Improvements in Making Iron of any Quality, Pig Iron, Wrought Iron, Cast Steel, Rough Steel.
Year: 1890

page_text: Date of Application, 12th June, 1890
Complete Specification Left, 2nd Feb., 1891-Acceptel, 6th June, 1891
PROVISIONAL SPECIFICATION.
Improvements in Making Iron of any Quality, Pig Iron, Wrought
Iron, Cast Steel, Rough Steel.
I AUGUST DAUBER of Bochum, Province of Westfalia, Germany Merchant
do hereby declare the nature of this invention to be as follows :—
It is a well known fact that in burning carbon in gaseous state in combination
with oxygen over 100% of calories or units of heat more are obtained, than when
the combination of the oxygen with the carbone in a solid state takes place. For
this reason many trials have been made of late years to use gascous combustibles
instead of such in a solid state for heating purposes of any sort.
If anywhere this extraordinary. gain must prove profitable in the iron industry,
the largest coal consuming industry, provided for, that it will be possible to introduce
the casily obtainable gas in place of coal and cokes into the high furnace in a
practicable manner and at the proper place.
Combined with this gain obtained by using gaseous fuel there is another, which
is the absolute consequence of the use of gaseous fuel in high furnaces, namely the
space gained in a furnace which otherwise is occupied by the coal or coke, and
which now will be free.
All that space formerly occupied by the coal or coke, about of the whole volume
of a furnace, is now available for ores and lime stone or flux.
The production of a high furnace worked by gaseous fuel as compared with one
where coal or coke or other solid fuel is used, therefore must be larger in propor-
tion to the space gained in the first case, or a furnace of the first class may be built
so much smaller from the beginning to give out the same quantity of iron as in the
other case, and the first costs of building will therefore be reduced considerably
also.
The object of my invention is to realize the gains-named-by-the-use-of-gaseous-
fuel or carbon in a fluid that is to say carbon as contained in liquid fuel or pulverized
state which is blown into the furnace at certain stages in such combinations with or
without heated air or superheated steam and in such proportions as will correspond
to the reaction going on in the furnace at that stage in that place and at that time;
injector-like tuyeres being used for regulating the quantities of each gas so as to
obtain the proper mixture required.
The success will be doubtless if the zones of preparation, of reduction, of
carbonisation of melting and of maturation so created will be placed at the right
place in the furnace, and if the reactions taking place there, are caused at the
proper time and in the proper proportions to the fuel blown into the furnace.
In order to secure this result I introduce the gases into the furnace at those
places in such a state that answers the reactions having to take place there by
means of adjustable injector like combined tuyeres.
The gases used, superheated steam and hot air, each for itself or in combination
with the others in adjustable proportions are produced in separate generators so as
to have them always ready in sufficient quantities and in proper condition.
For the sake of following the process going on in a furnace designed to corre-
spond to my method of iron making let us suppose the furnace be at work.
The starting having to be done as usual with solid fuel and only when the work
is going on in regular order, the new method is being introduced gradually by
reducing by degrees, and replacing the solid fuel-coal or coke-by at first
gradual and then continuous charges of gases and carbon which are blown into the
furnace.
At the bottom of the zone of preparation, or as near as this place can be fixed, I

page_text: arrange a row of tuyeres by means of which superheated steam or heated air are
blown in, in order to dry and roast the charges, ore and flux, and to free them
from the humidity contained therein and from other volatile materials and to
prepare them so for the reception of oxide of carbon and to make them loose and
open.
"
:
In the zone of carbonisation I arrange a similar row of tuyeres; the object of
which is to introduce carbon and to mix it with the ores so as to prepare them for
the melting process.
The blowing in of carbon may be done by the use of gaseous carbon or in a fluid,
that is as contained in liquid fuel or in a pulverized state, or any of these combined
with the other.
In the melting zone 1 arrange tuyeres by means of which I blow into the furnace
a mixture of heated gas and air, to which superheated steam may be added, in
order to produce the high temperature which is necessary to reduce into a fluid
state also the earthen material and so to separate completely the iron from the
slag and cinders in consequence and according to the difference of their specific
weights.
