IMPROVE. MENTS IN THE MANUFACTURE OF ARTIFICIAL COAL FUEL, AND IN APPARATUS EMPLOYED IN SUCH MANUFACTURE
Year: 1860

page_text: LETTERS PATENT to Ferdinand Charles Warlich, of 14, London Street,
Fenchurch Street, in the City of London, for the Invention of "IMPROVE.
MENTS IN THE MANUFACTURE OF ARTIFICIAL COAL FUEL, AND IN APPARATUS
EMPLOYED IN SUCH MANUFACTURE"
Sealed the 12th September 1860, and dated the 10th July 1860.
PROVISIONAL SPECIFICATION left by the said Ferdinand Charles Warlich
at the Office of the Commissioners of Patents, with his Petition, on the
10th July 1860.
I, FERDINAND CHARLES WARLICH, of 14, London Street, Fenchurch Street,
in the City of London, do hereby declare the nature of the Invention for
"IMPROVEMENTS IN THE MANUFACTURE OF ARTIFICIAL COAL FUEL, AND IN APPARATUS
EMPLOYED IN SUCH MANUFACTURE," to be as follows :--
The manipulation of small coal into artificial coal fuels according to my
Invention is as follows:-The small coal which is to be used is first deprived
of foreign matters as far as is practicable by mechanical means, such as
screening, picking out slate, stones, and other impurities. Then, according to
the nature of the coals and its associated foreign matters, it undergoes a
washing process, as hereafter described; or the coal, which requires a stronger
purifying agency than washing, is placed on to a covered calcining hearth, and
subjected to a calcining or charring process previous to or after washing it.
From the calcining hearth the coal is conveyed in its hot state to the washing
Price 1

page_text: apparatus. The coal in this state heats the water and causes it to produce a
stronger action. From the washing apparatus the coal is removed to be dried,
and then to the mixing machine, where the coal is mixed with about ten per
cent. of coal tar, more or less, and for some special purposes in addition
thereto, with from one to three per cent of well dried and powdered vegetable
pitch. The mixture is introduced into the moulds of the pressing machine,
and is removed from it as compressed fuel on iron carriages into the improved
carbonizing retort, where it is left from 6 to 12 hours and upwards, subject to
the influence of heat varying in temperature from 500° to 800 Fahrenheit,
according to the purpose for which the fuel is intended, and according to the
composition of the fuel, whether of calcined or not calcined coal, or the
mixture of both.
A coke fuel in regular shapes for close stowage is produced in the coking
retort, hereafter explained, by placing moulds filled with coals into it, and
such coal may be transformed or converted into a coke fuel of any desired
quality according to the kind of coal selected, the coking action being caused
to proceed rapidly or slowly by exhausters or pumps, and by the influence of a
higher or lower temperature. A similar coke fuel may also be produced by
compartments filled with coals in a suitably arranged coke oven,with exhaust-
ing apparatus and regulators for the more or less rapid removal of the vapours
from the influence of the heat within, and by elevating and lowering the
temperature at pleasure. These processes produce tar and other products of
value. Coalwhich contains in its natural state earthy and other foreign sub-
stances, even in considerable quantities, may thus be converted into a superior
and a cheap fuel.
The apparatus employed for the above purposes consists, first, of a series of
screening or jigging sieves fixed in a frame one above the other, the whole
being worked by an ascending and descending motion immersed in water.
The upper sieve being composed of the largest meshes, the next below of
smaller meshes, and so on however many sieves may be used in a set. The
coal is supplied on to the upper sieve, and by the up-and-down motion of the
sieves in the water the coal will be washed, and the coal will also be separated
into several sizes and received into the several sieves. The coal thus washed
and separated into sizes is then dried.
The calcining or charring hearth which is used by me for the preparation of
small coal intended to be converted into compressed artificial fuel, and from
which are to be collected the volatile ingredients evolved or expelled in the
form of vapours therefrom, is as follows:-Afoundation, either built of bricks,
stones, or formed of cast iron, is used, on which iron rails are fixed, leaving or

