IMPROVEMENTS IN THE TREATMENT AND PRODUCTION OF IRON AND IN THE APPARATUS EMPLOYED THEREFOR
Year: 1884

page_text: I, SAMUEL RICHARD SMYTH of Ducie Street, Clapham, in the County of Surrey,
Civil Engineer do hereby declare the nature of my invention for "IMPROVEMENTS
IN THE TREATMENT AND PRODUCTION OF IRON AND IN THE APPARATUS EMPLOYED
THEREFOR" to be as follows:-
The object of this invention is to produce at a single heat iron of the best
quality either in balls, blooms, billets or ingots ready for the rolling mills or
hammers to be made either into bars, plates, or forgings.
By my invention I entirely dispense with the various processes known as
puddling shingling, cutting, piling heating reheating lamination and welding
thereby effecting an enormous economy in the time labour and cost of production
and totally obviating the great waste of iron and consumption of fuel hitherto
inseparable from this industry.
To carry out my invention the iron may either be smelted from the ore in the
blast furnace by my improved process described in the Specification of Letters
Patent No 5025 of 1884, or in an ordinary blast furnace, or cupola or the pig may
be melted in my improved refining manipulator next hereafter described.
Such manipulator consists of a cylindrical body or shell mounted on a cradle and
trolly frame running on wheels made to any convenient rail gauge-This frame or
cradle is furnished with suitable brackets or pedestals carrying large roller cog
flange wheels connected together by the framing forming the cradle into or out of
which cradle the cylindrical body or shell can be lifted as desired and taken like a
ladle to have the charge of metal tapped into it at the furnace.
Whole charges may be so tapped and treated from the blast furnace but in
practice it will be found that 10 ton charges are the best to manipulate being more
easy to handle and preferably I place the manipulator near the blast furnace so
hat the charge may be tapped directly into it.
When so charged it is removed and attached to the blast pipe of the blast engine
ud rotated by toothed gear actuated by steam or any other suitable power.
Duplicate apparatus may be provided so that while the charge in one is being
efined and manipulated the other can be at the furnace having its charge tapped
nto it-Or the apparatus can be run up to the furnace and take its chargo
nd then run back to the place where the metal has to be worked. off from the
nanipulator.

page_text: The body of the manipulator is lined with any suitable refractory material and
is furnished with a blow off fitted with a fall down cap or cover. It is also fitted
externally with a box into which the compounds air and gases are forced through
holes in the refractory lining into the body of the metal while a tapping out hole
is provided so as to draw out the charge.
A central inlet aperture for the introduction of the atomized liquid compounds
air and gases is formed in one end of such shell through which apertures they.
pass into an internal chamber formed therein and communicating with the box on
the outside above mentioned.
The liquid compounds which I employ are Chlorine compounds such as hydrochloric
acid Alkaline compounds such as sodium hydroxide, or potassium hydroxide;-
Carbon and hydrogen compounds as present in any hydro-carbon oil, such as
petroleum and Oxyhydrogen compounds as water or vapour These after being
atomised in the apparatus presently described are carried forward into the body of
the metal in the manipulator by the aid of either atmospheric air, carbonic oxide,
carbonic acid carburetted hydrogen, oxyhydro compounds, oxygen or hydrogen
which serve as carriers and may be employed either separately or in combination
with each other or together with such atomized liquid compounds for refining and
treating the metal contained in the manipulator.
To effect this only a low pressure blast such as that employed at the blast
furnace is necessary-Or a blower such as Roots may be employed such pressure
only being required as is sufficient to balance the column of metal in the manipulator
and the blast engine at the blast furnace or a Roots blower may be employed to force
in such liquid compounds, gases, and elements through the atomizing apparatus into
the metal in the manipulator.
The apparatus which I employ to atomise such liquid compounds and convey
the air, gases and other clements before mentioned into the metal is attached to
the refining manipulator and to the blast pipe leading from the blast engine or
blower.