In order to be able to vary the composition of the produce or its quality in the
hearth at will, so as to receive spiegeleisen, for instance, with a high percentage of
carbon down to mottled iron containing but traces of carbon, as well as steel of
any sort, I here provide a zone of maturation by arranging a similar row of tuyeres
through which I blow into the furnace at this place a mixture of gas and superheated
steam and hot air, which may be varied as desired, so as to reduce the carbon in the
iron to the required degree.
It may be added here, that my method differs materially from that used for a short
time in England and America by Glay Bull, who blew the gas and air into the
furnace each at opposite sides and only at the bottom of the furnace, for which
reason his furnaces after a short period were "blown cold."
Dated this First day of Juns 1800.
KARL S. MAYER,
Agent for Applicant.
COMPLETE SPECIFICATION.
Improvements in Making Iron of any Quality, Pig Iron, Wrought
Iron, Cast Steel, Rough Steel.
1 AUGUST DAUBER of Bochum in the Province of Westfalia Germany
Merchant 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 tlie
following statement :-
It is a well known fact that in burning carbon in gaseous state in combina-
tion with oxygen over
100% of calories or units of heat more are obtained
than when the combination of the oxygen with the carbon in a solid form takes
place. For this reason many trials have been made of late years to use gaseous
combustibles instead of those in a solid state for heating purposes of any sort.
If anywhere this extraordinary gain must proof profitable in the iron industrie,
the largest consumer of coal, provided for that, it will be possible to introduce
the easily obtainable gas in place of coal and cokes in the blast furnace in a
practicable manner and at the proper place. Combined with this gain obtained
by using gaseous fuel there is another, which is the absolute consequence of the
use of gaseous fuel in blast furnaces, namely the room gained in a furnace and
otherwise occupied by the coal or coke which now will be free.
All that space formerly occupied by the coal or coke, about of the whole volume of
a furnace, is now available for ores and lime stone or flux. The production of a
blast furnace worked by gaseous fuel as compared with one where coal or coke
or other solid fuel is used therefore must be larger in proportion to the space gained

page_text: in the first case, or a furnace of the first class may be built so much smaller from
the beginning to give out the same quantity of iron as in the other case and the first
costs of building will therefore also be considerably reduced.
The object of my invention is to realize the gains named by the use of gaseous
fuel in combination with heated air and superheated steam & with pulverized coal
in iron making. This fuel is blown into the furnace in certain stages of the progress
in such combination with or without heated air and superheated steam and in such
proportion as corresponds to the reaction going on in the furnace at that place and
in that stage or at that time; injector like tuyeres being used for regulating the
quantities of each sort of gas to obtain the proper combination-mixture-
required.
The success will be doubtless if the zones of preparation, of reduction, of carbonisa-
tion, of melting and of maturation so created will be placed at the right place in the
furnace and if the reactions taking place there are caused at the proper time and in
the proper proportion to the fuel (single or combined gases) blown into the
furnace.
The gases used, superheated steam and air, each for itself or in combination with
the others in adjustable proportions are produced in separate generators so as to
have them always ready in sufficient quantities and in the proper condition.
In order to obtain this result I introduce the gases into the furnace at those places
in such a state that will correspond to the reactions having to take place there by
means of adjustable injector like combined tuyeres.
I have designed the furnace shown in the annexed drawing similar in the whole to
an ordinary blast furnace, but differing from it that the said injector like tuyeres
are arranged in various horizontal rows round the furnace.
In the drawing
Fig. 1 is a vertical section of a furnace.
Fig. 2 is a similar section at right angle to Fig. 1.
Fig. 3 is a horizontal section along line I-I.
Fig. 4 is a horizontal section along line II-II.
Fig. 5 shows one manner of constructing the injector like tuyeres.
The blast furnace A is similar to the ordinary furnaces of this kind. At the head
of it is placed the casing B-from- which the gas-mains-C-C are taken off & the
casing is shut by means of the cone or bell shaped cover D of usual construction.
The upper part of the furnace rests upon a plate F which is supported by
6 columns E.
