An Improved Process for Treating Iron and other Ores, and Apparatus therefor.
Year: 1890

page_text: Date of Application, 3rd Feb., 1890
Complete Specification Left, 3rd Nov., 1890-Accepted. 31st Jan., 1891
PROVISIONAL SPECIFICATION.
An Improved Process for Treating Iron and other Ores, and
Apparatus therefor.
We, MICHAEL ROBERT CONLEY of Brooklyn in Kings County Engineer and
JAMES HARDING LANCASTER, Engineer of 169 & 171 Broadway, in the City of
New York both in the State of New York one of the United States of America do
hereby declare the nature of this invention to be as follows:-
Our invention relates to deoxidizing, desulphurizing and dephosphorizing iron
and other ores. Heretofore, the processes having these objects in view, have failed
to overcome many of the difficulties that arise during the treatment of the ore,
thereby causing the metal produced to be of an inferior character.
The object of our invention is to overcome these difficulties by means of direct
treatment of the granular or granulated ore in closed retorts, so constructed that
the ore can be stirred and also purified by gases being passed through the same;
also in conveying the prepared ore to the melting furnace without exposure to the
oxidizing action of the atmosphere. These objects we accomplish by a newly
constructed furnace or retort provided with the necessary appliances.
In carrying our invention into practice we provide a retort supported by a
suitable brick setting and made of metal or retort clay. This retort is heated by the
fire place or furnace adapted to use coal, or wood or gas. The retort can be heated
by these means to about fifteen hundred degrees (Fahrenheit). The said retort is
closed at one end and partially open at the other and its open portion or mouth
piece is provided with a hinged door containing a small sliding door. A tube is
provided for admitting purifying gas into the retort, while another tube serves for
the discharge of impure gases from the retort, a chute furnished with a lid being
used for filling the retort with ore.
These several communications complete the means of access to the interior of the
retort. The above mentioned mouth piece is provided with a shelf shaped lip,
with an opening having a covering. Directly underneath this lip is the chute
secured to the brick setting aforesaid and provided with an opening at the top, over
which is placed an air tight cover. This chute terminates into a spout at the bottom,
and is of sufficient length to be within range of a moveable vessel provided with a
discharge valve.
In order to prevent a too violent action of the heat under the retorts thereby
warping them and rendering the retorting action uneven, we partially incase or
surround the outside of the said retorts with fire brick or slabs of fire clay held in
position by means of lugs casted upon the retorts. This arrangement permits the
retorts being constructed of iron without any fear of burning them by a too rapid
application of heat.
In some cases the retort is furnished with revolving stirrers placed within the
same and mounted upon a shaft passing through stuffing boxes at each end of the
retort and supported at each end in water cooled bearing.
One end of this shaft is provided with a worm wheel acted upon by a worm
driven by a suitable cog gearing mechanism. The worm is so arranged upon
another shaft as to be acted upon by means of clutches controlled by suitable levers.
This is done to throw the worm in and out of gear for regulating the movement of
the stirrers as the treatment should require.
When one or more retorts are used the mechanism for revolving and stopping
them is independent of one another, so that a retort can be discharged or cleansed
without interrupting the action of the others.
The arms of the before mentioned stirrers are preferably arranged on their

page_text: respective shaft in straight rows for facilitating the cleaning of the retort. When
the retort is required to be cleansed its door is thrown open, and held open as long
as required by means of a latch.
In carrying our process into practice we bring the granulated or natural ore over
the retorts by means of a hopper car which runs on rails laid on top of the retort
and of its setting and along the entire length of the same. When the car is over
the mouth of the chute its contents are discharged into the same. The retort is
supposed to be heated by this time to about 1500 degrees (Fahrenheit).
The stirring mechanism being now set in motion, hydro-carbon gas is admitted
into the retort. It is afterwards decomposed by the heat and combines with the
oxygen, phosphorus, sulphur and other impurities in the ore and passes off out of
the retort through an outlet pipe or tube from whence it may be led under the
retort to the furnace and used to assist the energy of the same as a fuel. During
this purifying process, which usually requires from three to six hours, the ore is
constantly stirred by the agitating mechanism above mentioned but when hand
labor is used, the stirring should occasionally take place. As the stirring by hand
requires the opening of the sliding door formed in the retort door to insert a slicing
bar, care should be taken not to open the door too wide, for the admission of too
much air would materially affect the working of our process.
We may introduce the carbon in the form of granulated charcoal or coke mixed
with the ore previous to charging the retort, but we prefer to use gas as described.
