FERROUS METALSFERROUS METALS

OutlineOutlineWrought Iron (Prehistoric Era to 1500 AD)Wrought Iron (Prehistoric Era to 1500 AD)Pig Iron & Molten “Cast” IronPig Iron & Molten “Cast” IronBlast FurnaceBlast FurnaceMineral FuelsMineral FuelsPuddling FurnacePuddling FurnaceBessemer & Thomas ProcessesBessemer & Thomas ProcessesBasic Oxygen ProcessBasic Oxygen ProcessSiemens Process & Open-Hearth FurnaceSiemens Process & Open-Hearth FurnaceElectric FurnacesElectric Furnaces

ClassificationsClassifications

Open-Hearth Iron & Wrought IronOpen-Hearth Iron & Wrought IronFew Hundredths Of 1% CarbonFew Hundredths Of 1% Carbon

SteelsSteels0.04 to 2.25% Carbon0.04 to 2.25% Carbon

Cast Iron, Malleable Cast Iron, & Pig IronCast Iron, Malleable Cast Iron, & Pig Iron2 to 4 % Carbon2 to 4 % Carbon

White-Heart Malleable IronWhite-Heart Malleable IronVirtually No CarbonVirtually No Carbon

Iron CharacteristicsIron Characteristics

Fourth Most Abundant Element In WorldFourth Most Abundant Element In World Iron OresIron Ores

Dusty Reddish-Brown RockDusty Reddish-Brown RockMixture Of Iron & Oxygen (Iron Oxide)Mixture Of Iron & Oxygen (Iron Oxide)

Iron Has A Strong Affinity For Oxygen - Rusts Iron Has Strong Affinity For SulfurCarbon Has A Greater Affinity For OxygenCarbon & Oxygen Unite To Form A Gas

Small Quantities Of Other ElementsSmall Quantities Of Other Elements25 to 75% Iron25 to 75% Iron

Wrought Iron (Before 1500 AD)Wrought Iron (Before 1500 AD)Beginnings - Speculation (Absence Of Facts)Beginnings - Speculation (Absence Of Facts)

Accidental Smelting Of Iron OresAccidental Smelting Of Iron Ores Iron Ore Stones Reduced To Iron By Wood FireForced Draft - High WindHammering Iron While Hot To Produce Tools

Iron Implements - Egypt (3000 BC)Iron Implements - Egypt (3000 BC)Hardening By Heat Treatment - Greeks (1000 BC)Hardening By Heat Treatment - Greeks (1000 BC)Spread To Europe & Britain (1000 BC)Spread To Europe & Britain (1000 BC)

Fibrous Structure - Like WoodFibrous Structure - Like WoodShaped & Welded By Hammering While HotShaped & Welded By Hammering While Hot

Wrought Iron (Before 1500 AD)Wrought Iron (Before 1500 AD)Early Production - BloomeryEarly Production - Bloomery

Small Furnace Made Of ClaySmall Furnace Made Of ClayHeated By Charcoal FireHeated By Charcoal FireForced BellowsForced BellowsCharcoal & Iron Ore Fed Through Aperture At TopCharcoal & Iron Ore Fed Through Aperture At TopOxygen In Ore & Carbon From Charcoal Formed Oxygen In Ore & Carbon From Charcoal Formed

Gas That Burned a Blue FlameGas That Burned a Blue FlameAfter Oxygen Burnt Off Ore, Tapped From BottomAfter Oxygen Burnt Off Ore, Tapped From BottomBloom - Small, Spongy Ball Of Iron ProducedBloom - Small, Spongy Ball Of Iron ProducedHammered On AnvilHammered On Anvil

Drive Out Slag, And Weld & Consolidate Iron

BloomeryBloomeryNever Operated On A Large ScaleNever Operated On A Large ScaleProduced Iron Containing About 3% Slag & 0.1% Produced Iron Containing About 3% Slag & 0.1%

Other ImpuritiesOther ImpuritiesAccidental Production Of SteelAccidental Production Of Steel

Heat Wrought Iron & Charcoal In Clay Boxes For Heat Wrought Iron & Charcoal In Clay Boxes For Several DaysSeveral Days

Absorbed Carbon To Produce True SteelAbsorbed Carbon To Produce True Steel

Wrought Iron (Before 1500 AD)Wrought Iron (Before 1500 AD)

Early Blast FurnaceEarly Blast Furnace First Great StepFirst Great Step In Iron Production In Iron Production Introduced In Liege, Belgium (Late 1400s)Introduced In Liege, Belgium (Late 1400s) Reached England In 1500sReached England In 1500s Short Square Chimney Built Of Brick Or StoneShort Square Chimney Built Of Brick Or Stone 10 to 16’ High10 to 16’ High Similar To Bloomery, Only BiggerSimilar To Bloomery, Only Bigger

