At the intersection of State Route 582, Gilbert and Luckey
Roads just north of Luckey, Ohio sits a broken and forlorn reminder of a bygone
age: the wartime factory that once housed the Magnesium Reduction Company. Built
on a crash basis in the early days of World War II due to a national shortage
of magnesium, the plant has not been used in more than 15 years, and the Army
Corps of Engineers is actively engaged in cleaning up the plant site with plans
to tear down the factory within the next few years. It is a sad ending for a
structure that once formed an important part in the Arsenal of Democracy which
gained the victory in World War II.
Magnesium Reduction Co. plant at Luckey, Ohio (Luckey Historical Society) |
At the
outset of World War II, the United States found itself desperately short of
magnesium and the Axis powers controlled 60% of the world’s total output.
Pre-war production of this metal occurred only at the Dow Chemical Company’s
plant in Midland, Michigan which could produce about 18 million pounds per year.
Forecasted demand for magnesium, bolstered by President Roosevelt’s directive
to ramp up U.S. aircraft output to 50,000 planes per year, far outstripped
Dow’s capacity. “The War Production Board recommended that magnesium production
be extended more than 90 times that of 1939, to approximately 610 million lbs,”
a government report stated in 1942. Production totals in 1941, buttressed by
the opening of two more plants, supplied only roughly 5% of that forecasted
demand. “Events in 1941 forecast that an unprecedented quantity of magnesium
would be required for military purposes for the production of aircraft and
incendiary bombs. Demand for the metal was much greater than the supply and to
meet military requirements, mandatory priorities were invoked on magnesium on
March 3, 1941.” This action placed all sale and distribution of magnesium
firmly under Federal government control.
The dilapidated plant shown in a photo from April 2019. The exposed south wing of the plant once housed 20 furnaces in which magnesium was "reduced" from ferrosilicon and calcined dolomite. |
The Federal government,
through the War Production Board, embarked on a rapid industry expansion to
cover the magnesium shortfall. The expansion occurred in two phases; the first
phase in 1941 called for the construction of eight new plants, but by February
1942 projected magnesium needs rose to 725 million pounds and drove a second
wave of expansion totaling seven more plants: the Luckey plant was part of this
second expansion. The new facility, with a designed capacity of 10 million
pounds per year, required 120 million pounds of dolomite per year and this fact
played a major role in determining where the plant was built. A national search
conducted to identify plant sites sufficiently close to both raw materials and
railroads identified northwest Ohio, noted for its abundant limestone industry
and extensive railroad network, as a natural choice. “In this district there
are large deposits of dolomite and of suitable quality. Natural gas and electric power are available.
In the vicinity of the site there are several lime plants from which calcined
dolomite can be obtained and it was decided to purchase the calcine instead of
installing facilities to produce it,” wrote National Lead Co. engineer Andrew
Mayer in 1944. The National Gypsum Co. quarry located on Gilbert Road directly
across the street from the plant supplied the calcined dolomite which was then
delivered in 12-ton batches via dump truck while the ferrosilicon was brought
in on railcars. The New York Central Railroad, specifically its Toledo &
Ohio Central branch line, handled all rail traffic to and from the plant. With
the New York Central’s Stanley Yard located only a few miles north, expedited
delivery of the vital metal to war industries was considerably enhanced.
With the Luckey site
identified, the Defense Plant Corporation (a Federal entity) entered into an
agreement with National Lead Company in May 1942 in which the DPC would build
and own the $5 million magnesium plant, while National Lead (which formed a new
subsidiary called the Magnesium Reduction Company) would operate the facility.
The DPC purchased the land from Melissa A. Laymen on June 1, 1942 and
construction quickly commenced. United Engineering & Development Co. of
Philadelphia undertook the construction job under the guidance of architects
Singmaster and Breyer of New York and completed their work by December. The plant
featured two parallel wings: the northern wing housed the briquetting operation
while the reduction furnaces were set along the southern wing. Shortages of
construction materials and workers slowed construction progress. “All primary
facilities under construction experienced delays in obtaining structural steel,
electrical equipment, and the complicated components necessary for the
completion of the plants,” reported the chairman of the U.S. War Production
Board in 1945. Andrew Mayer reported that “steel was conserved as much as
practicable in construction on account of emergency conditions.” A shortage of
workers, a common problem for U.S. industry in World War II, played a role in
the delayed startup. “The work is progressing so rapidly that already
applications for the hundreds of workers that will be required are being taken
at a room in the Hotel Secor,” the Toledo
Blade reported.