Such atomizing apparatus consists of a horizontal vessel (hereafter termed "the
reservoir") to which the blast pipe is connected at one end while at the other end
it is provided with an outlet pipe and which vessel acts as a reservoir and cushion
for the air and other gases Fixed over this reservoir are three or more upright
cylindrical tanks placed on suitable brackets-Each of these tanks lias a pipe fitted
with a suitable valve tapped therefrom into the reservoir-These pipes convey the
air and other compounds from the reservoir into such tanks Another pipe is also
tapped into the top of each of such tanks leading nearly to their bottom These
latter pipes convey the liquid compounds air, and other elements to the atomizing
injectors fixed to a mixing box from which they are passed through a connecting
pipe into the box on the outside of the body of the manipulator before described
Such connecting pipe is fitted with a fall in valve having an asbestos face and
furnished with a slip gland to allow of its sliding to and fro to form connection
with a gland in the shell or body of the manipulator.
This apparatus is fitted with suitable pressure and other gauges, valves and floats
and also with supply pipes leading from accumulators wherein the liquid compounds
are stored and the supply of which to the metal under treatment is regulated by
means of the atomising injectors before referred to by the action of which injectors
the liquid compounds are broken up into infinitesimal atoms and are conveyed
into the body of the charge of metal by the air blast or by any of the gases herein-
before mentioned as acting as carriers.
The quantities required to be used of such compounds are governed by the
quantities of the metalloids in the metal under treatment and also by the
preponderance of any particular metalloid but I have found in practice that a fair
average is about 1 quart of such compounds to each ton of metal and further I find
that about 2 minutes of time for each unit of metalloids is sufficient to oxidise the
metalloids from each ton of metal under treatment,

page_text: I also employ as an absorbent base to absorb the carbonic oxide and iron oxide
from the charge of metal, good iron ore or oxide silica, carbon of a pure base-or
calcium and add them to the charge in such proportions as the quality of the metal
under treatment may render desirable.
I also pole the charge of metal with green birch or other poles in the
same way as is practised in the manufacture of Copper, in order to absorb the oxide
or oxygen contained therein.
The important advantages attendant upon the use of my invention are as
follows
Firstly By my improved treatment of the metal with the before mentioned
liquid compounds, air and gases I am enabled to oxidise the metalloids such as
silicon-phosphorus-sulphur-alumina-calcium-and graphite therefrom at a low
pressure and without the excessive waste of metal hitherto unavoidable and to
maintain the heat in the charge of metal.
Secondly By the aid of the liquid compounds I carbonise the metal under
treatment and hold the charge at such a degree of heat as to maintain the necessary
degree of liquifaction for producing pure wrought iron at a single heat which is
easily discharged from the manipulator either through the tap hole or the blow off.
Thirdly By my invention I can obtain from any brand or make of iron a solid
ductile homogeneous mass of pure iron having the power to break up the atoms to
the finest degree, and then deal with them in a liquid mass.
Fourthly By my invention I produce pure iron from any metal whose base is
iron at a low blast pressure at the blast furnace and with the aid of the blast
furnace plant-I therefore avoid the enormous outlay of capital hitherto required
to produce the same results by effecting a great saving in plant labor and fuel.
Lastly-By my invention 1 carbonise or decarbonise-oxidise or de-oxidise the
charge of metal at will and maintain the caloric therein without the great waste
incurred under any other system of treatment at present practised and produce at
the furnace as the iron is smelted from the ore and in one single lieat, pure ductile
homogeneous, wrought iron, in masses of any size ready for mechanical treatment.
Dated this 4th day of Tune 1001

page_text: 1 SAMUEL RICHARD SMYTII, Ducie Street Clapham Surrey Civil Engineer do
hereby declare the nature of my invention for IMPROVEMENTS IN THE TREATMENT
AND PRODUCTION OF IRON AND IN THE APPARATUS EMPLOYED THEREFOR and in
what manner the same is to be performed, to be particularly described and
ascertained in and by the following statement :----
The object of this invention is to produce at a single heat iron of the best quality
either in balls blooms billets or ingots ready for the rolling mills or hammers to be
made either into bars, plates, sheets or forgings.
By my invention I entirely dispense with the various processes known as
puddling, shingling, cutting, piling, welding, laminating, heating and re-heating
thereby effecting an enormous economy in the time labour and cost of production
and totally obviating the great waste of iron and consumption of fuel hitherto
inseparable from this industry.
To carry out my invention the iron may either be smelted from the ore in the
blast furnace by my improved process described in the Specification of Letters
Patent No 5025/4, or in an ordinary blast furnace or cupola, or the ore may he
sinelted, or the pig iron may be melted in my improved refining manipulator next
hereinafter described.
