3 3 r d National Safety Council Congress A STAFF REPORT
T H E thirty-third national congress, which was also the third wartime meet ing of the National Safety Council, was held in Chicago during the first week of October. Well attended and swiftly mov ing, the convocation was dedicated to victory, and the members heard a large number of reports and suggestions that were designed to speed war manufacture through the reduction of accidents. The meeting was opened by Colonel John Stil well, president of the National Safety Council for the past five years. President Stilwell reviewed progress during the years he was in office, all of them years of war and years of great significance to the safety movement. Since he took office, said Colonel Stilwell, the National Safety Council has increased in membership some 20 per cent. The awareness of the work in the public mind has increased, so that where formerly one person was con scious of the work of the council, 100 are aware of the work today. The budget has been increased 170 per cent, and the staff has 75 per cent additional personnel. The direct results of the increased endeavors of the Safety Council, he intimated, were as follows: A 68 per cent cut in accident frequency and estimated savings of 400,000 rnandays of production among 300,000 em ployees of Army Air Service Command. A 16.9 per cent reduction in accident frequency among about 1,500,000 workers in 300 Navy and contract shipyards, and savings of 5,000,000 man-hours and $6;000,000 in production in Gulf Coast shipyards alone. A 61 per cent cut in off-duty accidents among servicemen leaving Army Sixth Service Command posts on pass or furV O L U M E
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N e d H . Dearborn, new president οί the Mational Safety Council, speaking at annual meeting
lough in month following distribution of off-the-job safety pamphlet. A 26 per cent drop in accident fre quency and 41 per cent in severity in vari ous explosives plants. Fifteen to 55 per cent reductions in ra.ilroad grade-crossing accidents in eig;ht of the nine states where special programs have been put in operation thus far. Reduction of training accidents to point where Army Air Forces are training 95 ont of 100 pilots without injury of any kind. Injury rates held constant, despite increasing employment and inexperienced workers, in several thousand plants making material for Army, under supervision of Office of Provost Marshal General. A 21 per cent reduction in home ac cident deaths in city of over a million population. Fifteen to 31 per cent reduction in farm accident work deaths in important agri cultural states. During Colonel Stilwell's term tiie council entered fields of activity that were entirely new, such as the development of comprehensive programs of safety for tlie farm and home, and the introduction of the subject of safety into programs of women's organizations. The Chemical Section of the council held three sessions during the week, lay ing emphasis heavily on round-cable dis cussions, committee- reports, and short talks on waste disposal. During the symposium on waste dis posal, Allan L. Cobb, of the Eastman Kodak Co., spoke on the disposal of ma terials which may not be safely dumped.
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iVlr, Cobb, wiio is the safety supervisor for Uhe Eastman company, said that flamirlable liquids are usually burned by being spread in pits but that other precautions m ust b e observed. Such a burning ground stiould be remote from plant buildings and axiy other structures, he said. The loca tion should be selected with the prevailing wind in mind, and liquids burned only when the winds are favorable. The loca tion of the burning ground is particularly important when the waste material gives off toxic fumes when burning. Some of tbiese materials will cause damage to crops a-md livestock, so that farms, as well as residential areas, must be considered. Explosive waste is a special problem, andnrust b e burned under the supervision of a safety engineer. Usually there are several fields, and the waste is piled in small quantities, with adequate spacing between piles. As an extra precaution, the axon should be wet down with a sprinkler truck, after a day's burning. Poodle give a lot of thought to what they e a t and drink, but pay almost no attention t o the air they breathe, H. F. Reinhard told the Chemical Section during the same w&3te disposal symposium. People will complain to the high heavens about water pollution b y our industrial plants, but breiithe polluted air with nothing more than a, passing thought, said Mr. Reinhard, "who is consulting engineer for the Linde Air Products Co., New York City. 1907
