A survey of the equipment of APCM and BPCM was performed in 1924, and subsequently revised. This was no doubt initiated as part of the failed takeover by Henry Horne, and the subsequent Boardroom coup d'état. In some respects, it reads like a "due diligence" document. The data gathered were used to decide upon numerous plant closures that took place in the following ten years. Of the 41 sites listed, all are now gone, the longest-lasting being Shoreham, which closed in 1991, while 26 closed before the end of the 1920s. The APCM and BPCM pages are now complete but require annotation.
The text of the survey was kindly contributed by Chris Down (Note 1).
Data are given in a standardised format for each plant, including lime and whiting plants. I have rendered the document as-is except for correcting a few spellings and illiteracies. A particular feature is that dimensions given are (almost) invariably in feet and inches, although much of the plant described was metric. These data are mostly inaccurate to varying degrees - often considerably so. One can only speculate why this is so. One suspects that the returns were compiled by non-technical people. Many plants probably did not employ anyone who could be described as "technical". But the errors may also be deliberate disinformation.
Annotations for this page are still under construction, as is the APCM page and a page summarising the data.
The BPCM plants were as follows. Plants that survived beyond 1945 are in bold.
Artillery and Albion plants were probably operated briefly during the post-war boom, and in the panic during the upgrading shut-down of Bevans. However, closure followed immediately, and the plants were already half-demolished by 1924.
This works is largely dismantled, all kilns and chimneys with the exception of the boiler chimney having been demolished and sold.
The following gear which is in very poor condition and almost useless for all practical purposes is still in situ:
Raw Material Preparation :—
2 washmills 18' diameter
1 small set of 2-throw slurry pumps
Cement Grinding Plant :—
2 Chain & Bucket Clinker Elevators
4 pairs of 4'6" Millstones
1 Separator
1 Smidth type Tube mill 16' × 4'0"
2 Collis Mills without sieves
Cement Storage & Loading :—
The form of storage is not mentioned, but it was four open warehouses, total 9300 sq.ft.
Maximum Capacity 3,500 T
Working Capacity 2,500 T
Gas, Oil and Steam Engines, Boilers & Producers :—
1 240 H.P. Marine type Steam engine by Earles of Hull
2 Lancs. Boilers 30' × 7'6" (one condemned)
1 Lancs. Boiler 26' × 7'6" (very bad condition)
1 3-ton Smith Crane without grab
Cooperage :—
dismantled of all useful plant but still contains:
1 Erith Dryer
1 Crozer machine
1 Head turning machine
Fitters' Plant :—
1 small lathe
1 drilling machine
The Beddington plant was running in 1924, but the decision was made to close it at this stage, on the grounds of high production cost and lack of scope for a cost-reducing upgrade. However, the plant was used for the experimental development of white cement. Final closure was in 1933.
Dryer, Ruggles Coles 35'0" × 5'0"
Coal fired, internally heated. Output 2 tons per hour from 10% - 4% H2O
One Combination Tube Mill, Edgar Allen. 24'0" × 3'10" inside diameter Lining Cast Iron. Charge 3 tons 2" Steel Balls, 2½ tons 1" C.I. Balls. H.P. 95 @ 28 rpm. Output 1¾
tons per hour. Fineness 16% on 180#
Two Powdered Coal Hoppers, each holding 2 tons i.e., about 2½ hours' run
Three Powdered Coal Silos each holding 12 tons
Two Raw Coal Hoppers, each holding 10 tons
Cement Grinding Plant :—
Two Ball Mills F.L. Smidth 6'4" inside diameter (Kominor B). Lining, chrome & manganese steel step plates. Charge 2 tons 3" - 2" steel balls. H.P. 45 @ 25 rpm. Output, 2½ tons per hour to 45% on 180#, 27% on 100#
One Tube Mill, Jenisch & Lohnert. 19'8" × 5'7" inside diameter. Lining, Fuller Metallic. Charge 7 tons 1" C.I. Balls, 120 H.P. @ 25 rpm. Output 5 tons per hour to 6.5% on 180#
Cement Storage & Loading :—
Flat bottomed Warehouse
6500 ton maximum capacity
5000 ton working capacity
Hand packing
Gas, Oil and Steam Engines, Boilers & Producers :—
1 Vertical Compound steam engine by Musgrave, Bolton fitted with Musgrave valve gear. Jet Condenser and air pumps. Bore 18½ in. high pressure, 38 in. low pressure.
Stroke 36 in. 90 rpm, 350 HP, Vacuum 23-24 in. Working steam pressure: 170 psi. Superheat @ engine 120° F. Main drive by ropes.
1 Bellis steam engine Vertical Compound. Direct coupled to Westinghouse 3 phase Alternator 200 kW.
Bore 13 in. high pressure, 22 in. low pressure. Stroke 11 in. rpm. 400 with Ledwart & Becket ejector condenser.
1 Air Compressor by Broom & Wade. Bore 6", Stroke 7", 2 cylinders. Belt driven.
1 Two drum 160 tubes Babcock & Wilcox with Chain Grate Stoker. Working pressure 175 psi. Babcock Superheater - Superheat temperature 150° F. Boiler evaporation under normal conditions 10,000 lb per hr. Softening plant - Boby system. Greens Economiser 96 tubes
2 Weir feed pumps
Cooperage :—
Nil
Sacks :—
One Steam heated sack drier
One Rotary cleaning machine (shaker)
One Singer Darning Machine
Fitters' Plant :—
Motor driven, consisting of :
One 19' × 6" centres S.C. Lathe
One 6' × 9" centres S.C. Lathe
One 8' stroke planing machine
One 3' stroke planing machine
One Drilling Machine from ¼ in to 1½"
One Punching and shearing machine, to shear up to ½ in
One 16" hack saw machine
One 10" double Emery Wheel
One 3' Grindstone
One Blacksmith's Forge with motor driven fan
Water :—
Deep well water (350 ft.) in chalk for boiler feed
Surface spring water for condensing purposes and washing mills
Sutton Water Company's supply
The lime plants at Blows Down, Burghclere, Buriton, Sewell and Sundon were the plants previously owned by Forders, which were taken over by BPCM along with the Sundon cement plant, while the brick works formed the nucleus of what became London Brick.
Blows Down Lime
Registered Capacity :— 250 T/week (1924)
Raw Materials :—
White Chalk
Tenure of Property :—
Leasehold - 50 years from 01/01/1895.
Rent of Property :—
£250 per annum
Royalties :—
Nil
Loading Facilities :—
Wharf on to railway siding 29 yards long, 7 yards wide
1 Harrison Carter 2½ "B" type Disintegrator, output 1½ T/hr (also used for Lime grinding)
Gas, Oil and Steam Engines, Boilers & Producers :—
1 Horizontal non-condensing steam engine about 25 H.P. (also used for Lime grinding)
The lime plants at Blows Down, Burghclere, Buriton, Sewell and Sundon were the plants previously owned by Forders, which were taken over by BPCM along with the Sundon cement plant, while the brick works formed the nucleus of what became London Brick.
Burghclere Lime
Registered Capacity :— 100 T/week (1924)
Raw Materials :—
Chalk (Grey)
Tenure of Property :—
Leasehold - 60 years from 29/09/1899 with breaks to Lessees at end of any complete 7 years or on exhaustion of the chalk
Rent of Property :—
£100 per annum and £33 per annum to Lessor's tenant for 11 acres land taken from him for Works purposes
The lime plants at Blows Down, Burghclere, Buriton, Sewell and Sundon were the plants previously owned by Forders, which were taken over by BPCM along with the Sundon cement plant, while the brick works formed the nucleus of what became London Brick. Buriton was Forder's original plant.
Buriton Lime
Registered Capacity :— 240 T/week (1924)
Raw Materials :—
Chalk (Grey & White)
Tenure of Property :—
Leasehold - 60 years from 29/09/1899.
Rent of Property :—
£450 per annum
Royalties :—
6d per ton of lime sold over 18,000 tons in any one year
Loading Facilities :—
on rail
Nearest Station & Railway :—
Petersfield, Southern Railway
Siding :—
Buriton Sidings, Petersfield, Southern Railway
Lime Kilns :—
5 Shaft Kilns, 240 T/week, product: grey or white lime.
Lime Grinding Plant :—
1 Harrison Carter 3½ type Disintegrator, capacity 2 T/hr
Gas, Oil and Steam Engines, Boilers & Producers :—
1 Semi-portable loco (25 H.P.) Marshall, Gainsborough (Grinding)
1 Semi-portable loco (16 H.P.) Ransomes, Ipswich (Fuel)
1 Semi-portable loco (12 H.P.) Robey (Silent)
1 Vertical Barrow & Stewart steam engine 4 H.P. (silent)
The Cousland plant was operational at the time of the survey, but the decision to close it followed immediately, and the plant ceased production before the end of 1924. Production costs were high, and the lack of substantial reserves precluded an upgrade.
1 20' diameter, 12' deep steel plate clinker storage tank, 130 tons with 3 feed tables
1 12" × 8" Blake crusher
1 Conveyor 100 ft in 10 ft lengths
Fitters' Plant :—
1 Lathe geared, 12' × 1'8" × 24" (poor condition)
The Harefield plant was operational at the time of survey, but was assessed as having insufficient reserves for an uprate, and was kept running only until the uprated Swanscombe plant started up in 1929.
Denham, Great Central & Great Western joint lines, 2½ miles away
Siding :—
No railway siding, private dock off Grand Junction Canal
Raw Material Getting :—
Chalk: The chalk is won from a quarry not far from the Works. The working face is about 40 feet high and the material is milled into tip trucks, which are hauled to the Washmills by a small petrol locomotive.
Clay: This is dug from a pit about 200 yards from the Works and 80 feet above it. The clay is carried to the Washing plant by an Aerial Ropeway.
Uncallowing :—
There is about a foot to 2 feet of top soil over the Chalk. In the case of the clay, the overburden varies, but averages about three to four feet.
Outside Plant :—
Aerial Ropeway mechanically driven from washmill shaft
One 2½ ton Simplex Petrol Locomotive 20" gauge
Barges:
Capacity (tons)
Otter (20 H.P. Motor Boat) & Doe
23 & 27
Hilda (20 H.P. Motor Boat) & Faith
22 & 30
Lion (20 H.P. Motor Boat) & Bear
24 & 28
Gwendoline & Two Sisters (Horse-drawn)
25 & 30
Wolf (wooden)
25
Doe (wooden)
25
Newt (wooden)
25
Fawn (wooden)
25
Badger (iron)
25
Kangaroo (concrete)
20
Raw Material Preparation :—
One chalk mill, 18 sq.ft. screening area, 55 H.P. @ 14 rpm. Output 20 tons per hour
One slurry mill, 26 sq. ft. screening area, 55 H.P. @ 20 rpm. Output 25 tons per hour
Seven Inclined shaking sieves 53 sq.ft. screening area
Two elevators: one chalk and the other finished slurry
Two triple mixers 125 clinker tons each, both under kiln
One set 3-throw Pumps
Cement Kilns :—
One rotary kiln, 140'0" × 7'11" and 6'11" diameters. Burning zone 30'6" × 7'11" lined 9" bricks. Remainder lined 6" and 4½" bricks
Cubic capacity
4165 cu. ft.
Output
67 cwt/hr
Output per 1000 cu. ft.
16.1 cwt/hr
Surface inside lining
2715 sq. ft.
Output per 1000 sq. ft.
24.8 cwt/hr
Coal consumption as rec'd
42%
Coal consumption standard
31.1%
Coal Plants :—
Dryer: F. L. Smidth 39'6" × 4'0". Externally and internally heated by hot air from Cooler. Output 1.58 tons per hour from 13% to 4.8% H2O
Tube Mill: F. L. Smidth No.14 18'6" × 4'2". Lined chilled iron blocks. Charge 3½ tons 1" C.I. balls. Output 1.75 tons per hour, 16% on 180#, 45 H.P. @ 27 rpm.
Fine Coal Storage: Silo holding 36 tons and hopper over kiln feed screws holding 1½ ton. Total storage for 25 hours
Cement Grinding Plant :—
One ball mill F.L.S. Kominor B. 6'0" diameter × 4'6". Lined cast steel step plates. Charge 2½ tons 4"-3" steel balls. H.P. 45 @ 24 rpm Output 3½ tons per hour to 52% on 180#: 31% on 76#
Two tube mills F.L.S. No.14 18'6" × 4'2". Lining Quartzite blocks. Charge 5 tons 1" C.I. balls. H.P. 55 @ 26 rpm Output 2¾ tons per hour to 10% on 180#
Cement Storage & Loading :—
Flat-bottomed Stores
Maximum Capacity 2,780 T
Working Capacity 2,500 T
Hand packing
Gas, Oil and Steam Engines, Boilers & Producers :—
3 National Single Cylinder Horizontal suction Gas engines of 150 B.H.P. each 22 in. bore, 34 in. Stroke, 160 rpm . Main drive by ropes. Last indication approx. 140 I.H.P. each
1 2-cylinder Carels Vertical Diesel engine, 160 B.H.P. Last indication 156 I.H.P. Cylinders each 16½ in. bore, 24 in. stroke, 165 rpm Main drive by ropes
1 Crossley Single Cylinder Horizontal Suction Gas Engine direct coupled to a Bruce Peebles DC Generator of 65 kW at 230 volts. 18½ in. bore, 24 in. stroke, 200 rpm.