Such manipulator consists of a cylindrical body or shell mounted on a cradle and
trolly truck or frame running on wheels made to run on any convenient rail gauge
This trolly truck or frame is furnished with suitable brackets or pedestals which.
carry large double flanged cog wheels that revolve on roller bearings fixed in the
pedestals or brackets attached to the trolly truck frame-These cog wheels are
connected by a framing forming a cradle into or out of which the shell can be
lifted; and taken, like a ladle to have the charge of metal tapped into it at the
furnace Whole charges may be so tapped into it, but in practice it will bo found
that ten ton charges are the best to manipulate as being more easily handled—
I prefer to place the manipulator near the blast furnace so that the charge may be
tapped directly into it-When so charged it may be removed and attached to the
combined induction and atomising apparatus hereinafter described which is attached
to the blast pipe of the blast engine and rotated by cog wheel gear actuated by
steam, or hand, or any other suitable power-Duplicate apparatus may also be
provided so that while the charge in one is being refined and manipulated the
other can be at the furnace having its charge tapped into it Or the apparatus can
be run up to the furnace and take its charge and then run back to the place where
the metal has to be worked off from the manipulator The body of the manipulator
is lined with any suitable refractory material but that composed of about 96 parts
of Silica, such as quartz sand, and about 2 to 3 parts of alumina having a portion
of iron oxide in it and about 2 parts of plumbago wetted moist and hand rammed
will be found well calculated to withstand the intense heat generated in the
manipulator The manipulator is furnished with a blow off outlet which may be
fitted with a full-down cover faced with refractory material It is also fitted
externally with a chamber or box provided with a movable cover, into which
chamber the liquid compounds, air gases and other elements are forced through
holes in the refractory lining into the budy of the metal in the manipulator-
A tapping out hole is provided so as to draw out the charge of metal.--À central

page_text: inlet aperture for the introduction of the atomised liquid compounds, air gases and
other elements is formed in one end of the body of the manipulator through which
aperture they pass into an internal chamber formed therein which communicates
with the external chamber or box before mentioned.
The liquid compounds which I employ are Clorine compounds such as hydro-
chloric acid-alkaline compounds such as sodium hydroxide potassium hydroxide
carbon and hydrogen compounds as present in any hydro carbon-oils such as
petroleum or creosote and oxyhydrogen compounds such as water or vapour Theso
after being atomised in the apparatus presently described are carried forward into
the body of the metal in the manipulator by the aid of either atmospheric air,
carbonic oxide carbonic acid carburetted hydrogen oxyhydrogen compounds, oxygen
or hydrogen which serve as carriers and may be employed either separately or in
combination with each other or in combination with such atomized liquid compounds
for refining and treating' the metal contained in the manipulator.
To effect this only a low pressure blast such as that employed at the blast furnace
is necessary-Or a blower such as Roots' may be employed-such pressure only
being required as is sufficient to balance the depth or column of metal in the
manipulator-and the blast engine at the blast furnace or a Root's blower may be
employed to carry in such liquid compounds gases and elements through tho
atomizing apparatus into the metal in the manipulator.
The apparatus which I employ to atomize such liquid compounds and convey the
air gases and other elements before mentioned into the metal is attached to the
refining manipulator and to the blast pipe leading from the blast engine or blower
and is hereafter referred to as "the combined induction and atomising appparatus
Such combined induction and atomizing apparatus consists of a horizontal vessel
(hereafter termed "the reservoir") to which the blast pipe is connected at one
end-while at the other end it is provided with an outlet pipe and which vessel
acts both as a reservoir and a cushion for the air and other gases-Fixed' over this
reservoir are three or more upright cylindrical tanks placed on suitable brackets-
Each of these tanks has a pipe fitted with a suitable valve tapped therefrom into
the reservoir-These pipes convey the air and other gases from the reservoir into
such tanks Another pipe is also tapped into the top of each of such tanks leading
nearly to their bottom-These latter pipes convey the liquid compounds air and
other gases to the atomizing injectors fixed to a mixing box from which they are
passed through a .connecting pipe into the box or chamber on the outside of the
body of the manipulator before described-Such connecting pipe is fitted with a
fall-in valve having an asbestos face and furnished with a slip gland to allow of
its sliding to and fro to form connection with the boss fixed on the end of the
manipulator as hereinbefore described.
