.PROVEMENTS IN THE MANUFACTURE OF IRON AND STEEL AND. CASTINGS OF THE SAME, AND IN APPARATUS EMPLOYED THEREFOR
Year: 1870

page_text: LETTERS PATENT to George Haseltine, of the International Patent
Office," Southampton Buildings, London, for the Invention of "IM-
.PROVEMENTS IN THE MANUFACTURE OF IRON AND STEEL AND. CASTINGS OF THE
SAME, AND IN APPARATUS EMPLOYED THEREFOR."-A communication from
abroad by John Ware Middleton, of Philadelphia, Pennsylvania,
United States of America, Iron Master.
.
Sealed the 12th May 1871, and dated the 24th November 1870.
PROVISIONAL SPECIFICATION left by the said George Haseltine at the
Office of the Commissioners of Patents, with his Petition, on the
24th November 1870.
I, GEORGE HASELTINE, of the "International Patent Office," South-
ampton Buildings, London, do hereby declare the nature of the said
Invention for "IMPROVEMENTS IN THE MANUFACTURE OF IRON AND STEEL AND
CASTINGS OF THE SAME, AND IN APPARATUS EMPLOYED THEREFOR," a communi-
"cation, to be as follows:-
This Invention relates, first, to a process and apparatus for making iron
castings direct from the ore, and refining the metal previously to casting;
A

page_text: also to a process and apparatus for making steel and malleable iron
railway rails or any other bars and plates of the usual merchantable
shapes and sizes, and for solidifying malleable iron or steel ingots, cross-
heads for engines, and other irregular shaped objects heretofore required
to be forged into such shapes. I use a gravity vessel, vertical, inclined,
or horizontal in position for use, and made adjustable or movable by a
crane or otherwise for the purpose of taking iron or scoria from a furnace.
The gravity vessel is sometimes fixed in position in the passage way
between an ore reducing furnace and the liquid steel or iron. The said
gravity vessel is sometimes arranged under the scoria and iron pool with
an oven enclosing or surrounding the whole, and warmed or heated by a
hot blast or by a special fire. The said gravity vessel is adapted for the
use of chemical reagents or means for purifying molten iron. Chemists
having heretofore only a very limited mechanical arrangement or means
for the purpose.
I intend to fasten to the inside of the bottom of the said gravity vessel
suitable jars or crucibles containing chemicals, such as carbonate of soda,
chloride of sodium, or chloride of calcium, and to be opened by an
electric wire exploding a small torpedo or its equivalent, so that the
contents of the crucibles or jars shall be liberated and rise up through a
perforated fire brick, or otherwise upward through the liquid metal. I
also intend placing the chemical matter or liquids combined with solids
or a porous material saturated with chemically acting fluids or thin layers
of soft clay intervening between each alternate brick or cake, and con-
taining small hollow spheres with powerful explosive materials therein,
so that the said dangerous properties may be used without risk of injury
to the operativos. All of the said gravity vessels are intended to have
as many openings fitted with adjustable sliding stops for drawing off the
fluid iron or the scoria as may from time to time be desirable.
Gravity moulds are arranged below the run out of a furnace for casting
fluid iron and scoria from the ore reducing furnace into pigs and other
like bars in vertical positions for the purpose of more effectually freeing
the iron from the scoria, so that the said scoria may be readily separated
or broken off from the solid metal pig or bar.
The furnace blast is intensified by passing it through a special furnace
burning coal, coke, wood, peat, or other heating substances (with a flux
to carry off the earthy matter when needed) for the purpose of putting a
chilled blast furnace again into "blast" by liquifying the chilled iron