There are various ways of disposing of toxic a n d flammable gases, pointed o u t Mr. Reinhard, and if this can be done b y converting them into useful products o r b y utilizing the heat units they contain, so much t h e better. M a n y gases will react with other elements or compounds to form products of value, Mr. Reinhard said. F o r example, sulfuric acid can be produced from t h e sulfur dioxide and sulfur trioxide in t h e flue gases from smelters. If the flow of gas is continuous and fairly constant, explained Mr. Reinhard, it is advantageous to pipe it to boilers or other combustion chambers where t h e heat generated b y the burning can be utilized. I n any case, he concluded, it takes only a little research and ingenuity to make profitable use of these gases. T h e Rubber and Petroleum Sections both h a d full sessions, the former concentrating on the safety problems introduced by the new synthetics. According to Henry C. Jones, vice president of t h e Arkwright M u t u a l Fire Insurance Co., the wide use of synthetics instead of n a t u r a l rubber in the manufacture of tires, shoes, belting, and other products, has greatly increased the fire hazard in t h e rubber industry. Lacking the substances which keep t h e layers of crude rubber together, B u n a S m u s t be covered with a film of rubber cement, explained Mr. Jones. This increases the fire and explosion hazards, especially in plants where the employees are not familiar with the properties of rubber cement. E v e r y step in the process of spreading rubber cement on synthetic rubber, M r . Jones said, requires special study in order to provide the proper safeguards, with t h e ventilation of the rooms where t h e work is done being an extremely important factor. Static sparks s t a r t most of the fires at the spreaders, he continued, and while it
is impossible to prevent the generation of static electricity a t rubber spreaders, it can b e neutralized or conducted t o the ground harmlessly. Accident control in the processing of synthetic compound is almost the same as the controls necessary in t h e use of natural compound,said Glen D. Cross,safety director of t h e Firestone Tire and Rubber Co., in his paper analyzing the accidents occurring in this field. T h e rubber mill is still one of t h e most dangerous pieces of equipment in t h e processing division and Mr. Cross spent much of his paper developing t h e technique of prevention for this machine. Various new safety devices, said Mr. Cross, such as an emergency-stop actuating mechanism that extends farther do\vn along the side of t h e mill roll, are being tried t o determine their usefulness as a means of increasing the safety of mill operations. " A great many of the most serious accidents on rubber mills occur to employees who a r e n ' t authorized to operate mills or who a r e new employees in so far as the operation of mills is concerned", continued the speaker. Such accidents as t h e following illustrate these points: 1. A mill operator with only three weeks' experience was operating a 22 X 60-inch batch-off mill. Shortly before this m a n completed his shift he was stripping t h e last sheet of stock from t h e mill to t h e strainer conveyor. Only a small a m o u n t of stock remained on the mill. In fact, it was too small to strip to the conveyor and had to be cut from t h e roll. While the employee stated t h a t h e had made a horizontal cut preparatory to pulling t h e stock off the roll, it is t h e opinion of those who investigated t h e accident t h a t he did not t a k e a cut but tried to pull the stock off. I n attempting to pull t h e stock off, his right hand became caught in it, and, although the mill was equipped with dynamic braking, t h e employee did not have presence of mind to trip t h e safety until his finger tips entered t h e bite.
This latter point clearly demonstrates how i m p o r t a n t it is to have mill operators frequently t r i p their safeties. Some firms have their operators use the safeties constantly to s t o p mills t h a t are individually driven. 2. A janitor, working around a wash mill, decided t o take a piece of soap from his pocket a n d wash his hands in the w r ater spray from t h e wash mill. The janitor dropped the soap in t h e bite, and in attempting to recover it, caught his finger in the mill. These two accidents emphasize the necessity t»f training new mill operators thoroughly a n d of making certain that only authorized emploj'ees are exposed to t h e hazards of mill operations. All mill m e n should familiarize themselves with safe practices a n d follow such practices constantly. Some of the more important a r e as follows: 1. N o one shall operate a rubber mill until he is properly trained in its safe operation. 2. Test t h e safety stop on the mill at the s t a r t of each shift or at a n y other time, before placing t h e machine in operation. 3. Before starting the mill, be sure that everyone is o u t of danger. 4. If shirt sleeves are long, they should fit snugly. Loose aprons, coat jackets, or long neckties must n o t be wrorn. Gloves should not b e worn except when t h e stocks run hot and no torn gloves should be worn at any time. Gloves should be of the type t h a t do not fit tightly a t the wrists. 5. D o n o t cut rubber on the top of the rolls. Always keep t h e knife down and away from t h e bite. 6. Never stand in the mill pan. When loading mill, always put rubber in with one hand a n d hold on to t h e apron or safety bar w i t h t h e other. 7. If when c u t t i n g y o u don't catch the cut, let i t go ; never try to reach for it. 8. W h e n batching off, hold the end of the slab until it is c u t off. D o not throw it back over t h e a r m o r shoulder. 9. If a t o o l (knife or shovel) slips from your hand a n d goes into t h e mill, do not t r y to catch it; let it go, and pull the safety.
