IMPROVEMENTS FOR MANUFACTURING CAST IRON, STEEL, AND WROUGHT IRON
Year: 1858

page_text: LETTERS PATENT to Alexander Gordon, Member of the Institution of
Civil Engineers, in London, and residing at Little Fife House, Whitehall,
in the City of Westminster, for the Invention of "IMPROVEMENTS FOR
MANUFACTURING CAST IRON, STEEL, AND WROUGHT IRON."-A communica-
tion from Antoine Galy Cazalat, of Paris.
PROVISIONAL SPECIFICATION left by the said Alexander Gordon at
the Office of the Commissioners of Patents, with his Petition, on the
14th October 1858.
I, ALEXANDER GORDON, Member of the Institution of Civil Engineers, in
London, and residing at Little Fife House, Whitehall, in the City of West-
minster, do hereby declare the nature of the said Invention for "IMPROVEMENTS
FOR MANUFACTURING CAST IRON, STEEL, AND WROUGHT IRON," as communicated to
me by Antoine Galy Cazalat, residing in Paris, to be as follows:-
Firstly, to decarbonize and purify gradually pig iron or the iron of first
running, so as to convert it into malleable cast iron, natural or cast steel, and
wrought iron (fonte malleable, en acier naturel, et en fer); secondly, to obtain
directly the steel or the iron in a furnace similar to Wilkinson's charged with
alternate layers or beds of wood, charcoal, and of ore suitably prepared;
thirdly, to substitute for the usual coke (coke metallurgique) or wood charcoal
coal or wood in the manufacture of iron or steel.

page_text: The means which I employ are as follows:-
Firstly, for the gradual decarbonization (decarburation) of the pig iron,
I cause to pass through a body of liquid cast iron a current of very highly
heated steam mixed with hydrogen and carbonic oxide, so as to bring all the
molecules of the metallic bath into contact with this triple current.
Secondly, for obtaining steel directly I charge the cupulo (cubilot) or furnace
similar to Wilkinson's with alternate layers of wood, charcoal, and ore suitably
prepared; then I induce the combustion of the charcoal by means of a very
hot current of atmospheric air mixed with hydrogen and carbonic oxide. This
triple current takes from the ore the oxygen and other matters foreign to the
iron, which charges itself with carbon to convert itself into steel.
Thirdly, for the usual coke employed (coke metallurgique) to substitute gas
coke or coal in the direct manufacture of iron and of steel, I confine the ore
without mixing it with charcoal in one or more earthenware retorts (cornue de
terre refractaire) placed in the same oven, similar to the oven used in gas
making for purposes of illumination. I burn in the furnace of this oven (dans
le foyer du four) gas coke or wood, the flame of which heats exteriorly all the
retorts (les cornues) before escaping into the atmosphere. When the ore is
raised to the highest possible temperature, I admit into each retort (cornue) an
excessively hot current of hydrogen and carbonic oxide, which double current
flows through the whole length and breadth of the bed of ore, of which the
oxygen combines with the hydrogen and with a portion of the carbonic oxide,
the other portion of which converts the iron into a bar or mass of steel.
I obtain the different decarbonizing currents above mentioned by passing a
current of steam over or through a mass of coke in a state of incandescence
by its own combustion in a refractory furnace (dans un cubilot refractaire)
hermetically sealed. If the steam be in excess, part of it will traverse the hot
coke without being decomposed, whilst the other portion of the steam yields
its oxygen to the coke and produces hydrogen and carbonic oxide, and some
carbonic acid. In this case we obtain the current of steam, hydrogen, and
carbonic oxide raised to the temperature of the incandescent coke. When we
diminish the current of steam for the purpose of decomposing it all, by the
passage over or through the incandescent coke, the result is hydrogen, carbonic
oxide, and a very little carbonic acid.

