Seasoning of Wood Part 18

The operation of the kiln is simple. The heated air rises above the pipes HH and between the piles of lumber. As it comes in contact with the piles, portions of it are cooled and pa.s.s downward and outward through the layers of boards into the s.p.a.ce between the condensers GG.

Here the column of cooled air descends into the spray flue B, where its velocity is increased by the force of the water spray. It then pa.s.ses out from the baffle plates to the heaters and repeats the cycle.

One of the greatest advantages of this natural circulation method is that the colder the lumber when placed in the kiln the greater is the movement produced, under the very conditions which call for the greatest circulation--just the opposite of the direct-circulation method. This is a feature of the greatest importance in winter, when the lumber is put into the kiln in a frozen condition. One truckload of lumber at 60 per cent moisture may easily contain over 7,000 pounds of ice.

In the matter of circulation the kiln is, in fact, seldom regulatory--the colder the lumber the greater the circulation produced, with the effect increased toward the cooler and wetter portions of the pile.

Preliminary steaming may be used in connection with this kiln, but experiments indicate that ordinarily it is not desirable, since the high humidity which can be secured gives as good results, and being at as low a temperature as desired, much better results in the case of certain difficult woods like oak, eucalyptus, etc., are obtained.

This kiln has another advantage in that its operation is entirely independent of outdoor atmospheric conditions, except that barometric pressure will effect it slightly.

KILN-DRYING

Remarks

Drying is an essential part of the preparation of wood for manufacture. For a long time the only drying process used or known was air-drying, or the exposure of wood to the gradual drying influences of the open air, and is what has now been termed "preliminary seasoning." This method is without doubt the most successful and effective seasoning, because nature performs certain functions in air-drying that cannot be duplicated by artificial means. Because of this, hardwoods, as a rule, cannot be successfully kiln-dried green or direct from the saw.

Within recent years, considerable interest is awakening among wood users in the operation of kiln-drying. The losses occasioned in air-drying and in improper kiln-drying, and the necessity for getting material dry as quickly as possible from the saw, for shipping purposes and also for manufacturing, are bringing about a realization of the importance of a technical knowledge of the subject.

The losses which occur in air-drying wood, through checking, warping, staining, and rotting, are often greater than one would suppose. While correct statistics of this nature are difficult to obtain, some idea may be had of the amount of degrading of the better cla.s.s of lumber.

In the case of one species of soft wood, Western larch, it is commonly admitted that the best grades fall off sixty to seventy per cent in air-drying, and it is probable that the same is true in the case of Southern swamp oaks. In Western yellow pine, the loss is great, and in the Southern red gum, it is probably as much as thirty per cent. It may be said that in all species there is some loss in air-drying, but in some easily dried species such as spruce, hemlock, maple, etc., it is not so great.

It would hardly be correct to state at the present time that this loss could be entirely prevented by proper methods of kiln-drying the green lumber, but it is safe to say that it can be greatly reduced.

It is well where stock is kiln-dried direct from the saw or knife, after having first been steamed or boiled--as in the case of veneers, etc.,--to get them into the kiln while they are still warm, as they are then in good condition for kiln-drying, as the fibres of the wood are soft and the pores well opened, which will allow of forcing the evaporation of moisture without much damage being done to the material.

With softwoods it is a common practice to kiln-dry direct from the saw. This procedure, however, is ill adapted for the hardwoods, in which it would produce such warping and checking as would greatly reduce the value of the product. Therefore, hardwoods, as a rule, are more or less thoroughly air-dried before being placed in the dry kiln, where the residue of moisture may be reduced to within three or four per cent, which is much lower than is possible by air-drying only.

It is probable that for the sake of economy, air-drying will be eliminated in the drying processes of the future without loss to the quality of the product, but as yet no method has been discovered whereby this may be accomplished.

The dry kiln has been, and probably still is, one of the most troublesome factors arising from the development of the timber industry. In the earlier days, before power machinery for the working-up of timber products came into general use, dry kilns were unheard-of, air-drying or seasoning was then relied upon solely to furnish the craftsman with dry stock from which to manufacture his product. Even after machinery had made rapid and startling strides on its way to perfection, the dry kiln remained practically an unknown quant.i.ty, but gradually, as the industry developed and demand for dry material increased, the necessity for some more rapid and positive method of seasoning became apparent, and the subject of artificial drying began to receive the serious attention of the more progressive and energetic members of the craft.

Kiln-drying which is an artificial method, originated in the effort to improve or shorten the process, by subjecting the wood to a high temperature or to a draught of heated air in a confined s.p.a.ce or kiln.

In so doing, time is saved and a certain degree of control over the drying operation is secured.

The first efforts in the way of artificial drying were confined to aiding or hastening nature in the seasoning process by exposing the material to the direct heat from fires built in pits, over which the lumber was piled in a way to expose it to the heat rays of the fires below. This, of course, was a primitive, hazardous, and very unsatisfactory method, to say the least, but it marked the first step in the evolution of the present-day dry kiln, and in that particular only is it deserving of mention.