Operated At Higher TemperatureOperated At Higher TemperatureHigher Ratio Of Charcoal To OreHigher Ratio Of Charcoal To OreIron Absorbed More Carbon From Blast Of AirIron Absorbed More Carbon From Blast Of AirProduced Molten (Cast) IronProduced Molten (Cast) Iron

Molten (Cast) Iron Accumulated At BottomMolten (Cast) Iron Accumulated At BottomTapped At IntervalsTapped At Intervals

Molten (Cast) Iron Channeled To Form “Pigs”Molten (Cast) Iron Channeled To Form “Pigs”Pig IronPig Iron

As Charcoal & Iron Are Used, More Is Added As Charcoal & Iron Are Used, More Is Added At TopAt Top

Limestone Was Added - “Flux”Limestone Was Added - “Flux”Combined With Waste MaterialsCombined With Waste MaterialsFormed Molten Waste - “Slag”Formed Molten Waste - “Slag”

Early Blast FurnaceEarly Blast Furnace

Pig IronPig Iron

As Produced From Blast Furnace, ContainsAs Produced From Blast Furnace, ContainsIron, 92%Iron, 92%Carbon, 3 To 4%Carbon, 3 To 4%Silicon, 0.5 To 3%Silicon, 0.5 To 3%Manganese, 0.25 To 2.5%Manganese, 0.25 To 2.5%Phosphorous, 0.04 To 2%Phosphorous, 0.04 To 2%Sulfur, Trace AmountsSulfur, Trace Amounts

Molten “Cast” Iron (1500 - 1700)Molten “Cast” Iron (1500 - 1700)

Few Uses - Must Be Cast On Site At TimeFew Uses - Must Be Cast On Site At TimeCast Iron Cannons - Sussex (1543)Cast Iron Cannons - Sussex (1543)

Molten Iron Went Through Second ProcessMolten Iron Went Through Second ProcessFineryFineryProduce Wrought IronProduce Wrought IronRational Was Increased ProductionRational Was Increased ProductionBlast Furnace Could Make 10 Times BloomeryBlast Furnace Could Make 10 Times Bloomery

Finery - FurnaceFinery - FurnaceCharcoal As Fuel & Waterwheel-Driven BellowsCharcoal As Fuel & Waterwheel-Driven BellowsCast Iron Re-Melted To Drive Off CarbonCast Iron Re-Melted To Drive Off Carbon

FineryFineryProduced Large Pieces Of Wrought IronProduced Large Pieces Of Wrought Iron

Led To ProblemsLed To ProblemsIronworkers Needed Long Thin BarsIronworkers Needed Long Thin Bars

Power Hammer (Late 1500s)Power Hammer (Late 1500s)Waterwheel-DrivenWaterwheel-DrivenPounded Iron Into Flat Thin SlabsPounded Iron Into Flat Thin Slabs

Slitting Mill (Late 1500s)Slitting Mill (Late 1500s)Cut Slabs Into StripsCut Slabs Into Strips

Rolling MillRolling MillSketch - Leonardo da Vinci (1486)Sketch - Leonardo da Vinci (1486)

Mineral FuelsMineral Fuels

Till 1700, Charcoal Was Used As FuelTill 1700, Charcoal Was Used As FuelMade By Burning Large Heaps Of WoodMade By Burning Large Heaps Of WoodImpurities Burn Off In SmokeImpurities Burn Off In SmokeCool Quickly With WaterCool Quickly With Water

Coal Was Tried Unsuccessfully In FurnaceCoal Was Tried Unsuccessfully In FurnacePatent - Dud Dudley (1600s)Patent - Dud Dudley (1600s)Contains SulfurContains SulfurSulfur Easily Unites With Iron - Iron SulfidesSulfur Easily Unites With Iron - Iron Sulfides

Makes Iron Brittle When Hot Or Cold

Mineral FuelsMineral Fuels Second Great StepSecond Great Step In Iron Production In Iron Production

Beginning Of Industrial RevolutionBeginning Of Industrial RevolutionUse Of Coke In Blast FurnaceUse Of Coke In Blast Furnace

Abraham Darby (1709)Coalbrookedale In Shropshire - MuseumFirst Blast Furnace Using CokeSlow Spread Of Technology

Coke Was Already Invented - Make Malt (Brewing)Coke Was Already Invented - Make Malt (Brewing) CokeCoke