1 Crossley Single Cylinder Horizontal Oil Engine driving Fitting Shop. 8½ in. bore, 18 in. Stroke, 230 rpm.
1 Small Generator of approx. 15 kW for works lighting & power at 100 volts.
1 Campbell Open Hearth Gas Producer 300 H.P. supplying two 150 H.P. & one 80 H.P. engine
1 Campbell oven hearth Gas Producer 150 H.P. supplying one 130 H.P. engine
Cooperage :—
Nil.
Sacks :—
1 Singer Sewing Machine
Sacks cleaned by hand
Fitters' Plant :—
1 Radial Drill 4'0" radius
1 Planing Machine 2'4" × 4' table
1 Screwing Machine to take 2" pipe (Power driven)
1 Lathe 11" centre to take 12 ft. shaft, and swing 4 ft. pulley in gap
1 Lathe 7" centre to take 9 ft. shaft and swing 2'4" pulley
1 Emery Wheel 7" diameter
1 Grindstone 4' diameter × 6" face
1 Smiths forge - Roots blower
Saw Bench 7' × 3' with 15 H.P.
Water :—
Canal Water used for washing and power from Grand Junction Canal
Drinking water from well
The Afonwen plant seems to have come to a standstill during the war, and evidently the deteriorated chamber kilns were not thought worth re-starting afterwards.
Kiln site - £8 per annum; lease expires 25/03/1941
Limestone quarry - £5 per annum; lease expires 10/10/1926
Royalties :—
1d per ton or 1¼ per cubic yard of material leased at rent of £5 per annum and expiring 10/10/1926
Loading Facilities :—
By road to Store at Caerwys Station
Rail & road
Nearest Station & Railway :—
Caerwys, LMSR
Siding :—
Denbigh, Caerwys, LMSR
The cement kilns originally consisted of 10 Batchelor chamber pattern, 25 tons capacity each, but are now in a derelict state, the only complete working unit being the mill plant
6 Trailers - 6 tons each, 5 being non-tipping and 1 back tipping
Cement Grinding Plant :—
1 Ball Mill, Newell's No.3, 8'10½" × 4'6½"
1 Tube Mill, Smidth No.12; 15'9" × 4'2"
1 Newago Screen - Sturtevant Engineering Co
1 Roller Crusher, 2' width; 1'10" diameter; opening about 3"
Cement Storage & Loading :—
3 Bins at Works, Maximum Capacity 3,000 T
Working Capacity 2,500 T
Warehouse at Station siding, 130' × 40' × 14'
Gas, Oil and Steam Engines, Boilers & Producers :—
1 275 H.P. Vertical Compound Condensing Steam Engine, Corliss gear by Victor Coates; diameter of cylinders 16½" & 29", stroke 30"
1 45 H.P. non- condensing steam engine by Willans and Robinson, diameter of cylinders 9½" & 14", stroke 6" coupled to 1 D.C. dynamo 700 rpm, 110 volts by Siemens Bros.
1 Lancashire boiler, 30' × 7", 120 psi by Galloway
Fitters' Plant :—
1 Lathe, 11'1" × 1'0¾"
1 Drill, 6' 4 gears
The Sundon plant was the smallest of the six BPCM plants that survived into the 1970s, and was not a triumph of plant design even in its early days, having been developed in a piecemeal manner. However, against the odds, it was easily the lowest cost Blue Circle plant at the time of the survey, and remained among the lowest cost plants until its last few years, so pretexts for closure were hard to find. In 1924, the plant was still running the last "first generation" kiln (No.1) and, there being modest reserves, it was decided to replace it with another kiln the same size as No.2. The oil crisis finally killed the plant off in 1976.
Private siding about 2 miles from Harlington Station, LMSR
Raw Material Getting :—
The Raw Material is a marl, which is obtained by dragging a harrow up and down the working face. This is done by a Steam Ploughing Engine, while a Steam Digger picks up the marl and loads it into trucks, which are hauled to the foot of the inclined creeper. This takes the trucks to a Tippler over the crushing rolls.
Uncallowing :—
Sufficient done for a year or more by an Erie Shovel and Petrol Loco, the former being now on loan to another Branch (April 1924).
Outside Plant :—
One Steam Ploughing Engine, Fowlers Compound 20 H.P.
One Ruston Steam Digger (12 ton) with Bucket 2 yard capacity
One 2½ ton Simplex Petrol Loco 20 H.P.
One Whitaker Navvy now in course of erection. Transferred from Martin Earle (April 1924)
Raw Material Preparation :—
One set of Kibbling Crushers
Two Washmills, screening area 49.5 sq. ft., H.P. 80 @ 20 rpm. Output 22½ tons per hour
Five Clarkes Mills each 7.6 sq. ft. screening area, 5 H.P. @ 135 rpm
Two Slurry elevators
Two Sun & Planet Mixers, Triple, in Quarry, capacity 1000 tons each
Three Small Triple Mixers - 2 in Rotary Slurry House, capacity 150 tons each, and 1 near office, capacity 800 tons
Five sets of 3-Throw Pumps; 2 for Washmills, 1 for Triple Mixer near office, 2 for Rotary Kilns
Cement Kilns :—
One Kiln FLS, 60'0" × 6'0", lined 4½" bricks throughout
Cubic capacity
1298 cu. ft.
Output
24 cwt/hr
Output per 1000 cu. ft.
18.5 cwt/hr
Surface inside lining
990 sq. ft.
Output per 1000 sq. ft.
24.3 cwt/hr
Coal consumption as rec'd
52%
Coal consumption standard
40.1%
One Kiln Edgar Allen 150'0" × 8'6" and 7'6", Burning zone 30'0" long lined 9" bricks. Remainder lined 9" & 4½" bricks
Cubic capacity
5109 cu. ft.
Output
92 cwt/hr
Output per 1000 cu. ft.
18.1 cwt/hr
Surface inside lining
3100 sq. ft.
Output per 1000 sq. ft.
29.7 cwt/hr
Coal consumption as rec'd
40.6%
Coal consumption standard
31.4%
Four Schneider Kilns: not in use at present time (April 1924)
Fourteen Chamber Kilns: not in use at present time (April 1924)
Coal Plants :—
One Dryer, FLS 23'0" × 4'0" Externally heated by furnace. Output 25 cwt per hour.
One Dryer, Edgar Allan 30'4½" × 4'6", internally & externally heated by flue gas and hot air. Output 2½ tons per hour from 13% to 2½% H2O
Coal Mills: Two Bradley 30" 3-Roll Pulverisers each taking 70 H.P. @ 150 rpm. Output 2¼ tons per hour to 20% on 180#
Powdered coal storage for 12 hours
Cement Grinding Plant :—
One Giant Griffin Mill - 40" single Roll 60 H.P. @ 170 rpm. Output 2 tons per hour to 6% on 180#
Two FLS Kominor C, 4'0" × 6'0" long lined steel step plates. Charge 2 tons 4" steel balls. 30 H.P. @ 25 rpm. Output 3.2 tons per hour to residue on 76#: No.1 27%, No.2 48%
One FLS Tube Mill, No.16 4'11" × 20'0" lined Quartzite. Charge 7 tons 1" C.I. balls. 75 H.P. @ 25 rpm. Output 3.2 tons per hr to 4% on 180#
One FLS Tube Mill, No.17.5 5'6" × 20'0" lined Quartzite. Charge 9 tons 1" C.I. balls. 100 H.P. @ 24 rpm. Output 3.2 tons per hr to 4% on 180#
Cement Storage & Loading :—
6 Flat Bottomed Stores
Maximum Capacity: 6000 tons
Working Capacity: 5000 tons
Hand Packing
Gas, Oil and Steam Engines, Boilers & Producers :—
No.1 1 National Horizontal Gas Engine, 2 cylinders, each 22½" bore, 30" stroke, 300 I.H.P. @ 170 rpm
No.2 1 National Horizontal Gas engine, Single cylinder 22½" bore, 30" stroke, 150 I.H.P. @ 180 rpm
No.3 1 National Horizontal Gas engine, 2 cylinders, each 24" bore, 30" stroke, 350 I.H.P. @ 150 rpm
No.4 1 Premier Horizontal Gas Engine, 6 cylinders, each 20" bore, 28" stroke, 750 B.H.P. @ 190 rpm, last indication 980 I.H.P.
No.5 1 Fielding & Platt Horizontal Gas Engine, 2 cylinders, each 14" bore, 22" stroke, 160 I.H.P. @ 210 rpm
No.6 1 Crossley Vertical Petrol Paraffin engine 4 cylinders, each 6½" bore, 7" stroke, 650 rpm direct coupled to 35 kW Generator 220 volts.
1 National Compressor Horizontal single cylinder, 4" bore, 4" stroke for No.3 engine, 1 B.H.P.
1 Premier Compressor for No.4 engine, 1 cylinder, 4" bore, 5" stroke
1 Vickers Generator 300 kW at 230 volts
4 Crossley Open Hearth Gas Producers, suction pressure system with tar extractors, each producing 350 I.H.P.
1 Field & Platt old type of producer 160 I.H.P., suction system
Cooperage :—
Nil.
Sacks :—
Hand Sorting
Repairs by hand, and by two Singer Sewing Machines, electrically driven.
Fitters' Plant :—
1 Keyway Cutting Machine
2 Drilling Machines
1 Emery Wheel
1 Power Hack Saw
2 Screw Cutting Lathes, 8" centres
1 Lathe, 12" centres
1 Lathe, 6" centres
1 Shaping Machine, 12" Stroke
1 Punching & Shearing Machine, 12" Jaw
Water :—
Artesian Well
8" Bore Suction Pump by Potter Co.
The Johnsons plant had the best raw material reserves of any of the 1924 BPCM plants. The early kilns 1-3 had been replaced with a larger kiln (No.5) in 1921, and the survey confirmed the plan to quadruple its capacity, which was completed in 1928. The plant was finally superseded by Northfleet in 1971, its still-substantial lands becoming part of the Northfleet reserve.
PC - 1 tidal berth for s/s up to about 600 tons, 8 tidal berths for barges, direct rail, direct lorries
Sand - 2 tidal barge berths
Chalk, Clinker etc: 1 tidal berth s/s to about 1,000 tons. (Now out of commission due to bad condition of jetty and tips)
Nearest Station & Railway :—
Greenhithe, SE Section, Southern Railway
Siding :—
Own private siding into Works
Permanent Way:- 7 miles 3'9" & 4'8½" gauge
Raw Material Getting :—
One 18 ton Ruston Navvy
One 12 ton Ruston Navvy
Outside Plant :—
1 Loco: 12" bore × 20" stroke
3 Locos: 10" bore × 15" stroke
1 Loco: 9" bore × 15" stroke
1 Loco: 9" bore × 14" stroke
1 Loco: compound gear-driven ex Cliffe (Quarry) works
1 Crane: 3 ton Coles for clay unloading
1 Crane: 3 ton Coles for coal etc unloading
1 Crane: 5 ton Grafton for coal etc unloading
Chalk wagons: 58
Clinker etc wagons: 100
Cement trollies: 30
Coke, coal, etc wagons: 35
Sand wagons: 18
Raw Material Preparation :—
Chalk:
One set of 4'9" × 2'0" Roller Crushers (Motor driven) with a Tray Conveyor for flint picking, delivering into an 18 ft. washmill
One Intermediate 18 ft. mill
Two Screening mills 24 ft. diameter
Slurry delivered by 20 ft. double Elevator Wheel to a standard 66 ft. Mixer
Three sets of 8" diameter three-throw slurry pumps deliver to another Mixer of 66 ft. diameter
Flint Grit extracting and washing gear is attached to these mills
Clay:
is discharged at Jetty by a three ton Coles Crane and Grab delivering direct into a 17'9" diameter mill and then pumped by a set of 12" diameter three-throw pumps to a standard 66 ft. mixer alongside the chalk washmill, clay being delivered as required to No.1 washmill by belt elevator
Cement Kilns :—
No.4 Kiln, 202 ft. × 8'6" and 10' diameter. Open ended cooler 76 ft. × 7'0" and 5'6"
The plant did not submit the standard kiln performance data
Cubic capacity
cu. ft.
Output
cwt/hr
Output per 1000 cu. ft.
cwt/hr
Surface inside lining
sq. ft.
Output per 1000 sq. ft.
cwt/hr
Coal consumption as rec'd
%
Coal consumption standard
%
No.5 Kiln, 202 ft. × 9 ft. and 10 ft. diameter. Open ended cooler 82'6" × 6'5" and 8'6": separate flues connect with one 300 ft. Chimney.
The plant did not submit the standard kiln performance data
Cubic capacity
cu. ft.
Output
cwt/hr
Output per 1000 cu. ft.
cwt/hr
Surface inside lining
sq. ft.
Output per 1000 sq. ft.
cwt/hr
Coal consumption as rec'd
%
Coal consumption standard
%
30 ft. diameter Elevator Wheel delivers slurry by two APCM Spoon feeds to kilns
All motor driven from the Kent Works Power House and Johnsons transformers
Tray Conveyors with Jaw Crushers and Elevator deliver clinker to Hopper 75 tons capacity above No.1 mill
Coal Plants :—
One set of 24" Roller Crushers, chain and bucket elevator deliver to a dryer 50 ft. long × 5 ft. diameter Conveyor screws deliver to three Smidth Tube mills 14 ft. × 4 ft. (divided by diaphragms into two Chambers of 4 ft. and 10 ft.) and charged with steel balls and pellets.
