Improvements in the Manufacture of Iron and other Metals and Apparatus therefor.
Year: 1890

page_text: Date of Application, 3rd Dec., 1890
Complete Specification Left, 1st Sept., 1891-Accepted, 3rd Oct., 1891
PROVISIONAL SPECIFICATION.
Improvements in the Manufacture of Iron and other Metals and
Apparatus therefor.
I JAMES YATE JOHNSON of 47 Lincolns Inn Fields in the County of Middlesex
Gentleman do hereby declare the nature of this invention which has been com-
municated to me from abroad by Antoine Imbert and Gabriel Jullien both of
Lyons in the Republic of France Engineers to be as follows:-
This invention relates to an improved method and apparatus for directly extracting
iron and certain other metals from their ores and obtaining them immediately in the
metallic state weldable and forgeable in the case of iron and capable of being
directly utilised in all cases without going through the blast furnace and other
refinery processes. With this object the iron for example obtained by the
reduction of its oxides without fusion as hereinafter described in a closed or other
vessel is subjected to powerful hydraulic or other pressure immediately on its
removal from the reducing chamber and without exposing it to the air. The
pressure applied to the metal whilst in the condition of an incandescent powder
produces an intimate welding together of the particles and reduces the metal to the
form of blooms or ingots.
According to this invention the ore of iron or other metal is reduced in reducing
apparatus preferably such as that hereinafter described although the operation may
be performed with any other construction of apparatus. The apparatus constructed
according to this invention is provided with a reducing retort preferably of
rectangular form in section constructed with slabs or blocks of plumbago or other
suitable refractory material supported and strengthened by an iron frame and
casing. This retort is heated by a gas or other suitable furnace similarly
constructed and is closed at the bottom by a sliding or removeable slab and at the
top by a removeable cover perforated by a suitable orifice for the escape of the gases.
Underneath the retort there is a series of stationary rollers over which a metal
mould of shape internally corresponding to that of the retort can be readily
moved up to or away from the bottom of the latter. This mould is constructed
with a bottom secured by pins which can be readily removed and can be moved
from under the retort on to the plate of a hydraulic press. Another hydraulic press
preferably of smaller size is provided above the first press with its plunger fitting
into the mould.
A charge composed of ore and suitable fluxes if required is placed in the retort
being intimately mixed with the reducing agent and the whole being finely crushed
or ground. After heating to the requisite temperature for the necessary time that
part of the charge in the retort situated in the lower part of the latter which is
exposed to the direct action of the blast becomes completely reduced. Bars or the
like are then introduced through the sides in order to support the unreduced part
of the charge in the upper part of the retort and the removeable bottom being with-
drawn the contents of the lower part are allowed to fall out into the mould placed
underneath. The mould is then quickly moved on to the hydraulic press and after
the small press has been caused to rapidly apply pressure with its plunger the
metal is subjected to more powerful pressure from the larger press placed
underneath.
In the meantime the bottom of the retort is replaced and the charge is allowed to
descend until it rests upon the bottom again. The void thus produced in the upper
part is then filled up with fresh materials and the operation is thus rendered
continuous.
The mould containing the bloom of compressed and welded metal is then moved

page_text: over other rollers to a suitable position where the bottom is released and the contents
allowed to drop out.
In the block of iron for example thus obtained it is impossible to find traces of
the original constituents and the metal is ready without further preparation for
treatment in a Martin furnace or other manufacturing processes. Purifying agents
or other substances destined to take effect on the metal may be employed in this
treatment or the metal may be taken directly to a welding or reheating furnace and
then be worked in a press; between rolls or under a hammer for example in order
to drive out the cinder and obtain iron in the condition of a shingled ball from the
puddling furnace.
The reduction may be performed in any suitable apparatus such for example as
an ordinary furnace with crucibles whose contents are simply discharged into the
welding mould. In working on a large scale apparatus such as that employed
in gas works may be employed by modifying the heads of the retorts so
as to facilitate the discharge of the incandescent powder into the mould or matrix.
For very large works a series of reducing chambers similar to coke ovens may be
employed the heat being applied to the sides and bottoms and the internal width of
the chambers being regulated so as to present the charge in the form of a relatively
thin layer.