The stirring is stopped when the impurities of the retort have ceased to show them-
selves, which is noticeable by the appearance of the flame at the end of the vent
pipe or by an examination of samples of the ore. When the treatment has reached
perfection, the retort mouth piece door is opened by simply raising it and is held in
position by the catch as described, while the retort is being cleansed.
The chute cap covering the mouth of the chute is then removed and the products
of the retort is as rapidly as possible hauled into the said chute and the same
instantly closed when the removal is finished.
This operation must be so conducted that it will expose the purified and
deoxidized ore as little as possible to the oxidizing action of the atmosphere.
The purified ore within the chute is now run off into the moveable vessel through
the spout aforesaid and the said vessel is hoisted and held on the top of the open
hearth furnace while its valve is opened to allow of the ore being poured into the
molten bath within the said furnace.
This is
In some cases we use a gas producer of any suitable construction for instance of
the "Siemens "type producing gas from soft coal with the aid of steam.
connected to a gasholder and from this producer, gas is carried by means of pipeing
through the retorts for the purpose of purifying, and thence into the retort furnace
to assist the combustion. In some cases the gas from this producer is taken direct
to furnace and not passed through retort.
Dated this 1st day of Wohm 1900
HUGHES, SON & Co.,
38, Chancery Lane, Agents.
COMPLETE SPECIFICATION.
An Improved Process for Treating Iron and other Ores, and
Apparatus therefor.
We MICHAEL ROBERT CONLEY, of Brooklyn, in Kings County, and JAMES
HARDING LANCASTER, of 169 Broadway, New York City, both in the State of
New York, U.S.A., Engineers, 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:-
_
Our invention relates to deoxidizing, desulphurizing and dephosphorizing iron
and other ores. Heretofore, the processes having these objects in view, have failed

page_text: to overcome many of the difficulties that arise during the treatment of the ore,
thereby causing the metal produced, to be of an inferior character.
The object of our invention is to overcome these difficulties by means of direct
treatment of the granular or granulated ore in closed retorts, so constructed that
the ore can be stirred and also purified by gases being passed through the same;
also in conveying the prepared ore to the melting furnace without exposure to the
oxidizing action of the atmosphere.
These objects we accomplish by a newly constructed furnace or retort with
necessary appliances, attached, which will be fully described hereafter, after
references being had to the accompanying drawings
:-
Fig. I. is a vertical sectional view of our improved retort, showing our apparatus
for stirring the ore, under treatment, by manual labor.
Fig. II. is a front elevation showing the arrangement of the retort.
Fig. III. is a detached front elevation of the month piece of a retort.
Fig. IV. is a sectional elevation of Fig. III. on liner,
Fig. V. is another sectional elevation of our retorts, showing the apparatus for
stirring, operated by mechanical means and also the retort using gas fuel.
Fig. VI. is another sectional elevation similar to Fig. V. except that the retort
shows a construction for using coal or wood, instead of gas as a fuel.
Fig. VII. is a rear elevation of our improved retort.
Fig. VIII. is a detached view of the latch for holding open the retort door.
Fig. IX. is a detached sectional view of the clutch worm used for driving the
shaft for revolving the stirrers.
Fig. X. is a cross sectional elevation of our retort, showing the arrangement for
mechanical stirring.
Figs. 11. 12. 13, are detail side, plan, and end view of one of the stirring arms
as used in the mechanical stirring.
Fig. 14. is a front elevation of the retort, showing the arrangement of the
apparatus pertaining especially to the use of gas fuel and purifying gas.
Fig. 15. is another central sectional elevation of the retort, showing modifications.
Fig. 16. is a rear view of the retort as shown in Fig. X.
Similar letters refer to similar parts throughout the several views.
Letter A, represents the brick setting with brick lining. Supported within
this brick setting is placed the retort T, made of metal or retort clay. A², is the
fire place or furnace adapted to use coal or wood or gas, in which case the pipe t,
is employed. The retort can be heated by these means to about fifteen hundred
degrees (Fahrenheit). The retort T, is closed at one end and partially open at
the other and the open portion or mouth piece M, is provided with a hinged
door containing a small sliding door. v, is a tube for admitting purifying gas
into the retort, and C, is a tube for the discharge of impure gases from the retort,
and A³, is a chute for filling the retort with ore, provided with a lid or cover.