page_text: and scoria, and thus causing them to run out at the hearth without
taking out any of the chilled contents of the furnace, and also for the
purpose of more rapidly reducing ore into iron and scoria. The blast is
diffused as it enters the ore reducing furnace, thus differing from the
blow pipe or focus like blast, which cutting in a contracted area melts
the limestone into calcium and the silex into silicon, thus alloying the
iron with metals which require chemical means to remove. Either cold
or hot blast or superheated steam or other acriform, vaporizing, or
gaseous substance may be used in my diffused blast.
I use a stack having a contracted portion or neck to serve as a support
to hold up the crude or unmelted stock and prevent its pressing too.
heavily upon the pasty or semi-fluid iron and scòria in the spherical
portion below the said neck at the lower part of the said orc reducing
furnace. A crucible is surrounded by an oven or hot blast flue and
having any desired number of tuyere iron and scoria openings that may
be readily closed, as the fluid iron rises in the crucible using the openings
successively from the lower to the upper ones and the upper ones then
until reached or until a very large quantity of iron is melted into it from
the ore-reducing furnace above. A pool for fluid iron and scoria is
located in the blast-diffusing passage way constructed and arranged so
that the fluid or liquid iron and slag or scoria will flow directly from the
ore-reducing furnace into said pool. The lower portion of this pool con
tains or forms a gravity vessel to receive the iron, and the said vessel
has suitable openings for drawing off the iron, and also to be surrounded
by an oven heated by a special fire or by flues heated by the hot-blast to
prevent chilling and thus enable the workman to draw off the iron- in a
highly heated state and free from slag.
An automatically working purifying pool is used to decarburize and
work out the impurities in the fluid iron by gun shot like, or short and
very sudden gushes of blast, thus purifying any quantity at one opera-
tion and dispensing with the present laborious mode of working by hand
tools.
I employ mechanism acting automatically for cutting off the blast at
from one-tenth to nine-tenths of a second under a pressure of from one
to fifty pounds to the square inch. A pouring ladle is made to
pour
from its bottom through a side spout opening fitted with a sliding stop
so as to run the metal out from below the floating scoria or slag.

page_text: I use a floating indicator working like a hydrometer for the purpose
of showing the top surface of the metal below the scoria or slag in any
containing vessel. A transparent plate of mica or glass is fixed in a
sliding plate arranged to cover blast-tight respective peep openings in
the walls of the furnaces, and operating so as to allow the transparent
portion to be brought opposite to the opening in the wall and removed
therefrom as occasion may require to view the interior and afterwards to
withdraw the transparent portion from injury by the heat and replace.
the blank portion.
An orc reducing furnace is arranged to communicate by a close hot-
blast passage way with a special furnace, whereby the hot blast may be
superheated to any higher degree required for operating more effectively
on the orc-reducing furnace and upon the metal in boiling, refining, and
purifying iron and steel, and allowing the reduced or purified metal to
be withdrawn at any stage required to be used either for iron castings,
stcel or malleable iron in ingots irregularly shaped articles, railway rails,
or other bars by the one or single heat process. A special heat is conveyed
by hot blast flues or otherwise under, around, and over all the gutters,
pools, and passages thereof to prevent the possibility of any chilling
taking place in any part of the apparatus during the process.
SPECIFICATION in pursuance of the conditions of the Letters Patent,
filed by the said George Haseltine in the Great Seal Patent Office on
the 24th May 1871.
TO ALL TO WHOM THESE PRESENTS SHALL COME, I, GEORGE
HASELTINE, of the " International Patent Office," Southampton Buildings,
London, send greeting.
WHEREAS Her most Excellent Majesty Queen Victoria, by Her
Letters Patent, bearing date the Twenty-fourth day of November, in
the year of our Lord One thousand eight hundred and seventy, in the
thirty-fourth year of Her reign, did, for Herself, Her heirs and suc-
cessors, give and grant unto me, the said George Haseltine, Her special
licence that I, the said George Haseltine, my executors, administrators,
and assigns, or such others as I, the said George Haseltine, my exe-
cutors, administrators, and assigns, should at any time agree with, and no
others, from time to time and at all times thereafter during the term

