and Apparatus therefor.
Year: 1884

page_text: and Apparatus therefor.
I, WILLIAM ROBERT LAKE, of the firm of Haseltine, Lake, & Co, Patent Agents,
Southampton Buildings, in the County of Middlesex do hereby declare the nature
of my invention for "IMPROVEMENTS RELATING TO THE REDUCTION OF IRON OR
ZINC ORES AND APPARATUS THEREFOR" to be as follows:-
This invention relates to the separation of iron and zinc from their ores and to
apparatus therefor, its principal object being to save fuel.
The improved apparatus consists of three furnaces, two heat regenerators, two
air-heating chambers, suitable connecting pipes, and four valves. The furnaces
have closed mouths, shafts, and hearths.
Two powerful blowing engines are provided, one for the gases and the other for
the blast.
I will describe the working of the furnace as the entire construction will be very
easily understood from this description.
The mode of working for producing zinc is as follows.
When the apparatus is to work, what I will term the central furnace is filled
with briquettes of calcined zinc ore and coal powder. The other furnaces, herein-
after termed the outer furnaces, are on the contrary filled with only fuel, charcoal
or coke. Cold regenerated gas consisting principally of carbonic oxide is driven in
by means of the blast engine for the gas, through pipes and a valve to the first
regenerator which has been previously heated. Here the gas is heated strongly
and then passes further through to the bottom of the central furnace. Through
the heat, brought with the gas, the oxide of zinc is reduced by the solid carbon,
and the zinc vapours follow with the gas to the bottom of the first outer furnace.
On its passage through this furnace, which is kept comparatively cool, the zinc
vapours are condensed to liquid zinc, which is collected at the hearth of this
furnace. The gas passes further through a second valve and a pipe to the blast.
engine, from where it is again driven in the same manner as before as long as the:
Price 8.11

page_text: temperature in the first regenerator is sufficiently high. When this regenerator
has become cool, the first and third valves are reversed so that the functions
performed by one regenerator are performed by the other, and vice versa.
Air for the blast is driven in by the engine through one heater and between two
pipes and thence passes to the tuyeres and into the second outer furnace, where it,
with the fuel, forms gases which go out through the fourth valve, a pipe, and the
third valve to the second regenerator where the gases are burned by means of air
which is drawn into the heater and thence passes to the said regenerator. The
products of combustion heat the regenerator during their passage through it thence
passing to the heater and to the chimney. The gas generated by the oxygen
contained in the oxide of zinc and by the solid carbon in the central furnace may
be said to form a surplus, and a corresponding part of gas is therefore separated
from the gas arriving from the blast engine, from the fact that a valve in the first
valve is opened a little, passes the third valve where it joins the gas generated by
air in the second outer furnace, and accompanies the latter gas to the second
regenerator to be burnt there.
When the first outer furnace becomes so hot that the zinc vapours will not easily
condense there, the valves are reversed, so that the functions performed by one
outer furnace may be performed by the other and vice versa, but before air is
conducted to the first outer furnace hot gas is caused to stream through it for some
minutes from one of the regenerators, which gas brings with it to the central
furnace, the zinc vapour. Since the zinę vapours have thus been driven out from
the first furnace, air is let into it in the manner already described (concerning the
second outer furnace) when this furnace may be used to generate gas for heating
the regenerators. Immediately before the first outer furnace again serves as a
condenser for the zinc vapours, a stream of water is let into it through the tuyeres,
when the furnace will be rapidly cooled.
The residue of the briquettes remaining in the central furnace may be taken
out at the hearth of the said furnace. If there be lead contained in the zinc ore
this will be reduced and collected in the bottom of the hearth.
When the furnace, is to be employed for producing iron, it is worked in the
following manner.
The outer furnaces are filled with coal, ore and fluxes about in the same manner
as is usual in a common blast. furnace. The central furnace on the contrary, is
filled with only coal, charcoal or coke. While the ore is reduced in the one furnace,
say for instance in the first outer furnace the ore already reduced is melted in the
other outer furnace. The central furnace is used to regenerate or again carburet
the gases arriving from the reducing furnace.
The process takes place in the following manner. Comparatively cold regenerated
and consequently strongly reducing gas is driven by the blast engine for gas through
the first valve to the bottom of the first regenerator where it is strongly heated; it
thence passes from the top of the regenerator into the bottom of the first outer
furnace. On its passage through the last mentioned furnace the gas reduces the
ore and passes, oxidized, from the top of the furnace to the bottom of the central
furnace where, as it passes the mass of coal, it is carburetted, and, leaving at the
top of the central furnace, passes to the fourth valve and thence to the blast-engine,
where the circuit of the gas recommences.
In order to maintain the temperature in the central furnace sufficiently high for
completely regenerating the gas, it is convenient to introduce through the tuyeres
of the furnace, heated air.
Into the second outer furnace, where the ore has been reduced in the manner
described, air is introduced through the tuyeres which air has been heated by the
gases on their passage through the heater and in the space between the pipes.
The temperature in the second outer furnace will thus be sufficiently bigh for
melting iron and scoria which in the usual manner are discharged at the bottom of
the furnace. The gases generated pass out from the top of the furnace through the
fourth valve to the second valve, and from there to the second regenerator,