Screws and elevator deliver to separate hoppers in connection with each kiln with the usual feed screws, fans, etc.
All motors driven from the Kent Works Power House and Johnsons transformers.
Driven electrically from the Kent Works Power Station through a 400 H.P. motor
There is a hopper of about 150 ton capacity as clinker storage for Nos. 3 & 4 mills, the clinker being brought from the kilns by truck and then elevated to hopper.
Cement Storage & Loading :—
The form of storage is not mentioned, but there were several flat-bottomed warehouses, divided into bins.
Maximum capacity 17,600 tons
Working capacity 14,600 tons
One Bates Filler with Drag Scraper
Gas, Oil and Steam Engines, Boilers & Producers :—
The Kiln and coal plants and the Nos. 3 and 4 cement grinding mills are operated by electric current taken from the Kent works. On-site power plant includes:
No.1 325 H.P. 3300 volt autosynchronous motor by Metropolitan Vickers Ltd. driving by ropes one 260 H.P. 220 volt Siemens generator
No.2 325 H.P. 3300 volt squirrel cage motor by English Electric Co. driving by ropes one 260 H.P. 220 volt Siemens generator
At Washmill:
1 4 cylinder 450 H.P. Premier Gas Engine
1 120 H.P. Electric Generator to supply power to clay washing plant, pumps, etc
1 Open hearth Campbell Gas Producer
At No.1 Cement Grinding Mill:
1 375 H.P. three cylinder Premier Gas Engine
1 Open hearth Gas Producer plant
1 Exhaust Heat boiler for hydrating purposes
At Cooperage:
1 120 H.P. Single cylinder National Gas Engine
1 Wood chip Eureka Producer plant
At kilns, and 3&4 Mills, on standby since supply of power from Kent Works:
1 National Gas Engine Co twin horizontal engine 250 HP
2 National Gas Engine Co twin horizontal engines, each 235 HP
All direct coupled to electric generators by Siemens:- one of 170 kW, two of 160 kW
1 170 H.P. vertical compound condensing engine by Stevenson of Preston with 1 175 kW generator attached
6 Gas Producer plants:- one open hearth Campbell, two National Gas Engine type, three Dowson type
Two Lancashire boilers:- 1 28' × 8'6", 100 psi and 1 30' × 8'0", 100 psi
One 120 tube economiser
Cooperage :—
Three Shaking Machines
Three stave tongue-and-groove machines
One Chimer, Crozer & Printer connected with dryer
Five Magnetic Bells
One Head tongue-and-groove machine
One Head printing machine
One Head turning machine
Two Hoop Punching Machines
One Splaying Machine
Three Riveting Machines
Three sets standard three-throw Pumps
The cooperage is protected with a Mather & Platt Sprinkler Installation
Driven by a 120 H.P. single cylinder National Gas Engine with a wood chip Eureka Producer Plant
Fitters' Plant :—
3 Smiths Hearths
1 No.1 Fan for Smiths Forge
1 Shearing and Punching Machine
1 Pillar Drilling Machine, 2¼" Spindles
1 Sensitive Drill 2" Spindle
1 3'6" Radial Drilling Machine
1 5' Side Planing Machine
1 Heavy Type Bed Planing Machine, 2 tool holders 5'0" × 2'6" × 2'6"
2 Power Hack Saws
1 SSS Lathe, gap bed, 8½" C., Swing 2'6"
1 SSS Lathe, gap bed, 10½" C., Swing 3'0", 8' bed
1 SSS Lathe, 6½" C., 4' bed
1 18" Centre Lathe 20' bed, no gap. Old but powerful machine
1 12½" Centre Lathe gap swing 3'9"
1 20" Power emery wheel
1 Power Screwing Machine, Maximum 1½" bolts, 3" pipe
1 16 H.P. Motor 220 V
1 20 H.P. Motor 220 V
Current supplied from Kent Works Power Station through Johnsons transformers
2 Portable Acetylene Cutting and Welding plants
1 Portable Electric Welding plant
1 Circular Saw
1 Band Saw
1 Hand Power Mortising Machine
1 16" Stroke shaping machine ex Imperial Works
The Lees plant was one of eight plants on the Medway remaining in 1924, and the comparatively large Holborough plant was under construction. Since the upper Medway was inefficient for the export trade, the area's production capacity was excessive, and the relatively backward Lees and Halling Manor plants, after the departure of their old-guard protectors from the Blue Circle board, were rapidly closed, despite fairly good raw material reserves.
2 Lancs. Boilers, 30' × 8'6" @ 180 psi fitted with induced draught, superheaters, on site but not installed. The economiser has been transferred to Burham Branch
Saw Mill :—
1 Frame Saw for log cutting
2 Circular Saws
1 Band Saw
Electrically driven
Fitters' Plant :—
5 Smiths Hearths
1 Pillar Drilling Machine
1 2'6" Radial Drilling Machine
1 Shaping Machine 14" stroke
1 Planing Machine 6' stroke
1 Slotting Machine 10½" stroke
1 Power Screwing Machine up to 2½" pipes
1 Power Hacksaw
1 Lathe 10" centres with gap bed to swing 3'6"
1 Lathe 10½" centres with gap bed to swing 3'6"
1 Lathe 21½" centres to swing 3'10"
1 Lathe 7½" centres
1 Lathe 5" centres
1 Punching & Shearing machine for ⅝" plate
1 Portable Acetylene Welding Plant
1 Portable Forge
1 Portable Electric Drilling Machine
1 Mortise & Boring Machine (to bore up to 1¼")
1 Frame Saw 22"
1 Band Saw
1 Circular Saw 2'6" diameter
1 Circular Saw 1'3" diameter
Power supplied through 2 - 15 and 1 - 10 H.P. motors from Main Power Station
Lees Lime
Registered Capacity :— ?
Kilns :—
8 Brockham Continuous Kilns.
1 Electrically driven Chalk Hoist
1 Electrically driven Fuel Lift
25 Flare Kilns - not now in use. (6 fit for immediate use - 19 require repairs)
Dry Carbonate Plant :—
Small Chalk is brought in 30 cwt trucks by loco and is fed by hand to :-
1 Feeding Belt
1 pair Roll Crushers 19" × 16"
1 Drying Drum 60' × 5'
1 Carters Disintegrator
1 Rotating Sieve 10'3" × 2'10"
1 Automatic Sack Filling & Weighing Machine
1 Dust Collecting Plant
all electrically driven
Lime Plant :—
1 set of Roll Crushers 18" × 12"
1 Rotating Sieve 10'3" × 2'10"
1 Disintegrator
1 Automatic Sack Filling & Weighing Machine
Electrically driven
1 Edge Runner Mill (disused)
3 pairs 4'6" Millstones (disused)
1 70 H.P. Steam Engine (Boiler Condemned)
Hydrating Plant :—
1 Table Feed Gear
1 set of Roll Crushers 24' × 10½"
12" Hydrating Screw fitted with water supply
1 Bolting Machine 7'0" × 2'6"
Various screws, elevators, hoppers and a Roulette mill in the cement Raw Mill Plant all used in connection with this plant
Lees Whiting
Registered Capacity :— ?
Washing Plant :—
1 Washmill, 24' diameter, with necessary drains, backs, floors, etc
This mill is newly erected and is not quite complete
The lack of a capacity figure perhaps reflects the 1924 decision to convert part of the plant for calcium aluminate cement production. The latter was predicated on the availability of bauxite nearby. It also reflects the total loss of southern Irish market in the early 1920s. After the calcium aluminate experiment, the plant was rebuilt, and extended in the 1950s. The installation of the efficient Cookstown and the oil crisis rendered it redundant in the 1970s, and it closed in 1980.
£400 which represents the annual rent for the whole of the property (cement, whiting, lime etc.)
Royalties :—
3d per ton of Limestone
3d per ton of Clay calculated, from cement produced (0.372 factor)
Loading Facilities :—
Rail and Water. Vessels up to approx. 330 tons burden 11 ft. draught.
Nearest Station & Railway :—
Magheramorne, LMS (NCC)
Siding :—
Runs into works alongside warehouse from the main Larne-Belfast line of the LMS.
Raw Material Getting :—
Clay is dredged from the Lough by an oil engined Hopper Dredger on which is mounted a steam grab by Priestman. It is washed in a mill on the jetty and pumped up to the Raw Mill House.
Limestone is blasted from a quarry close to the Works. The fallen stone is picked up by a steam navvy and put into trucks which are hauled by electric winches to the crushing house in the quarry, whence the crushed material is conveyed by a ropeway to the Raw Mill House.
Uncallowing :—
There is a great deal of overburden, some of which has been removed by a hydraulic gun. The present method utilises a steam navvy, a petrol locomotive being used to haul away the material.
Outside Plant :—
One oil engined dredger
One steam engined dredger (spare)
Two steam navvies
One 40 H.P. petrol locomotive
One standard gauge fireless steam locomotive
Two coal unloading cranes
Raw Material Preparation :—
One clay washmill 80 sq. ft. screening area, 30 H.P. @ 17 rpm, output 12 tons per hour
One set 8" 3-throw pumps
Two jaw crushers in quarry, one by F.L. Smidth, one by Hadfield
Three FLS Kominor 52, 7'6" × 7'3" long, lined steel plates, charge 5.2 tons steel balls, 95 H.P. @ 21 rpm, output 13 tons per hour to 30% on 100#
Two FLS tube mills No.20, 6'5" × 24'4" long, lined quartzite, charge 16 tons punchings and bar ends mixed, 220 H.P. @ 23 rpm, output - 13 tons per hour
One FLS tube mill No.20, lined manganese steel, otherwise as above
One small tube mill, 18' × 5', lined manganese steel, charge 5 tons punchings, 23 rpm
Three FLS Trix Mills 2'6" diameter 10 sq.ft. screening area 8 H.P. @ 130 rpm
Four sets of 8" 3-throw slurry pumps
One set of 8" 3-throw clay slurry pumps
Two quadruple mixers slurry volume of each 9,848 cu.ft. = 175 tons clinker each
One quadruple mixer clay slurry volume same as above = 230 tons clay
Three quadruple slurry mixers as above - total storage = 875 clinker tons
Two sets 8" 3-throw Slurry Pumps
Cement Kilns :—
Two Rotary Kilns by F. L. Smidth, 165'6" × 7'10" and 9'1½" diameter, burning zone 23'6" long lined 9¼" bricks; remainder lined 6¼" bricks
Cubic capacity
6362 cu. ft.
Output
116 cwt/hr
Output per 1000 cu. ft.
18.2 cwt/hr
Surface inside lining
3640 sq. ft.
Output per 1000 sq. ft.
31.9 cwt/hr
Coal consumption as rec'd
36%
Coal consumption standard
31.0%
Coal Plants :—
One FLS dryer 5'3" × 45'6" long, heated externally and internally either by hot air from kiln or by coal firing. Output 3½ tons per hour from 13% - 3% H2O
One FLS Kominor C, 6'0" × 4'3" long lined steel plates. Charge 2 tons steel balls. Output 3½ tons per hour. 36 H.P. @ 25 rpm
One Polysius Tube Mill 6'0" × 20'0" long, lined quartzite. Charge 12 tons 1" C.I. balls, 100 H.P. @ 24 rpm Output 3½ tons per hour to 10% on 180#
Powdered coal Hopper sufficient for two hours over each kiln
Cement Grinding Plant :—
Two FLS Kominor 50, 7'6" × 7'3" long lined steel plates. Charge 5 tons steel balls 95 H.P. @ 21 rpm Output 7 tons per hour to 54% on 180#
Two FLS Tube Mills No.20, 6'5" × 24'4" long lined Quartzite. Charge 16 tons punching 220 H.P. @ 23 rpm Output 7 tons per hour to 3% on 180#
Cement Storage & Loading :—
Two Silos each 2500 tons
Four Flat bottom Stores
Exilor and Hand Packing
Maximum capacity 6000 tons
Working capacity 5400 tons
Gas, Oil and Steam Engines, Boilers & Producers :—
1 Curtis, British Thompson Houston Co. turbo-alternator 1250 kW, 500 volts, 3-phase, 50 cycles, Direct Coupled Set, 3000 rpm, surface condenser, C.M. & M. air pumps, motor driven. Vacuum 28 in.
1 Richardsons Westgarth English Electric Co. turbo-alternator 750 kW, 500 volts, 3-phase, 50 cycles, direct coupled set, 3000 rpm, condensing plant: contraflow condenser, Kinetic air pump motor driven by Pulsometer. Vacuum 28 in.
1 vertical compound high-speed engine by Allen, Bedford, with Körting ejector condenser, Vacuum 25, bore of cylinder high pressure 9 in., bore of cylinder low pressure 15 in., stroke 7 in., 425 rpm, direct coupled to 250 kW 3-phase alternator, 500 volts
1 Belliss 2-stage air compressor, direct coupled. Bore high pressure 11 in., bore low pressure 18½ in., stroke 9 in., 360 rpm
4 Babcock & Wilcox 2 drum 160-tube boilers with chain grate stokers, Babcock superheaters, working pressure 200 psi, superheat 250 deg. F
Softening plant - Babcock & Wilcox
Boiler evaporation normal conditions about 26,000 lbs. per hour
Green Economiser of 360 tubes
3 Weir feed pumps
Cooperage :—
Nil
Sacks :—
1 Automatic cleaning machine
1 Steam-heated dryer
2 Singer sewing machines
Fitters' Plant :—
Two forges
One radial drill
One sensitive drill
One 8" lathe
One 14" lathe
One screwing machine
One shaping machine
One planing machine
One shearing machine
One power hacksaw machine
One grinder
Water :—
Surface drainage to culvert
One set 3" three-throw plunger pumps by Pearn as stand-by
Magheramorne Lime
Registered Capacity :— ?