Made By Burning Large Heaps Of CoalMade By Burning Large Heaps Of CoalImpurities (Sulfur) Burn Off In SmokeImpurities (Sulfur) Burn Off In SmokeCool Quickly With WaterCool Quickly With Water

History Of Blast FurnacesHistory Of Blast Furnaces

1600160085 Charcoal-Fired Blast Furnaces In Britain85 Charcoal-Fired Blast Furnaces In Britain

1788178853 Coke-Fired Blast Furnaces In Britain53 Coke-Fired Blast Furnaces In Britain24 Charcoal-Fired24 Charcoal-Fired

Early 1800sEarly 1800sNo Charcoal-Fired Furnaces Still OperatingNo Charcoal-Fired Furnaces Still Operating

FranceFrance

Montcenis-Le CreusotMontcenis-Le Creusot 17851785 First French Coke-Fired First French Coke-Fired

Blast FurnaceBlast Furnace Very Slow Very Slow

Dissemination Of Dissemination Of Technique From BritainTechnique From Britain

Developments Of Blast FurnacesDevelopments Of Blast Furnaces

Preheating Of Air Blast - J.B. Nelson (1828)Preheating Of Air Blast - J.B. Nelson (1828)Increased ProductionIncreased Production

Previously - 8 Tons Coal For 1 Ton IronAfter - 2.25 Tons Coal For 1 Ton Iron

Increased QualityIncreased QualityReshaping Furnaces - John Gibbons (1832)Reshaping Furnaces - John Gibbons (1832)

Round Hearth - 33% More ProductiveRound Hearth - 33% More ProductiveUse Of Waste GasUse Of Waste Gas

Inflammable Gas In ProducedInflammable Gas In ProducedPreheating Of Hot Air BlastPreheating Of Hot Air Blast

Bell & Hopper (Cup & Cone) - G. Perry (1850)Bell & Hopper (Cup & Cone) - G. Perry (1850)Multiple Hopper Prevent Loss Of GasMultiple Hopper Prevent Loss Of Gas

Increasing Oxygen Content Of Hot Air Blast Increasing Oxygen Content Of Hot Air Blast Pressurizing FurnacesPressurizing Furnaces

Throttling The Flow Of Gas From Furnace VentsThrottling The Flow Of Gas From Furnace VentsIncreases Pressure To 1.7 atmIncreases Pressure To 1.7 atmBetter CombustionBetter CombustionPost W.W.IIPost W.W.II

Developments Of Blast FurnacesDevelopments Of Blast Furnaces

InternationalInternational

Le Creusot, 1865Le Creusot, 1865 Pontypool, 1865Pontypool, 1865Gluwitz In Silesia, 1830Gluwitz In Silesia, 1830

Typical IronworksTypical Ironworks

Mechanically-Charged Blast FurnaceMechanically-Charged Blast Furnace Corby, NorthhamptonshireCorby, Northhamptonshire 19001900

ComponentsComponentsCylindrical Steel Shell Lined With RefractoryCylindrical Steel Shell Lined With Refractory

Nonmetallic Substance - FirebrickApproximately 100’ High

Shell Is Tapered At Top & BottomShell Is Tapered At Top & BottomCreates Nozzle Effect

Lower Portion Is Called BoshLower Portion Is Called BoshTubular Openings Called Tuyeres - Hot Air BlastHoles At Bottom Are Tapped

Upper - Slag Lower - Molten Pig Iron To Torpedo

Top Portion Lets Gases Escape (Vent)Top Portion Lets Gases Escape (Vent)

Typical Blast FurnaceTypical Blast Furnace

Components (Continued)Components (Continued)HoppersHoppers

Charge Is Introduced Through Bell-Shaped Valves

ChargeChargeMixture Of Iron Ore, Coke, & Limestone

Hot Air StovesHot Air StovesProduce Hot Air

Dump Cars Or SkipsDump Cars Or SkipsDeliver Charge To Hopper

Typical Blast FurnaceTypical Blast Furnace

OperationOperationOperate ContinuouslyOperate ContinuouslySmall Charges Are Introduced At 10-15 MinutesSmall Charges Are Introduced At 10-15 MinutesSpontaneous Combustion Of ChargeSpontaneous Combustion Of ChargeSlag Is Tapped Every 2 HoursSlag Is Tapped Every 2 HoursMolten Iron Tapped Five Times A DayMolten Iron Tapped Five Times A DayHot Air Enters At 1000 To 1600Hot Air Enters At 1000 To 1600ooFFWaste Gases Are Recirculated ?Waste Gases Are Recirculated ?

Typical Blast FurnaceTypical Blast Furnace

Typical Blast FurnaceTypical Blast Furnace