Improvements in the Manufacture of Iron and Steel and in Apparatus therefor.
Year: 1898

page_text: Improvements in the Manufacture of Iron and Steel and in
Apparatus therefor.
I, WASSILY IVANOFF, of Pushkinskaya 20, St. Petersburg, in the Empire of
Russia, Engineer-Technologist, do hereby declare the nature of this invention
to be as follows:-
-
This invention has for its object an improvement in the manufacture of iron
and steel directly from ores, and also in a new combination of apparatus for this
purpose. The said method and combination will hereinafter be clearly explained
with reference to the accompanying drawings, in which:-
Figure 1 shows a vertical section on the line 1-1 of Figure 2.
Figure 2 a horizontal section on the line 2-2 of Figure 1.
Figure 3 a vertical section on the line 3-3 of Figure 1.
The ore and fluxes, but without fuel, are filled into the furnace A, where they
are subjected to reduction, to carbonisation, and to fusion, by the hot gases led
through the tuyeres a from the furnace B. The fuel is introduced into the
lower part of this furnace A through the tube L, which is suspended by chains
in such a manner, that it can be raised or lowered at will during the working of
the furnace and can be set to a suitable level. The furnace B is filled with crude
fuel (wood, coal, turf, or the like) through the funnel E. These raw materials
are heated and carbonised in the upper chamber of the furnace B above the
valve d. By opening this valve, the carbonised fuel drops into the lower
chamber of the furnace B, where it is subjected to an imperfect combustion by
the hot air, supplied from the air-heating chambers C, C through the tuyeres b, b
or by the carbonic acid and the free oxygen of the products of combustion of the
furnace D passing through the port e. The products of the incomplete com-
bustion in the lower chamber of the furnace B being of a very high temperature,
are conveyed through the conduit m and the tuyeres a into the furnace A, while
the products of the dry distillation, in the upper chamber of the furnace B, are
directed by the pipe g to the air-heating chambers, to fire boxes of steam boilers
or the like, for serving as fuel. In the furnace B and in the conduit m some
lime, alkalis, or iron, or manganese ore is introduced, to catch the sulphur of
the fuel. The hot air from the heating chambers C may be directed at will by
means of valves K to the tuyeres b of the furnace B or to the tuyeres f of the
furnace D. The air-heating chambers C may be of any suitable construction
and therefore their description is superfluous. The cast iron, obtained in the
furnace A is transferred in allotted portions by means of a channel or of a
movable casting ladle, into the furnace D. After the cast iron, has been poured
into the furnace D, hot air is blown into the said furnace, so as to produce the
combustion of the carbon, silicon, manganese and of a part of the iron contained
in the cast iron; this latter is gradually transformed into steel or iron, the
temperature of the bath rises and, at the end of the operation the steel or iron
obtained is poured out according as desired through the tap-hole n. To facilitate
this operation, the furnace D is made rotatory, but its weight is borne not by the

page_text: trunnions, but by independent rollers, while the trunnions serve to supply and
exhaust the gases. The tap hole n of the furnace 1) serves at the same time for
watching over the course of the melting process, the gases escaping from this
aperture, giving the necessary indications as to the progress of the operation;
the tap hole serves also for taking samples of metal and slags. The products
of combustion of the furnace D pass through the port e into the furnace B,
where the carbonic acid contained in them is decomposed into carbon monoxide
in proportion to the fuel contained in this furnace. When the melting process
is ended in the furnace D, the air supply is cut off and the whole mass of hot
air is directed towards the furnace B; during this time the passage e may remain
open when the furnace D will remain filled with hot gases, or may be closed by
the valve p.
The following are the advantages of the above described method for the manu-
facture of steel or iron directly from ores.
1). The reduction and the carbonisation of the metal are obtained exclusively
by means of gases and, therefore, in the most advantageous manner possible.
2). The finished product is obtained by a single heating operation. Although
the metal is in the form of cast iron, yet all the impurities of the iron are burnt
away in the course of the process and are utilised as fuel.
3). All the products of the operation are obtained in a melted form.
4). The course of the process depends neither on the properties of the ore, nor
on the composition of the cast iron; the production of iron from cast iron by
means of treating the same by blowing in hot air, may be successfully performed
from cast iron of any composition.
5). All combustible bodies contained in the cast iron in the form of impurities
are utilised in the course of the process as fuel for the furnace D; passing
through the furnace B, the said bodies are regenerated and utilised in the
furnace A.
6). All the slags and the splashings of the furnace Dare collected in the
furnace B, where the slags are transformed into metals; the metals are melted,
carbonised and then poured out from the furnace B.
7). For the reworking of the cast iron into steel and iron, the same apparatus
may be applied, as serves for producing cast iron, as well as the same motors,
the same blast devices, the same air-heating chambers etc.
8). In this process crude fuel may be used, as wood, coal, turf and the like;
liquid fuel may also be used for the furnace B, being injected by means of
burners.
9). The sulphur, contained in the fuel, is easily separated by introducing iron,
manganese, lime, or alkalis into the furnace B or into the conduit m.
10). Thanks to the fact, that the production of cast iron, steel and iron and the
treatment of the crude fuel are performed in a single operation, useless loss of
heat and of work is considerably curtailed.
The constructive details may, of course, be varied without influencing the
substance of the present invention. Thus the furnaces A and B may have several
compartments or may be inclined; the upper chamber of the furnace B may be
heated from the exterior or from the interior by burning away the products
of the distillation or of the gases escaping from the top of the furnace. The
furnace D may be fixed; a single furnace D may serve for a whole series of
furnaces A and so on. The substance of the invention will not be changed by
these alterations.
Dated this 23rd day of Novamhan 1000
CARPMAEL & Co.,
Agents for the Applicant.

