot coke, which, by over-baking the gas, destroyed the illuminating hydrocarbons. There is no doubt that the question of rapidly removing the gas, as soon as it is properly formed, from the influence of the highly-heated walls of the retort and residual coke, is one of the most important in gas manufacture.
In the case of horizontal retorts the space between the top of the coal and the retort is of necessity considerable in order to permit the introduction of the scoop and rake; the gas has therefore a free channel to travel along, but has too much contact with the highly heated surface of the retort before it leaves the mouthpiece. In the case of inclined retorts this disadvantage is somewhat reduced, but with vertical retorts the ideal conditions can be more nearly approached. The heating as well as the illuminating value of the gas per unit volume is lowered by over-baking, and Dr Bueb gives the following figures as to the heating value of gas obtained from the same coal but by different methods of carbonization:—
| Vertical | Retorts, 604 British thermal units per cub. ft. |
| Inclined | Retorts, 584 British thermal units per cub. ft. |
| Horizontal | Retorts, 570 British thermal units per cub. ft. |
Of the existing forms of vertical retort it remains a matter to be decided whether the coal should be charged in bulk to the retort or whether it should be introduced in small quantities at regular and short intervals; by this latter means (the characteristic feature of the Settle-Padfield process) a continuous layer of coal is in process of carbonization on the top, whilst the gas escapes without contact with the mass of red-hot coke, a considerable increase in volume and value in the gas and a much denser coke being the result.
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| Fig. 7.—Hydraulic Main. |
From the retort the gas passes by the ascension pipe to the hydraulic main (fig. 7). This is a long reservoir placed in a horizontal position and supported by columns upon the top of the retort stack, and through it is maintained a slow but Hydraulic main. constant flow of water, the level of which is kept uniform. The ascension pipe dips about 2 in. into the liquid, and so makes a seal that allows of any retort being charged singly without the risk of the gas produced from the other retorts in the bench escaping
