Improvements in the Manufacture of Steel and Iron.
Year: 1894

page_text: Date of Application, 27th Apr., 1994
Complete Specification Left, 27th Feb., 1895-Accepted, 30th Mar. 1895
Improvements in the Manufacture of Steel and Iron.
1 BENJAMIN PRYOR STOCKMAN of Grosvenor Mansions, Victoria Street
Westminster, Civil Engineer do hereby declare the nature of this invention to be
ns follows:
-
My invention has for its object the production of steel and iron by the conversion
of crude pig iron or the ore direct from the blast furnace automatically by chemical
action and reaction. And for the purpose of effecting the same I use a mixture of
nitrate of soda and iron sand such as is found in New Zealand and various other
countries. I pulverize the nitrate of soda and add to it a proportion of iron sand
with some smaller quantities of other oxidizing ingredients and fluxes as may be
required according to the quality or nature of the pig iron to be converted, the
particular and chief part of my invention being the use of the mixture of nitrate of
sola and iron sand as before mentioned. I also mix iron sand with fireclay lime or
ganister to form a plastic compound for lining all vessels ladles or shanks and for
luting joints, & for any surfaces which in the process, may come into contact with-
the molten pig iron. I also sometimes mix with the nitrate of soda and iron sand, :
black oxide of manganese, lime, chloride of sodium chlorate of potash & nitrate of
potash to assist and facilitate the oxidization of the impurities in the pig iron, and
their removal to slag; the proportions varying according to the amount & chemical
nature of the impurities to be eliminated in the crude pig iron.
My invention also includes the apparatus machinery and means by which I carry
out the process, and which may be described as follows:-
The pig iron of any quality or grade whether hematite or the commonest phos-
phoric pig iron, is melted in an ordinary cupola, but to correct the sulphur in the
coke or the sulphur and phosphorus in the pig-iron I sometimes use Jime in the
cupola.
In close proximity to the cupola is the converting apparatus comprising a
measuring or gauging vessel by which the metal is either weighed by a steel yard
arrangement or simply measured; also a tall stack or chimney of iron at the under
part of which is the converter or vessel into which the molten pig iron is poured
from the cupola. The gauger or measurer is provided with an opening and plug
at bottom, so that when the plug is lifted the molten pig iron is discharged freely
into the converter by a channel or duct provided for the purpose.
The converter contains the chemical ingredients, mainly consisting of the nitrate
of soda & iron sand. These ingredients, having been well mixed in a powdered
state, are placed in the bottom of the converter. The iron sand, besides its use as
an oxidizer, acts as a diluent to prevent the too rapid deflagratory action of the
nitrate of soda. There is also an iron plate which may be either cast or wrought;
but I make this plate out of the converted and refined steel or iron produced by the
process. The plate is perforated by holes like a cullender, and is laid down on a
ledge in the converter close to the surface of the chemical ingredients.
The converter which is of cylindrical form has an upper flanged rim which has
a U shaped projection, forming a spout for pouring the metal, and a bridge across
this spout keeps back the slag when pouring the metal. The upper stack or
chimney has a lower flange with a corresponding Ụ shaped projection so that when
the two are in contact the flanges are continuous and sealed hy the lute.
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page_text: The converter being charged with the nitrate of soda and iron sand and other
ingredients is moved along a tramway by machinery until it arrives immediately
under the stack or chimney, when by hydraulic pressure, or otherwise it is forced
or pressed upwards into contact with the stack, the flanged joint being luted; and
when thus prepared and ready, the cupola containing the molten pig iron is tapped,
and the fluid metal runs first into the measurer or gauger which discharges into the
converter; and the moment the molten metal reaches the iron perforated plate it
pours through the holes and falls upon the mixture below. A sudden re-action
takes place; gases are given off and the plate finally melts and mixes with the fluid
metal; the carbon sulphur phosphorus, & other metalloids are oxidized forming
slag; & steel or iron is thus produced in the converter.
The converted metal is finally dealt with by puddling balling or refining in 'a
reverberatory furnace & by the use of iron-sand I also regulate the quality of the
steel. I sometimes inject steam from a boiler into the furnace to facilitate the
refining process by the decomposition of the steam.
Dated this 27th day of April 1894.
COMPLETE SPECIFICATION.
Improvements in the Manufacture of Steel and Iron.