Left to right. Colonel John Stilwell, Rear Admiral E. C. White, Leslie J. Sorenson, Major General James L. Collins, Walter S. Paine, Major General Johnathan W . Anderson, H. T. Heald, and Major General Archer L. Lerch 1908
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10. Do n o t work on t h e back roll, un less it is absolutely necessary, then be care ful, and always lower the apron. 11. Learn t h e location and use of emergency e q u i p m e n t t h a t is provided t o release an employee from t h e rolls of a mill : (.a) Screw the rolls of the mill apart. (b) If that is not possible, take the emer gency wedges and by using the emergency sledge force t h e rolls apart. (c) Do not- reverse the mill. The Petroleum Section heard from H . Emerson T h o m a s t h a t accidents are all too common in t h e handling of petroleum products, p a r t i c u l a r l y hydrocarbons like b u t a n e and propane. Mr. T h o m a s , who is a petroleum consultant of Westfield, NT. J., said t h a t i n some areas t h e shortage of butane hias caused producers a n d dis tributors to "spike" the available b u t a n e with some p r o p a n e . This results in an in creased -vapor pressure, which could cause t h e relief valve t o give way, with resulting ignition of t h e discharged gases. T h e r e a r e three m a i n causes for ac cidents in the industry, according to Tiiomas: (1) The operating personnel needs t o h a v e bettex training and to understand b e t t e r the dangers a n d characteristics of these gases. (2) The installations are not always triade according to t h e National Board of Fire Underwriters Standards. (3) The installations are not always engineered properly to correlate all dif ferent equipment so t h a t safety equipment will perform, its function. The Liquefied Petroleum Gas Associa tion Safety Committee is working in tensively t o m a k e the industry more safety conscious, announced T h o m a s . Real strides are being made through regional
Colonel John Stilwell speaking at the annual meeting oi the National Safety Council. President Dearborn at left.
committees, district committees, and com p a n y committees. T h e failure of a single fitting in a n oil weld can "open up t h e pipe line to H a d e s " , T h o m a s S. Bacon, research engineer for
t h e Lone Star Gas Co., Dallas, warned the Petroleum Section. " G a s pressures as high as 8,000 pounds per square inch are k n o w n to exist in some CONTINUED ON PAGE 1 9 4 8
Ρ "I,-*c&.'« M a j . G e n . Archer L. Lerch speaking at banquet. V O L U M E
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Rear A d m i r a l E. C. W h i t e , Leslie J. Sorenson, and M a j . G e n . James L. Collins. 10,
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Safety Council Conference (CONTINUED FROM PAGE 1909) reservoirs," pointed out Mr. Bacon, " a n d t e m p e r a t u r e s far above the boiling point of water a r e common. T h e deep oil or gas well is a direct pipe line to H a d e s , so it is necessary t o rely on the mechanical equipment to keep Hades in its proper place." T h e internal surfaces of the pipe and fittings m u s t b e examined for corrosion a t regular and frequent intervals, said Mr. Bacon. " E v e r y available fitting m u s t be inspected individually, as some fittings are relatively more free of corrosion than o t h e r s " , he said. Research is now being carried on, ex plained Mr. Bacon, to find o u t w h a t cor rosion-resisting alloys can be used . for these fittings. T h e r e are m a n y possible alloys, b u t m o s t of t h e m seriously increase the cost of e q u i p m e n t . Other possibilities are t h e chemical t r e a t m e n t of the produced fluids, or t h e use of protective films on the production equipment, said Bacon. L'ntil the problem is solved, careful examination of all high-pressure wells should be m a d e a t frequent intervals, he said. F r a n k l i n L. N e w c o m b , senior specialist for t h e S t a n d a r d Oil Development Co., authored a p a p e r on " T h e Effect of W a r time S t a n d a r d s of Construction in Oil Refineries". M r . Newcomb's thesis w a s developed from the fact t h a t when t h e supply of materials first began to be criti cal, various governmental agencies r e quested t h e cooperation of i n d u s t r y in their conservation. A t t h e same t i m e , these agencies stressed the necessity for continuity of operation and safety of b o t h e q u i p