The apparatus is fitted with suitable pressure and other gauges, valves, and floats
and also with supply pipes leading from accumulators wherein the liquid compounds
are stored and the supply of which to the metal under treatment is regulated by
means of the atomising injectors before referred to by the action of which injectors'
the liquid compounds are broken up into infinitesimal atoms, and are conveyed into
the body of the charge of metal by the air blast or by any of the gases herein before
mentioned as acting as carriers.
"
The quantities required to be used of such compounds are governed by the
quantities of the metalloids in the metal under treatment and also by the pre-
ponderance of any particular metalloid but I have found in practice that a fair
average is about one quart of such compounds to cach ton of metal and further
I find that about 2 minutes of time for each unit of metalloids is sufficient to
oxidise the metalloids from each ton of metal.
I also employ as an absorbent base to absorb the carbonic oxide and iron oxide
from the charge of metal good iron ore or oxide, silica carbon of a pure base
nanganese or calcium and add them to the charge in such proportions as the
quality of the metal under treatment may render desirable.

page_text: I also pole the charge of metal with green birch or other poles in the same way
as is practised in the manufacture of Copper in order to absorb the Oxyde or
Oxygen and other gases contained therein."
The important advantages of my invention are as follows
Firstly By my improved treatment of the metal with the before mentioned
liquid compounds air and gases I am enabled to oxidise the metalloids such as
silicon-phosphorus-sulphur-alumina-calcium-and graphite therefrom at a low
pressure of the blast and without the excessive waste of metal hitherto unavoidable
and to maintain the heat. in the charge of metal.
Secondly By the aid of the liquid compounds I carboniso the metal under treat- 1
ment and hold the charge at such a degree of heat as to maintain the necessary
degree of liquifaction for producing pure wrought iron at a single heat which is
easily discharged from the manipulator either through the tap hole or the blow off.
Thirdly By my invention I can obtain from any brand or make of iron a solid
ductile homogeneous mass of pure iron having the power to break up the atoms to
the finest degree and then deal with them in a liquid mass.
Fourthly By my invention I produce pure iron from any metal the base of which
is iron with a low blust pressure at the blast furnace and with the aid of the blast
furnace plant I therefore avoid the enormous outlay of capital hitherto required to
produce the same results by effecting a great saving in plant, labor, time and fuel.
Lastly By my invention I carbonise or decarboniso oxidise or de-oxidise the
charge of metal at will and therefore I can produce steel at will having by my
invention obtained pure iron which is indispensable for the manufacture of good
steel-I can, also maintain the caloric in the charge without the great wasto
incurred under any other system of treatment at present practised and produce at
the furnace as the iron is smelted from the ore and in one single heat pure ductile
homogeneous wrought iron in masses of any size or weight ready for mechanical
treatment.
In the accompanying drawings Fig 1 is a side elevation-Fig 2 an end elevation
and Fig 3 a longitudinal section of the manipulator.
(1) is the framing of the trolly truck to which the pedestals or brackets marked
(2) are attached (3) are the roller bearings which carry the double flange cog
wheels marked (4).
The wheels which carry the trolly truck framing of the manipulator are marked
(5) and the axle which couples the wheels is marked (6).
The cradle which carries the shell that holds the metal is marked (7)-This cradle
is fastened together by rivets or bolts and nuts and is attached to the flanges of the
cog wheels (4).
Wrought iron brackets or lugs (8) are rivetted to the top of the cradlo frame
having slot holes in them through which taper keys (9) are driven over wrought
iron lugs rivetted to the shell.
A pedestal or bracket (10) is attached to the trolly truck frame this carries the
double action cog wheel gear that rotates the shell or body by a pinion (11) acting
on the cog wheels (4).
(12) is the pinion which actuates the spur wheel (13) of the double action gear
(14) is the spindle to which a crank is attached so that it may be rotated by hand
steam hydraulic or other suitable power.
The shell or body that holds the metal to bo manipulator is made of about /
boiler plates rivetted together in the usual way and is marked (15)—The ends are
fixed to internal angle irons marked (16)-(Fig 3)-with countersunk bolts and
nuts so that they may be removed for ramining in the refractory lining hereinbefore
mentioned.