page_text: enclosing a hollow space beneath it, similar to a vault, into which either water,
steam, or air can be admitted, by suitably arranged pipes and valves, at will,
the whole standing in a water trough. A cast-iron frame on four wheels
similar to a truck holding a calcining grate, which represents the hearth
moveable when required on the rails fixed upon the foundation. The calcining
grate or calciner is made, by preference, of iron slabs combined together like
a Venetian blind, to open and shut more or lessat pleasure. A cover or hood
made of thin sheet iron is suspended by tackle in a frame, so as to cover the
whole of the hearth, and it is arranged to be raised or lowered more or less at
pleasure for charging and discharging the hearth, and enlarging or contracting
the space above the calcining grate. One or more wirework nets are
suspended in the interior of the hood or cover, and are adjusted by a suitable
tackle for being raised or lowered, and to approach more or less the coal
which is on the calcining grate.
Another calciner or oven used by me is constructed in several tiers one
above the other, and built of brickwork or stone, in a somewhat similar
manner to those used for calcining or roasting crushed, pounded, or ground
mineral ores in metallurgy. The lower tier has a calcining grate, and the
upper tiers are heated when the operation has commenced by the heat from
the lower tier, which causes the process in all the tiers to proceed nearly
simultaneously. The vapours from these ovens are condensed into liquids in
the same manner as heretofore.
. For carbonizing fuel a retort is built, by preference of brickwork, and of a
size according to the quantity of compressed fuel which it is intended to hold.
The bottom of the carbonizing retort forms the top of a coking oven, and the
flues which surround the carbonizing retort conduct the heat to the retort
from the coking oven beneath. The arrangement of this carbonizing retort,
its construction, and its appendages, are similar to the carbonizing retorts
heretofore used by me, and which are well known, but heretofore no coking
ovens were placed beneath them. The construction of these coking ovens is
simple, each consisting of a vault about two feet deep built beneath the
carbonizing retort. The coke oven is of brickwork or stone, and is constructed
with compartments or divisions for holding the coals to be transformed or
coked into regular shaped coke fuel suitable for close stowage. The size or
the coking ovens correspond with the retorts used for carbonizing compressed
fuel.
In some cases I employ a retort for coking small coal into regular shaped
fuel; this retort is of a size according to the quantity of product the operation
is intended to furnish by one change. This retort is of cast iron in three.

page_text: parts, consisting of a cylinder in the middle, and two spherical or curved ends:
its lowest part set in brickwork or any suitable material. In the lower part
of this retort iron pipes are inserted, one of which, the largest, has affixed to
it an exhauster or a pump for drawing off the vapours; the other smaller pipes
serve as escape pipes for the liquids, which descend into the tar cistern placed
beneath the retort. The moulds or forms with their contents are suspended
from a plate at the upper part of the retort. The cover or upper end is to be
removed to introduce and remove each charge, and provision is made for
introducing air or steam, and for the exit of vapours or gases from the interior
of the retort. The vapours are condensed in the ordinary manner.
SPECIFICATION in pursuance of the conditions of the Letters Patent, filed
by the said Ferdinand Charles Warlich in the Great. Seal Patent Office
on the 10th January 1861.
TO ALL TO WHOM THESE PRESENTS SHALL COME, I, FERDINAND
CHABLES WARLICE, of 14, London Street, Fenchurch Street, in the City of
London, send greeting.
WHEREAS Her most Excellent Majesty Queen Victoria, by Her Letters
Patent, bearing date the Tenth day of July, in the year of our Lord One
thousand eight hundred and sixty, in the twenty-fourth year of Her reign,
did, for Herself, Her heirs and successors, give and grant unto me, the said
Ferdinand Charles Warlich, Her special licence that I, the said Ferdinand
Charles Warlich, my executors, administrators, and assigns, or such others as
I, the said Ferdinand Charles Warlich, my executors, administrators, and
assigns, should at any time agree with, and no others, from time to time and
at all times thereafter during the term therein expressed, should and lawfully
might make, use, exercise, and vend, within the United Kingdom of
Great Britain and Ireland, the Channel Islands, and Isle of Man, an
Invention for "IMPROVEMENTS IN THE MANUFACTURE OF ARTIFICIAL COAL FUEL
AND IN APPARATUS EMPLOYED IN SUCH MANUFACTURE," upon the condition
(amongst others) that I, the said Ferdinand Charles Warlich, my execu-
tors or administrators, by an instrument in writing under my, or their, or
one of their hands and seals, should particularly describe and ascertain the
nature of the said luvention, and in what manner the same was to be per.
formed, and cause the same to be filed in the Great Seal Patent Office
within six calendar months next and immediately after the date of the said
Letters Patent.

