Improvements in the Conversion of Crude Iron into Malleable Iron and Steel, and Apparatus therefor.
Year: 1889

page_text: PROVISIONAL SPECIFICATION.
Improvements in the Conversion of Crude Iron into Malleable Iron
and Steel, and Apparatus therefor.
I, HUGO AUGUSTE BECKER of Blaenavon in the County of Monmouth Metallurgist
do hereby declare the nature of this invention to be as follows:-
The conversion of crude Iron into Malleable Iron and Steel is effected by blowing
cold or hot air through the liquid crude Iron. This is conveniently effected in the
following apparatus. It consists of a cylinder formed of iron or steel plate around
which two or more rings are placed, and the cylinder rests horizontally or nearly so,
on these rings, which in their turn bear on four or more antifriction wheels rotating
on fixed supports, two on each side of the cylinder. The cylinder can be turned
round on its axis by means of its bearing on these wheels, and therefore is a rotating
cylinder. The turning is effected by a tooth-wheel, the teeth of which grip in a
screw or another tooth wheel attached to the cylinder which is thus moved by hand
or any other power. The cylinder is lined inside with such materials as are compatible
with the Iron to be used. The lining can be made of Silica brick or composition, or
of Basic material such as Dolomite, Magnesite or Chrom-ore or other suitable sub-
stances, or of any of these in combination.
The tuyeres for the blast go through the lining all in one line parallel to the axis,
and can be directed either horizontally to the centre from the outside or at any
preferred angle.
The wind-box is parallel to the axis of the cylinder.
On both ends of the cylinder man-holes or suitable openings are left of sufficient
size, through which the converter is charged and repaired. These openings or man-
holes are provided with lids lined with the same material as the inside of the apparatus.
Both or only one may be left open while blowing.
To work the converter it is turned so that the tnyeres are in such a position as
not to be touched by the metal, which is let in by one of the openings available for
cleaning, and it lies on the bottom of the converter. Then the converter is turned
until the tuyeres are near the surface of the metal when the blast is turned on and the
tuyeres submerged in the metal to such a depth as may be thought proper by the
operator.
It will be seen that any required depth can be obtained according to the pressure
of blast employed. All the tuyeres are engaged and disengaged simultaneously.
After the blowing is over Spiegel, Ferro-manganesse, Ferro-silican, Alluminium steel,
or other material can be added either in the converter or in the ladle in which the
metal is poured through a suitable tap-hole. If the addition is done in the converter
a better mixture can be obtained by turning the converter round to such extent as
not to submerge the tuyeres. The tap-hole may be put in any suitable part of the
converter.
COMPLETE SPECIFICATION.
Improvements in the Conversion of Crude Iron into Malleable Iron
and Steel, and Apparatus therefor.
I, HUGO AUGUSTE BECKER of Godwith Cottage, Blaenavon in the County of
Monmouth, Metallurgist, 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 relates to an improved form of "Converter" for containing the

page_text: changed or converted into malleable iron or steel, and to the
advantages resulting from its employment.
The conversion of crude iron into steel etc. is effected by forcing blasts of hot or
cold air through the liquid metal. -
The "Converters "at present mostly in use are termed the " Bessemer," " Walrond,”
and Robert," from the names of their Inventors.
They are all vertical chambers lined with the usual fire-resisting composition, the
two first being cylindrical, and the latter D shaped in section. All are mounted on
horizontal trunnions and when they have to be moved with a charge of molten metal
inside, they require powerful and costly appliances for the purpose, because the dead-
weight of the metal lying at the bottom of "Converter" has to be lifted as well as
the "Converter" itself.
In the case of the "Bessemer" there is another disadvantage owing to the tuyeres
or blast orifices being at the lower end of the "Converter." From the position of
the tuyeres they cannot be all simultaneously freed from the molten metal, when it is
time to tip the "Converter" and remove the charge, consequently the blast must be
continued during the tipping to prevent the metal choking some of the tubes, and the
blast from the uncovered tuyeres blows some of the metal out of the "Converter "
thus increasing the per-centage of loss.
In the "Walrond Converter" the blast is introduced horizontally at a line not far
below the level of the molten metal or charge.
In this "Converter" also some of the tuyeres are uncovered during the tipping thus
again wasting the metal, and choking the covered tuyeres.