These several communications complete the means of access to the interior of the
retort. The mouth piece M, is provided with a shelf shaped lip S, with an
opening having a covering. Directly underneath this lip S, is the chute B,
secured to the brick setting A, and provided with an opening at the top, over
which is placed the air-tight cover . This chute terminates into the spout B10,
at the bottom, and is of sufficient length to be within range of the moveable
vessel D, (see Fig. I.) which is provided with a discharge valve. Although this
vessel is shown resting on a truck E, it can be hoisted up by means of pulley and
tackle I, J, K, & H, and moved upon and along the rail G, to a point over the
depression P, formed in the roof of the furnace. Upon the removal of the cap P¹,
the contents of the vessel is discharged into the said furnace C³, which is an open
hearth of approved modern construction.
In order to prevent a too violent action of the heat under the retorts thereby
warping them and rendering the retorting action uneven, we partially incase or
surround the outside of the said retorts with fire brick or slabs of fire clay, held in
position by means of lugs casted upon the retorts (see Fig. 10.). This arrangement

page_text: permits the retorts being constructed of iron without any fear of burning them
by a too rapid application of heat. In Fig. 6, the retort is set in precisely the
same manner as that shown in Fig. I, excepting the mouth piece of the retort has
merely a plain hinged door A, instead of shelf shaped lip. In this fig. the
retort is shown with revolving stirrers d', placed within the same and mounted on
the shaft U, passing through stuffing boxes at each end of the retort and supported
at each end in water cooled bearing d².
One end of this shaft is provided with a worm wheel dª, acted upon by the
worm g, on shaft g, driven by a suitable cog gearing mechanism. The worm g
is so arranged upon the shaft as to be acted upon by means of clutches h, controlled
by levers i. This is done to throw the worm in and out of gear for regulating
the movement of the stirrers as the treatment should require. Where one or more
retorts are used, the mechanism for revolving and stopping them is independent of
one another, so that a retort can be discharged or cleansed without interrupting
the action of the others.
The arms of the stirrers are preferably arranged on their respective shaft in
straight rows for facilitating the cleaning of the retort.
When the retort is required to be cleansed, the door a, is thrown open, and by
means of the latch a', is held open as long as required. The retorts are filled at
opening a³, and discharged into chute B.
:-
Operation In operation, the granulated or natural ore is brought over the
retorts by a hopper car o², which runs on rails laid on the top of the retort,
setting A, and along the entire length of the same.
As
When the car is over the mouth of the chute (the cap having been previously
removed) its contents are discharged into the same after which the cap is
replaced. The retort is supposed to be heated at this time to about fifteen
hundred degrees, (Fahrenheit). The stirring mechanism is then set in motion,
hydro-carbon gas is then admitted into the retort. It is afterwards decomposed
by the heat and combines with the oxygen, phosphorus, sulphur and other impurities
in the ore, and passes off and out of the retort at the outlet pipe or tube,
from whence it may be led under the retort to the furnace and used to assist the
energy of the same as a fuel. During this purifying process, which usually requires
from three to six hours, the ore is constantly stirred by the mechanical mechanism,
but when hand labor is used, the stirring should occasionally take place.
the stirring by hand requires the opening of the sliding door formed in the retort
door to insert a slicing bar, care should be taken not to open the door too wide
for the admission of too much air would materially affect the working of our
process. We may introduce the carbon in the form of granulated charcoal or
coke mixed with the ore previous to charging the retort, but we prefer to use
gas as described. The stirring is stopped when the impurities of the retort have
ceased to show themselves, which is noticeable by the appearance of the flame at
When the
the end of vent pipe C, or by an examination of samples of the ore.
treatment has reached perfection, the retort mouthpiece door is opened by simply
raising it and is held in position by the catch as described, while the retort is
being cleansed. The chute cap covering the mouth of chute B, is then removed
and the products of the retort is as rapidly as possible hauled into the said chute
and the same instantly closed when the removal is finished. This operation must
be so conducted, that it will expose the purified and deoxidized ore as little as
possible to the oxidizing action of the atmosphere. The purified ore within the
chute B, is then run off into the closed vessel D, through the spout 60. The
vessel D, is then hoisted and held above the depression h, on the top of the open
hearth furnace C2.
After-
The cap P, is then removed. The valve L2, of the vessel is then opened and
the ore allowed to pour into the molten bath within the said furnace.
wards the cap is replaced and the vessel removed and replaced upon the truck and
wheeled again into position for future use.
Referring to Fig. 14, a gas producer Y, is shown of any suitable construction,

page_text: for instance on the Siemens type, producing gas from soft coal with the aid of
steam. This is connected to the gas holder Z, and from this producer, gas is carried
by means of piping through the retorts for the purpose of purifying, and thence
into the retort furnace to assist the combustion. In some cases the gas from this
producer is taken direct to furnace and not passed through retort.