Underlying Principles

In addition to marking the first step in artificial drying, it ill.u.s.trated also, in the simplest manner possible, the three underlying principles governing all drying problems: (1) The application of heat to evaporate or volatilize the water contained in the material; (2) with sufficient air in circulation to carry away in suspension the vapor thus liberated; and (3) with a certain amount of humidity present to prevent the surface from drying too rapidly while the heat is allowed to penetrate to the interior. The last performs two distinct functions: (a) It makes the wood more permeable to the pa.s.sage of the moisture from the interior of the wood to the surface, and (b) it supplies the latent heat necessary to evaporate the moisture after it reaches the surface. The air circulation is important in removing the moisture after it has been evaporated by the heat, and ventilation also serves the purpose of bringing the heat in contact with the wood. If, however, plain, dry heat is applied to the wood, the surface will become entirely dry before the interior moisture is even heated, let alone removed. This condition causes "case-hardening" or "hollow-horning." So it is very essential that sufficient humidity be maintained to prevent the surface from drying too rapidly, while the heat is allowed to penetrate to the interior.

This humidity or moisture is originated by the evaporation from the drying wood, or by the admission of steam into the dry kiln by the use of steam spray pipes, and is absolutely necessary in the process of hastening the drying of wood. With green lumber it keeps the sap near the surface of the piece in a condition that allows the escape of the moisture from its interior; or, in other words, it prevents the outside from drying first, which would close the pores and cause case-hardening.

The great amount of latent heat necessary to evaporate the water after it has reached the surface is shown by the fact that the evaporation of only one pound of water will extract approximately 66 degrees from 1,000 cubic feet of air, allowing the air to drop in temperature from 154 to 84 degrees Fahrenheit. In addition to this amount of heat, the wood and the water must also be raised to the temperature at which the drying is to be accomplished.

It matters not what type of dry kiln is used, source or application of heating medium, these underlying principles remain the same, and must be the first things considered in the design or selection of the equipment necessary for producing the three essentials of drying: Heat, humidity, and circulation.

Although these principles const.i.tute the basis of all drying problems and must, therefore, be continually carried in mind in the consideration of them, it is equally necessary to have a comprehensive understanding of the characteristics of the materials to be dried, and its action during the drying process. All failures in the past, in the drying of timber products, can be directly attributed to either the kiln designer's neglect of these things, or his failure to carry them fully in mind in the consideration of his problems.

Wood has characteristics very much different from those of other materials, and what little knowledge we have of it and its properties has been taken from the acc.u.mulated records of experience. The reason for this imperfect knowledge lies in the fact that wood is not a h.o.m.ogeneous material like the metals, but a complicated structure, and so variable that one stick will behave in a manner widely different from that of another, although it may have been cut from the same tree.

The great variety of woods often makes the mere distinction of the kind or species of the tree most difficult. It is not uncommon to find men of long experience disagree as to the kind of tree a certain piece of lumber was cut from, and, in some cases, there is even a wide difference in the appearance and evidently the structure of timber cut from the same tree.

Objects of Kiln-drying

The objects of kiln-drying wood may be placed under three main headings: (1) To reduce shipping expenses; (2) to reduce the quant.i.ty necessary to maintain in stock; and (3) to reduce losses in air-drying and to properly prepare the wood for subsequent use. Item number 2 naturally follows as a consequence of either 1 or 3. The reduction in weight on account of shipping expenses is of greatest significance with the Northwestern lumbermen in the case of Douglas fir, redwood, Western red cedar, sugar pine, bull pine, and other softwoods.

Very rapid methods of rough drying are possible with some of these species, and are in use. High temperatures are used, and the water is sometimes boiled off from the wood by heating above 212 degrees Fahrenheit. These high-temperature methods will not apply to the majority of hardwoods, however, nor to many of the softwoods.

It must first of all be recognized that the drying of lumber is a totally different operation from the drying of a fabric or of thin material. In the latter, it is largely a matter of evaporated moisture, but wood is not only hygroscopic and attracts moisture from the air, but its physical behavior is very complex and renders the extraction of moisture a very complicated process.

An idea of its complexity may be had by mentioning some of the conditions which must be contended with. Shrinkage is, perhaps, the most important. This is unequal in different directions, being twice as great tangentially as radially and fifty times as great radially as longitudinally. Moreover, shrinkage is often unequal in different portions of the same piece. The slowness of the transfusion of moisture through the wood is an important factor. This varies with different woods and greatly in different directions. Wood becomes soft and plastic when hot and moist, and will yield more or less to internal stresses. As some species are practically impervious to air when wet, this plasticity of the cell walls causes them to collapse as the water pa.s.ses outward from the cell cavities. This difficulty has given much trouble in the case of Western red cedar, and also to some extent in redwood. The unequal shrinkage causes internal stresses in the wood as it dries, which results in warping, checking, case-hardening, and honeycombing. Case-hardening is one of the most common defects in improperly dried lumber. It is clearly shown by the cupping of the two halves when a case-hardened board is resawed.