page_text: therein expressed, should and lawfully might make, use, exercise, and
vend, within the United Kingdom of Great Britain and Ircland, the
Channel Islands, and Isle of Man, an Invention for "IMPROVEMENTS
IN THE MANUFACTURE OF IRON AND STEEL AND CASTINGS OF THE SAME, AND IN
APPARATUS EMPLOYED THEREFOR," a communication to me from abroad
by John Ware Middleton, of Philadelphia, Pennsylvania, United States
of America, Iron Master, upon the condition (amongst others) that I,
the said George Haseltine, my executors or administrators, by an instru-
ment in writing under my, or their, or one of their hands and seals,
should particularly describe and ascertain the nature of the said In-
vention, and in what manner the same was to be performed, 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.
NOW KNOW YE, that I, the said George Haseltine, 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 statoment, reference being had to the accompanying Drawings.
forming a part of this Specification:-
In the production of refined cast iron, and castings, merchantable
malleable iron and steel, it has heretofore been the general practice to
accomplish the said results by special, distinct, or separate and inde-
pendent processes in operations, and furnaces therefor, and consequently
allowing the product of a preceding operation to become cold before the
succeeding one would be commenced, thus losing a large amount of
heat which should be made available for the subsequent operations upon
the said product.
To be more explicit, the iron reduced from the ore in the blast furnace
had, firstly, to be run into pigs, and allowed to become cold, and being
very impure from the large proportion of scoria and slag contained or
intermingled with and adhering thereto, secondly, to be remelted in a
cupola for the production of finer castings. For the production of
malleable iron and steel the impure pigs of the blast furnace had to be
reheated and melted in a refining furnace for decarburization and balling
for the squeezers or hammer for the production of puddled or muck bars.
Thirdly, these puddled or muck bars had to be cut, faggotted, and
reheated for the production of the bars, slabs, or plates for the market.
Fourthly, for the production of shear steel the bars had to be reheated in
cementing cases, or for the production of cast steel the said bars had to

page_text: bc cut and remelted in a crucible and cast into ingots, and thus again
heated for the hammer or rolls. It is true that iron has been run
directly from the blast furnace in an open gutter into a refining fire of
charcoal for the production of a superior cast iron without losing the
first heat. It is also true that the decarburization and purifying of
melted pig iron for the production of malleable iron, and again re-
carburizing the same for the production of steel, as practiced at present
in the "Bessemer process," require but the one heating of pig iron, and
thus far economise the fuel and time heretofore required in the old
processes of refining and puddling or boiling to produce malleable iron,
and of cementation to produce steel; but this "Bessemer process" is an
improvement of only one or two links in the chain of operations required
to produce during one continuous heat first iron and steel from the ore
reducing furnace to the flattening or straightening plate ready for the
market.
The first part of my Invention relates to the combination with a
puddling, boiling, or refinery furnace, of a series of blast pipe tuyeres
projecting downward through the top or sides, or both, of the furnace so
as to open near the surface of the melted nictal in a pool or pools in the
bottom of the latter in such a manner that hot air, superheated steam, or
gas may be driven through the said tuyers at various angles in relation
to the bottom of the furnace into the melted metal in the pool by a very
strong or powerful blast, and in sudden, powerful, alternating gushes or
jets from the said tuyeres, the object of this part of my Invention being
to produce by means of the said powerful jets or sudden guslics trans-
verse interruptions of the melted mass in the pool, and such other
.agitations, effervescings, and kneadings of the whole mass as will
thoroughly expose every part of the same to the chemical and mechanical
action of the said powerful jets, and thus effecting in a more thorough,
perfect, and expeditious manner the result obtained by the severe labor
peculiar to the usual mode of puddling.
Another part of my Invention relates to the application of a series of
slides of fire-brick or other refractory material over suitable openings
made for the purpose through the furnace walls for the observation of
the progress of the puddling and purifying processes on the melted
metal in the pool, a small opening being made and closed by mica or
glass, and the same protected against the external pressure of the blast
by making the slide moveable, so that it can be brought into and out of

page_text: juxta-position with the opening in the wall of the furnace as occasion
may require without uncovering the said opening.
Another part of my Invention relates to the combination with a
puddling, boiling, or refining furnace provided with the tuyere blast,
pipes and tuyeres previously named herein, of a vertical, stationary
reservoir for receiving and purifying by gravitation melted cast iron
direct from a blast furnace, and communicating by an adjustable stop at
its lower end, and suitable channels in the bottom of the furnace with
the pool or pools for puddling the melted metal in such a manner that
the metal freed from its lighter impurities and slag by gravitation in the
vessel, may be run into the said pool or pools when required, the object
of this part of my Invention being to economise labor, time, heat, and
fuel, by kneading the iron in the pools automatically, and by making
the whole process continuous from the blast furnace to the completion of
the puddling operation.
.
Another part of my Invention relates to an apparatus to be put in
connection with the tuyere pipes, and operated so as to open and close
communication between the main blast supplying pipe and the tuyeres
respectively in the sudden or quick periodical, alternating, manner
hercin-before mentioned..
Another part of my Invention relates to the employment of a floating
metallic indicator within the vessel for purifying by gravitation, the
said indicator to be of such specific gravity and construction as to sink
down through the slag and scoria, and float upon the fluid metal
beneath the said vessel, its stem projecting vertically up through the
top of the furnace; the object of this indicator being to shew the
height of the top surface of the metal in the gravity vessel.
Another part of my Invention relates to the employment on the
bottom of a deep vessel containing melted iron of a disk of porous
burnt clay saturated either with hydrocarbons, acid, or alkaline solutions
or water, and confined in the bottom of said, vessel, so that when the
melted iron is run into the vessel the heat of the contained iron will
gradually expel the substances previously absorbed by the said disk, and
thus cause them to pass upward through the melted iron, the object
of this part of my Invention being to subject the melted iron to
the gradually and slowly developing exhalations of the disk, in order
that sufficient length of time be afforded for the chomically purifying