page_text: SPECIFICATION in pursuance of the conditions of the Letters Patent, filed
by the said Alexander Gordon in the Great Seal Patent Office on the
14th April 1859.
TO ALL TO WHOM THESE PRESENTS SHALL COME, I, ALEXANDER
GORDON, Member of the Institution of Civil Engineers, in London, and
residing at Little Fife House, Whitehall, in the City of Westminster, send
greeting.
WHEREAS Her most Excellent Majesty Queen Victoria, by Her Letters
Patent, bearing dato the Fourteenth day of October, One thousand eight
hundred and fifty-eight, in the twenty-second year of Her reign, did, for
Herself, Her heirs and successors, give and grant unto me, the said
Alexander Gordon, Her special licence that I, the said Alexander Gordon,
my executors, administrators, and assigns, or such others as I, the said
Alexander Gordon, my executors, administrators, and assigns, should at any
time agree with, and no others, from time to time and at all times there-
after during the term therein expressed, should and lawfully might make,
use, exercise, and vend, within the United Kingdom of Great Britain and
Ireland, the Channel Islands, and Isle of Man, an Invention for "IMPROVE-
MENTS FOR MANUFACTURING CAST IRON, STEEL, AND WROUGHT IRON," upon the
condition (among others) that I, the said Alexander Gordon, by an instru-
ment in writing under my hand and seal, should particularly describe and
ascertain the nature of the said Invention, and in what manner the same
was to be performed, and cause the same to be filed in the Great Seal Patent
Office within six months next and immediately after the date of the said
Letters Patent.
NOW KNOW YE, that I, the said Alexander Gordon, do hereby declare
the nature of the said Invention (which has been communicated to me by
Antoine Galy Cazalat, of Paris, and residing abroad,) and the manner in
which the same is to be performed, to be particularly described in and by the
following statement, that is to say:—
My improvements for manufacturing cast iron, steel, and wrought iron are
as follow: First, to purify and decarbonize gradually pig or cast iron, or the
iron as it runs from the blast or smelting furnace, so as to convert it at
pleasure into malleable cast iron, steel, or wrought iron; second, to obtain
steel or iron directly in a furnace or cupola or cupulo charged with alternate
layers of ore or mineral suitably prepared, and charcoal; third, to substitute for
the combustion of the coke usually employed or charcoal the combustion of
coal or wood in the manufacture of iron or steel.

page_text: The means that employ are as follow-
First, viz, the decarbonization of the pig iron. I cause to pass through a
mass of liquid cast iron a current of steam of an exceedingly high temperature
mixed with hydrogen and carbonic oxide, in such a manner as to bring the
molecules of the metallic bath into contact with the triple current, so as to
decarbonize it.
Second, to obtain steel directly. I charge a cupula or cupulo or furnace with
alternate layers of suitably prepared ore and charcoal; then I effect the com-
bustion of the charcoal by means of an exceedingly hot current of air mixed
with hydrogen and carbonic oxide, which deoxidizes the ore in carbonizing the
iron and converting it into steel.
Third, to take from the ore the oxygen, and to purify it. I confine the ore
without mixing it with charcoal in one or more earthenware retorts or
cylinders placed in an oven similar to that in which retorts are placed for
making gas for illumination, or in any other convenient manner. I burn in
the furnace of the oven coal or wood, or any other suitable fuel, the flame of
which heats exteriorly all the cylinders or retorts before escaping into the
atmosphere. Or I heat the retorts with the very hot products of any com-
bustion, such as those produced by the coking of coal. When the ore is
raised to the highest temperature that can be effected, I allow an exceedingly
hot current of hydrogen and carbonic oxide to pass into cach cylinder or
retort. This double current spreads itself throughout all the bed of mineral,
of which mineral the oxygen combines with the hydrogen and carbonic oxide,
converting the ore into a bar of iron or steel. Sometimes instead of taking
from the mineral its oxygen by means of a current of pure hydrogen and
carbonic oxide, the mineral can be deoxidized by causing a very hot current
of protocarburet of hydrogen to pass through and over it. This gas is
produced by causing fine sawdust or liquid rosin, or any hydrocarburet free
from sulphur, to fall upon incandescent coke.
The generator of the decarbonising and deoxidising currents which I prefer
is a generator of superheated steam mixed with hydrogen, carbonic oxide, and
carbonic acid. It is a cupola formed of moulded blocks of fire-clay, fire-
bricks, or fire luups, forming a vertical cylinder of such materials, of which
cylinder the upper end is open at the centre. The earthenware cylinder is
surrounded by an outer casing of wrought iron or other suitable material to
prevent expansion of the brick or earthenware cylinder, and to resist the
pressure of the gas which is formed by the steam when coming into contact
with the incandescent coke. This generator or cupola is charged with coke
by the opening at the upper end; then I close this opening by a tube curved