Raw Materials :—
Limestone
Tenure of Property :—
Leasehold - 60 years from 01/01/1903
Rent of Property :—
Portion of £410, which represents the annual rent for the whole of the property (Cement, Whiting, Lime, etc.
Royalties :—
6d per ton of Limeshells produced
Loading Facilities :—
Direct into Railway wagon
Nearest Station & Railway :—
Magheramorne, LMS (NCC)
Siding :—
Runs alongside kiln and joins main line Larne to Belfast, LMS N.C.C. Section
Raw Material Getting :—
Quarried by hand in Portland cement limestone quarry
Lime Kilns :—
2 Brockham shaft kilns 120-130 T/week large & small lime
3 Draw kilns, completely out of repair and can be considered obsolete
1 Draw kiln, could be repaired and used if necessary
The two Brockham Lime kilns output will be totally used for the production of Aluminous cement
Magheramorne Whiting
Registered Capacity :— 25 T/week (1924)
Raw Materials :—
Limestone
Tenure of Property :—
Leasehold - 60 years from 01/01/1903
Rent of Property :—
Portion of £410, which represents the annual rent for the whole of the property (Cement, Whiting, Lime, etc.
Royalties :—
3d per ton of Limestone used
Loading Facilities :—
Rail trade only direct into railway wagon from Whiting store.
Nearest Station & Railway :—
Magheramorne, LMS (NCC)
Siding :—
Connects main line Larne-Belfast
Raw Material Getting :—
Quarried by hand in Portland cement limestone quarry
Washing Plant :—
2 open pan mills and grit separator
Settling Vats :—
4 vats, open type
Drying Floors :—
4 Hand fired, output per hour 10 cwt
Air Drying Sheds :—
Nil
1 Store for stocking lump whiting after removing from drying floor
Grinding Mills :—
Nil
Power Plant :—
Nil
Motor driven current supplied by central power station of cement works
Water :—
Surface, fed by gravity and pumped when necessary
The Globe whiting plant had already ceased activity by this stage. Whiting production was centralised at Swanscombe.
New Globe Whiting
Registered Capacity :— ?
Raw Materials :—
Chalk
Tenure of Property :—
All Freehold
Rent of Property :—
Nil
Royalties :—
Nil
Loading Facilities :—
Whiting & Chalk
1 tidal berth s/s up to about 1,500 Tons
3 tidal barge berths
Direct Rail
Nearest Station & Railway :—
Greenhitbe, SE Section, Southern Railway
Siding :—
Permanent Way 2½ Miles 4'8½" gauge
Outside Plant :—
One Loco 10" bore 15" stroke
One Loco 8" bore 12" stroke
One Loco 10" bore 14" stroke (This is loaned to Bevans Branch)
One three ton Coles crane
175 wagons of various types
Washing Plant :—
2 Washmills 16 ft. diameter (only one in use) receive the chalk, the slurry flows by gravity to:-
Seven rotary sieves 5'6" long and 2 ft. diameter and then by elevator & drains to the settling backs
Grinding Mills :—
1 Rough grinding machine
2 Bolting machines with necessary elevators and conveyors
Power Plant :—
1 Tangye gas producer plant
1 Single cylinder Tangye gas engine of 60 H.P. with an electric generator of 33 kW
The Washmill Plant is driven direct and the powdering plant is driven electrically
1 Lancs boiler 18'0" × 4'6" disused
1 Lancs boiler 14'0" × 4'6" disused
1 Vertical boiler 9'0" × 3'9" disused
1 Vertical boiler 6'0" × 3'0" disused
The Newhaven plant was still operational in 1924, and a new washmill plant was being built, but the use of the past tense indicates that closure must have been announced as the report was compiled, and production had ceased by the end of the year.
Leasehold - works site, chalk quarry and clay lands - lease expires 29th September 1983
Rent of Property :—
Works, chalk & clay: £250 per annum
Extra land: £25 per annum
Right to make tramways from Glynde Station to clay pit: £23 per annum
Royalties :—
Not more than 4d per ton of chalk and 6d per ton of clay dug over and above such quantities as would in the aggregate amount to the yearly sum of £250
Loading Facilities :—
Rail and road
Nearest Station & Railway :—
Newhaven Town - Southern Railway
Siding :—
Cement siding, Newhaven Town, Southern Railway
Raw Material Getting :—
The Quarry face is within 200 yards of the rotary kiln. Under the old method of working, the chalk is got by blasting, broken, loaded into 1-yard tip wagons, and pushed (all by hand) to the Chalk washmill. Under the new scheme, the system of working was to be in galleries: the chalk to be dug and loaded by a Whittaker Steam Shovel of ¾-yard capacity dipper into trucks. These trucks were pushed, and the chalk dumped into crushers situated near the face, and by conveyor to roughing mills
The clay was procured from a pit at Glynde. The pit which is situated about miles from the Railway Company track is connected by broad gauge siding: the trucks being drawn up and down by horse. The siding branched into several headings to the face where the clay was loaded by hand. The average height of the face is approximately 12ft.
Uncallowing :—
Chalk: There is approximately 9" to 15" of topsoil which was taken off and wheeled to dumps, from which farmers carted and scattered over the adjoining land
Clay: The clay being up to the surface no uncallowing was necessary
Outside Plant :—
One Whittaker Steam Shovel, ¾-yard capacity dipper for chalk getting
(The 45 H.P. Simplex Paraffin Locomotive was transferred to Shoreham for use of New Work Staff, but is now available for return)
Raw Material Preparation :—
The old washing plant consisted of one washmill, into which the chalk and clay was tipped, passing into screening mill and thence by elevator wheel to 25ft. mixer. (This mixer has now been demolished to make room for new engine house)
A new plant was in course of construction, but the work was not completed, the position being as follows:-
One roughing mill 18'0" diameter Only excavations completed
Two finishing mills 18'0" diameter About 75% of brickwork complete
Slurry Mixer 52'0" diameter Transferred to Shoreham
Slurry Pump and Motor House. Excavations only
Main Motor House. The four walls are erected
Cement Kilns :—
One Rotary Kiln 110' × 6'10¾", Smidth
capacity data not supplied
Twenty-one Chamber Kilns (to be sold)
Coal Plants :—
One Ballmill, Krupp No.6
One Tube Mill, Smidth No.12, 15'9" × 4'2"
One Coal Dryer, Smidth - heated by hot air from cooler
Cement Grinding Plant :—
One Crusher "Acme" Stone Breaker, by Goodwin, Barsby & Co., Leicester - size of jaw 20"
Two Ball Mills, Krupp No.8
One Tube Mill, Smidth No.17.5, 20' × 6'
Two Tube Mills, Smidth No.12, 15'9" × 4'2"
Cement Storage & Loading :—
Maximum Capacity 7,000 tons
Working Capacity 6,500 tons
"J" Warehouse, 211' × 121' × 30' high
Three bays with overhead travelling cranes
Gas, Oil and Steam Engines, Boilers & Producers :—
One B. & W. Water Tube, 49 sq.ft. grate area, pressure 140 psi. It is understood the B. & W. Boiler has been condemned by the Insurance Co.
Economiser - Green's 64 pipes
Four Crossley Gas Producers
One Tar Extractor Plant
One Coal Crushing Plant
Cooperage :—
Nil
Sacks :—
No plant for drying
Fitters' Plant :—
One Lathe - gap bed - 12" centres
One Lathe - gap bed - 6" centres
One Shaping Machine - 13" stroke
One Radial Drilling Machine - 4'0" arm
One Machine Power Hack Saw
One Drilling Machine - swing table
One Emery Wheel
One Grindstone
Two Smith's Forges and Blowers - all power driven
Water :—
All drinking water is supplied from Newhaven Town supply. Water for power plant was pumped from a well in the Engine House, approximately 20ft. deep. The pump has been transferred to Shoreham
Chalk land (6 acres) leasehold - 60 years expiring 25/03/1977
Rent of Property :—
Chalk Pit - £12 per annum (part land sublet at rent of £9 per annum)
Royalties :—
1½d per ton of chalk dug out with minimum of £20 per annum
Loading Facilities :—
Covered Railway Siding alongside loading shed. Capable of accommodating 4 - 10 ton Railway wagons.
Nearest Station & Railway :—
Cambridge LNER nearest station but traffic is dealt with by Fulbourn station LNER
Siding :—
Consists of 4 Roads having a total length of 1063 yards the steepest gradient being 1 in 200. Siding is worked by steam driven locomotive. Portion of siding in front of loading shed is roofed. Maximum working capacity of siding one hundred 10 ton standard railway wagons
Raw Material Getting :—
The Raw Material is a Marl, to which about 16% of Chalk has to be added.
The Marl is milled from a face about 60 ft. high into trucks which are hauled by a petrol locomotive to the washing plant situated in the quarry.
The Chalk is got from a quarry about a mile and a half from the works, whence it is brought in steam lorries and tipped into the quarry. It is picked up again into trucks and taken with the marl to the washmill.
Uncallowing :—
There is only about two feet of topsoil over the Marl deposit
Outside Plant :—
One 2½ tons Petrol "Simplex" locomotive
One Standard gauge Steam Locomotive
Raw Material Preparation :—
One Roughing washmill with 51 sq. ft. screening area, 70 H.P. @ 21 rpm Output 27 tons per hour
Three Clarkes Mills 4'6" diameter 8½ sq. ft. screening area 8 H.P. @ 120 rpm
Two slurry elevators
Four sets of 3-throw pumps
Three Sun & Planet Mixers, 2 in quarry, one in works: capacity 800 tons of Slurry each mixer
Cement Kilns :—
One Rotary Kiln by Newell 200' × 9'0" & 10'0", burning zone 30'8" long lined 9" bricks, remainder 6" and 4½" brick lining
Cubic capacity
10,340 cu. ft.
Output
160 cwt/hr
Output per 1000 cu. ft.
15.5 cwt/hr
Surface inside lining
5,460 sq. ft.
Output per 1000 sq. ft.
29.3 cwt/hr
Coal consumption as rec'd
36%
Coal consumption standard
28%
Coal Plants :—
Dryer, 4'0" × 40'0" long. Coal fired, heat being applied both internally and externally. Output 3 tons per hour from 15% - 6% H2O
Three Griffin Mills, say 20 H.P. each (two used). Output 1½ tons per hour to 28% on 180#
Powdered coal hopper holding 8 tons equivalent to 2½ hours on full output
Cement Grinding Plant :—
Nine Griffin Mills for rough grinding (6 in use), 30 H.P., Output 1¾ tons per hour to 40% on 180#
One Newell combination tube mill, 6'0" × 25'0" long, lined Silex. Charge 16 tons 1" C.I. balls, 225 H.P. @ 21 rpm. Output 9-10 tons per hour to 6% on 180#
Cement Storage & Loading :—
Hopper-bottom stores 16,000 ton working capacity
Extractor screws, elevators and two Simons automatic weighing and packing machines
Gas, Oil and Steam Engines, Boilers & Producers :—
1 Horizontal tandem compound steam engine with Corliss valve gear and condenser by Pollit & Wigzell, cylinder bore: high pressure 17⅜", low pressure 34¾", stroke 5'0", 70 rpm. Main drive by rope. Vacuum 23", 675 I.H.P.
1 Horizontal tandem compound steam engine with Corliss valve gear and condenser by Pollit & Wigzell, cylinder bore: high pressure 11⅜", low pressure 22 15/16", stroke 3'6", 80 rpm. Main drive by rope. Vacuum 22", 275 I.H.P.
1 Horizontal tandem compound by Pollit & Wigzell. This engine exhausts into No.2 condenser, vacuum 19", cylinder bore: high pressure 9", low pressure 13⅞", stroke 2'0", 100 rpm, 120 I.H.P.
A 75 kW 220 volt generator is belt driven by this engine
2 150 kW 220 volt generators belt driven from main shafting
1 small air compressor, motor driven, by J. Thom, Patricroft, bore 9", stroke 9"
3 Babcock & Wilcox single drum boilers, 90 tubes, 2 with chain grate stokers and one with pulverised fuel Atritor system of Alfred Herbert. Babcock superheaters, working pressure 150 psi, Superheat 100 deg. F, boiler evaporation under normal conditions 11,500 lb. per hour
Green economiser, 180 tubes
1 Weir feed pump
1 Worthington feed pump
Cooperage :—
Nil
Sacks :—
Storage for 10,000 to 15,000 sacks. No cleaning or repairing plant
Fitters' Plant :—
1 Lathe S&S 12" centres
1 Lathe S&S 8½" centres
1 Shaping Machine
1 Radial Drilling Machine
1 small fixer machine
1 power Hacksaw
3 Grinding Wheels
1 Punching & Shearing Machine
all above driven by 7 H.P. motor
Water :—
Obtained from 2 bores through the Blue Gault into the Greensand. Bore situated near boiler house 171 ft. deep and bore in quarry about 120 ft. deep. Continuous supply of water from both bores all year round
The Peters plant was operational at the time of the survey, but although there were plentiful reserves, the plants of the middle Medway could not efficiently export, and were crushed out by the much larger neighbouring plants at Burham and Holborough, and closure ensued in 1928.