The hearth may be stationary, forming one with the upper part as shown on the
left side of Fig. 2 or it may be arranged on wheels so that it can be pulled out with
its contents as shown on the right half of Fig. 2 and in Fig.
but this is no
peculiarity of my invention.
The distinctive features of my furnace consist in that that I arrange, as said
above, the rows of tuyeres G, H & I in the zones of reduction carbonisation & in
the melting zone by means of which I blow into the furnace superheated steam,
heated air & gas or carbon in pulverized solid or liquid state.
The proportions in which these materials are blown into the furnace depend from
the quality of the ores & flux used and from the progress of the work in the
furnace itself.
In properly mixing them the forman melter regulates the work & the progress of
the smelting.
Below the melting zone I arrange a similar row of tuyeres K & thus I create the
zone of maturation in which I determine the final result, that is the contents of
carbon to be contained in the fluid material so as to obtain wrought iron, steel of
various qualities, foundry iron or pig iron as may be desired.
The proportion of the mixed gases, (air, carbon & steam) are determined by the
state of the fluid mass in the hearth and by the final product desired to be
produced.
Fig. 5 shows an arrangement of constructing the combination tuyeres, L being

page_text: the central air tube, M is the steam pipe & N is the gas pipe; by means of
the pipe carbon in a finely pulverized solid state or in a fine spray when
used in a fluid state, may be introduced. Each pipe is provided with a valve
or cock P1, P2, P3, P4 by means of which the admission may be regulated
at will.
They all unite or blow in a common tuyere R leading horizontally or by preference
somewhat inclined downwards into the interior of the furnace.
For the sake of following now the process going on in a furnace designed to
correspond to my method of iron making, let us suppose the furnace be at work.
The starting having to be done as usual with solid fuel and only when the work
is going on in regular order the new method has to be introduced gradually by
replacing the solid fuel (coal or coke) by gradual "charges" of gas,-carbon-
which is blown into the furnace.
At the bottom of the zone of preparation (as near as this place can be fixed :)-I
arrange a row of tuyeres by means of which superheated steam or superheated air
are blown in, in order to dry and roast the charges-ores & flux-and to with-
draw from them the humidity contained therein and other volatile materials and to
prepare them for the reception of oxyde of carbon and to make them loose and
opened.
In the zone of carbonisation or thereabouts I arrange a similar row of tuyeres,
the object of which is to introduce carbon and to mix it with the ores, so as to
prepare them for the melting process.
The blowing in of carbon may be done by the use of gaseous carbon or in a fluid
or pulverized state or any of these combined with the other, that is to say carbon
contained in gaseous, liquid or pulverized fuel.
It may be added here that my method differs from that used for some time in
England & America by Glay Bull, who blew the gas and air into the furnace
at opposite sides and only at the bottom of the furnace, for which reason his furnaces
after a short period were blown cold.
In the melting zone I arrange tuyeres by means of which I blow into the furnace
a mixture of superheated gas and air to which superheated steam may be added in
order to obtain the high temperature which is necessary to reduce into a fluid state
also the earthen material and so to separate completely the iron from the slag &
cinders in consequence & according to the difference of their specific weights.
In order to be able to vary the composition of the produce in the hearth at will
so as to receive spiegeleisen with a high percentage of carbon down to mottled iron
containing but traces of carbon, as well as steel and cast steel, I here provide a zone
of maturation by arranging a similar row of tuyeres through which I blow into the
furnace at this place a mixture of gas and superheated air or steam which may be
varied as desired so as to reduce the carbon in the iron to the desired degree.
Having now particularly described and ascertained the nature of my said
invention, and in what manner the same is to be performed, I declare that what I
claim is :
_
The process of making iron of any sort (pig iron, wrought iron, steel, cast steel)-
in one operation direct in the blast furnace which consists in blowing into the same
carbon gases in any suitable combination and mixed with heated air or superheated
steam (the charges of solid coal or coke having before been gradually stopped :)
by the use of injector like tuyeres arranged horizontal rows round the furnace
and at various heights of the same so as to produce that reaction of the charges of
ore and flux corresponding to the locality and time and desired state of the operation
in the furnace.
"
KARL S. MAYER,
Agent for A. Dauber.