page_text: In the central furnace there will always be a little surplus of gas, which,
together with the other gas, passes to the blast engine. When the gas arrives
therefrom through the first valve, the surplus is separated and passes to the second
valve and from there with the gases arriving from the second outer furnace, to the
regenerator to be burnt with air. This air is drawn by the chimney draught
through the heater, the second valve, and suitable passages. The products of
combustion, after having. passed and heated the second regenerator enter the heater
and thence pass into the chimney.
When the ore has been reduced in the above described manner in the first outer
furnace, and melted in the second outer furnace the valves are reversed, so that the
functions of the furnace are reversed also, this action being continued until a new
exchange can conveniently take place.
In reducing by degrees the quantity of coal compared with ore placed in the
furnace, such a working of the furnace can be obtained that the reduction and the
melting of the ore is effected chiefly with gas, whereby malleable iron is obtained
instead of pig iron. The only modification needed for this, is to conduct simul-
taneously into both outer furnaces heated gas and heated air, and to regenerate the
whole quantity of gas in the central furnace. With this mode of working, the
number of the furnaces may be reduced to two, of which one is used for reducing
and melting the ore, and the other for regenerating the gases.
And
1001
:

page_text: Figure 5 is a diagram hercinafter referred to.
The said apparatus comprises three furnaces a, a, and as two heat regenerators pl
and, two air-heating chambers z and t and the necessary pipes or flues and four
valves ¹³¹³. The furnaces have cups and cones b', 6, 6 for closing their
mouths and hearths h¹, h³, h³.
The general arrangement of the apparatus will easily he understood by reference
to the diagram Figure 5, where the position of each furnace is indicated by two
circles and the position of each regenerator by means of two rectangles. Of these
circles and rectangles the smaller ones represent the bottoms of the furnaces and
regenerators respectively and the larger the tops of the furnaces and regenerators
respectively. The valves and the heaters are also indicated together with all the
pipes or flues connecting them with each other and with the furnaces and the
regenerators.
Two powerful blowing engines are provided, one for forcing the gases through
the regenerator and the other for producing the blast, which engines, however, are
not represented in the drawings, as they may be of any suitable construction.
In order not to mention the same matter several times I will describe the
working of the furnace for reducing both iron and zinc ores.
The mode of working for producing zinc is as follows, that is to say:
The furnace a² is filled with briquettes of calcined zinc ore and powdered coal.
The other furnaces a¹ and a³ are filled with coal, charcoal or coke. Cold regenerated
gas consisting principally of carbonic oxide is now forced, by means of the blast
engine for the gas, through the pipe m, the valve at and the pipe w to the
regenerator ³, which has been previously heated. The gas is here heated and then
passes through the pipe d to the bottom of the furnace a². By means of the heat,
brought with the gas, the oxide of zinc is reduced by the solid carbon present and
the zinc vapours follow with the gas through the pipe e to the bottom of the

