Old fashioned methods for making steel

Hematite pig-iron smelted with coke and hot-blast has chiefly been used. The metal is melted in a reverberatory furnace, and is then run into a founder's ladle, and from thence it is transferred to the vessel in which its conversion into steel is to be effected. It is made of stout plate iron and lined with a powdered argillaceous stone found in this neighborhood below the coal, and known as ganister. The converting vessel is mounted on axes, which rest on stout iron standards, and by means of a wheel and handle it may be turned into any required position. There is an opening at the top for the inlet and pouring out of the metal, and at the lowest part are inserted 7 fire-clay tuyeres, each having five openings in them; these openings communicate at one end with the interior of the vessel, and at the other end with a box called the tuyere-box, into which a current of air from a suitable blast engine is conveyed under a pressure of about 14 lbs. to the square inch, a pressure more than sufficient to prevent the fluid metal from entering the tuyeres. Before commencing the first operation, the interior of the vessel is heated by coke, a blast through the tuyeres being used to urge the fire. When sufficiently heated, the vessel is turned upside down and all the unburned coke is shaken out. The molten pig-iron is then run in from the ladle before referred to; the vessel, during the pouring in of the iron, is kept in such a position that the orifices of the tuyeres are at a higher level than the surface of the metal. When all the iron has run in the blast is turned on, and the vessel quickly moved round. The air then rushes upwards into fluid metal from each of the 35 small orifices of the tuyeres, producing a most violent agitation of the whole mass. The silicium, always present in greater or less quantities in pig-iron, is first attacked. It unites readily with the oxygen of the air, producing silicic acid; at the same time a small portion of the iron undergoes oxidation, hence a fluid silicate of the oxide of iron is formed, a little carbon being simultaneously eliminated. The heat is thus gradually increased until nearly the whole of the silicium is oxidized; this generally takes place in about 12 minutes from the commencement of the process. The carbon now begins to unite more freely with the oxygen of the air, producing at first a small flame, which rapidly increases, and in about three minutes from its first appearance we have a most intense combustion going on: the metal rises higher and higher in the vessel, sometimes occupying more than double its former space. The frothy liquid now presents an enormous surface to the action of the oxygen of the air, which unites rapidly with the carbon contained in the crude iron, and produces a most intense combustion, the whole, in fact, being a perfect mixture of metal and fire. The carbon is now eliminated so rapidly as to produce a series of harmless explosions, throwing out the fluid slags in great quantities while the union of the gases is so perfect that a voluminous white flame rushes from the mouth of the vessel, illuminating the whole building, and indicating to the practiced eye the precise condition of the metal inside. The workman may thus leave off whenever the number of minutes he has been blowing and the appearance of the flame indicate the required quality of the metal. This is the mode preferred in working the process in Sweden. But here we prefer to blow the metal until the flame suddenly stops, which it does just on the approach of the metal to the condition of malleable iron: a small quantity of charcoal pigiron, containing a known quantity of carbon, is then added, and steel is produced of any desired degree of carburation, the process having occupied about 28 minutes from the commencement. The vessel is then turned, and the fluid steel is run into the casting ladle, which is provided with a plug rod covered with loam: the rod posses over the top of the ladle, and works in guides on the outside of it, so that, by means of a lever handle, the workmen may move it up and down as desired. The lower part of the plug, which occupies the interior of the ladle, has fitted to its lower end a fireclay cone, which rests in a seating of the same material let into the bottom of the ladle, thus forming a cone valve, by means of which the fluid steel is run into different-sized moulds, as may be required, the stream of fluid steel being prevented by the valve plug from flowing during the movement of the casting ladle from one mould to another. By tapping the metal from below, no scoria or other extraneous floating matters are allowed to pass into the mould.

_Uchatius Steel._

Pig iron is first granulated by running it in a small stream into cold water kept constantly agitated. The granulated metal is mixed with sparry iron ore, and if necessary a small portion of manganese, and heated in crucibles in the ordinary cast-steel blast furnace.

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