Improvements in and Apparatus for or connected with Puddling Raw, Cast, or Pig Iron.
Year: 1894

page_text: Date of Application, 4th Apr., 1894
Complete Specification Left, 3rd Jan., 1895-Accepted, 23rd Feb., 1895
PROVISIONAL SPECIFICATION.
Improvements in and Apparatus for or connected with Puddling
Raw, Cast, or Pig Iron.
1, EMILE BONEHILL of Marchiennes in the Kingdom of Belgium, Engineer
do hereby declare the nature of my invention to be as follows:-
According to my invention I employ in puddling raw cast or pig iron the gases
coming from the blast furnace which are always in excess when closed furnace
mouths are used, and I combine when required, with the said gases the gases
coming from gas-generators or gas producers in order to ensure the desired regular
and uniform temperature.
1 further mingle with these gases hot air from the blast furnace so as to dispense
with the heat regenerator or heat regenerators which are rendered necessary by the
use of cold air supplied from the outside. I maintain the cast iron run directly
from the blast furnace, in the liquid state in a reservoir situated close to the
puddling furuaces, by causing gases coming from the blast furnace and from gas
producers or from either of them to pass into the said reservoir.
In order to carry my invention into practice I prefer to arrange the plant or
apparatus as follows: although I do not limit myself to the precise details.
Mounted on columns or on a bed of masonry centrally above a group of say four
puddling furnaces is a reservoir adapted to receive the cast iron coming from the
blast furnace by an open-topped conduit at the level of the tapping hole and where
the scum and other impurities may be removed.
Underground I arrange two main flues one of which serves for the passage of the
gases coming from the blast furnace and is split up into branch flues rising towards
each of the puddling furnaces.
The other main flue serves for the passage of the gases coming from the gas
producers and conveys the same by branch flues to the entry of the puddling
furnaces. The gases coming from the gas producers are for the purpose of
supplementing, if required, any deficiency in the gases from the blast furnace.
is advantageous however to employ them in any case.
It
At the entrance to the puddling furnaces these gases meet hot air coming from
the blast furnace through suitable pipes opening into chambers of such a shape that
the gases have a tendency to ascend therein, whilst the air descends; this causes an
intimate mingling, and the ignition of the gases is ensured before their entrance
into the furnaces; that is to say, the carbonic oxide is converted into carbonic acid
and this produces a very high temperature.
To ensure this with greater certainty I arrange refractory bricks at the
entrances of the puddling furnaces so as to act as baffles and these being always
at a very high temperature serve to ignite portions of gas that may have escaped
ignition by contact with the hot air. The gases ignited by these means, pass
into the puddling furnaces and on leaving them they escape through flues or
chimneys after having if desired heated a boiler for example. These furnaces
are not provided with fire places as in the arrangements heretofore employed.
The pipes by which hot air from the blast furnace is admitted are fitted with
valves for regulating the amount of hot air to be admitted to each puddling
furnace in order to ensure the proper combustion of the entering gases.

page_text: From the aforesaid main flues there also branch off ascending pipes which
convey a portion of the gases into the aforesaid reservoir for the purpose of
maintaining therein a temperature sufficient to ensure that the cast iron will
remain liquid in the said reservoir. Before these gases enter the reservoir they
ought to be mixed with a small quantity of hot air coming also from the blast
furnace for the purpose of igniting the said gases, but not enough to decarburise
the cast iron.
On leaving the reservoir these gases pass through a conduit on their way to the
chimney after having if required heated a boiler for example.
The apparatus being arranged as herein before describe.l, the order of operations
is as follows:-
The cast iron comes from the blast furnace along the open-topped conduit at the
level of the tapping hole, and here the scum and other impurities may be removed,
and the cast iron passes directly into the reservoir and when the reservoir is
sufficiently charged, the hole is closed.
When either of the puddling furnaces is empty, the hole leading from the
reservoir thereto is opened and the cast iron flows thereinto through a conduit
and funnel, and when the desired charge has been introduced the holes in the
reservoir and in the furnace are stopped.
It is to be understood that I do not limit myself to the precise details and
arrangement described such for instance as the shape, number, and arrangement
of the furnaces, the arrangement of the pipes for gas and hot air, the shape or
the situation of the reservoir of liquid cast iron.
The following are advantages of the arrangement of apparatus hereinbefore
described.
The employment of hot air coming from the blast furnace in combination with
the gases coming from the blast furnace and from gas producers, whilst doing away
with heat-regenerators, whereby a great saving is effected as regards cost of
construction and working.
The old puddling furnace requires for a charge of 275 kilogs., one hour and a half,
of which three quarters of an hour are required for melting the cast iron, and three
quarters of an hour for converting the same into wrought iron.
Now, according to my invention, since the cast iron is always in a molten state in
the reservoir one half of the time and even more is saved, and consequently with
the same furnaces, I can considerably increase the output.
Of the two working puddlers which are necessitated by the furnace as at present
arranged, one must almost always attend to the fireplace, whereas according to my
invention the puddlers are no longer obliged to attend to anything besides their
furnaces and to the operating of the valves, which is extremely easy, so that they
are able to make iron of better quality.
With the furnaces at present in ust, 1000 kilogs, of coal are required to make
1000 kilogs. of puddled iron, with proper working, whereas according to my
invention this fuel is almost wholly saved, with consequently, a considerable
economy.
The conveyors or lifts for the charges of cast iron, coal, and ashes, required by
the old arrangements of furnaces are dispensed with and are replaced by one man
whose duty is to attend to the gas-producers. Furthermore as the pig iron is
run directly from the blast furnace into the reservoir, there is less labour for the
smelters and weighers of the pig iron, and consequently there is an appreciable
saving in wages.
In turnaces burning coal, the waste in iron is always great, because the oxidizing
flames of the coal burn the pig iron. Now according to this invention, the waste
is considerably reduced, and, in addition, the iron made is of better quality.
As utilize the gases that have already passed through the furnaces and the
reservoir, for heating boilers, I thus effect a great economy.
The repairs to the furnaces are considerably reduced, because the gases are not
so destructive to the said furnaces as are the flames of coal.