m e n t a n d personnel. I t was realized t h a t accidents to equipment would r e s u l t in less production t h a n planned or m o r e equipment would h a v e to b e constructed to assure t h e required production. T h e latter alternative would h a v e resulted in the use of m o r e critical material t h a n would be required to construct a lesser a m o u n t of safe e q u i p m e n t . T h e petroleum industry, said he, gen erally designed equipment for a life of 10 or more years. Also, design was based on balancing repairs with a high n o r m a l service factor t o obtain the m o s t economi cal u n i t . I t w a s felt t h a t e q u i p m e n t b e ing constructed during t h e war emer gency m i g h t b e designed for a m u c h shorter life a n d t h e probability of m o r e repair, with a v e r y large saving in critical materials. O n M a r c h 3 1 , 1942 t h e W a r Production B o a r d held a conference i n Cleveland, Ohio, t o consider a probable order limiting t h e use of nickel a n d chro mium. A t t h i s meeting t h e p e t r o l e u m i n d u s t r y s u b m i t t e d twTo r e c o m m e n d a tions:
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Where nickel and chromium are used t o extend t h e life of a plant, t h e basis of design of new plants should be an estimated three-year life with out t h e necessity for major repairs t h a t m i g h t reduce t h e normal serv ice factor more t h a n 2 per cent, a n d T h e principle of t h e previous recom mendation should apply t o all planned alterations a n d m a i n t e nance of existing plants, wherever practical.
Later, as other items became critical, the design basis of a three-year life writh a slightly reduced normal service factor was t a k e n as t h e s t a n d a r d for a n y critical time. T h e application of t h e above principles resulted in a n u m b e r r of major changes in design s t a n d a r d s as w ell as numerous small changes . . . which affected t h e safety of equipment. I n some cases a reduction in corrosion allowance, w i t h o u t change in material, was employed t o secure a shorter estimated life. In such case, t h e corrosion r a t e was a known factor I n other cases less corrosion-resistant materials were employed to obtain a shorter estimated life. I n m a n y cases such material had previously been used and replaced by a more corrosion-resistant material to obtain longer life. I n such case, t h e corrosion r a t e would be known and the proper inspection interval could be readily determined. . . . Where pressure vessels were subject t o severe corrosion, linings of canister, r e inforced concrete, or acidproof brick were substituted for alloy linings. Linings made of such material h a v e a shorter life t h a n alloy linings a n d generally require more frequent repair. On the other h a n d , when they are properly maintained, t h e y afford a d e q u a t e protection against cor rosion. E q u i p m e n t protected against cor rosion with these lining materials should be just as safe as equipment protected with alloy lining if time is allowed t o m a k e a n y necessary repairs. Simplification of equipment involved a much wider range of changes t h a n was afforded by designing for a shorter life T o clean economically, inspect, a n d repair equipment a n d t o provide ease of operation, i t was customary t o install a considerable n u m b e r of platforms, w i t h access b y stairways, around operating equipment. Only a few of these p l a t forms were required for easy access t o equipment by operators. B y locating operating valves a t lower levels or pro viding remote operating devices, some of the operating platforms could be elimi nated. Those platforms which were used only for maintenance could frequently be spaced further a p a r t b y using low wooded scaffolds on t h e m . Also they could fre quently b e reduced in width w i t h o u t seriously impeding t h e necessary main tenance work. Stairs for access t o plat forms used frequently b y operators a p peared essential, b u t t h e use of ladders for access t o t h e remainder of t h e platforms seemed feasible. While such changes d e layed m a i n t e n a n c e work to some extent and increased costs, t h e y h a v e n o t af fected t h e safety of operation a n d h a v e
CHEMICAL