Having now particularly described and ascertained the nature of my said inven-
tion, and in what manner the same is to be performed, I declare that what I
clain is:
1st. In a retort furnace for deoxidizing ore, the method or system of treating the
same within a retort containing revolving stirrers alternately operated by suitable
clutch mechanism; said retort is charged with hydro-carbon gas and heated by
means of coal, wood, or gas, substantially as set forth.
2nd. In a retort furnace for deoxidizing ore, the method or system of treating the
same within a retort with revolving stirrers; said retort being charged with hydro-
carbon gas and the gaseous product therefrom utilized for heating the same,
substantially as set forth.
3rd. In a retort furnace for deoxidizing ore, the method or system of treating the
same within a retort heated to about fifteen hundred degrees Fahrenheit; said
retort being charged with hydro-carbon gas and agitated by suitable revolving.
stirrers placed within the same.
4th. In a retort furnace for deoxidizing ore, the method or system of treating the
same within heated retorts charged with hydro-carbon gas, stirred mechanically or
by manual labor, and conveying the purified ore to a molten furnace without
submitting it to atmospheric action, substantially as described, and for the purpose
set forth.
5th. In a retort furnace for deoxidizing ore, the method or system of treating the
same within a retort charged with hydro-carbon gas stirred by manual labor and
heated by coal, wood, gas or the gaseous products from the said retort, substantially
as and for the purpose set forth.
6th. The improvement in deoxidizing ore consisting in heating the same in a
vessel closed to the atmosphere and circulating through it a hydro-carbon gas, sub-
stantially as specified.
7th. The improvement in deoxidizing or consisting in heating and agitating
the same within a closed vessel, and circulating through it a hydro-carbon gas, sub-
stantially as specified.
8th. The improvement in deoxidizing ore consisting in heating the same and
circulating through it hydro-carbon gas and carrying off the gas resulting from the
treatment of the ore to a furnace whereby the ore is heated, substantially as
specified.
9th. The combination of a retort for deoxidizing ore, a stirrer arranged within
the retort and a gas pipe leading thereto, substantially as specified.
10th. The combination of a retort for deoxidizing ore, a stirrer arranged within
the retort, a gas pipe leading thereto at one point and a gas pipe leading therefrom
at another point, substantially as specified.
11th. The process of manufacturing iron consisting in deoxidizing iron ore, in
storing the ore after deoxidation in a closed vessel to protect it against oxidation
from the air, and in introducing the deoxized ore from the place where it is stored,
into the smelting furnace, substantially as specified.
12th. The combination of the retorts, the chamber through which they extend,
having portions of the side walls downwardly inclined and converging, two furnaces
below, the chamber and an intermediate bridge wall, substantially as shown.
13th. The combination of a retort, a stirrer arranged within the same, a worm
wheel upon the shaft of the stirrer, a driving shaft, a worm on the driving shaft, a
clutch for engaging the worm with and disengaging it from the driving shaft, and a
lever for operating the clutch, substantially as specified and for the purposes
described.

page_text: 14th. The combination with a number of retorts, of stirrers arranged therein,
worm wheels on the shafts of the stirrers, a driving shaft common to all stirrers,
worms on driving shaft and clutches for engaging and disengaging the worms from
the driving shaft, substantially as specified.
15th. The combination with a combustion chamber, of disconnected retorts
arranged therein, clutches communicating with said retorts through which the ore
or other material may be supplied, stirrers arranged in said retorts, gearing for
causing the rotation of stirrers, discharge chutes for the retorts and a furnace, said
retorts being fully closed to the products of combustion from the furnace and to the
atmospheric air, substantially as described and for the purpose set forth.
16th. The combination with the combustion chamber of a non-rotary retort
arranged therein, a discharge chute for said retort and a car adapted to be moved
beneath the outer end, substantially as set forth and specified.
17th. The process of treating granular iron, or other ore to relieve it of
impurities, consisting in subjecting it to a heat in a closed retort, and when
sufficiently heated, subjecting it to agitation and passing through it, hydrogen or
other suitable gas for the purpose of dephosphorizing, deoxidizing and desulphurizing
said granular ore, substantially as and for the purpose specified.
18th. As a new article of manufacture, deoxidized carburated granular iron
or other ore, substantially as and for the purpose specified.
19th. In an apparatus for retorting ore, the firebrick shields placed under the
retorts, substantially as shown and for the purpose set forth.
Dated this 3rd day of November 1890
HUGHES, SON & Co.,
38, Chancery Lane, London, Agents.