The West Kent plant was more dynamic than most other Medway plants, and were early adopters of rotary kilns, but the early kilns were inefficient and were a drag on the plant subsequently. Like Peters, there was no scope for expansion and the plant closed for Portland cement in 1925, although the kiln was used for a while in a failed attempt at making calcium aluminate cement.
1 complete set of steel drum making machinery not now actually in position
Fitters' Plant :—
1 Radial Drill, 4ft. arm, 2" spindle
1 Pillar Drill, 2" spindle, table 2'6" diameter
1 planing machine, 1'8" × 4 ft. stroke
1 small lathe, 6" centres, 6 ft. bed
1 shaper, 11" stroke
1 lathe, 12" centres, 19 ft. bed
2 smith's hearths
1 10 H.P. motor for forge and fitting shop
1 auxiliary steam engine, 5 H.P.
The Premier plant was operational at the time of survey. When running at full production, its costs were among the lowest in BPCM and the dry process kiln had a low fuel consumption, belying the commonly expressed belief of the time that dry process was of no advantage. However, the raw materials were limited and marginal, and the local market was small, so the plant was closed in 1928.
A 4'8½" gauge rail track allows of the coal wagons being run to the coal stocks, and a branch also runs to the cement warehouse. The siding is about one mile long, and joins the LMS branch line running from Northampton to Peterborough. Situated in the track is a 20 ton weighing machine, also a brick building for housing the locomotive.
Raw Material Getting :—
Hard blue limestone is obtained from a quarry about half a mile from the works by hand drilling and blasting. A steam loco hauls the trucks to storage sheds from which they are hauled as required by a winch up to the floor above the crushers.
The clay is dug from a pit close to the works. The trucks are hauled up to the crushing floor by a rope
Uncallowing :—
There is about 9 - 15 feet of uncallow over the limestone consisting chiefly of loam. An Erie steam navvy is employed clearing this, the spoil being taken away by a steam loco, and tipped into a disused part of the quarry
Clay pit. There is about 10 feet of uncallow which is worked by hand labour
Outside Plant :—
3 steam locomotives - 24" gauge
1 ¾-yard Erie steam navvy
1 standard gauge steam locomotive
Raw Material Preparation :—
One jaw crusher for limestone
One set rolls for clay
One Newell ball mill 6'6" × 3'10" long lined C.S. step plates. Charge 1½ tons 4" steel balls 40 H.P. @ 25 rpm, output 4.2 tons per hour to 50% on 180#
One Newell tube mill 4'0" × 16'6" long, silex lining. Charge 4 tons helipebs & 3 tons pebbles 75 H.P. @ 27½ rpm, output 4.2 tons per hour to 9% on 180#
Cement Kilns :—
One rotary kiln by FLS 98'10¾" × 6'10⅞" diameter, lined for 73'6" with 6" bricks, remainder lined 4½" bricks
Cubic capacity
2726 cu. ft.
Output
50 cwt/hr
Output per 1000 cu. ft.
18.4 cwt/hr
Surface inside lining
1840 sq. ft.
Output per 1000 sq. ft.
27.2 cwt/hr
Coal consumption as rec'd
24.5%
Coal consumption standard
21.7%
Coal Plants :—
Dryer, FLS 3'4½" × 22'4" long heated both externally and internally by hot air from kiln, output 12 cwt per hour from 8% to 3% H2O
One FLS combination mill, 3'8⅞" × 16'2½" lined corrugated steel plates in bell section 4' long, and silex in remainder. Charge 18 cwt 3" balls and 57 cwt pebbles. 35 H.P. @ 28 rpm, output 13 cwt per hour to 15% on 180#
Powdered coal hopper holding 2 tons i.e. sufficient for 3 hours' run
Cement Grinding Plant :—
One FLS Kominor "A" 6'2" × 4'10" long lined C.S. plates. Charge 3 tons 4" steel balls, 55 H.P. @ 23 rpm, output 3 tons per hour to 67% on 180#
One FLS tube mill No.17.5 5'4" × 20'0" long lined silex. Charge 10 tons C.I. balls, 95 H.P. @ 24 rpm, output 3 tons per hour to 8% on 180#
Cement Storage & Loading :—
Flat bottomed warehouses
Maximum capacity 3000 tons
Working capacity 2700
Hand packing
Gas, Oil and Steam Engines, Boilers & Producers :—
2 horizontal Premier gas engines, 4 cylinders per engine, each cylinder bore 16", stroke 24". Maker's speed 210 rpm but running 214 @ 300 B.H.P. Last indication for two engines 825 I.H.P. Main drive by ropes
1 twin-cylinder petrol paraffin engine direct coupled to a 15 kW generator 220 volts
1 150 kW Vickers generator 220 volts, rope driven from main shaft
3 Crossley open hearth gas producers, suction pressure system, with tar extractors, each 350 I.H.P.
Cooperage :—
Nil
Sacks :—
Brick building with ground and top floor. The ground floor is 36 feet × 30 feet, and the top floor 30 feet × 30 feet. A portion of the ground floor is partitioned off to act as a Sack Foreman's office. Sacks are sorted and repaired on the bottom floor, after which they are transferred to the top floor.
Fitters' Plant :—
Brick building with iron roof, length 48 ft., width 30 ft. The machine tools consist of :
1 small planing machine 4'6" × 2'6" table
1 radial drilling machine 3'6" arm
1 lathe 8½" centres
1 gap lathe 11" centres
1 power saw
1 grind stone
1 emery wheel
The blacksmith's shop is attached, 30 feet long and 12 feet wide. There are two blacksmith's hearths which are blown by a small fan. The fitting shop machine tools, also the fan in blacksmith's shop, are driven by a 12 B.H.P. DC electric motor.
Water :—
The town supply is laid on to the works for drinking water, offices and laboratory. Water for manufacturing purposes is drained from the quarries and surrounding land into a reservoir; a supply is also pumped to the works from the Ebbw Vale Co. Ltd. From the reservoir the water is delivered by a 3-throw, motor driven reciprocating pump to different parts of the works.
The Saxon plant had always been operated in conjunction with the Norman plant, operating the same raw material reserves. With Norman provided with a relatively efficient rotary kiln, there was no further need for Saxon's shaft kilns, and the plant was closed in 1927.
17½" Sirocco cased fan and motor 2½ B.H.P. @ 700 rpm
1 blow-through heating battery, 350 lbs. water pressure in steel casing
1 drying chamber (brick)
1 dust removal plant with 20" diameter Sirocco fan and:
1 8-B.H.P. motor, 1440 rpm
1 bag shaking machine with interior drum in steel case
2 sewing machines with motors
1 bag filter with 24 sleeves enclosed in steel case
Fitters' Plant :—
1 power hacksaw
1 20" shaping machine
1 lathe 12" centres 15'0" long
1 drilling machine with swinging table and emery wheel
Water :—
From artesian well, 200' deep in Greensand by Evans Cornish steam pump
The lime plants at Blows Down, Burghclere, Buriton, Sewell and Sundon were the plants previously owned by Forders, which were taken over by BPCM along with the Sundon cement plant, while the brick works formed the nucleus of what became London Brick.
£239 per annum, viz. £100 for right of chalk used for lime burning, £100 for rent of 9 kilns, £12 for site of 9 kilns, and £27 for 9 acres of works land
Royalties :—
By arrangement made in June 1916, 2d per ton is payable on all waste chalk sent from the works
The Shoreham plant had a large raw material reserve, and it was decided that it should be re-organised for lower manpower and production costs. This was completed in 1933. In the late 1930s, it was decided to expand the plant seven-fold with the "state-of-art" wet process technology of the time. Delayed by WWII, the project was finally completed in 1951. Shoreham was the longest-lived if the BPCM plants listed, finally closing in 1991.
Works and chalk quarry held under lease expiring 29/09/1979
Clay land at Horton - freehold
Rent of Property :—
Works: £100 per annum plus £10 per annum for each acre of chalk land (£34/7/0 at January 1924)
Ground rent cottages £18/12/0 per annum
Ground rent bungalow £4/0/0 per annum
Royalties :—
Nil
Loading Facilities :—
Warehouse is built with bins back-to-back and opening on to a loading wharf on either side, which is fed by a railway siding. At the south end of the warehouse, there is a platform for the loading of lorries
The sidings are connected up to the Horsham-Brighton section of the Southern Railway. The railway company's siding has a capacity of 16 wagons. There are approximately 1½ miles of sidings throughout the yard, which connect up the main operative buildings, and at either end of the works are so arranged that coal or other material for storage, can be dumped on either side.
Raw Material Getting :—
The chalk is got by blasting in a quarry close to the works, the material being loaded into tip wagons and pushed to the washing plant by hand. The working face is about 150 feet high.
The clay pit is about three miles from the works. The clay is hauled partly by a motor winch and partly by a horse to the river side, where it is loaded into barges which are towed to the works by steam tugs.
The winch has a 14 H.P. Tangye oil engine, and there is a 9 H.P. Blackstone oil engine driving a centrifugal pump for quarry drainage.
Uncallowing :—
Chalk: there is approximately 9" of marl topsoil which is not uncallowed. There are several veins and pockets of a clay and sand mixture running through the face which has to be cleared. These pockets run in places to a depth of 15-20 feet.
Clay: there is very little top soil. The only uncallowing done is the grubbing of quick set shrubs, and sand pockets.
Outside Plant :—
Two steam tugs - one built by Vesper & Co., Ltd, the other by Thames Ironworks Ltd.
One Grafton 3-ton travelling crane fitted with 1-yard Westwood grab, used for the discharge of clay, coal, etc.
One 45-H.P. standard gauge paraffin Simplex loco.
Two compound traction type steam locomotives, with flywheel and gearing, standard gauge, by Aveling & Porter
One portable elevator - motor driven
Raw Material Preparation :—
There are two sets of chalk and clay mills, the chalk being tipped into the first mill and washed into the second, where it is washed up with the clay. After passing through the screens it is elevated by a 25ft. slurry wheel and run into storage mixers :-
No.1 Unit
No.1 chalk mill, screening area 28 sq. ft.
No.2 clay mill, screening area 30 sq. ft.
No.2 Unit
No.3 chalk mill, screening area 14 sq. ft.
No.4 clay mill, screening area 28 sq. ft.
The output of each unit is approximately 10 tons per hour and the total power taken is approximately 200 H.P.
One 25 ft. slurry wheel
One set of 10" × 8" three-throw slurry pumps
One set of 8" × 6" two-throw slurry pumps which feed the rotary kiln
One 52 ft. sun & planet mixer
Three sets of small double-armed mixers
Total storage capacity 450 clinker tons
Cement Kilns :—
One rotary kiln by Krupp 164'4" × 7'10½" diameter, burning zone 25 feet long lined 6" bricks, remainder lined 4½" bricks
Cubic capacity
6472 cu. ft.
Output
105 cwt/hr
Output per 1000 cu. ft.
16.2 cwt/hr
Surface inside lining
3627 sq. ft.
Output per 1000 sq. ft.
29.9 cwt/hr
Coal consumption as rec'd
32.5%
Coal consumption standard
29.2%
Coal Plants :—
Dryer by Krupp 4'8" × 46'0" long heated internally and externally by hot air from kiln. Output 38 cwt per hour from 7% - 1% H2O
Combination tube mill, Krupp 3'1" × 26'0" long, lined chilled C.I. plates. Charge 4 tons 3" steel balls and 6 tons punchings and cylpebs, 96 H.P. @ 28 rpm, output 38 cwt per hour to 12% on 180#
Ground coal hopper holding 30 tons or sufficient for 17 hours' run
Cement Grinding Plant :—
One ball mill, Krupp No.8, 10'2" × 5'2" long (overall), lined C.S. plates, charge 2½ tons 4" steel balls, 50 H.P. @ 26 rpm, output 4½ tons per hour to 60% on 180#
One ball mill Krupp No.6 9'2" × 5'2" long lined C.S. plates, charge 35 cwt 4" steel balls, 35 H.P. @ 26 rpm, output 3 tons per hour to 60-70% on 180#
One Edgar Allen tube mill 4'8" × 26'0" long, lined chilled C.I. plates, charge 12 tons 1" C.I. balls, 130 H.P. @ 27½ rpm, output 4 tons per hour to 6.5% on 180#
One tube mill 4'8" × 24'0" long lined chilled C.I. plates, charge 10 tons 1" C.I. balls 120 H.P. @ 27½ rpm, output 3½ tons per hour to 6.5% on 180#
Cement Storage & Loading :—
11 flat bottomed stores
Maximum capacity 5000 tons
Working capacity 4500 tons
Extractor screws, elevators & 2 platform weighing machines for 12 tons per hour
Hand packing
Gas, Oil and Steam Engines, Boilers & Producers :—
Two 550 B.H.P. "Robey" uniflow steam engines, single cylinder, 27½" × 30" stroke, 145 rpm, flywheel 11'6" diameter to take 16 1¾" ropes. Suitable for 200 psi and 200° F superheat
Jet condensers and direct coupled air pumps to give a vacuum of 27½" Hg. Guaranteed steam consumption 10.8 lb per I.H.P. hour at full load
One DC generator by Crompton & Co., 350 kW @ 115 V, rope-driven from countershaft
One DC generator, 220 kW @ 115 V, rope driven from countershaft
Two Vickers five-drum vertical curved water tube boilers each of 4250 sq.ft. of heating surface, economisers containing 160 tubes 12'6" long and superheaters
Mechanical stokers by Babcock & Wilcox each of 98 sq.ft. grate area. Normal evaporation of one boiler from feed water at 90 deg. F:- 16,000 lb steam per hour at 220 psi and 220 deg. F superheat. Guaranteed overall efficiency 80%
Electrically-driven induced draught fans are fitted discharging into a self-supporting steel chimney 60 ft. high
Water softener by Lassen Hjort, capacity up to 20,000 lb per hr
Cooperage :—
Nil
Sacks :—
All sacks are dealt with by hand. Drying is done under the rotary kiln cooler
Fitters' Plant :—
One lathe, gap bed, screw cutting, 14" centres, 15'0" between centres
One lathe, gap bed, screw cutting, 9" centres, 10'0" between centres
One lathe, gap bed, screw cutting, 7½" centres, 5'0" between centres
One radial drilling machine, 4'0" diameter
One 16" shaping machine
One power hack saw, 17" blades
Emery and twist drill grinder, screwing machine, grindstone, sensitive drill - all power driven
Smith's forge and blower
Acetylene plant and portable forge, and portable electric drills
One vertical drilling machine, swing table
Water :—
Water for power plant and works use is pumped from a well situated in the chalk pit. The pump is a motor-driven three-throw, with a capacity of 18,000 gallons per hour
The lime plants at Blows Down, Burghclere, Buriton, Sewell and Sundon were the plants previously owned by Forders, which were taken over by BPCM along with the Sundon cement plant, while the brick works formed the nucleus of what became London Brick.