page_text: NOW KNOW YE, that I, the said Ferdinand Charles Warlich, do hereby
declare the nature of the said Invention, and in what manner the same is
to be performed, to be particularly described and ascertained in and by the
following statement thereof, that is to say :-
The manipulation of small coal into artificial coal fuel according to my
Invention is as follows:-The small coal which is to be used is first deprived of
foreign matters, as far as is practicable, by mechanical means, such asscreening,
picking out slate, stones, and other impurities. Then according to the nature
of the coal and its associated foreign matters, it undergoes a washing process,
or the coal which requires a stronger purifying agency than washing is placed
on to a covered calcining hearth, and subjected to a calcining or charring
process previous to or after washing it. From the calcining hearth the coal
is conveyed in its hot state to the washing apparatus. The coal in this
state heats the water and causes it produce a stronger action. From the
washing apparatus the coal is removed to be dried, and then to the mixing
machine, where the coal is mixed with about ten per cent. of coal tar, more or
less, and for some special purposes, in addition thereto, with from one to
three per cent. of well dried and powdered vegetable pitch. The mixture
is introduced into the moulds of the pressing machine, and is removed from
it as compressed fuel on iron carriages into the improved carbonizing retort,
where it is left from 6 to 12 hours and upwards, subject to the influence of
heat varying in temperature from 500° to 800° Fahrenheit, according to the
purpose for which the fuel is intended and according to the composition of
the fuel, whether of calcined or not calcined coal, or the mixture of both.
A coke fuel in regular shapes for close stowage is produced in the coking
retort hereafter explained, by placing moulds filled with coals into it,and such
coal may be transformed or converted into a coke fuel of any desired quality
according to the kind of coal selected, the coking action being caused to
proceed rapidly or slowly by exhausters or pumps, and by the influence of a
higher or lower temperature. A similar coke fuel may also be produced by
compartments filled with coals in a suitably arranged coke oven, with ex-
hausting apparatus and regulators for the more or less rapid removal of the
vapours from the influence of the heat within, and by elevating and lowering
the temperature at pleasure; these processes produce tar and other products
of value. Coal which contains in its natural state earthy and other foreign
substances, even in considerable quantities, may thus be converted into a
superior and cheap fuel. The calcining or charring hearth which is used by
me for the preparation of small coal intended to be converted into compressed
artificial fuel, and from which are to be collected the volatile ingredients