probably only very slightly affected the safety of maintenance personnel. Exchangers, coolers, reflux and distillate drums, a.nd similar equipment were installed . . . « . at much, lower eleva tions, much of it a t ground level w h e r e no supporting steel is χ-equired. R a t h e r t h a n increasing the hazard, this was a real safety measure. It permutted cleaning a n d re pairing of this equipment at ground level. . . eliminating the? hazard of working at high elevations In prewar prac-fcicc large numbers of manholes were instiallcd in b u b b l e towers t o facilitate inspecrtion, cleaning, and re pairs. . . . Many o f these manholes were eliminated. RcnoLovable sections were provided in the b e l l cap plates t o permit access to all p a r t s of t h e t o w e r s . This practice may h a v e increased t h e possi bility of gas being present i n some parts of the tower w i t h o u t having been detected before entry of personnel. However, if proper gas-freeing: procedure is carried out, t h e r e should "be little d a n g e r of any gas remaining. .. . To avoid shutdowns and permit con tinuity of opérations, equipment . . . was frequently duplicated in p r e w a r construction. . . . Pimping with m a n y valves was required to isolate a n d by-pass individual pieces. . - . Much of thus spare equipment was deleted in w a r t i m e construction. . . . New equipment is usually designed on the basis of handling a certain g r a d e of charging stock a j i d producing certain definite products. Prior to t h e w a r , however, consideration, used to b e given to the fact t h a t different charging stocks could be handled from t h a t c o n t e m p l a t e d . . . . I n wartime construction t h e extra piping required for this flexibility w a s eliminated. . * . Safety or relief valves were o n e of the prime bottlenecks. T h e manufacturers had m a d e these i n a wide r a n g e of sizes and styles. I t WSLS felt t h a t if industry and t h e manufacturers could agree on fewer sizes and ferwer s t y l e s , it would be possible t o manufacture these valves on a production line ra^ther t h a n as individual· units. . . . I t i v a s agreed t h a t n o great hardship would b « imposed upon the ind u s t r y b y greatlv reducing t h e line of valves formerly m a n u f a c t u r e d . . . . When the exebuanger industry became overloaded a similar committee was formed t o standardize o n exchangers. . . . I n concluding h i s address, Mr. N"ewcomb said: A number of miscellaneous changes in s t a n d a r d s of design have been adopted which do not fall i m any of t h e above three categories. They involve such things a s •substitution of wooden buildings for.steel in nonhazardous locations; t h e use of wooden doors, windows, roofs, flooring on platforms, etc.; a l l of which probably somewhat increased t h e fire h a z a r d or a t least t h e intensity of the fire if o n e s t a r t e d . On t h e other hand, the u s e of wood w a s p r e t t y generally confined to» places where fires were not likely t o s t a r t and a p p a r e n t l y to d a t e has not been responsible for a n y great material loss. Bessemer steel was substituted for open—hearth steel in locations Avherejthe higher grade d i d n o t appear essential. T h e nationual emergency steels were substituted for higher alloys for bolting material; cast iron valves were used more extensively in noxihazardous services t h a n previously; mass- concrete w a s used i n t h e place of reinforced concrete; a n d , in general, things formerly employed m a i n l y for appearances werei eliminated. M a n y misCONTINIXED ON" PAGE 1 9 7 1
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Seminars on High Polymers T h e P o l y t e c h n i c I n s t i t u t e of B r o o k l y n a n n o u n c e s a series of 15 s e m i n a r s o n t h e p h y s i c s a n d c h e m i s t r y of h i g h p o l y m e r s , t o be h e l d a t t h e i n s t i t u t e o n a l t e r n a t e S a t u r d a y s f r o m 1 1 : 0 0 A . M . t o 1:00 P . M . , u n d e r t h e c h a i r m a n s h i p of A r t h u r V . T o b o l s k y . I n i t s c o u r s e s b e g u n O c t . 2, t h i s is t h e first
Safety Council
i n s t i t u t i o n to offer a unified p r o g r a m at t h e g r a d u a t e level h a v i n g t o d o witla. all p h a s e s of p o l y m e r c h e m i s t r y . Under "the leader s h i p of H e r m a n F . M a r i e , 10 c o o r d i n a t e d e v e n i n g courses i n t h e formation a n d p r o p e r t i e s of high p o l y m e r s a r e p r e s e n t e d , l e a d i n g to the Ph.D. degree.