In the Converter "Robert" the tuyeres enter on the flat side and are arranged in
a horizontal line at some distanee from the bottom of the Converter and near the top
of the molten metal. This method of arrangement allows the tuyeres to be uncovered
simultaneously thus permitting the blast to be stopped when tipping and no doubt it
answers fairly well when the "Converter" is new, but in all converters the lining
wears rapidly away and consequently the cavity of the chamber rapidly increases in
size.
It is thus evident that if the charge is uniform in the "Walrond" and "Robert "
converters the blast soon becomes too high for the metal unless the quantity of the
charge is constantly increased.
My improved "Converter" aims at overcoming all the foregoing disadvantages
while affording increased advantages not hitherto available.
I will now describe it in relation to the accompanying drawings in which Fig. 1
shews a longitudinal section of my improved "Converter." Fig. 2. shews a transverse
section of the same. Fig. 3. shows a plan in section. Fig. 4 shews a central
transverse section without the rings regarded from the rear, when the "Converter "
is preparing to pour out the metal. Fig. 5 is a sectional plan of another form of my
improved Converter."
"
It will be seen that this "Converter" differs from the others by being horizontal
instead of vertical.
It consists of the usual plate metal skin or casing in which is built the fireproof
lining. The casing is encircled and strengthened by two or more grooved metal
rings a, a, which rest on the wheels 1. It is therefore a cylinder which can turn round
its longitudinal axis, which axis is horizontal.
One of the ends of this cylinder is extended as shewn in Fig. 1, forming the
mouth o.
This part can be formed of any convenient shape for blowing and pouring
out. The other end is spherical or of similar shape and has an opening p, which can
be closed at will. The mouth, o, may be placed at another part of the "Converter"
as shewn in Fig. 5, and then two of the openings, p, can be made, one at each end of
the " Converter." The space inside the lining, 1, is cylindrical or nearly so with
hemi-spherical or nearly hemi-spherical ends.
In small sizes or for special uses the cylindrical form of the "Converter "
shortened so as to make the interior spherical or nearly spherical if preferred.
may be
In the lining, l, opposite the mouths o.p, are the tuyeres, t, which are in connection

page_text: with a blast fan through the windbox, b, and the tubes, d, and h
For
These tuyeres, /,
pass through the lining and end inside the "Converter" in a line parallel to its axis
as shewn in Fig. 1. But from their orifices outwards they can be arranged at any
preferred angle to that line, that is to say, as shewn in Fig. 1, they may be all in a
plane and all inclined at one uniform angle in that plane or not as preferred.
instance although ending in a line they need not be all in one and the same plane nor
at the same angle, as shewn in Figs. 4 & 5. The inside of the "Converter" can
be elliptical in section or of any other suitable shape. The rotary movement is given
to the apparatus by any convenient kind of power. Thus it may be acted on by the
pipe h, which could be strongly fastened to the "Converter," or by rotating the wheels, r,
or by employing a toothed wheel engaging with a toothed ring placed round the
cylinder or otherwise. The lining, l, of the "Converter" can be made of bricks or
composition. These bricks or composition can be of a material, either "acid," "basic"
or "neutral" or can be of any other material compatible with or suitable to. the
metal or metals to be worked in the apparatus.
It will be seen that the blast coming through the tuyeres can meet the metal, m,
at any required angle and drive it towards the bottom of the " (Converter" opposite
to the opening, º.
"
"
The form and the horizontal position of the "Converter" compels the liquid metal, m,
always to remain in the lower part of the chamber even if the Converter be
turned; it is therefore easy to see that in order to give the "Converter" any required
position there is no necessity to lift the dead-weight of the metal in the apparatus..
If the converter is turned so for as to bring the month, o, lower than the surface of
the molten metal the contents will naturally flow out, without the metal being lifted,
or the converter itself being tilted.
The repairing of the lining is generally done with composition. To do this it is
only necessary to turn the spot to be repaired towards the ground to lay the composition.
on it and the "Converter" can then be left in that position until the composition has
become hard. The position of the mouth, o, and the hole, or holes, p, which can be
opened, facilitate these repairs.