page_text: evolved or expelled in the form of vapour therefrom is as follows:-A founda-
tion, either built of bricks, 'stones, or formed of cast iron, is used, on which iron
rails are fixed, leaving or enclosing a hollow space beneath it, similar to a
vault into which either water, steam, or air can be admitted by suitable
arranged pipes and vaults at will, the whole standing in a water trough. A
cast-iron frame on four wheels similar to a truck holding a calcining grate
which represents the hearth moveable, when required, on the rails fixed upon
the foundation. The calcining grate or calciner is made by preference of
iron slabs combined together like a Venetian blind to open and shut
more or less at pleasure.
A cover or hood of thin sheet iron is suspended by tackle in a frame so as
to cover the whole of the hearth, and it is arranged to be raised or lowered
more or less at pleasure, for charging and discharging the hearth and en-
larging or contracting the space-above the calcining-grate. One or more
wirework nets are suspended in the interior of the hood or cover, and are ad-
justed by a suitable tackle for being raised or lowered and to approach more
or less the coal which is on the calcining grate.
Another calciner or oven used by me is constructed in several tiers one
above the other, and built of brickwork or stone, in a somewhat similar
manner to those used for calcining or roasting crushed, powdered, or ground
mineral oils in metallurgy. The lower tier has a calcining grate, and the
upper tiers are heated when the operation has commenced by the heat from
the lower tier, which causes the process in all the tiers to proceed nearly
simultaneously. The vapours from these gases are condensed into liquids in
the same manner as heretofore. For carbonizing fuel a retort is built by pre-
ference of brickwork, and of a size according to the quantity of compressed
fuel which it is intended to hold. The bottom of the carbonizing retort forms
the top of a coking oven, and the flues which surround the carbonizing retort
conduct the heat to the retort from the coking oven beneath. The arrangement
of this carbonizing retort, its construction, and its appendages,are similar to the
carbonizing retorts heretofore used by me, and which are well known, but
heretofore no coking ovens were placed beneath them. The construction of
these coking ovens is simple, each consisting of a vault about two feet deep,
built beneath the carbonizing retort. The coke oven is of brickwork or stone,
and is constructed with compartments or divisions for holding the coals to be
transformed or coked into regular shaped coke fuel suitable for close stowage.
The size of the coking ovens corresponds with the retorts used for carbonizing
compressed fuel. In some cases I employ a retort for coking small coal into
regular shaped fuel; thisretort is of a size according to the quantity of product

page_text: the operation is intended to furnish by one charge. This retort is of cast
iron in three parts, consisting of a cylinder in the middle and two spherical or
curved ends; its lowest part is set in brickwork or any suitable material. In
the lower part of this retort iron pipes are inserted, one of which (the largest)
has affixed to it an exhauster or a pump for drawing off the vapours; the
other smaller pipes serve as escape pipes for the liquids, which descend into
the tar cistern placed beneath the retort. The moulds or forms with their.
contents are suspended from a plate at the upper part of the retort. The
cover or upper end is to be removed to introduce and remove each charge, and
provision is made for introducing gas or steam, and for the exit of vapours or
gases from the interior of the retort. The vapours are condensed in' the
ordinary manner.
Having above generally described the nature of the Invention, I now
proceed more particularly to describe the manner of performing the same.
It is preferred, when the classes of coals to be used in making compressed
fuel require washing to remove some of the impurities, that the washing
process should be resorted to after charring or calcining such coals, and they
are heated to as low a degree as may be found sufficient to drive off the
bituminous properties thereof. This heating, charring, or calcining generally
takes about two hours. The coals thus heated, charred, or calcined are
then in their hot condition as they come from the hearth or oven thrown into
water, which by repeated use on successive quantities of such heated coals
becomes highly heated, and as a consequence the water so heated will be
found more effective in removing impurities. I prefer to use the means
hereafter described for thus heating or calcining the coals before washing, but
other modes may be resorted to so long as the coals are introduced into the
waters used for washing them in a heated state. The machinery used for
washing such coals is the same as now employed for washing coal in an
uncharred and cold state.
DESCRIPTION OF THE DRAWINGS.
Figure I. is a section, Figure II. is a ground plan, and Figure III. shews a
plan of the calcining grate or hearth. A, A, are iron rails resting on the
foundation B, B; Cis the hollow space or vault; D, D, the water trough
surrounding the foundation walls B, B, through which the pipes a, a, pass for
conveying water, steam, or air to the space C. E, Figure III., is the calcining
hearth or grate; F, F, Figure I., is the cover or hood suspended by suitable
tackle b, b; c, c, Figure I., are wire nets suspended by the tackle d, d; G, G,