page_text: action of the same, whatever they may be, upon the impurities in the
melted mass of iron in the said vessel.
Another part of my Invention relates to the employment of a torpedo
or torpedoes in a suitable case or cases containing any suitable chemical
reagents, and secured firmly to the bottom of a deep vessel containing
melted iron to be purified, the said case or cases being also in connection
with respective conducting wires, so that the said torpedoes can be
exploded separately or in succession when desired, and thus the reagents.
whatever they may be contained in the respective cases liberated; the
object of this part of my Invention being to subject the said melted iron
in the vessel to the suddenly acting and purifying reagents as the
presence of any particular sort of impurities may require.
Another part of my Invention relates to the combined arrangement
of a deep crucible or hearth having a vertical series of tuyere or blast
holes through its sides, and adjustable tuyere pipes adapted thereto with
an ore reducing furnace, so that as the fluid iron and slag or scoria run
down into the said crucible and rise in the same, the entrance of the
blast can be raised higher accordingly until the crucible be filled; the
object of this part of my Invention being to separate the fluid slag and
iron in the said crucible by gravitation and thus permit the iron to
be drawn off more free from the slag and therefore in a more suitable
state for making castings direct from the ore reducing furnace and for
the further purification and refining of the same by a one heat process.
acting continuously from the said ore reducing furnace to the usual
flattening or straightening plate in which the finished or merchantable
article is left to cool.
Another part of my Invention relates to the construction of the
interior of an ore reducing blast furnace with a contraction so made as
to form a burden supporting projection around in the inner side of tho
stack in combination with a spherical chamber between the said pro-
jection and the crucible, the object of this part of my Invention being
to diminish the pressure of the burden upon the pasty or partially melted
metal which is supported by the boshes, and to afford or allow a more
general and effective action of the blast in liquifying the metal and slag
before they enter the crucible or hearth, and also to prevent the usual
wedging action of the burden upon the pasty mass whereby the blast
would otherwise be liable to be shut off.

page_text: Another part of my Invention relates to the employment of a hot
blast channel, flue, or chamber, around and under the crucible or hearth
of an ore reducing furnace so constructed that a blast of waste heat or
gas, or the heat of a special fire, or the usual blast on its way to the said
reducing furnace will pass into and through the said channel around
and under the crucible or hearth and thence into the crucible; the
object of this part of my Invention being two-fold, first, to prevent the
possibility of the melted iron and slag in the crucible from becoming
chilled; and, second, to keep the contents of said crucible at all times
in the most fluid condition possible, and therefore, in the most ad-
vantageous state for the separation of the iron and slag therein, by
gravitation preparatory to casting in flasks or molds, or to the further
refinement or decarburization of the iron without cooling or the loss
of its heat.
Another part of my Invention relates to the construction and relative
arrangement of the heat generating furnace, the ore reducing furnace,
and the intervening or side chambers (for separating the iron and slag
by gravitation in a refining vessel, purifying, decarburizing, working, or
kneading automatically the iron and thus producing malleable iron or
steel), so that in driving the hot blast continually through from the
heat generating furnace to the ore reducing furnace the portion of the
said blast which may from time to time be required in the purifying,
decarburizing, and puddling or kneading chamber shall pass with the
exhalations or impurities derived in a different direction, or so as not to
re-enter the reducing furnace, but so that portions of the blast so turned
aside may be used for heating the main blast generating steam, or
calcining ores; the object of this part of my Invention being to use the
hot blast for reducing and refining without returning the expelled
impurities-into the ore reducing furnace.
Another part of my Invention relates to the combination with the hot
blast of an ore reducing furnace of a special heat generating furnace in
such a manner as to enable the workman to readily superheat or intensify
the heat of the said hot blast on its passage through the special furnace
to any degree required; the object of this part of my Invention being to
enable the workman to melt out either cast or malleable iron when the
same may by accident or neglect have become chilled in the said ore
reducing furnace, thus avoiding the great expenditure of time, labor,