The pressure may be applied by means of a stamp or power hammer or any other
suitable apparatus in place of the hydraulic presses hereinbefore described and the
charge may be previously prepared in the form of a block of agglomerate which
after reduction is compressed in the final pressing operation.
This process is applicable to the manufacture of iron or of any other metal whose
oxides are capable of reduction under similar conditions even when the metals do
not possess the property of welding. By these means blocks are obtained which are
very well adapted for the formation of alloys without necessitating the preliminary
fusion which is frequently difficult and inconvenient as heretofore performed.
Dated this 3rd day of December 1890.
J. H. JOHNSON & Co.,
47, Lincoln's Inn Fields, London, W.C., Agents.
COMPLETE SPECIFICATION.
Improvements in the Manufacture of Iron and other Metals and
Apparatus therefor.
I JAMES YATE JOHNSON of 47 Lincoln's Inn Fields in the County of
Middlesex, Gentleman, do hereby declare the nature of this invention which has
been communicated to me from abroad by Antoine Imbert and Gabriel Jullien
both of Lyons in the Republic of France, Engineers, 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 method and apparatus for directly
extracting iron and other metais from their ores and obtaining them immediately
in the form of a metal which after having been welded and forged is capable of
being directly utilised in all cases without going through the blast furnace and
other refinery processes. With this object the iron for example obtained by the
reduction of its oxides without fusion as hereinafter described in a closed vessel is
subjected to powerful hydraulic or other pressure immediately on its removal from
the reducing chamber and without exposing it to the air. The pressure applied to
the metal whilst in the condition of an incandescent powder produces an intimate
welding together of the particles and reduces the metal to the form of blooms or
ingots.
In carrying out this invention the ore is reduced in reducing apparatus preferably
such as that hereinafter described although the operation may be performed with
any other suitable construction of apparatus.
And in order that the invention may be well understood I will now proceed more

page_text: particularly to describe the same and for that purpose shall refer to the several
figures on the annexed sheet of drawings the same letters of reference indicating
corresponding parts in all the figures.
Figure 1 of the accompanying drawings represents in vertical section the general
arrangement of an apparatus employed for the purposes of this invention.
Figure 2 represents the apparatus in two horizontal sections taken respectively
on the lines X-Y and X-Y' Figure 1.
Figure 3 represents in vertical section a retort 1 the lower extremity of which is
likewise represented on the right hand side of Figure 1.
The apparatus constructed according to the example illustrated in the accom-
panying drawing provided with a reducing retort 1 preferably of rectangular
form in section (Figure 2) constructed with slabs or blocks of plumbago or other
suitable refractory material forming a lining supported by an iron casing
strengthened by ribs or bands of angle iron. This retort is heated by a gas or
other suitable furnace 2 similarly constructed and is closed at the bottom by a
sliding or removeable slab 3 which can be withdrawn when required in order to
discharge the reduced metal at the bottom of the retort.
The upper end of the retort 2 is closed by a removeable cover 4 and is provided
with an orifice 5 for the escape of the gases generated by the chemical reactions
taking place in the interior of the retort."
Underneath the retort 1 there is a series of stationary rollers 6 over which a metal
mould 7 of a shape internally corresponding to that of the retort (Figure 2) can
be readily moved up to or away from the bottom of the latter. This mould 7 is
constructed with a removeable bottom 8 secured by pins (Figure 1) which can be
readily taken out so as to enable the bottom 8 to be removed for the purpose of
rapidly discharging the contents of the mould. The rollers 6 are so arranged as
to enable the said mould to be moved in the direction of the horizontal arrow in
Figure 1 so as to be placed underneath the retort 1 where it is filled with reduced
metal after which it is placed upon the plate a of a powerful hydraulic press 10.
Over this press another hydraulic press 11 of smaller size is provided having a
piston 12 provided at its lower extremity with a plunger 13 closely fitting into the
mould 7.
Another series of rollers not represented in the drawing is provided on the left
hand side for example of these presses for the purpose of enabling the mould to be
removed after the compressing operation in order to enable the metal to be taken
out of the mould.