page_text: Improvements in the Manufacture of Iron and Steel and in
Apparatus therefor.
I, WASSILY IVANOFF, of Pushkinskaya, 20, St. Petersburg, in the Empire of
Russia, Engineer-Technologist, do hereby declare the nature of this invention
and in what manner the same is to be performed, to be particularly described and
ascertained in and by the following statement:-
This invention has for its object an improvement in the manufacture of iron
and steel directly from ores, and also in a new combination of apparatus for this
purpose. The said method and combination will hereinafter be clearly explained
with reference to the drawings accompanying the Provisional Specification in
which;--
Figure 1 shows a vertical section on the line 1-1 of Figure 2.
Figure 2 a horizontal section on the line 2-2 of Figure 1.
Figure 3 a vertical section on the line 3-3 of Figure 1.
The ore and fluxes, but without fuel, are filled into the furnace A, where they
are subjected to reduction, to carbonisation, and to fusion, by the hot gases led
through the tuyeres a from the furnace B. The fuel is introduced into the
lower part of this furnace A through the tube L, which is suspended by chains
in such a manner, that it can be raised or lowered at will during the working of
the furnace and can be set to a suitable level. The furnace B is filled with crude
fuel (wood, coal, turf, or the like) through the funnel E. These raw materials
are heated and carbonised in the upper chamber of the furnace B above the
valve . By opening this valve, the carbonised fuel drops into the lower
chamber of the furnace B, where it is subjected to an imperfect combustion by
the hot air, supplied from the air-heating chambers C, C through the tuyeres b, b
or by the carbonic acid and the free oxygen of the products of combustion of the
furnace D passing through the port e. The products of the incomplete com-
bustion in the lower chamber of the furnace B being of a very high temperature,
are conveyed through the conduit m and the tuyeres a into the furnace A, while
the products of the dry distillation, in the upper chamber of the furnace B, are
directed by the pipe g to the air-heating chambers, to fire boxes of steam boilers
or the like, for serving as fuel. In the furnace B and in the conduit m some
lime, alkalis, or iron, or manganese ore is introduced, to catch the sulphur of
the fuel. The hot air from the heating chambers C may be directed at will by
means of valves K to the tuyeres of the furnace B or to the tuyeres f of the
furnace D. The air-heating chambers C may be of any suitable construction
and therefore their description is superfluous. The cast iron, obtained in the
furnace A is transferred in allotted portions by means of a channel or of a
movable casting ladle, into the furnace D. After the cast iron, has been poured
into the furnace D, hot air is blown into the said furnace, so as to produce the
combustion of the carbon, silicon, manganese and of a part of the iron contained
in the cast iron this latter is gradually transformed into steel or iron, the
temperature of the bath rises and, at the end of the operation the steel or iron
obtained is poured out according as desired through the tap-hole n. To facilitate
this operation, the furnace D is made rotatory, but its weight is borne not by the
trunnions, but by independent rollers, while the trunnions serve to supply and
exhaust the gases. The tap hole n of the furnace D serves at the same time for
watching over the course of the melting process, the gases escaping from this
aperture, giving the necessary indications as to the progress of the operation :
the tap hole serves also for taking samples of metal and slags. The products