page_text: Figure 1 is a plan view of the ore reducing furnace in connection with
the heat generating furnace, the intervening chamber with the gravity
vessel for separating the slag and iron, and the chamber for refining
and converting the cast metal into stcel and malleable iron; Figure 2 is
a vertical longitudinal section of Figure 1.
Figure 3 is a vertical transverse section of the refining and decar-
burizing chamber detached with its pool and jet pipes or tuyeres for
working or kneading the metal automatically.
Figure 4 is a perspective view showing the interior of said refining
and decarburizing chamber, detached and its pipes or tuyeres opening in
slanting directions into its pool.

page_text: Figure 5 is a horizontal section showing the lower portion of one of
the ingot molds as closed.
Figure 6 is a vertical section showing one half of the mold as
divided in a vertical plane between two diagonally opposite corners of
the same.
Figure 7 is a representation of the four parts of the said mold
opened.
Figures 8 and 9 are modifications respectively of the crucible or hearth
of the ore reducing furnace.
Figure 10 is a vertical section of the insulated vessel for purifying
the melted metal by means of any suitable chemical reagents and
torpedoes discharged by electric wires or for the action of the saturated
porous burnt clay disk under the heat of the melted metal in the said
vessel; Figure 11 is a vertical central section of the same vessel shown
in Figure 10, cut in a plane at right angles to that of Figure 10;
Figure 12 is a horizontal. section of the vessel shewn in Figures 10
and 11, cut below the dotted line X, Y, of Figure 11.
Figure 13 is a vertical central section of the hollow ingot of iron or
steel and the mold in which it is cast.
Figure 14 is a vertical longitudinal central section of the portable
pouring vessel for transferring melted cast iron into the flasks.
Figure 15 is a front view partly in section of the apparatus for opening
and closing the series of tuyeres for discharging jets of hot air or gas
into the puddling pools in the hot chamber; Figure 16 is a vertical
transverse section of Figure 15.
The crucible A is a deep cylindrical chamber extending vertically
downward from the boshes aº, and provided with a vertical series of
tuycres or blast holes a¹, a². Around and beneath the crucible A the
chamber flue or channel B is constructed and arranged so that a portion
of the hot blast from the heat-generating furnace C will enter or pass
through the same, and thus keep the walls and bottom of the said
crucible or hearth highly heated. The blast from the heat-geucrating
furnace Centers the run out at the bottom of the crucible A, as con-
nected in the Drawing, but with the ordinary blast furnace blast and
this improved purifying crucible and heated chamber, as the melted
metal rises in the crucible the opening is to be stopped, and the blast
introduced through the hole to be then opened next above, and so on in

page_text: succession with all the holes until the crucible is filled with the melted
iron and slag. The said external blast is introduced through the several
tuyere holes, each of which is provided with a pipe a", which passes
through the surrounding hot channel or chamber B. All the said holes
are of course to be kept stopped except those through which the blast is
driven. Immediately above the crucible A there is a large spherical
chamber a, which produces an annular projection a for supporting
the heavy burden of the furnace in such a manner that the pasty mass
in the spherical chamber a¹¹ below will be sufficiently relieved to allow
the blast to penetrate it, and thus more rapidly reduce the same to the
fluid state for running into the crucible A below, and at the same time
permit a more diffused action of the blast upon the pasty mass, and thus
avoid that narrow, concentrated, and consequently intensely hot and
cutting action of the blast which reduces the calcium, silicon, or other
metallic clements which are contained in most of the ores and fluxes,
and render the iron impure or unsuitable for some purposes.
The heat-generating furnace C has a large fuel magazine c', with
air-tight fittings so constructed and applied as to hold the day's supply,
or more, of the fuel, and feed it to the blast by gravitation as the com-
bustion of the fuel may require, and at the same time prevent the ingress
and egress of air through the magazine. The fuel rests upon a grate if
cold blast be used for its combustion, or on the bottom of the furnace
if hot blast be used, and the blast is driven into it at this point so as to
produce a rapid combustion, and drive a steady and powerful current of
intensely-heated products of combustion upward and onward through
the passage way D and the crucible A of the ore-reducing furnace. A
'fluxing substance may be used with the fuel if necessary, and the slag
let out through a tap hole in the bottom of the furnace C.
1
The refining, puddling, and automatically kneading chamber E is
arranged at one side of the direct draught chamber D, and communicates
therewith through an opening eº, which is fitted with a sliding door, so
that when this chamber E is not in use, or needs repairs or any tem-
porary cessation of its operation, the same can be closed and the blast thus
prevented from entering the said chamber. The object of putting this
chamber aside from the line of the direct draught is to use a sufficient
portion of the latter for refining, puddling, and the like, without sending
the impuritics separated in the said chamber E back again into the
ore-reducing furnace, a result which would necessarily follow if the said