Bars or
A charge composed of ore (and suitable fluxes if required) intimately mixed with
a suitable reducing agent is placed in the retort 1 the whole of the charge being
finely crushed or pulverised. After heating the materials to the requisite tempera-
ture for the necessary time that part of the charge in the retort situated in the
lower part of the latter (within say about 15 inches from the bottom) which is
exposed to the direct action of the blast becomes completely reduced.
other supports not shown in the drawing are then introduced through the sides of
the retort in order to support the unreduced part of the charge in the upper part
of the retort and the removeable bottom 3 being withdrawn the portion of the
charge occupying the lower part is allowed to fall down into the mould 7 placed
underneath. The mould is then quickly transferred to the plate 8 of the hydraulic
press 10 and after the small press 11 has been caused to rapidly apply pressure
with its plunger 13 the metal is subjected to more powerful pressure by the action
of the larger press 10 placed underneath.
In the meantime the bottom 3 of the retort 1 is replaced in the position represented
in Figure 1 and by removing the temporary supports the charge is allowed to
descend until it rests upon the said bottom 3. The void consequently produced in
the upper part of the retort is then filled up with fresh materials and the operation
is thus rendered continuous as in an ordinary blast furnace.
The mould containing the bloom of compressed and welded metal is then moved
over the other rollers hereinbefore referred to and placed in a suitable position

page_text: where the bottom 8 is released being slightly inclined at the edges if required to
facilitate the operation and the contents allowed to drop out; the said bottom along
with the solid bloom of metal falling down by their own weight being loosened if
requi.ed by a few taps with a hammer.
These blocks or bloons are in condition without further preparation for treatment
in a Martin furnace or other manufacturing processes. This method of treatment
also enables the metal to be combined with purifying agents or other substances
destined to take effect on the metal in the Martin furnace for example.
In order to obtain the iron in the form of bars the block when removed from the
press may be taken directly to a furnace where it is heated to welding beat after
which it may be worked in a press or passed between rolls or under a hammer for
example. In the course of this operation the cinder is eliminated and the iron is
obtained in the condition of a shingled ball from a puddling furnace.
The construction of the apparatus and the details of the operation herein before
described may be modified according to the conditions under which the invention is
applied in practice the essential feature of the invention being the subjection of the
metal to a high degree of pressure immediately on leaving the reducing apparatus
and without allowing it to remain exposed to the air for any considerable period.
The reduction may be performed in any suitable apparatus such for example as
an ordinary furnace with crucibles whose contents are simply discharged into the
welding mould. In working on a large scale apparatus with a bench of retorts
such as is provided in gas works may be employed the heads of the retorts being
suitably modified so as to facilitate the discharge of the metal in the form of
incandescent powder into the mould or matrix in which it is subjected to the
pressure. For very large works a series of reducing chambers similar to coke
ovens may be employed the heat being applied to the sides and bottoms of the
chambers and the internal width of the chambers being regulated so as to present
the charge in the form of a relatively thin layer but any other construction of
heating apparatus capable of producing a similar effect may be employed if
preferred.
The pressure may be applied by means of a stamp or a power hammer acting on
the plunger for example or any other suitable apparatus may be employed for
compressing the materials in place of the hydraulic presses hereinbefore described.
The charge may be previously prepared in the form of blocks of agglomerated
materials which are compressed after reduction.
This process is applicable to the manufacture of iron or of any other metal whose
oxides are capable of reduction under similar conditions even when the metals do
not possess the property of welding. By these means blocks are obtained which are
very well adapted for the formation of alloys without necessitating the preliminary
fusion which is frequently difficult and inconvenient to obtain.
Having now particularly described and ascertained the nature of the said inven-
tion and in what manner the same is to be performed I declare that what I
claim is :-
1. Obtaining blooms or ingots of iron or other metals by heating ores or metal-
liferous materials (without melting them) and subjecting them to pressure substan-
tially as hereinbefore described.
2. For the manufacture of iron and other metals as hereinbefore described and
claimed apparatus constructed with a retort or reducing chamber in combination
with a mould for the reception of the materials treated in the said chamber and
means for compressing the contents of the said mould all arranged and operating
substantially as hereinbefore described with reference to the accompanying
drawings.
Dated the 1st dov of Sentember 1801