page_text: of combustion of the furnace D pass through the port e into the furnace B,
where the carbonic acid contained in them is decomposed into carbon monoxide
in proportion to the fuel contained in this furnace. When the melting process
is ended in the furnace D, the air supply is cut off and the whole mass of hot
air is directed towards the furnace B; during this time the passage e may remain
open when the furnace 1) will remain filled with hot gases or may be closed by
the valve p.
The following are the advantages of the above described method for the manu-
facture of steel or iron directly from ores.
1). The reduction and the carbonisation of the metal are obtained exclusively
by means of gases and, therefore, in the most advantageous manner possible.
2). The finished product is obtained by a single heating operation. Although
the metal is in the form of cast iron, yet all the impurities of the iron are burnt
away in the course of the process and are utilised as fuel.
3). All the products of the operation are obtained in a melted form.
4). The course of the process depends neither on the properties of the ore, nor
on the composition of the cast iron; the production of iron from cast iron by
means of treating the same by blowing in hot air, may be successfully performed
from cast iron of any composition.
5). All combustible bodies contained in the cast iron in the form of impurities
are utilised in the course of the process as fuel for the furnace D; passing
through the furnace B, the said bodies are regenerated and utilised in
furnace A.
the
6). All the slags and the splashings of the furnace Dare collected in the
furnace B, where the slags are transformed into metals; the metals are melted,
carbonised and then poured out from the furnace B.
7). For the reworking of the cast iron into steel and iron, the same apparatus
may be applied, as serves for producing cast iron, as well as the same motors,
the same blast devices, the same air-heating chambers etc.
8). In this process crude fuel may be used, as wood, coal, turf and the like;
liquid fuel may also be used for the furnace B, being injected by means of
burners.
9). The sulphur contained in the fuel, is easily separated by introducing iron,
manganese, lime, or alkalis into the furnace B or into the conduit m.
10). Thanks to the fact, that the production of cast iron, steel and iron and the
treatment of the crude fuel are performed in a single operation, useless loss of
heat and of work is considerably curtailed.
The constructive details may, of course, be varied without influencing the
substance of the present invention. Thus the furnaces A and B may have several
compartments or may be inclined; the upper chamber of the furnace B may be
heated from the exterior or from the interior by burning away the products
of the distillation or of the gases escaping from the top of the furnace. The
furnace I may be fixed; a single furnace D may serve for a whole series of
furnaces A and so on. The substance of the invention will not be changed by
these alterations.
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 manufacture of iron and steel directly from ores by the herein before
described method characterized by the following features:-
a) The fuel is separate from the ores; it is filled into one furnace B, while
the ore is loaded into another furnace A; coal or coke being introduced
into the furnace A through the tube L only when necessary to thoroughly
carburate the iron and to avoid the caking of the metal and slag.
6) The furnace B is filled with crude fuel (wood, coal, turf, etc.) which is
there carbonised but the products of combustion of said carburated matters

page_text: are not mixed in the furnace B with the products of the dry distillation,
performed in the same furnace B, which gives a high temperature with
an incomplete combustion of the coal.
c) The reduction and the carburation of the iron in the furnace A are per-
formed exclusively by the gases, proceeding from the incomplete combus-
tion in the furnace B.
d) The decarburation of iron in the furnace D is performed by the same hot
blast of air, which serves for the reduction and carburation of the iron
in the furnace A.
e) The decarburation is performed by the hot blast of air, which allows
the treatment of cast iron of any composition.
f) The products of combustion from the furnace D are regenerated by pass-
ing through the furnace B and serve to reduce and to carburate the iron,
and to melt the metals and the slags in the furnace A.
. The new combination of apparatus, serving for the above described method
producing cast iron, characterized by the following features:-
-
a) The ore with the fluxes is separate from the fuel, the ore being piled
into the furnace A, while the fuel is filled into the furnace B.
b) Coal is supplied only into the lower part of the furnace A through the
tube L, so as to avoid the noxious decomposition of the CO, into CO in
the furnace A.
c) The fuel for the furnace B, as wood, coal, turf and the like, is supplied
in a crude state; it is carbonised in the upper chamber of the furnace B
and the carbonised matters are burnt in the lower chamber of the same
furnace and serve to reduce and to carburate the iron in the furnace A.
The new combination of apparatus, serving for the production of iron and
el directly from ores and characterized by the following features:
a) The hot blast of air is directed into the furnace B alternately; either
directly or through the furnace D; in both cases the products of the in-
complete combustion of the fuel in the furnace B serve to reduce, to
carburate, and to melt the iron in the furnace A.
b) The furnace D), serving to burn away the alloys of the iron, is supplied
by the same hot blast, which serves for the reduction and the carburation
of the iron in the furnace A.
c) The products of combustion of the furnace D, serving for the decarbura-
tion of the iron are utilized for the furnace A by the intervention of the
furnace B.
The furnace B serves simultaneously for the carbonisation of the crude
fuel and for the combustion of the obtained coal or coke for the furnace A.
c) The coal is introduced only into the lower part of the furnace A by
means of the tube L.
The disposition of the furnace B, for use in the above described process,
furnace serving to carbonise the crude fuel and being characterized by the
owing features:
a) The furnace B is divided by means of the valve d into two chambers:
the upper one, where the carbonisation of the fuel is performed, and the
lower chamber, where the coal obtained is burnt.
b) The products of the dry distillation of the fuel are separate from the pro-
ducts of combustion from the coal obtained and may be utilized indepen-
dently.
c) The carbonisation of the fuel in the upper chamber of the furnace B
takes place owing to the heat from the combustion of the coal in the lower
chamber of said furnace; this heat is transmitted through the walls,
through the valve d and also by means of the gases, penetrating through
the leakage of said valve as well as by means of the burning of the pro-
ducts of dry distillation or of the gases escaping from the top of the
furnace inside or outside of the upper part of the furnace B.

page_text: 5. The special construction of the rotary furnace D, serving for the decarbura-
tion of the cast iron, and characterized by the following features:--
a) The weight of said furnace is not borne by its trunnions, but by indepen-
dent rollers, which allows the use of the trunnions for supplying and
emitting the hot gases.
b) The supply of the gases as well as their emission takes place through
the trunnions of said furnace, allowing these gases to be directed into
the furnace B.
CARPMAEL & Co.,
Agents for the Applicant.