page_text: at about a right angle, the horizontal branch of which is introduced into the
mouth of another pipe terminating in the chimney. The coke or coal is
lighted by a door at or near the bottom of the cupola, and the gaseous
products of the combustion pass off by the pipe into the chimney. When the
mass of coke has become incandescent, and also the earthenware lining, which
can be seen by any convenient opening, I close the opening to the hearth
hermetically by means of a covering which acts as the neck and bonnet of
a gas retort, and which being luted and screwed home by the usual bridle or
bar and screw, closes the opening effectually; then I take away the curved tube
that closes the opening or hole above described at the top of the earthenware
cylinder, which runs horizontally into the chimney, and then I close the said
opening with a suitable bonnet and luting as at the bottom.
After having obtained the proper heat in the cupola, and having the cupulo
well closed, I allow a current of steam to enter at the top of this chamber,
which descends and passes out by a suitable opening contrived on the pro-
jecting neck for the door or bonnet of the close chamber similar to the head
or end of a gas retort.
In traversing from top to bottom throughout the mass of coke a portion of
the gas is decomposed; its oxygen unites with the incandescent carbon to
form carbonic oxide, and a little carbonic acid which pass with the corre-
sponding hydrogen into the decarbonizing apparatus berein-after described.
When the exceedingly hot acriform current is required to be formed only of
hydrogen and carbonic oxide I only allow a slight quantity of steam to come
into the top part of the cupulo, in order that it may be entirely decomposed
during its passage through the incandescent coke. In this case the decomposed
steam produces only the hydrogen and carbonic oxide, which latter cannot be
changed into carbonic acid by combination with the oxygen of the steam as it
does when the steam is in excess. The pig iron can be decarbonized in a
state of fusion in the crucible of a high furnace, or in a solid state it may be
fused in a cumula.

page_text: The body of the decarbonizing apparatus is an iron ladle or pot of suitable
size, lined with fire-clay, such as is commonly used for removing liquid iron in
foundries; its capacity is divided for the occasion into two equal compartments
by a moveable vertical grating formed of iron tubes, the upper end of each of
which tubes is secured to au horizontal pipe with which it communicates. The
lower ends reach down near to the bottom of the pot. Each tube is pierced
with holes (suitably distanced) upon vertical lines, in such a manner that one
half of this grating of hollow tubes on one side of the pot has the holes so
arranged as to blow in one direction; the other half of the grating on the other
side of the pot has the holes so arranged as to blow in the opposite direction.
These tubes should have a covering of fire-clay, so that the portions in contact
with the fused iron be not injured. The horizontal pipe into which the said
vertical pipes are all fixed is retained upon the circumference of the said iron
ladle by its two extremities, of which one is stopped up whilst the other com-
municates by a tube with the generator of the quadruple current. To effect
the decarbonization I open the screw valve or other suitable contrivance,
which at once allows the steam, the hydrogen, the carbonic oxide, and carbonic
acid to come into the grating of hollow bars or tubes. The gases which have
traversed the incandescent coke of the generator rush from the grating into
the ladle or pot, and heat it for a few seconds before I let the iron fall into it
by opening the hole by which it flows from the furnace. The liquid metal
now comes under the influence of the aëriform currents, which rush in
contrary directions from the two halves of the grating of hollow tubes, and the
entire mass of liquid metal takes a rotatory movement in consequence. This
turning mass being continually divided by the bars of the grating, and lifted
by the ascending currents, is so mixed that the metallic carburetted particles
are brought into contact with the decarbonising gases. The decarbonization
can also be accomplished in the founder's furnace or cupola by bringing in at
the bottom the steam and the said gases to act upon the fluid metal there,
thus dispensing with the pot or ladle. By this contact the steam raised to
more than 800 degrees of the Centigrade, or 1440 Farenheit, becomes
decomposed; its oxygen burns off the carbon as well as the particles of other
substances that render the iron porous and brittle. The oxygen oxidizes at the
same time a portion of iron, but the hydrogen and carbonic oxide deoxidize
immediately the iron which carbonizes itself in mixing with the steel. The
operation is so easy that a few experiments suffice to shew the refining
workman the number of minutes and seconds during which he ought to leave