A central hole is formed through one end over which is fixed a cast iron bored
boss (17) this boss is grooved on the inside and has a V shaped ring fitted therein
such as is employed for hydraulic rams- -Beyond this boss a wrought iron chamber
(18) is formed on the inside of the shell or body-This chamber communicates with

page_text: the outside box or chamber (19) through which the liquid compounds air gases and
other elements are conveyed through the refractory lining by small apertures (20)
formed therein and theuce into the body of the metal in the manipulator.
A pipe (21) leads from the combined induction and atomising apparatus before
referred to and presently described in detail and passes into the cast iron bored
boss, this conveys the atomised liquid compounds air and gases to the metal.
The blow off (22) also forms the charging aperture.
A tapping out hole (23) is formed to let out the metal.-Wrought iron straps (24)
are rivetted to 'the outside having eyes in them to which sling hook chains may be
fitted to lift the manipulator in and out of its cradle.
In order to provide for the escape of the gases generated from the drying of the
refractory lining the body and ends of the manipulator are perforated.
The general construction of this manipulator will be readily understood by
practical engineers Fig 4 shews in elevation the vessels for holding the liquid
compounds together with the reservoir for the air and gases and the pipes injectors
mixing box pillar fall-in valve and other parts of the apparatus herein before referred
to as the combined induction and atomising apparatus.
(25) is the reservoir before referred to it is made of 3/8 or other suitable boiler
plates and otherwise constructed in a similar way to a steam boiler and caulked
tight The cast iron pipe with flanged elbow marked (26) is the inlet for the liquid
compounds, air, gases and other elements The outlet is at the valve marked (27)
which is connected to the hollow pillar marked (28).
The cast iron saddles or brackets which support the cylindrical tanks are
marked (29).
The cylindrical tanks marked (30) (31) (32) are made of plate iron rivetted and.
caulked thoroughly tight The one markod (30) holds the liquid hydrocarbon com-
pound the one marked (31) bolds the liquid alkaline compound the one marked
(32) holds the acid compound.
The pipes marked (33) (34) (35) supply the air or gases from the reservoir to the
cylindrical tanks and the shut off valves therein are marked (36) (37) (38)—The
quantities of the liquids consumed are registered by gauges (39) similar to those
fitted to steam boilers.
Pressure gauges are also fitted to each tank and are marked (40).
The outlet pipes through which the liquid compounds together with the air and
gases are forced to the injectors are marked (41).
The injectors fixed to the mixing box on the hollow pillar are marked (42) and
these are fully described in the Specification of my Letters Patent N° 5025/
Each tank has a safety valve fitted on it One of these only is shewn and
marked (43) The cylindrical tank marked (32) which hold the acid is lined with
a suitable acid resisting material such as vulcanite tin silica or glass and the pipes
and fittings thereof are also made of vulcanite.
On the top of the hollow pillar is fixed a pressure gauge marked (44) while a
clock to register the time is fitted therein This is marked (45).
On the pipe lending to the manipulator is the fall-in valve marked (46).
The slip socket and pipe leading to the manipulator are marked (47) (48)—A
small syphon and pipes are fixed at the foot of the hollow pillar to catch any of the
liquid compounds which might fall from the injectors it is marked (49) The supply
pipes leading from the accumulators are marked (50).
After the metal has been treated in the manipulator it may be tapped directly
into a dam and run along a main gutter having channels leading therefrom into
suitable moulds and after casting the ingots may be left in such moulds and with-
drawn therefrom as required By adopting this method I dispense with cast iron
ingot moulds as also with soaking pits and heating in a furnace thereby effecting
an immense economy.

page_text: Having now particularly described and ascertained the nature of my said
invention and in what manner the same is to be performed I declare that what
I claim is
1° The employment and application of the hereinbefore mentioned liquid com-
pounds, air, gases, and other elements, substantially in the manner and for the
purposes herein before specified.
2° The apparatus hereinbefore described and referred to as "the manipulator"
and the "combined induction and atomising apparatus" constructed, combined,
arranged, and fitted, substantially in the manner hereinbefore specified, for the
application of such liquid compounds air gases and other elements in the manner
herein before specified and claimed.
Dated this 1st day of January 1885.
SAMUEL RICHARD SMYTH.
Elt & Co.,
33, Southampton Buildings, Holborn, London,
Agents for the Applicant.