page_text: are exhaust pipes for vapours and gases from the interior of the hood or
cover F, and leading to the condensers.
Figure IV. is a section of another calciner or oven. A is the lower cal-
cining grate resting on the foundation a, a; B and C are likewise calcining
hearths beated one after the other, when the operation has commenced in
the lower grate A ; b, b, b, are exit or exhaust pipes to convey the gases and
vapours to the mains and condensers. The working of this calcining and
charring coal apparatus is performed as follows:-When D, D, tho water
trough, is filled with water to a suitable height, and the cover or hood Fis
raised for the admittance of the charge of coals on the moveable calcining
hearth or calciner E, which is on wheels; tar or tarred chips of wood are
placed in a pan into the vault C, and ignited, and the calciner or truck charged
with coals is run along on the fixed rails A, A, on the foundation B, under the
raised hood or cover F; the hood F is then lowered to its position several
inches below the water in the water trough,thus covering the calcined hearth
with its charge, so as to prevent the access of air. The valves a, a, admitting
air to the vault C, below the hearth E, are then opened according as the
ignition of the coals proceeds; the valves of the pipes G, G, are opened
likewise, and lead the gases and products arising from the process of charring
to the condenser in the usual manner. To control the progress of the ignition
and combustion of the coals on the calciner E, the hood or cover F is made
to descend lower into the water, and is moved as it is required more or less to
contract or expand the space above the coals; likewise the suspended wire nets
c, c, within the hood are, by lowering them, used for depressing the flame,
thereby protecting the evolved vapours from being converted into gases or
otherwise injuriously affected by heat. The process having proceeded for about
two hours, the hood F is raised, and the calciner or truck is withdrawn from
the apparatus and replaced by another, the process being again renewed and
conducted as before.
The other charring apparatus, Figure IV., is worked on the same principle
as the foregoing one, but being more simple will be more easily understood
and managed. The improved retort for carbonizing compressed coal fuel is
built of brickwork or the coking retort or oven, from whence it is supplied
with the necessary heat for carbonizing the fuel within. The size of the retort
will vary according to the quantity of compressed fuel which it is intended it
should hold at one charge. The bottom of the carbonizing retort forms the top
of the coking oven or retort, and the flues which surround it conduct the heat
to the retort, which is supplied by the coking process beneath. The whole

page_text: arrangement of the construction of the retorts and their appendages is similar
to the carbonizing retortspecified in ny former and now expired fuel Patent.
The present novelty, however, consists in the combination of a coking retort
or oven placed beneath the carbonizing retort serving as a heater, saving
thereby a considerable consumption of fuel, which was necessary in the
former method of carbonizing compressed fuel in retorts. The construction
of these coking ovens or furnaces consists in a simple vault about 2 to 3 feet
deep, built (beneath the carbonizing retort) of brickwork or stone, with
compartments forming grooves of the size of the coke fuel intended.
It has been found that compressed coal blocks which are placed in the
middle on the carriages when subjected to carbonization in the retorts are
less carbonized than those at the sides of the carriages. To obviate this
objection, and in order to carbonize them all equally or to modify this evil of
inequality, I introduce superheated steam by a pipe, and by preference by a
perforated pipe inside the retort between the rails on which the carriage or
carriages with the fuel rest. For this purpose ordinary steam from a steam
boiler is caused to flow through pipes running through or over the crown
of the coking ovens or furnaces, which pipes serve as a superheating steam
apparatus to supply superheated steam to the perforated pipe in the retort.
By the above apparatus a considerable consumption of coals for heating the
retorts as hitherto practised when manufacturing compressed carbonized
fuel is dispensed with, and consequently the expense of the process is reduced.
Figure V. is a transverse section of two of the carbonizing retorts, with the
improvement of being worked by coking ovens or furnaces; Figure VI.
shews an elevation of a retort and coke oven formed in brickwork or other
fit material; Figure VII. is a longitudinal section of the retort and coke
furnace flues and other parts of the apparatus. A, A, are the retorts or
chambers in which the fuel to be carbonized is placed, and which is highly
heated by the coke ovens B, B, and flues therefrom b, b, b, b; C, C, are
eduction ways, drawing off the gases and products from the retorts or
chambers A, A, to the mains and condensers; c, c, are moveable compart-
ments forming grooves for coking the fuel in regular shaped blocks, which,
however, may be removed when the coal is to be treated in the common
manner like the ordinary coking process in coke ovens.
The manipulations of the carbonizing apparatus is simply to run the
carriages which hold the fuel as it comes from the press into the retorts,
and by well securing the doors to prevent access of air within in the usual
way, compelling thereby the vapours arising from the fuel to find their way

