It all began in 1939 - this Works had a Government identification of G.C.3. The Government needed a plant that could extract Bromine from warm sea water in order to produce ethylene dibromine as octane boosters for aviation gasoline during World War Two.
The Hayle site of North Quay was chosen due to its remoteness and the nearby infrastructure of the railway, the sea and of course, Hayle Power Station (known as The Electric Works) Site clearance began in August 1939, with John Mowlem as the main contractor. At its peak, over 350 men were employed in this construction work. Over 80,000 cubic yards of blue elvin rock was removed from the site with most employees working an average of 80 hours per week - all through the winter of 1939/40 that was the coldest on record.
Although The Power Station was powered by coal, water was required for the turbines and as much as 2,000,000 gallons of water per hour was required for the I.C.I works. So a tunnel was driven from The Power Station for approximately 500 feet, followed by a 48 inch, cast iron pipe, laid over to Carnsew Basin to ensure continuity of water. This was also completed by the Mowlem Group. Another construction firm, Dingles of Redruth, built the culvert from The Power Station, through the I.C.I Works and on to the outfall at Clodgey Bay (now the Hayle Town Swimming Pool site)
Production began in July 1940. The four main raw materials for the alkali process were sulphuric acid, chlorine, soda ash and alcohol, using less chlorine but greater quantities of sulphuric acid. Sulphur came in by coastal vessels, with approximately 500 tons on board each time. In 1949 an Acid Plant was built on site.
The basic chemistry of the Alkali Process involved four separate reactions. Bromine is recovered from the alkaline absorption in two substages. The two towers used for this process were of mild steel, 42 inches in diameter, lined with acid resistant bricks. These towers were 14 feet tall with an acid mixing tank between the two. The acid effluent would be run off and held in a dilute acid tank prior to being recycled. The sulphur store was at the centre of North Quay.
On 26th October 1954 the Alkali Process that had operated for 14 years, producing 43,400 tons of bromine was closed down. All the tanks were cut down and the floor concreted over, ready to start using the Acid Process in 1956. This system was more efficient and two recirculation ducts were built around the main building.
At its height there were around 125 employed at the Associated Octel site. Nearing the closure period 85 in total were still employed. Economics were the deciding factor in closing the Hayle Works in 1974.
A large number of employees worked throughout the lifetime of the factory and were awarded service medals from five years onwards. A company magazine named The Octagon was made available, keeping members up to date with regular news from different sites.
On a much lighter note, we were able to sit in the warm water at Clodgey Bay in our bathers - but the following year we had to have new costumes because the previous one’s perished! (Thanks must go to the Editor of Curnow’s Hayle, Patricia Curnow, for a considerable amount of material I gleaned from the archive of her father, Reg Jose, long term employee of Associated Octel)
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