Sundon Lime
Registered Capacity :— 250 T/week (1924)
Raw Materials :—
Chalk (grey)
Tenure of Property :—
Freehold
Rent of Property :—
Nil
Royalties :—
Nil
Loading Facilities :—
Railway trucks (by barrows)
Nearest Station & Railway :—
Harlington, LMS
Siding :—
Private (Forders) sidings south, Harlington, LMS
Raw Material Getting :—
1 20 H.P. Petrol Loco
1 10 H.P. Steam Loco
Lime Kilns :—
8 shaft kilns, total 250 ton per week (150 lump, 100 ground)
8 flare kilns, total 400 ton per week (disused)
Lime Grinding Plant :—
1 2-roll pan mill with elevators and sifter
Power Plant :—
1 30 H.P. motor for grinding mill
1 8 H.P. motor for fuel haulage
Power supplied from Sundon Cement Works
Having been operated during the brief post-War boom, the Red Lion plant was by 1924 standing idle, and it was not re-started. The chalk became part of the Bevans reserve.
This consists of a small washmill with the necessary drains, back and floors, also a rough grinding machine
This plant has not been in use for many years and would require much repair before being put into commission.
The Trechmann-Weekes plant was standing idle in 1924, after having been used during the post-war boom, and was not re-started, as the Medway was over-capacity and reserves were insufficient to warrent an upgrade of an inefficient plant.
1 150 H.P. 2-cylinder Premier gas engine with electric generator of 100 kW at 250 volts
1 Suction gas producer plant
Spare power plant
1 35 H.P. Hornsby horizontal gas engine
2 small Hornsby gas engines
Cooperage :—
?
Sacks :—
?
Fitters' Plant :—
2 Smiths hearths
1 Pillar drilling machine
1 Shaping machine 9" stroke
1 Power screwing machine 2" pipe
1 lathe 21" centre to swing 11'
1 Power emery wheel
1 Power hack saw
1 Set plate bending rolls, lightly made, 3'0" wide
1 Power circular saw
1 Power band saw
Power supplied through 20 H.P. motor from main power station
1 Mortice machine in carpenters' shop
Humber was the newest of the plants listed, having been commissioned in late 1921, and was acquired by BPCM in 1923. The schedule can be compared with the description in the 1924 article in The Engineer. The plant was immediately upgraded with a third kiln and extra mills, and the schedule was revised to reflect this in January 1926. The plant remained among the more efficient into the 1960s, but was eclipsed by the proliferation of efficient dry-process plants in the North, and it finally closed in 1981.
2 (revised 3) Loading sidings alongside cement warehouse. Private sidings from LNER into works.
Raw Material Getting :—
Chalk
1 Bucyrus steam navvy
2 Steam locomotives
1 (revised) Ruston No.20 steam navvy (spare)
1 (revised) Whitaker steam navvy (spare)
Clay
1 Priestman crane & grab
2 40 B.H.P. "Simplex" petrol locomotives (1 spare)
1 (revised) Ransome crane and grab (spare)
Uncallowing :—
Hand labour and tip trucks, horse-drawn
Outside Plant :—
Two (revised one) clinker handling cranes
One steam shunting locomotive
Raw Material Preparation :—
Two washmills (only one used at any time) for clay washing with chalk slurry, screening area 2300 sq.in., 75 (revised 100) H.P. @ 18 rpm, diameter 20 ft., output 60 (revised 120) tons per hour
Two Edgar Allen combination mills, 5'6" (revised 6'0") × 32'0" for chalk, lined C.S. step plates in ball chamber (12'0"), remainder smooth steel plates. Charge 8 tons 4" steel balls and 12 (revised 18) tons 1" C.I. balls, 300 H.P. @ 28 rpm, output 12 (revised 18) tons per hour to 10% (revised 8%) on 180#
Two Edgar Allen tube mills 4'6" × 20'0" for slurry, lined silex. Charge 7 tons 1" C.I. balls, 75 H.P. @ 32 rpm. Output 16 (revised 30) tons per hour to 5% on 180#
One (revised) Smidth Unidan combination mill 36'0" × 6'0" for chalk, lined with smooth plates with Danula ring. Charge 10.5 tonnes 90 mm to 60 mm balls, 7.5 tonnes 50 mm and 40 mm balls and 19 tonnes of 22 mm to 16 mm balls. 400 H.P. @ 18.5 rpm. Output 30 tons per hour to 7% on 180#
One 10'0" diameter × 5'0" deep slurry mixer between combination mills and chalk slurry pump, capacity 7 clinker tons
One 66'0" × 10'0" deep APCM type slurry mixer at exit end of pipe line, 740 clinker tons
One 66'0" × 10'0" deep APCM type slurry mixer, 550 clinker tons
Two sets of "triple mixers" for semi-finished slurry after washmill, but before finishing tubes, 350 clinker tons
Six finished slurry storage tanks, agitated by compressed air, 1500 clinker tons
Cement Kilns :—
Two rotary kilns by Edgar Allen, 200'0" long × 9'0" diameter, burning cone 75' long lined 9" bricks, remainder lined 6" and 4½" bricks
Cubic capacity
9865 (revised 9820) cu. ft.
Output
142.6 cwt/hr
Output per 1000 cu. ft.
14.46 (revised 14.52 cwt/hr
Surface inside lining
4975 (revised 4964) sq. ft.
Output per 1000 sq. ft.
28.66 (revised 28.73) cwt/hr
Coal consumption as rec'd
32.2%
Coal consumption standard
29.0%
One (revised) rotary kiln 202 ft. long × 9 ft. & 10 ft. diameter, capacity 10,536 cu.ft., commenced work 27th June 1925
Coal Plants :—
One dryer by Edgar Allen 5'0" × 50'0" long, internally and externally heated by hot air from separate furnace, output 5½ tons per hour from 8.3% to 2.9% H2O
Two Edgar Allen combination mills 4'0" × 26'0", lined C.S. step plates in ball chamber (10'0"), remainder lined smooth plates. Charge 5 tons 2" steel balls and 7 tons 1" C.I. balls. 125 H.P. @ 30 rpm. Output 2.8 tons per hour 13% on 180#
Ground coal storage for kilns 1 & 2 of 16 tons each, equivalent to 7 hours' run
One (revised) Clarke Chapman turbo-pulveriser, capacity 7000 lb. of coal per hour
One (revised) combination air swept coal mill 9'0" × 5'0", charge 3 tons 2" balls, 5 tons 1" ballpebs, 100 H.P. @ 26 rpm. Output 2.8 tons per hour at 22% on 180#
Cement Grinding Plant :—
Two Edgar Allen combination mills 6'0" (revised 6'6") × 36'0" long lined C.S. step plates in ball chamber (14'0"), remainder lined smooth plates. Charge 11 tons 4" steel balls and 16 tons 1" C.I. balls. 400 H.P. @ 24 rpm. Output 9.5 (revised 9.0) tons per hour to 3% (revised 4%) on 180#
One Edgar Allen combination mill 6'6" (revised 7'0") × 36'0" long lined C.S. step plates in ball chamber (14'0"), remainder lined smooth plates. Three chambers 14'0", 15'0" and 7'0", charges respectively 16 tons 4" balls, 13 tons 1¼" balls and 6 tons 1" C.I. balls, 550 H.P. @ 23 rpm. Output 11.5 (revised 10.0) tons per hour to 3% (revised 4%) on 180#
One (revised) Edgar Allen combination mill 7'0" × 36'0", 600 H.P. @ 18 rpm. Output 12.5 tons per hour to 14% on 180#
Cement Storage & Loading :—
12 (revised 13) bins with a total capacity of about 6000 tons
(In 1924) Worked by hand labour, at present, into two screw conveyors feeding three Bates machines
(In 1926) Worked by two drag scoops into two screw conveyors feeding three Bates machines
Hand-barrows from Bates packers to trucks
(In 1926) Six concrete silos capacity about 1500 tons each, into screw conveyors
Gas, Oil and Steam Engines, Boilers & Producers :—
Nil
Power purchased from Hull Corporation Power Station
Cooperage :—
Nil
Sacks :—
One sack dryer
Two sack shakers
9 (revised 12) Singer sewing machines
Fitters' Plant :—
One S.S.S. 14" gap bed lathe 17'0" bed
One S.S.S. 9" lathe
One shaping machine
One power hacksaw
One screwing machine
One emery wheel
Three blacksmith's fires
plus revisions:
One radial drilling machine
One shearing machine
One milling machine
One hand keywaying machine
One circular saw
Water :—
One 6" Pearn three-throw pump 3000 gal. per hr. capacity
One (revised) 5½" Pearn three-throw pump 2000 gal. per hr. capacity
The Stoneferry plant was operational at the time of survey, but had become a rather small excrescence of the larger Wilmington plant, sharing its services, and with a cramped urban site, there was no point in keeping it going when efficient new plant could be constructed elsewhere. It closed when Hope started up.
1 Rotary kiln, 99'0" × 6'7": burning zone 25'0" long lined 7" bricks, next 25'0" lined 6" bricks, remainder lined 4½" bricks
Cubic capacity
2498 cu. ft.
Output
43 cwt/hr
Output per 1000 cu. ft.
17.2 cwt/hr
Surface inside lining
1762 sq. ft.
Output per 1000 sq. ft.
24.4 cwt/hr
Coal consumption as rec'd
34.5%
Coal consumption standard
29.6%
2 Rotary kilns, 98'5½" × 6'7": burning zone 25'0" long lined 7" bricks, next 25'0" lined 6" bricks, remainder lined 4½" bricks
Cubic capacity
2483 cu. ft.
Output
43 cwt/hr
Output per 1000 cu. ft.
17.3 cwt/hr
Surface inside lining
1752 sq. ft.
Output per 1000 sq. ft.
24.5 cwt/hr
Coal consumption as rec'd
34.5%
Coal consumption standard
29.6%
Coal Plants :—
One dryer by G. Fletcher & Co., 3'11¼" × 19'6" long, internally heated by coal firing. Output 3 tons per hour from 7% to 3% moisture.
Two Bradley 3-roll mills, 4ft. diameter, 60 H.P. @ 160 rpm, screen area 15 sq. ft., 50#
Ground coal hopper over each kiln sufficient for eight hours run
Cement Grinding Plant :—
One ball mill by Edgar Allen, 5'8" × 13'0" long, lined steel plates. Charge 12 tons steel balls, 220 H.P. @ 28 rpm. Output 9 tons per hour to 24% on 100#
One FLS tube mill, 4'8½" × 20'4" long, lined silex. Charge 9 tons Helipebs and punchings, 140 H.P. @ 23 rpm. Output 7 tons per hour to 9% on 180#
One Edgar Allen ball peb mill 5'6½" × 12'5" long, lined white iron bars. Charge 13 ton 1" ball and cylpebs, 200 H.P. @ 28 rpm. Output 8½ tons per hour to 9% on 180#
Cement Storage & Loading :—
Nine bins
Total capacity 5000 tons
Hand packing
Loading into boats and rullies
Gas, Oil and Steam Engines, Boilers & Producers :—
Nil
Power obtained ex Wilmington
Cooperage :—
Nil
Sacks :—
Normal stock about 15,000
Sorting, cleaning and repairs all done at Wilmington Works
Fitters' Plant :—
One lathe
One drilling machine
One screwing machine
One emery grinder
Water :—
Town supply and river
The Barton plant had been somewhat ineffectively upgraded to rotary operation. The site, possessing massive raw material reserves, was considered for development, but the Humber site was developed instead, perhaps because of the poor landward communications on the south bank. It closed with the start of Hope.