Program of Seminars SPEAKER
DATE
19U Oct. 14 Oct. 28 Nov. 11 Nov. 25 Dec. 9 19 45 Jan. 6 Feb. 3 Feb. 17 March 3 March 17 March 31 April 14 April 28 M a y 12 M a y 26
SUBJECT
H e r m a n M a r k , Polytechnic I n s t i t u t e of Formation, Structure, a n d Properties of High Brooklyn Polymers A r t h u r V. Tobolsky, Princeton Univer Growth, Branching, Crosslinking, a n d Depolysity merization of Vinyl and Diene Derivatives Hugh S. Taylor, Princeton University Mechanism of Polymerization P e t e r Debye, Cornell University Determination of Molecular Weights a n d Shapes of Macromolecules I. Fankuchen, Polytechnic I n s t i t u t e of X - R a y s in High Polymer Research Brooklyn A r t h u r V. Tobolsky, Princeton Univer Molecular Size Distribution of Linear and Crosssity Linked High Polymers W . E. Roseveare, E . I. du P o n t de N e Structural Principles and Properties of N a t u r a l mours & Co. and Synthetic Fibers H e n r y Eyring, Princeton University Flow Properties of Liquids and Solutions A r t h u r V. Tobolsky, Princeton Univer Physical Properties of Rubberlike S y s t e m s sity W . P. Hohenstein, Polytechnic Institute Organic Chemical Aspects of Higli Polymer of Brooklyn Structure Maurice L. Huggins, E a s t m a n Kodak Thermodynamics of High Polymer Structure Co. P a u l M . D o t y , Polytechnic Institute of Diffusion and Sorption of Small MToleculcs i n Brooklyn High Polymers R a y m o n d M . Fuoss, General Electric Electrical Properties of High Polymers Co. T u r n e r Alfrey, Monsanto Chemical Co. Visco-Elastic Behavior and Structixxc of High Polymers P a u l J . Flory, Goodyear Research Labo Swelling and Solubility of High Polymers ratories "Walter A. Stockmayer, Massachusetts General Review of the Statistical Tr-eatnaeat of Institute of Technology High Polymer Problems
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1948)
cellaneous smaller items were also affected by wartime conditions. Since consider able care was used in making such sub stitutions and since throughout t h e econ o m y program maintenance of a high stand ard of safety was stressed, it is unlikely that anything greatly reducing safety w a s done. The above covers the principles upon which the conservation program was based and an analysis of the principal items com prising this conservation program which has come to be known as the wartime standards of construction. Emphasis waa placed on the necessity for maintaining safe standards of construction t o assure continuity of operation. T h e analyses of the principal items comprising the pro gram do not indicate that a high standard of safety was sacrificed. M a n y of t h e items impose greatly increased costs on the industry. Some of the items require changes in procedures formerly used. M a n y of the changes involve more care on the part of the operator. This probably increases the possibility of human error. On the other hand, the essential features for safety are present. Probably the fair est conclusion is that the equipment is not quite as "foolproof" under wartime stand ards of construction as when it was built t o prewar standards. The Drug, Chemical, and Allied Tradee Section of the New York Board of Trade has announced the highest peak of aotivity in its history. Membership now stands at an all-time high of 500 American firms.
Wabash V a l l e y Section (CONTINUED FROM PAGE
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ALPHABETICAL LIST OF ADVERTISERS
sin, she taught in the high schools of Waynesville and Bloomington, 111., a t 1960 Ampco Metal, Inc Columbia, and at Cedar Crest College, 1940 American Instrument Co where she was head of the chemistry de American Potash & Chemical C o r p . 1938 partment from 1928 t o 1942. For more !932 Anachemia, Ltd than a decade she has been prominent Ansul Chemical Co *ggjj in ACS activities. She is now in the Armour & Co 18S8technical service division of the Com 1893 Atlas Powder Co mercial Solvents Corp. „ Dr. E g l y , Treasurer, has been a chem Baker Chemical Co., J. Γ 0 r j ^ ical engineer in the research department Bareco Oil Co of Commercial Solvents Co., Terre Haute, Becco Sales Corp 1958 since 1940. He was graduated from Pur Buffalo Electro-Chemical Co., Inc.. 1958 due University in 1936 with the degree Central Scientific Co of bachelor of science in chemical engineer 1930 . 1951 ing. In 1940 he received the P h . D . de | Charlotte Chemical Labs., Inc Corning Glass Works gree from the U n i v e r s ^ of Illinois. 1925 H. C. Wiediman spoke at the first meet D o w Chemical Co .0. .B.C. ing on "What Chemists and Chemical D u Pont de Nemours