I, BENJAMIN PRYOR STOCKMAN, of Grosvenor Mansions, Victoria Street,
Westminster, Civil Engineer, 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:-
My invention has for its object the production of steel and iron by the conversion
of crude pig iron by treatment with a mixture of nitrate of soda and iron sand such
as is found in New Zealand and various other countries. I pulverize the nitrate
of soda and add to it a proportion of iron sand with some smaller quantities of such
other ingredients and fluxes as may be required according to the quality or nature
of the pig iron to be converted. I also mix iron sand with aluminous fire clay or
lime, to form a plastic compound for luting joints and lining vessels, ladies, shanks
and other surfaces which, in the process, may come into contact with the molten
metal. I also, sometimes mix with the nitrate of soda and iron sand, black oxide
of manganese, lime, chloride of sodium, chlorate of potash, and nitrate of potash, to
assist and facilitate the elimination of the impurities in the metal; the proportions
varying according to the amount and chemical nature of the impurities to be
eliminated from the crude metal.
The apparatus by which I carry out the process may be varied; the following
arrangements may be adopted.
The pig iron of any quality or grade, even the commonest phosphoric pig iron,
is melted in an ordinary cupola, but to correct the sulphur in the coke, or the
sulphur and phosphorus in the pig iron, I sometimes use lime in the cupola.
In close proximity to the cupola I arrange the converting apparatus, comprising
a measuring or a gauging vessel by which the metal is either weighed or simply
measured. I also provide a tall stack or chimney which may be of iron having in
its under part the converter or vessel into which the molten pig iron is poured from
the measuring vessel through a hole furnished with a plug.
The converter contains the chemical ingredients, mainly consisting of the nitrate
of soda and iron sand well mixed and in a powdered state placed in the bottom of
the converter.
A metal plate which is preferably made of the steel or iron produced by the
process, is perforated with numerous holes and is laid down on a ledge provided in
the convertér, close to the surface of the chemical ingredients.

page_text: The converter which is of cylindrical form has an upper flanged rim having a
U shaped projection, forming a spout for pouring the metal when the converter is
canted over; this spout has a bridge across it to keep back the slag during the
pouring of the metal. The upper stack or chimney has a lower flange with a
corresponding Ushaped projection so that when the two flanges are in contact they
form a continuous joint sealed luting between them.
The converter charged with the nitrate of soda and iron sand and such other
ingredients as are necessary and having its flange luted is moved along a tramway
until it arrives immediately under the stack or chimney, when, by hydraulic
pressure, or otherwise, it is forced upwards so as to bring its flange into close
contact with that of the stack. When the converter is thus held, the cupola
containing the molten pig iron is tapped, and the fluid metal runs first into the
measuring vessel and then from it is discharged into the converter.
As soon as the molten metal reaches the iron perforated plate it pours through
the holes and falls upon the mixture below.
A sudden reaction takes place; gases are given off and the plate finally melts
and mixes with the fluid metal. The carbon, sulphur, phosphorus, and other
metalloids are oxidized and escape or form slag and iron is thus produced in the
converter.
By adding ferro manganese or spiegeleisen, steel may be produced in the
converter.
The converted metal is finally dealt with by puddling, balling or refining.
In the process above described, the iron sand besides promoting oxidation of the
impurities, acts as a diluent retarding and rendering less violent the reaction in
the converter. This iron sand may also be used with advantage in the refining
furnace, serving to regulate the quality of the steel. When it is applied in this
way, it may be made up with carbonaceous and agglutinant inaterials into bricks,
cakes or lumps which can be thrown into the molten metal in the furnace.
The proportions of the materials in the mixture employed in the converter may
be varied. I find a good proportion is 90 to 100 lbs. of nitrate of soda and 37 to
40 lbs. of the iron sand to the ton of metal to be converted.
With these may be mixed about 2 lbs. each of lime, oxide of manganese
and salt.
Having now particularly described and ascertained the nature of this inven-
tion and in what manner the same is to be performed, 1 declare that what I
claim is
1. The herein described process for the manufacture of steel and iron from crude
pig iron, by subjecting the molten pig iron in a converter to the action of a
mixture of nitrate of soda and iron sand.
2. For carrying out the process above referred to, the use of iron sand in
admixture with fire clay or lime for lining surfaces exposed to the action.
Dated this 27th day of February 1895.
ABEL & IMRAY,
Agents for the Applicant.