One Bagshaw wet tube mill 5'3" × 25'5" lined steel plates, charge 5½ tons 2" steel & 1" C.I. balls, 35 H.P. @ 35 rpm. Output 12 tons slurry per hour to 8.2% on 180#
3 stirrer arm type mixers 40' × 20' equivalent 120 tons clinker, each, adjoining kiln
Cement Kilns :—
One rotary kiln, 150'0" × 8'0" & 7'0", burning zone 30'0" long × 8'0" diameter lined 9" bricks, remainder lined 4½" bricks
Cubic capacity
4536 cu. ft.
Output
75 cwt/hr
Output per 1000 cu. ft.
16.53 cwt/hr
Surface inside lining
2923 sq. ft.
Output per 1000 sq. ft.
25.66 cwt/hr
Coal consumption as rec'd
33.6%
Coal consumption standard
30.3%
Coal Plants :—
One dryer, Edgar Allen 4'6" × 31'0" long, heated internally and externally by hot air from cooler. Output 2 tons per hour from 6% to 2% H2O
One Edgar Allen combination mill, 4'0" × 24'0", lined corrugated steel plates in ball chamber (8'0") and remainder lined silex. Charge 4 tons 2" to 3½" steel balls, 5 tons 1" C.I. balls. 60 H.P. @ 27 rpm. Output 2 tons per hour to 17% on 180#
Ground coal storage for 25 tons, i.e. about 20 hours run on the kiln
Cement Grinding Plant :—
Two Krupp No.8 ball mills 6'8" × 3'10" long, lined perforated steel plates. Charge 2¼ tons 4" steel balls. 30 H.P. @ 23 rpm. Output 3 tons per hour to 50% on 180#
Three Krupp tube mills 3'10" × 16'6" long, lined steel plates. Charge 8½ tons 1" C.I. balls 40 H.P. @ 29 rpm. Output 2.3 tons per hour to 3% on 180#
One Krupp tube mill 3'10" × 20'0" long, lined steel plates. Charge 9 tons 1" C.I. balls. 45 H.P. @ 29 rpm. Output 3 tons per hour to 3% on 180#
Cement Storage & Loading :—
6 bins, 2500 tons bulk
150 tons bagged
Filling & loading by hand
Loading into vessels and road transport by hand
Gas, Oil and Steam Engines, Boilers & Producers :—
No.1 steam engine 750 B.H.P.
No.2 steam engine 200 B.H.P. as standby for kiln
40 B.H.P. electric lighting engine
6 B.H.P. oil engine for pumping water at clayfield
59 kW generator
54 kW generator
2 Lancashire boilers each 30' × 9', 140 psi
Cooperage :—
Nil
Sacks :—
Normal stock 4000
No sack shaking or repairing done
Fitters' Plant :—
One lathe
One drilling machine
One planing machine
One screw cutting machine
One emery machine
One hacksaw machine
Water :—
From own bore well
The Wilmington plant had been developed piecemeal to a point where, due to its urban location, it could not be expanded further. It was ramshackle, even in 1924, had no raw materials on site, and costs were high. However, as G & T Earles' "home" plant, it had a charmed existence, and continued until closure in 1969, when northern cement distribution was reorganised.
Two roughing washmills each 3½ sq.ft. screening area. 20 H.P. @ 19.4 rpm. Output 20 tons per hour each
One roughing washmill 7.9 sq.ft. screening area. 30 H.P. @ 14.5 rpm. Output 25 tons per hour
Two Hammer screens, 14.3 sq.ft. screening area. 0.75 H.P. each
Two FLS No.50 wet ball mills 7'3" × 7'0" long, lined C.S. step plates. Charge 5 tons 4" - 5" steel balls. 80 - 90 H.P. @ 20 rpm. Output 20 tons per hour to 4.3% on 10#
Two FLS No.20 wet tube mills 6'2" × 23'6" long, lined C.S. ribbed plates. Charge 12 tons 1" C.I. balls. 215 H.P. @ 26 rpm. Output 35 tons per hour to 8.0% on 180#
One FLS cylpeb mill 6'2" × 9'0" long, lined C.S. ribbed plates. Charge 7 tons 1" C.I. balls. 120 H.P. @ 27 rpm. Output 18 tons per hour to 3% on 180#
One cylpeb mill as above but lined manganese steel bars and charged with 7 tons ⅞" helipebs
Three mixers attached to Nos. 1&2 kilns, 315 tons total capacity chalk equivalent
Two 66ft. APCM mixers for Nos. 3 & 4, 1000 tons total capacity chalk equivalent
Two triple mixers for Nos. 3 & 4, 275 tons total capacity chalk equivalent
Four correction mixers for Nos. 3 & 4, 200 tons total capacity chalk equivalent
Cement Kilns :—
Two rotary kilns, 106'0" × 6'7", burning zone 30'0" long, lined 9" bricks, remainder lined 8" and 4½" bricks
Cubic capacity
2640 cu. ft.
Output
40 cwt/hr
Output per 1000 cu. ft.
17.36 cwt/hr
Surface inside lining
1872 sq. ft.
Output per 1000 sq. ft.
22.68 cwt/hr
Coal consumption as rec'd
35.4%
Coal consumption standard
32.2%
One rotary kiln (No.3) 205'9" × 7'10½" & 9' 0 13/16", burning zone 23'6" long, lined 9" bricks, remainder lined 7" and 5" bricks
One rotary kiln (No.4) 204'9" × 7'10½" & 9' 0 13/16", burning zone 23'6" long, lined 9" bricks, remainder lined 7" and 5" bricks
Cubic capacity
7659 cu. ft.
Output
125 cwt/hr
Output per 1000 cu. ft.
16.32 cwt/hr
Surface inside lining
4441 sq. ft.
Output per 1000 sq. ft.
28.15 cwt/hr
Coal consumption as rec'd
30.1%
Coal consumption standard
27.6%
Coal Plants :—
One Ruggles Coles dryer, 30'0" × 5'10" diameter, heated internally by coke fire. Output 2½ tons per hour from 7.75% to 1.9% H2O
One Smidth dryer, 45'6" × 5'4" diameter, heated internally and externally by hot air from kiln. Output 5 tons per hour from 8 to 1.8% H2O
One FLS ball mill, Kominor C, 5'5" × 4'0" long, lined C.S. step plates. Charge 2¼ tons 4" steel balls. Output 4½ - 5½ tons per hour to 52% on 76#, 30 H.P. @ 28 rpm
One FLS ball mill, Kominor G, 4'2" × 3'0" long, lined C.S. step plates. Charge 18 cwt 4" steel balls. Output 2 - 2½ tons per hour to 58% on 76#. 20 H.P. @ 24 rpm
One FLS tube mill No.16, 4'10" × 20'0" long, lined silex. Charge 4 tons 1" C.I. balls, 1 ton cylpebs. 36 H.P. @ 28 rpm. Output 4½ - 5½ tons per hour to 10% on 180#
One FLS tube mill No.12, 3'8" × 15'9" long, lined silex. Charge 3½ tons 1" C.I. balls. 25 H.P. @ 24 rpm. Output 2½ tons per hour to 10% on 180#
Ground coal storage:- Nos. 1 & 2 kilns each have hoppers containing 7 hours run: Nos. 3 & 4 kilns each have hoppers containing 16 hours run
Cement Grinding Plant :—
One FLS ball mill, Kominor No.50, 7'1" × 7'0" long, lined C.S. step plates. Charge 5 tons 4" - 5" steel balls. 100 H.P. @ 22 rpm. Output 7 - 8 tons per hour to 45% on 76#
One FLS ball mill, Kominor A, 6'7" × 4'8" long, lined C.S. step plates. Charge 3 tons 4" - 4½" steel balls. 80 H.P. @ 23½ rpm. Output 4 tons per hour to 43% on 76#
Two FLS ball mills, Kominor B, 5'8" × 4'5" long, lined C.S. step plates. Charge 2½ tons 4" steel balls. 55 H.P. each @ 25 rpm. Output 2¼ tons per hour to 39% on 76#
One FLS tube mill No.20, 6'2" × 12'0" long, lined manganese steel bars. Charge 12¾ tons 1" C.I. balls. 225 H.P. @ 24 rpm. Output 7 - 8 tons per hour to 3% on 180#
One FLS tube mill No.16, 4'10" × 10'0" long, lined silex. Charge 6.3 tons 1" C.I. balls. 115 H.P. @ 25 rpm. Output 4 tons per hour to 3% on 180#
One FLS tube mill No.16, 5'2" × 8'0" long, lined C.I. plates. Charge 6.3 tons 1" C.I. balls. 115 H.P. @ 25 rpm. Output 4 tons per hour to 3% on 180#
One FLS tube mill No.16, 4'10" × 11'4½" long, lined silex. Charge 8 tons 1" C.I. bails. 110 H.P. @ 25 rpm. Output 5 tons per hour to 3% on 180#
One FLS tube mill No.16, 4'10" × 10'0" long, lined silex. Charge 6.7 tons 1" C.I. balls. 105 H.P. @ 22 rpm. Output 5 tons per hour to 3% on 180#
Cement Storage & Loading :—
This was unfortunately missing, but the plant had a 2800 T riverside warehouse divided into bins, a 3300 T railside warehouse divided into bins and two 1500 T silos
Gas, Oil and Steam Engines, Boilers & Producers :—
1 Brush-Ljungstrom 1500 kW turbo-alternator
2 Richardson Westgarth 1500 kW turbo-alternators
1 Siemens rotary converter 300 kW
2 Stirling water tube boilers each 96 sq.ft. grate area 3841 sq.ft. heating surface with superheaters 334 sq.ft. each, and economisers fitted with Bennis chain grate stokers
2 Lancashire boilers fitted with Triumph mechanical stokers, and with superheaters, one 31' × 10'3", one 30' × 9'9"
Cooperage :—
Nil
Sacks :—
1 Rotary shaker for sacks complete with dust filter, elevators & dust hopper
1 Star intermittent shaker
13 Singer sewing machines driven by small motor
1 sack dryer - steam heated by small boiler
Fitters' Plant :—
1 19 B.H.P. national oil engine ( standby)
2 Screw cutting & surfacing lathes
1 Break lathe
1 Radial drilling machine
1 Pillar drilling machine
1 Sensitive drilling machine
1 Milling machine
1 Side planing machine
1 Punch & shearing machine
1 Power hammer
1 Cutter grinder
1 Tool grinder
1 Drill grinding machine
1 Mechanical hacksaw
1 Pipe & bolt screwing machine
1 Slotting machine
1 Set tinners rolls
1 Set tyre rolls
Water :—
1 Worthington steam driven pump for river water
1 Three-throw 8" plunger pump for river water
Town water laid on all over works
The Penarth plant was operational in 1924. Some production also continued for a few years on Schneider kilns not listed here. The plant was consistently high-cost and relied upon base-load operation in a reasonably consistent local market. The plant finally closed in 1969 with the installation of Aberthaw kiln 5.
6½d per ton of cement delivered, with a minimum dead rent of £805
Loading Facilities :—
Ex warehouse to railway wagons alongside on own siding
Nearest Station & Railway :—
Penarth (Lower) GWR
Siding :—
Own private sidings with direct access to GWR Penarth and Cadoxton branch
Raw Material Getting :—
Part hand got, part machine got by Ruston No.2 steam navvy. The former is clean and is sent direct to works. The latter is a mixture of shale, clay and stone and to render it usable is passed through a cleaning machine (rumbler). After separation the clean material is hauled in trams to works by locos, a distance of about half a mile
Uncallowing :—
A considerable amount of uncallowing is necessary, the depth of topsoil varying from about 2 to 6 feet. The stone is interstratified with shale and clay, the ratio for the last 6 months being stone 2.46 : waste 1.00 exclusive of overburden
Outside Plant :—
Quarry:
1 Ruston steam navvy - 20 ton
1 Rees Roturbo pump electrically driven
1 Rope haulage to cleaner electrically driven
1 Cleaning machine (Rumbler) electrically driven
4 Locos. (steam) 2'6" gauge
72 Steel trams
1 Rock drill - Cyclone
Usual small loose quarry plant
Works:
2 Shunting locos. 4'8½" gauge
1 Steam crane with Hones grab
73 Wagons (completely paid up) suitable for main line traffic, viz: 43 10-tonners, 30 15-tonners
2 FLS Kominors type 50, 6'7¼" × 6'11¼". Output 11 tons per hour maximum each
1 Set of double chain slurry elevators (600 W bushed chain)
1 Slurry divider (FLS)
2 FLS tube mills type 20, 5'11½" × 23'8", output as above
1 FLS Trix separator 3'2¼" diameter with a screening area of 15 sq.ft.
4 Slurry mixers, each 3 sets of stirrers
3 Correction basins
3 Sets double plunger slurry pumps
1 water pump
Cement Kilns :—
One FLS Rotary kiln 228'6" long × 8'10½" diameter, burning zone 34'8" × 10'1" diameter
Cubic capacity
10,890 cu. ft.
Output
160 cwt/hr
Output per 1000 cu. ft.
14.7 cwt/hr
Surface inside lining
sq. ft.
Output per 1000 sq. ft.
cwt/hr
Coal consumption as rec'd
33.18%
Coal consumption standard
28.10%
One FLS rotary clinker cooler 12600 mm long overall × 1680 mm diameter, remarkably inefficient: forced draught fan
Coal Plants :—
One raw coal elevator
One FLS rotary coal dryer 5'2¼" internal diameter × 46' long, heated by superfluous hot air from clinker cooler. Output 3 tons per hour, heat applied internally and externally
One FLS Kominor type "C" 5'4" × 4'0¾", output 3 tons per hour
One FLS tube mill type 17.5, 5'5" × 19'6", output as above
Three sets of elevators
Six sets of conveyors
Four powdered coal hoppers each holding 45 tons
Coal firing fan
Dust collecting plant
Cement Grinding Plant :—
This was unfortunately missing, but the plant consisted of mills identical in size to the rawmills; i.e. two No.50 Kominors and two No.20 tube mills.