page_text: furnace a¹. On its passage through this furnace, which is kept comparatively cool,
the zinc vapours are condensed to liquid zinc, which is collected on the hearth h¹ of
this furnace. The gas then passes through the valve and the pipe o to the blast
engine, from whence it is again driven in the same manner as before as long as the
temperature in the regenerator 7 is sufficiently high. When this regenerator has
become cool the valves ¹ and ² are reversed so that the regenerator. is put into
operation. The blast produced by the blast engine then passes through the heater t
and between the pipes o and p and thence around the valve is to the tuyeres and
into the furnace a³, where, with the fuel, it forms gases which pass out through the
valve i³ the pipe f, the valve and the pipe g to the regenerator where the gases are
burned by means of air which is drawn into the heater z and thence passes through
the valve x and the pipe to the regenerator. The products of combustion heat
the regenerator during their passage through it and pass off through the pipe w,
the valve ¹, and the pipe k to the heater z, and thence to the chimney 3. The.
gas generated by the oxygen contained in the oxide of zinc and by the solid carbon
in the furnace as may be said to form a surplus, and a corresponding quantity of
gas is therefore separated from the gas (forced in by the blast engine) in the
valve x, for the reason that the upper left hand valve in valve ¹ is opened a little,
which gas passes through the valve ² where it mixes with the gas generated by
means of air in the furnace a³ and flows with the latter gas to the regenerator ³ to
be burnt there.
When the furnace a¹ becomes so hot that the zinc vapours will not easily condense
there the valves in the pipes e, e on both sides of the furnace a³ are reversed, so that
the functions performed by the furnace a¹ may be performed by the other a³, and
vice-versa; but before air is conducted to the furnace a' hot gas is caused to stream
through it for some minutes from one of the regenerators which gas brings with it
to the furnace at the zinc vapour condensed in the fuel. When the zinc vapours
have thus been driven out from the furnace a¹, air is let into it in the manner
already described in connection with the furnace a³, when the said furnace a³ may
be used to generate gas for heating the regenerators. Immediately before the
furnace a¹ again serves as a condenser for the zinc vapours, a quantity of steam is
let into it through the tuyeres, whereby the furnace is rapidly cooled.
The residue of the briquettes remaining in the furnace a² may be taken out at
the hearth of the said furnace. If lead is contained in the zinc ore this will be
reduced and collected at the bottom of the hearth h³.
When the apparatus is to be employed for producing iron, it operates in the
following manner.
The surfaces a' and a³ are filled with coal, ore, and fluxes in about the same
manner as a common blast furnace. The furnace a is filled with coal, charcoal or
coke. While the ore is reduced in one furnace, say for instance in the furnace a¹
the ore already reduced is melted in the other furnace a³; this order however is
sometimes reversed. The furnace a³ is used to regenerate or again carburet the
gases coming from the reducing furnace.
The process takes place in the following manner. Comparatively cold regenerated
and consequently strongly reductive gas is driven by the blast engine for gas
through the pipe m into the valve z; it then passes from this valve to the bottom
of the regenerator r¹ where it is highly heated; it thence passes from the top of
the regenerator into the bottom of the furnace a¹. On its passage through the
furnace a, the gas reduces the ore and passes oxidized, from the top of the furnace
through the pipe or channel n to the bottom of the furnace a³, where, as it passes
the mass of coal, it is carburetted and leaving at the top of the furnace a³ passes to
the valve and thence to the blast engine through the pipe o, whereafter the
circuit of the gas recommences.
In order to maintain the temperature in the furnace a sufficiently high for
completely regenerating the gas it is convenient to introduce through the tuyers.
of the furnace heated air, which passes through the pipes p q s. Into the furnace a³
where the ore is reduced in the manner described, air is introduced through the