Fig. 2, shews that in cross section the metal in the "Converter" takes the form of
a segment of a circle. It is easy to understand that by turning the "Converter"
more or less any depth of the metal from the minimum to the maximum thickness of
the charge, m, in the converter can be brought over the tuyeres; but as the counter
pressure of the metal against the blast depends on the height of the charge over the
tuveres, the pressure of metal can be regulated at will in this "Converter" by simply
covering or uncovering the tuyeres more or less. Thus the pressure of the blast can
be modified as desired. As the lining wears away the capacity of the "Converter"
becomes gradually larger but the metal will still take the shape of a segment, and the
operator can always put such a depth of metal over the tuyeres as he considers
necessary without being obliged to increase the quantity of the charge. This shows
also that the charges can be of a constant weight or the quantity of metal may vary
as required without losing the advantage of being able to pat any desired depth of
it over the tuyeres.
The "Converter" forming a. roof over the metal, the particles of metal thrown up
by the blast come in contact with this roof and fall back into the charge instead of,
as in other Converters, being thrown out of the "Converter" and wasted.
The blast causing the combustion of the carbon and other impurities of the metal.
throws the gases produced to the back of the chamber, so that the gases produced are
compelled to pass over the metal before leaving the "Converter" and they yield up
in consequence a large part of their heat before passing away, consequently there is
a clear gain for the metal of the beat of the gases passing over it.
Owing to this great heat the bath becomes very liquid, the metal and the slag
separate easily, and the blast not passing through the whole of the metal, the metallic
molecules weld well together and this ensures a product of high density and therefore
of superior quality.

page_text: It may be remarked that the dust or particles thrown out of the mouth, o, all fall
away from the "Converter" instead of falling on the apparatus and its bearings.
The metal owing to its high temperature and therefore its liquidity, will be in the
best condition to give sound castings.
To work the apparatus. I would turn it so as to bring the mouth and the tuyeres
near the height of the axis of the cylinder. Then the liquid metal is introduced;
this metal may come direct from the blast furnace, or from a cupola, or from any
other source, and may be poured through the mouth, o, or the orifice, p. The liquid.
iron falling to the lower parts of the "Converter" will not at first touch the tuyeres.
The "Converter" is then turned in such a way as to bring the tnyeres near the charge
and when at a short distance of it, the blast is turned on and the "Converter turned
until the tuyeres are covered by the metal. From that moment the operation begins
and according to the different stages of the process the operator will change the depth.
of metal-over the tuyeres or vary the pressure of the blast as he thinks proper.
"
When the operation is at an end, the tnyeres are uncovered by lowering the mouth
and lifting the tuyeres.
f
Ferromanganese, Ferro-silicum, Spiegal, Ferro-alluminium, or any other metal
material wanted can be then added, either direct in the "Converter," or in the ladle,
while pouring the metal out of the Converter into the ladle.
To pour the metal from the "Converter," the "Converter" is turned and the
mouth lowered below the base of the metal which will then flow into the ladle or
ladles.
..
The following advantages result from the use of my improved "Converter."-
1st. The power notwithstanding wear of interior to cover and uncover all the
tuyeres simultaneously with a charge of any dimension.
2nd. Power to regulate both the height of metal over the tuyeres and therefore the
pressure of the blast.
3rd. The power to make at will charges of a constant or variable weight in spite of
the increasing capacity of the "Converter " owing to the wear and tear of the lining.
4th. The advantage of power for the moving, filling, and emptying of the apparatus.
5th. The power to use low blowing pressure whatever the weight of the charge.
6th. Retaining the greater part of the heat from the gases before leaving the
"Converter.":
7th. To gain a very hot metal, and consequently very liquid.
• 8th. Increased convenience for repairing the lining.
9th. Less danger to operators owing to the "Converter" being always in a
permanent and stable equilibrium.
*P*..
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
claim is :-
..
1. A "Converter" for molten metal consisting of a horizontal, cylindrical, elliptical
or circular chamber with concave hemispherical or rectangular ends, and having a
suitable mouth piece and other openings as herein explained and set forth.
2. In a horizontal "Converter" the circular ribs a, a, the wheels and standards r,r,.
8, 8, or other mechanical equivalents as herein explained and set forth.
3. In a horizontal "Converter" the air pipes h, d, the air chamber, b, the tuyeres, t,
or other equivalents as herein explained and set forth.
S. S. BROMHEAD,
97, Newgate Street, London, E.C., Patent Agent.