page_text: the current to flow for transforming the metallic bath into malleable cast iron.
When the duration of the flowing and the color of the metallic bath shew
pure steel, the refiner stops the decarbonization by intercepting the current ;
then the metal can be run into moulds of the desired shapes in steel or in
malleable cast iron, if the metal is more carbonized than steel.
DECARBONIZATION OF CAST IRON IN THE STATE OF FUSION IN THE CRUCIBLE
OF A HIGH FURNACE.
Supposing we have established an earthenware reservoir near a high furnace,
in such a manner that its upper opening communicates with the crucible of
the furnace by a channel, the entrance to which is placed underneath the out-
flowing hole. This reservoir, which I call the "decarbonizing crucible," is
made of wrought-iron plates lined with earthenware or fire-clay, and its interior
is divided into an upper and under chamber by a horizontal earthenware
drainer pierced with small holes like a colander. The circumference of this
carthenware colander is luted on a shoulder-piece contrived in the interior
side of the wall of the reservoir. The bottom of the lower chamber communi-
cates with an earthenware tube covered by iron provided with a band or
bridle, which is to be fastened or bolted round the opening of the decarbonising
crucible. This tube is intended to conduct the iron suitably decarbonized into
a channel or current that distributes it to the ingot moulds. Opposite the
conducting pipe is fixed a tube communicating with the generator of the
quadruple gaseous currents. When I wish to work the decarbonization, I at
first let the current of steam, hydrogen, carbonic oxide, and carbonic acid
come, which heats the upper and lower chambers of the decarbonising crucible
and the wall of the flow pipe. Then we let the liquid iron run from the
bottom of the high furnace into the channel which conducts it to the decar-
bonising crucible. Soon the metallic bath covering the surface of the perfo-
rated plate or colander that separates the upper and lower chambers of the
reservoir, runs into the lower chamber by as many threads as there are holes
in the horizontal plate. Each metallic thread finding itself enveloped in an
atmosphere of steam mixed with gas, raised to more than 800 degrees Centi-
grade, or 1440 degrees Farenheit, decomposes instantly the steam which
takes up part of its carbon. The undecomposed steam mixed with hydrogen
and carbonic oxide, hurries away the liquid iron into the flow pipe where the
metal continues to decarbonize itself progressively. The degree of decar-
bonization depends on the length of the flow pipe which experience alone
determines as most suitable, according as I wish to obtain malleable iron or
steel at the outlet of this discharge pipe, which conveys them into the channel

page_text: abutting on the ingot mould. When we wish to manufacture iron, we push
the decarbonization almost to the limit beyond which the iron would cease to
be liquid. To effect this I make the flow pipe a sufficient length, for the
metal finishes decarbonizing itself in falling into a shallow crucible after
having traversed with the gaseous currents a partition pierced with holes
adjusted to the outlet of the pipe, I take out afterwards from the crucible
whilst it is hot, the mass of iron which I submit to a hammer to remove the
DIRECT MANUFACTURE OF IRON OR NATURAL STEEL.
I manufacture directly iron or steel by treating the ore after the Catalan
system perfected as explained below. Instead of exciting the combustion of
the charcoal in an uncovered chamber vessel as they do by the Catalan pro-
cess, and as in the Pyrences, I economise the fuel considerably by burning it in
a cupola or furnace after Wilkinson's plan. After having almost half charged
the furnace with charcoal, I finish by filling the other half with alternate
layers of ore and fuel, then I light it and hasten the combustion by a suitable
blast.
The tuyere of the blast has a branch pipe which communicates with the
generator of hydrogen and carbonic oxide. This tube is provided with a
suitable slide or valve, designed to intercept and regulate at pleasure the
double deoxidising current. As soon as the ore is incandescent, I open the
valve that allows hydrogen and carbonic oxide to pass into the tuyere. This
tuyere projecting, and suitably inclined into the interior of the furnace, the
blowing machine drives to the centre of the lower part of the burning mass a
suitable volume of air mixed with hydrogen and carbonic oxide, raised to a
very high temperature. This triple current, the proportions of which are
regulated at will, carry off rapidly from the ore the oxygen and other sub-
stances foreign to the iron, which 1 can thus convert directly into steel.
EMPLOYMENT OF COAL AND WOOD IN THE MANUFACTURE OF STEEL.
The ore mixed with a small quantity of powdered charcoal, is confined along
the whole length of one or several horizontal earthenware retorts fixed in the
same oven. These retorts, like those for making gas, carry on their projecting
ends an arrangement for fixing a pipe furnished with a suitable valve for regu
lating the opening for the escape of the gases from each retort into the
atmosphere. Towards the base of the retort, and at its posterior end, I have
an opening which communicates by an iron pipe with the generator of hydrogen
and carbonic oxide.

page_text: At first I burn coal or wood in the furnace of this oven, the flame of which
heats exteriorly all the retorts before escaping into the atmosphere. When
the ore has attained the highest possible temperature, I allow an overheated
current of hydrogen and carbonic oxide to pass into each retort. This double
current traverses the whole length of the ore, the oxygen of which combines
with the hydrogen and carbonic oxide. The steam and carbonic acid resulting
from these combinations pass off into the atmosphere by the tube placed upon
the head of the retort. The ore having lost its oxygen is reduced to the stato
of iron when not mixed with charcoal, and to the state of steel when mixed
with charcoal. I thus directly obtain bars or plates of steel, whether the ore
mixed with charcoal is decarbonised in cylyndrical retorts, or in any other
forms of gas retorts. And I can avail myself of the heat escaping from coke
furnaces to heat the retorts which contain the ore and powdered charcoal.
In witness whereof, I, the said Alexander Gordon have hereunto set
my hand and seal, this Fourteenth day of April One thousand eight
hundred and fifty-nine.
ALEXANDER GORDON. (L.S.)
Witness,
GEORGE H. TAIT.