One of the first
buildings completed was the production control unit that featured a furnace
with four full-scale retorts and auxiliary equipment. This site, later used as
a laboratory for improving plant processes, opened in October as a training
facility for plant personnel prior to full scale production beginning on
December 30, 1942. Eventually the plant operated 400 retorts in 20 furnaces
which enabled the facility to produce in excess of 14 tons per day of finished
magnesium ingots.
Pre-war
magnesium was produced by processing brine to extract pure magnesium through electrolysis;
this was known as the Dow process. But with urgent wartime needs to be met, several
new methods of magnesium production were explored and the Luckey plant employed
what is known as the ferrosilicon reduction process, named the Pidgeon process
in honor of chemist Dr. Lloyd Montgomery Pidgeon of the Canadian Research
Council who developed the process in 1941. This process today is the
predominant method by which magnesium is produced.
The primary components
for producing magnesium through the Pidgeon process are dolomite and
ferrosilicon. The input materials are crushed and ground in separate processes;
the dolomite is processed through a calciner which yields calcium oxide and
magnesium oxide. The ferrosilicon is produced in an arc furnace which generates
75% grade ferrosilicon, scrap iron, and coke. (Both of these materials were
shipped into the Luckey plant from other producers.) Ferrosilicon is then mixed
with the CaO and MgO and condensed to form the briquettes. The briquettes were
fed into “tubular retorts of chrome-nickel steel set horizontally in a furnace
with the open ends projecting outside the front wall,” wrote Andrew Mayer in
1944. “The retorts are then closed and evacuated.” Reduction took place under
vacuum at about 2,130 degrees Fahrenheit and the vaporized magnesium separated
from the rest of the mixture and condensed in the water-cooled removable sleeve
section of the retort. This magnesium deposit, called a muff, was removed from
the 10” diameter retort at the end of the cycle and sent along the process to
be re-melted and cast into ingots. “For
the daily rated capacity of 14 tons of magnesium there are required
approximately 170 tons of dolomite and 16.5 tons of ferrosilicon,” Mayer wrote.
Retort residue which was trucked off site as waste amounted to 87 tons per day.
“Attention was drawn to
the Pidgeon process because it requires a minimum of electrical power (chiefly
that used in the production of ferrosilicon), it utilizes dolomite (which is
very abundant), and a plant can be erected in a relatively short time. The
process, however, necessitates substantial expansion of ferrosilicon production
capacity and the use of a large quantity of critical nichrome steel for
manufacture of retorts.” (Minerals Yearbook, 1941, pgs. 747-748) The Pidgeon
process offered a number of other advantages important in wartime: “It does not
require a highly trained workforce or sophisticated engineering and only
requires a small amount of capital cost.”
Betty Wormley, a 1943 graduate of Pemberville High School, worked at the Luckey plant during the war. |
Demand for magnesium was
one of the most challenging aspects of the national defense program when the
Luckey plant commenced operations in December 1942. “During the emergency
period, firms sent most of the metal to aircraft plants leaving little
available for other purposes. Despite the fact that industry expanded its
facilities as rapidly as possible, for a time there was simply not enough metal
for the armed forces,” wrote Leo Brophy.
“Through the entire year
of 1942, the use of magnesium had to be curtailed, urgent export demands were
not fully met, and powder was not available in the requested amounts for flares
and ammunition,” Julius A. Krug of the War Production Board wrote in 1945.
“However, it was the incendiary bomb program which bore the brunt of the
shortage, receiving only 11.4 million pounds of magnesium compared with the
greatly reduced calculated requirements of 62 million pounds. Although a
substitute thermite bomb had been developed, it could not replace entirely the
urgent need for incendiaries in the European theater.”
Operations started off
slowly as the normal production problems were sorted out and improved methods
devised. The briquetting operation proved most troublesome at first as it took
a while to figure out how to make a sufficiently strong briquette. It was found
that binder could not be used in the process, and the finishing presses
suffered from excessive maintenance costs and power consumption. Over time, a
two-stage briquetting process was developed which used a coarser calcine and
this yielded better results. Each retort
load took five bags (235 lbs) of briquettes and took about 10 hours to complete
the reduction cycle; the removable sleeve was then extracted from the furnace
by a machine and the 31-lb magnesium muff was driven out of the sleeve with a
pneumatic hammer. The remaining waste product was emptied out via discharge
screws into hoppers and the retort prepared for its next charge. The magnesium muff
moved on to the alloy building at the eastern end of the plant where it was
“melted down and mixed with other metals by usual methods to make alloys for
incendiary bombs and aircraft parts,” Mayer wrote. The retorts after repeated
use would start to collapse and after about 250 days would fail altogether.