Chemical changes also occur in the wood in drying, especially so at higher temperatures, rendering it less hygroscopic, but more brittle.

If dried too much or at too high a temperature, the strength and toughness is seriously reduced.

Conditions of Success

Commercial success in drying therefore requires that the substance be exposed to the air in the most efficient manner; that the temperature of the air be as high as the substance will stand without injury, and that the air change or movement be as rapid as is consistent with economical installation and operation. Conditions of success therefore require the observance of the following points, which embody the basic principles of the process: (1) The timber should be heated through before drying begins. (2) The air should be very humid at the beginning of the drying process, and be made drier only gradually. (3) The temperature of the lumber must be maintained uniformly throughout the entire pile. (4) Control of the drying process at any given temperature must be secured by controlling the relative humidity, not by decreasing the circulation. (5) In general, high temperatures permit more rapid drying than do lower temperatures. The higher the temperature of the lumber, the more efficient is the kiln. It is believed that temperatures as high as the boiling point are not injurious to most woods, providing all other fundamentally important features are taken care of. Some species, however, are not able to stand as high temperatures as others, and (6) the degree of dryness attained, where strength is the prime requisite, should not exceed that at which the wood is to be used.

Different Treatment according to Kind

The rapidity with which water may be evaporated, that is, the rate of drying, depends on the size and shape of the piece and on the structure of the wood. Thin stock can be dried much faster than thick, under the same conditions of temperature, circulation, and humidity.

Pine can be dried, as a general thing, in about one third of the time that would be required for oak of the same thickness, although the former contains the more water of the two. Quarter-sawn oak usually requires half again as long as plain oak. Mahogany requires about the same time as plain oak; ash dries in a little less time, and maple, according to the purpose for which it is intended, may be dried in one fifth the time needed for oak, or may require a slightly longer treatment. For birch, the time required is from one half to two thirds, and for poplar and ba.s.swood, from, one fifth to one third that required for oak.

All kinds and thicknesses of lumber cannot be dried at the same time in the same kiln. It is manifest that green and air-dried lumber, dense and porous lumber, all require different treatment. For instance, Southern yellow pine when cut green from the log will stand a very high temperature, say 200 degrees Fahrenheit, and in fact this high temperature is necessary together with a rapid circulation of air in order to neutralize the acidity of the pitch which causes the wood to blue and discolor. This lumber requires to be heated up immediately and to be kept hot throughout the length of the kiln. Hence the kiln must not be of such length as to allow of the air being too much cooled before escaping.

Temperature depends

While it is true that a higher temperature can be carried in the kiln for drying pine and similar woods, this does not altogether account for the great difference in drying time, as experience has taught us that even when both woods are dried in the same kiln, under the same conditions, pine will still dry much faster, proving thereby that the structure of the wood itself affects drying.

The aim of all kiln designers should be to dry in the shortest possible time, without injury to the material. Experience has demonstrated that high temperatures are very effective in evaporating water, regardless of the degree of humidity, but great care must be exercised in using extreme temperatures that the material to be dried is not damaged by checking, case-hardening, or hollow-horning.

The temperature used should depend upon the species and condition of the material when entering the kiln. In general, it is advantageous to have as high a temperature as possible, both for economy of operation and speed of drying, but the physical properties of the wood will govern this.

Many species cannot be dried satisfactorily at high temperatures on account of their peculiar behavior. This is particularly so with green lumber.

Air-dried wood will stand a relatively higher temperature, as a rule, than wet or green wood. In drying green wood direct from the saw, it is usually best to start with a comparatively low temperature, and not raise the temperature until the wood is nearly dry. For example, green maple containing about 60 per cent of its dry weight in water should be started at about 120 degrees Fahrenheit and when it reaches a dryness of 25 per cent, the temperature may be raised gradually up to 190 degrees.

It is exceedingly important that the material be practically at the same temperature throughout if perfect drying is to be secured. It should be the same temperature in the center of a pile or car as on the outside, and the same in the center of each individual piece of wood as on its surface. This is the effect obtained by natural air-drying. The outside atmosphere and breezes (natural air circulation) are so ample that the heat extracted for drying does not appreciably change the temperature.

When once the wood has been raised to a high temperature through and through and especially when the surface has been rendered most permeable to moisture, drying may proceed as rapidly as it can be forced by artificial circulation, provided the heat lost from the wood through vaporization is constantly replaced by the heat of the kiln.

It is evident that to secure an even temperature, a free circulation of air must be brought in contact with the wood. It is also evident that in addition to heat and a circulation of air, the air must be charged with a certain amount of moisture to prevent surface drying or case-hardening.