IMPROVEMENTS IN THE MANUFACTURE AND PURIFICATION OF IRON, AND IN THE MANUFACTURE OF STEEL
Year: 1877

page_text: LETTERS PATENT to John Henry Johnson, of 47, Lincoln's Inn Fields, in the
County of Middlesex, Gentleman, for the Invention of "IMPROVEMENTS IN
THE MANUFACTURE AND PURIFICATION OF IRON, AND IN THE MANUFACTURE OF
STEEL." A communication from abroad by Charles Motier Nes, of York, in the
County of York, and State of Pennsylvania, United States of America.
PROVISIONAL SPECIFICATION left by the said John Henry Johnson at
the Office of the Commissioners of Patents on the 28th March 1877.
JOHN HENRY JOHNSON, of 47, Lincoln's Inn Fields, in the County of Middlesex,
Gentleman. "IMPROVEMENTS IN THE MANUFACTURE AND PURIFICATION OF IRON,
AND IN THE MANUFACTURE OF STEEL." A communication from abroad by Charles
Motier Nes, of York, in the County of York, and State of Pennsylvania, United
States of America.
This Invention has for its object chiefly the elimination of phosphorus and other
impurities from iron, and consists in the employment for this purpose of magnetic
silicide of iron ore. It is generally known that large quantities of iron ore exist
which cannot be utilized in the manufacture of iron and steel on account of the
amount of phosphorus which they contain.
By means of this Invention these and ordinary pig irons may be made available
in the production of a new metal, which in it is proposed to designate silicon plate
metal. This metal is formed by melting pig iron with the magnetic silicide of iron
ore in the following manner, vizt, an ordinary run-out is employed, such, for
example, as is used in forges of a sufficient capacity to contain, say, from one to
two tons of metal, water tuyeres being attached, so that a blast may be forced on
to the fuel and iron. From, say, eight to ten bushels of coke and one ton of pig
iron are then taken and placed in the run-out, in layers alternately. To one ton of
pig metal there is used, say, from one-fifth to one-third of a ton of the magnetic
silicide of iron ore, which is pulverized and damped to prevent it from being blown
away. This ore is mixed with the coke, or put into the pot of the run-out when
the metal is nearly melted. The blast from the tuyeres is then turned on to the
mass until the metal is thoroughly melted, when the blast is suspended and the
metal allowed to cease to agitate, and the cinder then tapped off.

page_text: If metal of a hard quality is required to be produced it is drawn out on to chill
plates, but if soft metal is desired the metal is tapped out into a sand bed, and
covered with sand until cold. If iron containing phosphorus has been used the
product will be found to be free from the same, and on analysis being made of the
cinder the impurities (phosphorus or other) will be found therein.
To produce very strong metal for cuttings, or any other purpose for which strength
of metal is required, there is introduced into a cupola, with ordinary pig iron, say,
about 25 per cent., more or less, of this silicon plate motal, charging the cupola with
ordinary fuel; the whole is melted together, as for ordinary foundry purposes, and
when thoroughly melted the cinder is tapped off through a special outlet before
tapping out the metal.
When it is required to produce silicon plate metal having the qualities of pro-
perties of wrought or bar steel, a suitable fire or puddling furnace is employed; the
metal having been partially decarbonized in the refinery soon comes to nature, it is
then put under the hammer and drawn out into bars; this metal can also bo
converted into wrought steel or iron by the Bessemer process, for which it is well
adapted on account of its freedom from phosphorus or other impurities, or by any
other suitable process.
The following are examples of analyses of the silicon plate metal produced,
SPECIFICATION in pursuance of the conditions of the Letters Patent filed by
the said John Henry Johnson in the Great Seal Patent Office on the 22nd
September 1877.
JOHN HENRY JOHNSON, of 47, Lincoln's Inn Fields, in the County of Middlesex,
Gentleman. "IMPROVEMENTS IN THE MANUFACTURE AND PURIFICATION OF IRON,
AND IN THE MANUFACTURE OF STEEL." A communication from abroad by Charles
Motier Nes, of York, in the County of York, and State of Pennsylvania, United
States, America.
The said Invention has for its object chiefly the elimination of phosphorus and
other impurities from iron. It is generally known that large quantities of iron ore
exist which cannot be utilized in.the manufacture of iron and steel on account of
the amount of phosphorus which they contain.
By means of the said Invention ordinary pig iron or cast iron containing
phosphorus may be made available in the production of a new metal, which it is
proposed to designate silicon plate metal. This metal is formed by melting pig iron
with the magnetic silicide of iron ore in the following inanner, videlicet, an ordinary
run-out is employed, such, for example, as is used in forges of a sufficient capacity
to contain, say, from one to two tons of metal, water tuyeres being attached, so that
a blast may be forced on to the fuel and iron or metal. From, say, eight to ton
bushels of coke and one ton of pig iron are then taken and placed in the run-out, in
layers alternately. To one ton of pig metal there is used, say, from one-fifth to one-
third of a ton of the magnetic silicide of iron ore, which is pulverized, and also stamped
to prevent it from being blown away. This ore is mixed with the coke, or introduced
into the pot of the run-out, when the metal is nearly melted. The blast from the

page_text: tuyeres is then turned on to the mass until the metal is thoroughly melted, when
the blast is suspended and the metal allowed to cease to agitate, and the cinder
then tapped off.
If metal of a hard quality is required to be produced it is drawn out on to chill
plates, but if soft metal is desired the metal is tapped out into a sand bed, and
covered with sand until cold. If iron containing phosphorus has been used the
product will be found to be free from the same, and on analysis being made of the
cinder the phosphorus and other impurities will be found therein.
To produce very strong metal for castings, or any other purpose for which strength
of metal is required, there is introduced into a cupola, with ordinary pig iron, say,
about twenty-five per cent., more or less, of silicon plato metal, prepared as herein-
before described, charging the cupola with ordinary fuel; the whole is melted
together, as for ordinary foundry purposes, and when thoroughly melted the cinder
is tapped off through a special outlet before tapping out the metal.
When it is required to produce silicon plate metal having the qualities or pro-
perties of wrought or bar steel, a suitable puddling furnace is employed; the metal
having been partially decarbonized in the refinery soon comes to nature, it is then
placed under the hammer and drawn out into bars; this metal can also be
converted into wrought steel or iron by the Bessemer process, for which it is well
adapted on account of its freedom from phosphorus or other impurities, or its con-
vertion may be effected by any other suitable process.
The following are examples of analysis of the silicon plate metal produced,
100.00
100.0
and varying between these extremes, according to the proportion of magnetic silicide
of iron ore used in producing the metal.
Having now described and particularly ascertained the nature of the said
Invention, and the manner in which the same is or may be used or carried into
effect, I would observe in conclusion that what I consider to be novel and original,
and therefore claim as the Invention secured to me by the herein-before in part
recited Letters Patent is,-
First. The production of silicon plate metal, substantially in manner herein-before
described.
Second. The purification of iron containing phosphorus by the use of the magnetic
silicide of iron ore, substantially as herein-before described.
Third. The production of an improved cast iron or metal suitable for casting, by
the employment of silicon plate metal, prepared substantially in the manner herein-
before described.
In witness whereof, I, the said John Henry Johnson, have to this my Speci-
fication set my hand and seal, this Thirtieth day of August, One thousand
eight hundred and seventy-seven.
J. HENRY JOHNSON. (L.S.)