Replacement of the retorts, which used expensive and hard-to-acquire
chrome-nickel steel (also called nichrome steel), was a downside of using the
Pidgeon process and this additional cost ultimately contributed to the plant
closing at the end of the war.
Luckey-produced magnesium
ended up in two primary destinations for war use: incendiary bombs and aircraft
components. Early war allocations gave most of the magnesium to the aircraft
industry, but by the end of 1943 the allocation between the armaments and
aircraft industries became even. In the aircraft industry, 64% of the magnesium
was used in the manufacture of engines and propellers, 23% used in wheels, 7%
for aircraft frames, and 6% for accessories. Types of aluminum-magnesium alloys
included Birmabright (1-7% Mg, remainder Al), Magnalium (5% Mg, 95% Al), and
Duralumin (1.2-1.8% Mg). “Wartime experience and advances have shown that the
metal is easily machined and that its alloys with aluminum, zinc, and copper
are not only very light, but high in strength.” (Minerals Yearbook, 1943, pg.
774) As the war progressed, the metal also started to be used for
rocket-launcher tubes, flares, and tracers.
Luckey also supplied
material which was used for explosives. Magnesium was used both in bomb casings
and as powder for incendiary bombs. In
early 1941 “the Joint Aircraft Committee, established to allocate American
material between the United States and Great Britain, recommended that the
Ordnance Department to produce a four-lb. magnesium bomb suitable for the Army,
Navy, and the British. Ordnance thereupon modified the British Mark II/A
four-lb. incendiary and standardized it as the American AN-M50. Most of the
bombs went to Great Britain on Lend-Lease and were dropped in air raids over
Europe. Aircraft dropped more four-lb. magnesium bombs than all other
incendiary bombs put together. Almost 30 million fell on Europe, and almost 10
million on Japan, causing damage that ran into astronomical figures,” wrote Brophy
The Luckey plant’s stated
capacity was 10 million pounds of processed magnesium per year, and the plant
reached its peak figure in 1944 when 12,384,000 pounds was produced. The Luckey
plant garnered two Army-Navy E Awards (E for excellence) for its production efforts
during the war. The first award was presented on February 16, 1944 in
impressive ceremony at the plant that was attended by military and governmental
representatives, including former women’s tennis champion Helen Hull Jacobs who
was then serving in the U.S. Navy. Fletcher W. Rockwell, president of National
Lead Co., accepted the plant award from Colonel E.W. Dennis of the 5th
Service Command. It is unclear when the second award was given.
By the beginning of 1944,
the Federal government possessed a burgeoning surplus of magnesium and began to
either curtail operations or close plants altogether. Production had increased
to more than 367 million pounds in 1943 and far exceeded demand. In February
1944, the first round of production curtailments went into effect followed by a
series of curtailments and plant closures throughout the year. In October 1944
the War Production Board removed all restrictions on the use of magnesium but
this generated little if any additional demand upon the national stockpile. “A
survey of the wartime record leaves no doubt that the industry was greatly over
expanded, even for war, but the great difficulty in predicting war demands made
this inevitable. The fact remains, however, that both private industry and the
government possess magnesium-producing facilities far in excess of any demand
foreseeable for at least a decade after the war,” reported the 1944 Minerals
Yearbook. It is worth noting that the highest demand for magnesium came in 1943
and totaled 362 million pounds, roughly half the 725 million-pound figure
projected by the War Production Board in February 1942.
By January 1, 1945, the
War Production Board had shut down 79% of national magnesium capacity and yet
the country still possessed a healthy stockpile of magnesium. The Luckey plant, however, avoided all of
these closures and continued operating right up to the close of hostilities in
August 1945. Production ceased altogether that month with annual production
totaling 7,296,000 pounds. Despite the plant’s efficiency, its production costs
(30 cents per pound) “could not hope to compete in a market in which magnesium
sells for 20.5 cents and in which capacity exceeds demand.” (Minerals Yearbook,
1945, pg. 768) “Orders to close the plant were issued two weeks ago by the
Reconstruction Finance Co. according to E.R. Rowley, plant manager,” the Toledo Blade reported on September 4,
1945. “The product extracted from the dolomite rock of Wood County was rated as
the purest magnesium produced in the U.S. But its production costs were double
the costs of pre-war magnesium.”