page_text: The area of ground required by my plant is much less than that required by
the old furnaces for an equal output of iron, whence there results great economy
and saving in the general expenses of all kinds.
The lighting of the furnaces can be effected very much quicker and at very much
5 less cost than is the case at present.
Dated this 4th dor of April 1891
Improvements in and Apparatus for or connected with Puddling
Raw, Cast, or Pig Iron.
I EMILE BONEHILL of Marchiennes in the Kingdom of Belgium, 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:-
According to my invention I employ in puddling raw cast or pig iron, the gases
coming from the blast furnace which are always in excess, when closed furnace
mouths are used, and I combine, when required, with the said gases the gases
coming from gas-generators or gas-producers in order to ensure the desired regular
and uniform temperature.
1 further mingle with these gases, hot air from the blast furnace, so as to
dispense with the heat regenerator or heat-regenerators which are rendered
necessary by the use of cold air supplied from the outside.
I maintain the cast iron run directly from the blast furnace, in the liquid state
in a reservoir situated close to the puddling furnaces, by causing gases coming
from the blast furnace and from gas producers or from either of them to pass into
the said reservoir.
In order to carry my invention into practice, I prefer to arrange the plant or
apparatus as shown in the accompanying drawings although I do not limit myself
to the precise details shewn therein―
Figure 1 is a longitudinal vertical section of the furnaces.
Figure 2 is a horizontal section taken at the level of the reservoir.
Figure 3 is a view taken below the reservoir, partly in plan and partly in
horizontal section through the puddling furnaces.
Figure 4 is a vertical cross section taken through the centre of the reservoir.
Mounted on columns or on a bed of masonry centrally above a group of four
puddling furnaces is a reservoir G adapted to receive the cast iron coming from
the blast furnace by an open-topped conduit L at the level of the tapping hole and
where the scum and other impurities may be removed.
Underground I arrange two main flues, one A of which serves for the passage
of the gases coming from the blast furnace and is split up into branch flues a rising
towards each of the puddling furnaces. The other main flue B serves for the
passage of the gases coming from the gas producers and conveys the same by
branch flues to the entry of the puddling furnaces. The gases coming from the
gas-producers are for the purpose of supplementing, if required, any deficiency
in the gases from the blast furnace. It is advantageous however to employ them
in any case.
At the entrance to the puddling furnaces these gases meet hot air coming from
the blast furnace through suitable pipes c opening into chambers D of such a shape
that the gases have a tendency to ascend therein, whilst the air descends; this
causes an intimate mingling, and the ignition of the gases is ensured before their