page_text: tuyers which air is heated by the gases on their passage through the heater t and
in the space between the pipes o and p. The temperature in the furnace a³ will
thus be sufficiently high for melting iron and scoria, which, in the usual manner,
are let out at the bottom of the furnace. The gases generated pass from the top of
the furnace through the valve and the valve and from thence pass to the
regenerator ². In the furnace a³ there will always be a little surplus of gas,
which, together with the other gas, passes to the blast engine. When the gas
therefrom reaches the valve a¹ through the pipe m the surplus is taken away and
passes to the valve and from there with the gases from the furnace a³ to the
regenerator to be burnt with air. This air is drawn by the chimney draft
through the heater Z, the pipe u, the valve x and the channel v; the products of
combustion, after having passed through and heated the regenerator pass through
дов
the pipe w and the valve ¹ to the heaters and further into the chimney y.
When the ore has been reduced in the above manner in the furnace a¹ and melted
in the furnace a³ the valves are reversed, so that the functions of the furnaces are
reversed also, this action being continued until a new exchange can conveniently
take place.
By reducing by degrees the quantity of coal compared with the ore filled in the
furnace, such a working of the furnace can be obtained that the reduction and the
melting of the ore is effected chiefly with gas, whereby melted malleable iron,
instead of pig iron, is obtained the only modification needed for this is to conduct
heated gas and heated air into both furnaces a¹ and a³ simultaneously and to
regenerate the whole quantity of gas in the furnace a². With this mode of working,
the number of the furnaces may be reduced to two, of which one is used for
reducing and melting the ore and the other for regenerating the gases.
Having now particularly described and ascertained the nature of my said
invention and in what manner the same is to be performed as communicated to me
by my foreign correspondent, I declare that what I claim is
First. The method of condensing zinc vapours in a shaft furnace filled with coal,
coke, or charcoal which is, at certain intervals, cooled by steam.
Second. In reducing oxide of zinc by means of coal, the method of producing the
heat by means of heated gases.
Third. The method of reducing zinc ore in a shaft furnace, in which the ore is
introduced in the form of briquettes made of calcined zinc ore and of powdered
coal.
Fourth. In reducing zinc ore, the employment of three furnaces, arranged in
combination, of which one is used for the reduction of the zinc, another for con-
densing the zinc vapours and the third for generating heat for the regenerators.
Fifth. The furnaces mentioned in the preceding claiming clause in combination
with two or more regenerators for reheating the gases.
Sixth. The combination of three furnaces two regenerators, two heaters for air,
and the connecting pipes or flues and valves substantially as above described and
as illustrated in the drawing.
Seventh. In the reduction of zinc ore by means of coal, supplying the heat by
means of heated gases, which by means of a blast engine are driven into the furnace
filled with briquettes composed of coal and calcined zinc ore, so that the same gas
is employed for transporting the heat.
Eighth. In reducing zinc or iron ore the method of combining a system of
apparatus consisting of furnaces, regenerators and air heaters with two blast
engines, one for driving the gases through the regenerators and the furnaces and
another for creating a blast for the furnaces.
Ninth. The method of reducing iron ore mixed with coal in shaft furnaces, by
means of heated gases, consisting principally of carbonic oxide.
Tenth. The method of regenerating the oxidized gas leaving the shaft, by means
of glowing coal, and again using the gas thus regenerated for the reduction of ore,

page_text: Eleventh. The method of reducing and melting iron ore combined with a small
quantity of air arranged substantially as described above, by means of carbonic
oxide so that malleable iron is immediately obtained; and then in one or more
furnaces filled with coal to regenerate the gases leaving the first mentioned
furnaces.
Twelfth. The employment of apparatus for reducing and melting iron ore, con-
sisting of three shaft furnaces so arranged that the gases leaving one or two of
these furnaces at the top may be conducted to the third furnace in order to be
regenerated there by means of glowing coal.
Thirteenth. The three shaft furnaces mentioned in the preceding claiming clause
in combination with two or more regenerators for heating the gas, which is to be
conducted to one or two of the furnaces.
Fourteenth. The furnaces and beat regenerators mentioned in the preceding
claiming clause combined with a heater for heating the air necessary for supporting
combustion in the regenerators.
Fifteenth. The method of reducing iron ore by means of gases driven in a heated
state into a furnace by means of a blast engine and afterwards regenerated by
means of glowing coal in another furnace, so that the same gas is used constantly.
Dated this 1st day of Sentember 1885.
HASELTINE, LAKE & Co.,
For the Applicant.