The plant was placed in
stand-by mode and remained idle until 1949 when the Brush Beryllium Company
moved in to produce beryllium for the Atomic Energy Commission. While operating
under AEC direction, radioactive steel was brought unto the plant site and
that, combined with the beryllium, left the plant a contaminated facility. It
was designated as a Superfund site in 1992 under FUSRAP (Formerly Utilized
Sites Remedial Action Program) and recent estimates show that it will take 12
years and $244 million to fully resuscitate the property. Tons of contaminated
soil will need to be removed to cleanse the area of beryllium, lead, radium,
thorium, and uranium.
Sources:
“Big U.S. Magnesium Plant to be Located at Luckey,” Toledo Blade, June 10, 1942
“Notables at Luckey for E Award Rites,” Toledo Blade, February 16, 1944
“Wood County Loses Magnesium Plant,” Toledo Blade, September 4, 1945
Mayer, Andrew. “Plant for the Production of Magnesium
by the Ferrosilicon Process” American Institute of Mining and Metallurgical
Engineers, Technical Publication No. 1670, 1944
Wulandari, Winny, et al. “Magnesium: current and
alternative production routes.” University of Wollongong, Australia, 2010
Government Documents:
Background Review
of the Brush Beryllium and Diamond Magnesium Plants in Luckey, Ohio. Department of Energy: Formerly Utilized Sites
Remedial Action Program. 1989
Brophy, Leo P., Wyndham D. Miles and Rexmond C.
Cochrane. The Chemical Warfare Service:
From Laboratory to Field. Washington: Center of Military History, 1988
Bureau of Mines, United States Department of Interior
Minerals Yearbooks:
Shore, F.M. Minerals
Yearbook 1941. Washington: Government Printing Office, 1943
Needham, C.E., editor. Minerals Yearbook 1942. Washington: Government Printing Office,
1943
Needham, C.E., editor. Minerals Yearbook 1943. Washington: Government Printing Office,
1945
Needham, C.E., editor. Minerals Yearbook 1944. Washington: Government Printing Office,
1946
Keiser, H.D editor. Minerals Yearbook 1945. Washington: Government Printing Office,
1947
Krug, Julius A. Wartime
Production Achievements and the Reconversion Outlook. Report of the
Chairman of the Chairman, War Production Board. Washington: Government Printing
Office, 1945
Yearly production totals:
1941 32,589,052 lbs.
1942 97,925,684 lbs.
1943 367,168,000 lbs. (183,584 short tons)
1944 314,200,000 lbs. (157,100 short tons)
1945 65,584,000 lbs. (32,792 short tons)
Yearly
domestic consumption totals:
1941 29,346,600 lbs.
1942 84,525,700 lbs.
1943 281,654,000 lbs. (155,547 short tons)
1944 265,396,000 lbs. (132,698 short tons)
1945 86,000,000 lbs. (43,000 short tons)
Yearly
export totals:
1941 3,098,424 lbs. (2.3 million lbs. to
England)
1942 8,090,449 lbs. (7.1 million lbs. to
England)
1943 80,858,000 lbs. (63.8 million lbs. to
England, 7.2 million lbs. to USSR)
1944 48,396,000 lbs. (32 million lbs. to
England, 10 million lbs. to USSR)
1945 1,036,000 lbs. (560 thousand lbs. to
USSR, 420 thousand lbs. to Mexico)
Prewar Production:
Dow
Chemical Co.
Midland,
Michigan Capacity:
18 million pounds/year
Continued
production postwar
June 1941 Expansion:
Basic
Magnesium
Las
Vegas, Nevada Capacity:
112 million pounds/year
Opened:
August 31, 1942
Curtailment:
40% effective April 1, 1944
Curtailment:
additional 20% effective July 25, 1944
Production Ended: August 31, 1944
Diamond
Magnesium
Painesville,
Ohio Capacity:
36 million pounds/year
Opened:
late September 1942
Curtailment:
25% effective September 25, 1944
Curtailment:
additional 25% effective November 25, 1944
Production ended: by September 1945
Dow
Chemical Co.
Freeport,
Texas Capacity:
36 million pounds/year
Opened:
Late 1941
Production ended: by September 1945
Dow
Magnesium
Velasco,
Texas Capacity:
72 million pounds/year
Opened:
June 1942
Curtailment:
50% effective August 31, 1944
Production ended: by September 1945
International
Minerals and Chemicals (Union Potash)
Austin,
Texas Capacity:
24 million pounds/year
Opened:
November 1942
Production Ended: August 31, 1944
Mathieson
Alkali Works, Inc.