page_text: entrance into the furnaces; that is to say, the carbonic oxide is converted into
carbonic acid, and this produces a very high temperature.
To ensure this with greater certainty I arrange refractory bricks d at the
entrances to the puddling furnaces so as to act as baffles, and these being always
at a very high temperature, serve to ignite portions of gas that may have escaped
ignition by contact with the hot air.
The gases ignited by these means, pass into the puddling furnaces and on leaving
them they escape through flues or chimneys after having, if desired, heated a
boiler H for example.
These furnaces are not provided with fire places as in the arrangements
heretofore employed.
The pipes c by which hot air from the blast furnace is admitted are fitted with
valves for regulating the amount of hot air to be admitted to each puddling
furnace in order to ensure the proper combustion of the entering gases.
From the aforesaid main flues A and B there also branch off ascending pipes a¹ b¹
which convey a portion of the gases into the aforesaid reservoir G for the purpose of
maintaining therein a temperature sufficient to ensure that the cast iron will remain
liquid in the said reservoir. Before these gases enter the reservoir they ought
to be mixed with a small quantity of hot air coming also from the blast
furnace, for the purpose of igniting the said gases, but not enough to decarburise
the cast iron.
On leaving the reservoir, these gases pass through a conduit P on their way to
the chimney after having if required heated a boiler H' for example.
The apparatus being arranged as hereinbefore described, the order of operations
is as follows:-
The cast iron comes from the blast furnace along the open-topped conduit Lat
the level of the tapping hole, and here the scum and other impurities may be
removed, and the cast iron passes directly into the reservoir G, and when the
reservoir is sufficiently charged, the hole is closed.
When either of the puddling furnaces is empty, the hole m leading from the
reservoir thereto is opened and the cast iron flows through a conduit n and funnel o
into the furnace, and when the desired charge has been introduced the holes in the
reservoir and in the furnace are stopped.
Naked arrows indicate the course of the gases passing through the reservoir,
and feathered arrows indicate the course of the gases passing through the
furnaces.
It is to be understood that I do not limit myself to the precise details and
arrangement described such for instance as the shape, number, and arrangement of
the furnaces, the arrangement of the pipes for gas and hot air, the shape or the
situation of the reservoir of liquid cast iron
The following are advantages of the arrangement of apparatus hereinbefore
described.
The employment of hot air coming from the blast furnace in combination with
the gases coming from the blast furnace and from gas-producers, whilst doing away
with heat regenerators, whereby a great saving is effected as regards cost of
construction and working.
The old puddling furnace requires for a charge of 275 kilogs., one hour and a
half, of which three quarters of an hour are required for melting the cast iron, and
three quarters of an hour for converting the same into wrought iron.
Now, according to my invention since the cast iron is always in a molten state,
in the reservoir G, one half of the time and even more is saved, and consequently
with the same furnaces, I can considerably increase the output.
Of the two working puddlers which are necessitated by the furnace as at present
arranged, one must almost always attend to the fireplace; whereas according to my
invention, the puddlers are no longer obliged to attend to anything besides their
furnaces and to the operating of the valves, which is extremely easy, so that they
are able to make iron of better quality.

page_text: With the furnaces at present in use 1000 kilogs. of coal are required to make
1000 kilogs. of puddled iron, with proper working, whereas according to my
invention this fuel is almost wholly saved, with, consequently a considerable
economy.
The conveyors or lifts for the charges of cast iron, coal, and ashes, required by
the old arrangements of furnaces are dispensed with and are replaced by one man
whose duty is to attend to the gas-producers.
Furthermore as the pig iron is run directly from the blast furnace into the
reservoir, there is less labour for the smelters and weighers of the pig iron, and
consequently there is an appreciable saving in wages.
In furnaces burning coal the waste in iron is always great because the
oxidizing flames of the coal burn the pig iron. Now according to this invention,
the waste is considerably reduced, and, in addition, the iron made is of better
quality.
As I utilize the gases that have already passed through the furnaces and the
reservoir, for heating boilers, I thus effect a great economy.
The repairs to the furnaces are considerably reduced, because the gases are not
so destructive to the said furnaces as are the flames of coal.
The area of ground required by my plant is much less than that required by the
old furnaces for an equal output of iron, whence there results great economy and
saving in the general expenses of all kinds.
The lighting of the furnaces can be effected very much quicker and at very
much less cost than is the case at present.
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. In puddling raw cast or pig iron the use of hot air from the blast furnace in
combination with the gases from the blast furnace or the gases from gas-producers
or gases coming from both sources without the use of heat-regenerators substantially
as and for the purposes herein before described.
2. In puddling raw cast or pig iron the combination of the gases of the blast
furnace with gases coming from gas-producers without the use of heat-regenerators,
for the purpose of ensuring the temperature requisite for the proper working of the
furnaces substantially as hereinbefore described.
3. The general arrangement and combination of parts constituting apparatus for
puddling raw cast or pig iron and comprising in particular a reservoir G wherein
the raw pig iron coming directly from the blast furnace is maintained in the liquid
state; conduits for supplying gases from the blast furnace and gas-producers, on
one hand to the reservoir G, and on the other hand to the puddling furnaces; pipes
for carrying hot air from the blast furnace to the place of contact with the gases
at the entrance or mouth of the furnaces, and also to the place of contact with the
gases passing to the reservoir, with valves for regulating the same as desired, and
without heat-regenerators, puddling furnaces without fire places and if desired,
boilers heated by means of the gases which have already passed through the
reservoir and through the furnaces before escaping into the chimneys all
substantially as and for the purposes herein before described and illustrated in the
accompanying drawings.
Dated this 3rd day of January 1895.
JOHNSONS & WILLCOX,
47, Lincoln's Inn Fields, London, W.C., Agents.