Cement Storage & Loading :—
This was unfortunately missing, but the plant had about 6000 T capacity of flat-floored warehouse, part divided into bins.
Gas, Oil and Steam Engines, Boilers & Producers :—
Part mended by 2 Singer sewing machines, type No. 45K74
Part mended by hand
Cleaning by hand
Fitters' Plant :—
Electric power (3 motors)
2 Forges - electric blowers ( motors included above)
1 Lathe 10½" centres × 12ft. S.S.S.S. lathe with gap
1 Lathe 16½" centres × 26ft. S.S.S.S. lathe with gap
1 Punching & shearing machine
1 Planing machine
2 Grindstones
1 Emery whee1
1 Travelling crane
1 Electric drill (portable)
1 Hand drilling machine
1 Acetylene welding plant
1 Power hammer
Usual small loose tools
1 Power hacksaw
1 Circular saw for timber
1 Screwing machine
Water :—
Town supply for power purposes
Waste from quarry pond for slurry when water is available
The Bridgend lime plant was acquired by SWPCC in 1907, and continued on a small scale until 1940.
Bridgend Lime
Registered Capacity :— 220 T/week (1924)
Raw Materials :—
Lias Limestone
Tenure of Property :—
Lease expires 1st June 1933
Rent of Property :—
£260 per annum
Royalties :—
Merged in above
Loading Facilities :—
Siding & Crane
Nearest Station & Railway :—
Bridgend, GWR
Siding :—
Own
Raw Material Getting :—
Hand dug
Outside Plant :—
Ordinary quarry equipment, trams, etc & crane
Lime Kilns :—
2 shaft, 220 tons per week of "Aberthaw" lime
Grinding Plant :—
Nil
Gas, Oil and Steam Engines, Boilers & Producers :—
Nil
The production of lias lime continued at Penarth, and in 1954 five new kilns were installed to make fat lime from Ruthin stone. Lime production ceased in 1965.
Penarth Lime
Registered Capacity :— 400 T/week (1924)
Raw Materials :—
Lias Limestone
Tenure of Property :—
Lease expires 24th June 1965
Rent of Property :—
Merged in cement works
Royalties :—
6½d per ton
Loading Facilities :—
Siding alongside kilns
Nearest Station & Railway :—
Penarth (Lower), GWR
Siding :—
Own
Raw Material Getting :—
Hand dug
Outside Plant :—
Ordinary quarry equipment, trams, etc
Lime Kilns :—
4 oval continuous, 400 tons per week of "Aberthaw" lime
Grinding Plant :—
Griffin mill
Gas, Oil and Steam Engines, Boilers & Producers :—
Cement works steam engine
The Martin Earles plant had retrenched after the war with two modern kilns replacing the sixteen first-generation kilns. The plant was above Rochester Bridge and its export activities were curtailed. The plant gradually degenerated into back-up capacity subsequently, clinker often being ground elsewhere, and lime manufacture becoming an alternate use of the kilns. The last clinker was made in 1967.
Standby lighting engine, Mather & Platt compound non-condensing, cylinder dimensions: HP 10", LP 17", stroke 12", speed 280 rpm, pressure 160 psi, normal I.H.P. approximately 90
Gas engine, Premier 4 cylinder horizontal, cylinder dimensions 20" diameter, stroke 2'4", speed 175 rpm, normal I.H.P. 530
Washmill engine, marine triple expansion, cylinder dimensions: HP 15¼", IP 24 23/64", LP 39", stroke 3 ft., speed 95 rpm, pressure 160 psi, normal I.H.P. approximately 550
5 Lancashire boilers, 27'0" × 7'6" diameter, working pressure 160 psi. 4 fitted with Crosthwaite grates, 1 natural draft
Economiser by E. Green & Son Ltd, 320 tubes in three groups 8 pipes wide, pressure 160 psi
3 Washmill Lancashire boilers, 27'0" × 7'6" diameter, working pressure 160 psi, with Crosthwaite grates
Campbell gas producer, open hearth type
ECC electric generator, 400 kW, 500 volts, 375 rpm
ECC electric generator, 320 kW, 500 volts, 375 rpm
Crompton electric generator attached to gas engine, 150 kW, 500 volts, 590 rpm
?Mather & Platt electric generator coupled to small lighting engine, 70 kW, 250 volts, 280 rpm
Cooperage :—
1 Printing machine
3 Jointers
3 Tonguing & grooving machines (staves)
1 Crozer
1 Saw bench
2 Punching machines
1 Tonguing & grooving machine (heading)
1 Band saw
3 Splaying machines
3 Riveting machines
1 Wire rope hand winding machine
1 Wood hoop head splaying machine
4 Iron feet for handling casks
4 Magnetic bells
1 Stave dryer
2 Sets of pumps for hydraulic power to work in conjunction with magnetic bells
All the above machines in use. The following not in use :-
1 Crozer (old pattern)
1 Heading machine
11 Old-type trussing bells
3 Bells of very old pattern
Sacks :—
1 Singers sewing machine
Fitters' Plant :—
1 5'0" plate roll
1 Sawing machine
2 Centre drilling machines
1 Emery wheel
1 12" slotting machine
1 8 ft. × 2'9" planer
1 Shearing & punching machine
1 Heavy lathe 11 5/16" centre
1 Heavy lathe 10½" centre
1 Light lathe 9" centre
1 10¾" centre to take 20 ft. shafting
1 Keyseater ¼" - 1½"
Water :—
North end:
One set three-throw pumps Martin Earle, 72,000 gallons per hour capacity, motor driven
1 Single plunger pump by Hall, steam driven 30,000 gallons per hour capacity
South end:
One three-throw plunger pump by A.C. Potter & Co.
The Wouldham plant was earmarked for modernisation and expansion. The six first generation kilns were still operable, although not always working, and were replaced by kiln 10 in 1930. Addition of kiln 11 in 1937 expanded the plant to 0.5 million tons a year. The plant initially survived the start of Northfleet by concentrating on sulfate resisting manufacture, but this was transferred back to Swanscombe, and the plant closed in 1976.
Four screening mills, total screening area, 576 sq.ft., total H.P. 130 @ 25 rpm
Combined output 80 tons dry slurry per hour
4 Sun and planet mixers equal to 1700 clinker tons total capacity near kiln houses
Cement Kilns :—
Four rotary kilns, 100'0" long, burning zone 30'0" × 8'0", remainder 6'4" diameter
Two rotary kilns, 100'0" long by 6'4" diameter
Two rotary kilns, 141'0" long by F.L. Smidth, burning zone 30' × 8'0", lined 9" bricks, remainder 6'10" diameter lined 4½" bricks
Cubic capacity
4202 cu. ft.
Output
71 cwt/hr
Output per 1000 cu. ft.
16.9 cwt/hr
Surface inside lining
2727 sq. ft.
Output per 1000 sq. ft.
26.0 cwt/hr
Coal consumption as rec'd
34.2%
Coal consumption standard
28.2%
One rotary kiln, 229'8" long by F.L. Smidth, burning zone 40' × 9'10", lined 9" bricks, remainder 8'10½" diameter lined 6" and 4½" bricks
Cubic capacity
11580 cu. ft.
Output
200 cwt/hr
Output per 1000 cu. ft.
17.3 cwt/hr
Surface inside lining
5780 sq. ft.
Output per 1000 sq. ft.
34.6 cwt/hr
Coal consumption as rec'd
33.9%
Coal consumption standard
27.6%
Coal Plants :—
One Erith dryer, 5'6" × 30'0", coal fired, heated internally and externally. Output 3¾ tons per hour from 10% to 5% H2O
One FLS 3'11¼" × 39'4", heated internally and externally by hot air. Output 2¾ tons per hour from 10% to 5% H2O
One FLS 4'7" × 45'10", heated internally and externally by hot air. Output 4 tons per hour from 10% to 4% H2O
One Krupp No.8 ball mill, 7'0" × 4'0" long, lined C.S. plates. Charge 2 tons 4" steel balls. 40 H.P. @ 24 rpm. Output 3½ tons per hour to 54% on 100#
One FLS Kominor E, 5'5" × 3'3" long, lined C.S. plates. Charge 1½ tons 4" steel balls. 25 H.P. @ 23 rpm. Output 2½ tons per hour to 64% on 100#
One FLS Kominor B, 6'4" × 4'5" long, lined C.S. plates. Charge 2¼ tons 4" steel balls. 47 H.P. @ 24 rpm. Output 4 tons per hour to 54% on 100#
Two Krupp No.16 tube mills, 3'10" × 16'0" long, lined silex. Charge 2½ tons pebbles and 2 tons cylpebs. 38 H.P. @ 27 rpm. Output 1¼ tons per hour to 16% on 180#
One FLS No.16 tube mill, 4'9" × 20'0" long, lined silex. Charge 8 tons 1" balls. 72 H.P. @ 25 rpm. Output 2½ tons per hour to 14% on 180#
One FLS No.20 tube mill, 5'9" × 24'0" long, lined silex. Charge 13 tons 1" balls. 180 H.P. @ 22 rpm. Output 4 tons per hour to 9% on 180#
Over the 100 ft. kilns, ground coal hoppers 19 tons each
Over 40 metre kilns, a 17 ton hopper reserve equivalent to a run of 7 hours
Over the 70 metre kiln, one hopper reserve holding 17 tons or 6 hours run on the kiln
Cement Grinding Plant :—
Three FLS Kominor 50 7'7" × 6'7" long, lined C.S. step plates. Charge 4¼ tons 4" steel balls. 90 H.P. @ 21 rpm. Output 7 tons per hour to 51% on 76#
One FLS Kominor A 7'0" × 6'0" long, lined C.S. step plates. Charge 3½ tons 4" steel balls. 75 H.P. @ 23 rpm. Output 5¼ tons per hour to 51% on 76#
One Krupp No.8 ball mill, 7'0" × 4'0" long, lined C.S. plates. Charge 2¼ tons 4" steel balls. 68 H.P. @ 29 rpm. Output 6 tons per hour to 59% on 76#
Three FLS No.20 tube mills, 5'9" × 24'0" long lined silex. Charge 11 tons pebbles, 4 tons cylpebs. 220 H.P. @ 23 rpm. Output 7 tons per hour to 7% on 180#
One FLS No.17.5, 5'3" × 20'0" long, lined silex. Charge 7½ tons pebbles, 4 tons cylpebs. 150 H.P. @ 25 rpm. Output 5½ tons per hour to 7% on 180#
One Krupp tube mill 4'7" × 26'0" long, lined silex. Charge 12½ tons 1" steel balls. 195 H.P. @ 25 rpm. Output 6 tons per hour to 6.3% on 180#
Cement Storage & Loading :—
Flat bottom warehouse divided into 50 bins 50 ft. × 10 ft. × 27 ft.
Total maximum capacity 25,000 tons
Gas, Oil and Steam Engines, Boilers & Producers :—
1 1500 kW Fraser & Chalmers turbo generator set
1 600 kW Brush Parsons turbo generator set
Stand-by 160 psi
1 700 kW Hick Hargreaves horizontal compound with D. Kerr generator
1 500 kW Brush Co. vertical H speed
2 John Thompson & Co. water tube boilers, 25,000 lb. capacity, 200 psi
Stand-by (160 psi)
2 Suckling W.T.
1 J Thompson (aged)
4 Davey Paxman (aged)
Total capacity 40,000 lb. per hour
Cooperage :—
Capacity 4/5000 casks weekly
2 Jointing machines staves APC
2 Tongue & grooving machines staves APC
1 Tongue & grooving machine heads APC
2 Rotary head cutters APC
6 Adjustable bells APC
3 Non-adjustable bells APC
2 Punching machines APC
2 Splaying machines APC
2 Rivetting machines APC
1 Hoop repairing machine Ransom
1 Thicknessing machine Johnston
Sacks :—
Shed capable of 100,000 storage
1 Star Dust shaker
2 Singer sack mending machines
Fitters' Plant :—
1 18" centre lathe 34 ft. bed (W. Asquith)
1 10" centre lathe 14 ft. bed (no name, very old)
1 9" centre lathe 10 ft. bed (W. Asquith)
1 6" centre lathe 6'6" bed (J. Archdale)
1 12" shaper (no name)
1 12" slotting machine (Ward Haggas)
1 4'6" × 20" planing machine (no name)
1 radial drilling machine (Archdale)
1 Drilling machine (no name) very old
1 Power hammer 15 cwt (Pilkington)
1 Set Shears, 15" jaws (Butterfield)
1 Screwing machine (Maiden) old
1 Power hacksaw 6" (Peerless Co. USA)
Water :—
Purchased SE.Essex for boilers
Quarry water used for factory purposes
NOTES
Note 1. It is important to stress that about a year later, while searching through the barn that serves as my overspill document store, I stumbled across my own rat-gnawed copies of the Schedules. They were routinely accessible to all at Greenhithe library.
Note 2. In 1911, Hall & Co sold only their cement plant to BPCM; they kept the Coulsdon chalk quarry.
Note 3. Curiously, the surface area is more or less correct, but the volume is way out.