Lake
Charles, Louisiana Capacity:
54 million pounds/year
Opened:
June 6, 1943
Production Ended: April 1, 1944
Permanente
Metals Corp.
Richmond,
California Capacity:
24 million pounds/year
Opened:
Late 1941
Production ended: by September 1945
Union
Potash
Carlsbad,
New Mexico Capacity:
24 million pounds/ year
Opened:
June 1943
Production ended: by September 1945
February 1942 Expansion:
Amco
Magnesium Co. (American Magnesium Co.)
Wingdale,
New York Capacity:
10 million pounds/year
Opened:
March 1943
Curtailment:
33% effective February 1, 1944
Production Ended: June 1, 1944
Dow
Magnesium
Marysville,
Michigan Capacity:
72 million pounds/year
Opened:
April 8, 1943
Curtailment:
40% effective May 1, 1944
Production Ended: July 25, 1944
Electro-Metallurgical
Co.
Spokane,
Washington Capacity:
48 million pounds/year
Opened:
May 26, 1943
Curtailment:
50% effective March 1, 1944
Curtailment:
additional 16% effective July 25, 1944
Production ended: by September 1945
Ford
Motor Co.
Dearborn,
Michigan Capacity:
40 million pounds/year
Opened:
May 1942
Production Ended: March 1, 1944
Magnesium
Reduction Co.
Luckey,
Ohio Capacity:
10 million pounds/year
Opened:
December 30, 1942
Curtailment:
40% effective November 25, 1944
Production ended: by September 1945
New
England Lime Co.
Canaan,
Connecticut Capacity:
10 million pounds/year
Opened:
September 1942
Curtailment:
60% effective October 15, 1944
Production ended: by September 1945
Permanente
Metals Corp.
Manteca,
California Capacity:
20 million pounds/year
Opened:
August 1942
Curtailment:
50% effective March 1, 1944
Production Ended: June 1, 1944
Process
Types:
Electrolytic
separation (Dow Process)
Dow Chemical Co.
Freeport,
Texas Capacity: 36 million
pounds/year
Midland,
Michigan Capacity:
18 million pounds/year
Dow Magnesium
Marysville,
Michigan Capacity:
72 million pounds/year
Velasco,
Texas Capacity: 72
million pounds/year
International Minerals and Chemicals
(Union Potash)
Carlsbad,
New Mexico Capacity:
24 million pounds per year
Carbo-electrothermic
reduction (Hansgirg Process)
Permanente Metals Corp.
Permanente,
California Capacity: 24
million pounds/year
Ferrosilicon
reduction (Pidgeon Process)
Amco Magnesium Co.
Wingdale,
New York Capacity:
10 million pounds/year
Diamond Magnesium
Painesville,
Ohio Capacity:
36 million pounds/year
Electro-Metallurgical Co.
Spokane,
Washington Capacity:
48 million pounds/year
Ford Motor Co.
Dearborn,
Michigan Capacity:
40 million pounds/year
Magnesium Reduction Co.
Luckey,
Ohio Capacity:
10 million pounds/year
New England Lime Co.
Canaan,
Connecticut Capacity:
10 million pounds/year
Permanente Metals Corp.
Manteca,
California Capacity:
20 million pounds/year
Magnesite
(M.E.L Process)
Basic Magnesium
Las
Vegas, Nevada Capacity:
112 million pounds/year
Mathieson Alkali Works Inc.
Lake
Charles, Louisiana Capacity:
54 million pounds/year
Magnesium Plant Expansion | |||
Plant | Opening Date | ||
Dow- Midland, MI | Jan-41 | ||
Dow-Freeport, TX | Oct-41 | ||
Permanente-Permanente, CA | Oct-41 | ||
Ford- Dearborn, MI | May-42 | ||
Dow- Velasco, TX | Jun-42 | ||
Permanente- Manteca, CA | Aug-42 | ||
Basic- Las Vegas, NV | 31-Aug-42 | ||
Diamond- Painesville, OH | Sep-42 | ||
New England- Canaan, CT | Sep-42 | ||
IMM- Austin, TX | Nov-42 | ||
Magnesium- Luckey, OH | 30-Dec-42 | ||
Amco- Wingdale, NY | Mar-43 | ||
Dow- Marysville, MI | 8-Apr-43 | ||
Electro-Spokane, WA | 26-May-43 | ||
Union- Carlsbad, NM | Jun-43 | ||
Mathieson- Lake Charles, LA | 6-Jun-43 |
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