page_text: through the exhaust pipe to the condenser.
After the fuel has remained
therein for the time above specified, the fuel is withdrawn and the work
proceeds as before. The coking furnaces or ovens beneath the carbonizing
retorts are charged and discharged once or twice within 24 hours, according
to the nature of the coal used, and otherwise treated in the manner of coke
burning, as is well understood by the workmen.
New retort for transferring and coking small coal into regular shaped coal
fuel. This retort is of a size according to the quantity of product the operation
is intended to furnish by one charge. It is constructed in three parts, a, b, c ;
its lowest part c may be of brick or any suitable material, and the two upper
parts of iron. In the lowest part of this pan iron pipes are inserted, one of
which, the largest d, has affixed to it an exhauster or a pump for drawing off
the volatile matters in the form of vapours; the others e,e, are smaller, serving
as escape pipes for the liquids descending into the tar cistern placed beneath
the retort. The middle, which is the part for holding the moulds or frames
with their contents, is furnished with a perforated iron plate f.f. The head
or cover a is to be removed or opened at each charging and discharging; it
is provided at its top with suitably arranged pipes and valves either for the
admission of air or steam, or for the oxit of vapours or gases from the interior
of the retort. The condensable vapours arising from the operation are
treated in the usual manner by condensation and liquifaction. The manipu-
lation is conducted for the most part like the processes of coke burning in
the usual manner; the only difference in the treatment required in coking
the coals in this retort is, when the filled moulds or frames are in their
places in the retort and the coals lit at the top of the moulds, the cover is left
partially open until iguition has taken place; it is then shut up or closed,
and when the exhaust apparatus has been put in motion the valves at the top
pipes are opened and kept partially opened as may be necessary. When
the coking process is finished, instead of air, steam is admitted and drawn
by the exhauster through the coke and through the pipe below, thus cooling
and extinguishing the incandescent coke in the moulds. The steam will be
mixed with gas when it makes its exit from the exhaust pipe into the air,
and will indicate after a short time the absence of gas, which is the time to
stop the exhauster and discharge the coke.
Having thus described the nature of my Invention, and the manner of
performing the same, I would have it understood that what I claim is,-
First, the calcining or charring apparatus, and the process of purifying
coals as described.

page_text: Second, the introduction of coal in a heated state into the water used for
washing the coal to remove impurities, thereby rendering the water a better
solvent and purifying agent.
Third, the carbonizing compressed artificial fuel in retorts heated by coking
ovens or furnaces placed beneath them, also the use of superheated steam to
assist the carbonization of the compressed fuel within the retorts, and also
mingling steam or vapour with the gases arising from the fuel.
Fourth, the coking of coal into regular shaped blocks of coke fuel by means
of forms or moulds placed in retorts or ovens without the application. of
external heat as herein described.
In witness whereof, I, the said Ferdinand Charles Warlich, have
hereunto set my hand and seal, this Sixth day of November, in
the year of our Lord One thousand eight hundred and sixty.
F. C. WARLICH. (LS.)