page_text: purifying chamber were placed in the direct line of the blast from the
heat-generating chamber to the orc-reducing furnace. Two or more.
of the refining chambers E may be connected with the direct blast
chamber D in the same manner as indicated by the dotted lines V in
Figure 1. The general structure of the chamber E with its tuyere
pipes e¹, e¹, and pool e¹¹, is shown in Figures 3 and 4, and the apparatus
for causing hot air or gas to be driven through the said tuyere pipes in
short, rapid, air-gun like shots, which will knead the contents of the
pool automatically, is shown in Figures 15 and 16, and will herein-after
be described.
Each one of the series of the said tubes, it may be here remarked, is
intended to make a shot per second of time, and in such succession in
relation to the other tubes as to keep the whole contents of the pool in,
rapid and thorough agitation.
The vessel d¹ in the chamber D for more perfectly separating the slag.
and iron by gravitation has a flue space 4 partially around it for keeping.
it hot, and is lined inside and outside with fire-brick material, and has
outlet spouts du, d, for drawing off the iron and slag as wanted outside
for castings. The spout opens inside of the chamber D, and serves
a double purpose-first, to allow the hot blast to enter and heat more
perfectly the interior of the said vessel preparatory to running the iron
and slag from the gutter or pool 6 above into it; and, second, to permit
the fluid iron which has gravitated toward the bottom of the said vessel
to run into a gutter 5, and thence into the refining chamber E through
an opening e". These spouts are intended to be fitted with clay stoppers
to be applied when required to close the same.
The floating indicator G, see Figure 2, consists simply of an egg-shaped
or globular body and a stem g', each of thin sheet platina filled with
solid cast iron, and the stem marked in regular division to indicate the.
depth of the surface line of the melted metal in relation to the top edge
of the vessel d¹ containing the said metal slag and indicator, so that the
attendant can at any time instantly ascertain the quantity of metal which
may be below the scoria or slag.
For the hearth or crucible of a stack which is without the contraction;
a and spherical chamber a¹¹, or as stacks are usually constructed for an
ordinary blast, the modification shown in Figure 8 is intended to be
used. .

page_text: The modification shown in Figure 9 relates to the hearth of a stack
constructed as in Figures 1 and 2 for an intensified diffused blast, and is
intended to allow a continuous flow of the melted iron and slag into a
deep pool or receptacle I, which is to be kept hot by a furnace ¹
beneath it, and also provided with a vertical series of tap holes.³
for drawing off either the iron or slag, which will separate therein by
gravitation of the iron.
The mold for casting ingots under a head pressure is made to open
readily, as represented in Figures 5, 6, 7, so that the ingot cast therein
can be quickly released while at a strong head, the stem produced by
the pressure column f¹ serving in part as a means for guiding it under
the hammer or into the rolls, whereby the said ingot may be elongated
or rolled or hammered into bars by the heat remaining in it after being
taken from the mold. The core f" of the mold shown in Figures 5, 6, 7,
allows three distinct ingots to be cast under one pressure column f¹ with
a like condensing or solidifying pressure of the column upon each.
One of the mica or glass peep holes is indicated at H, Figure 2. It
consists of a mica or glass covering over a small peep hole in a fire-clay
block made to slide horizontally in a corresponding recess (in the wall
of the furnace), provided with a corresponding hole, and so arranged
in a securely air-tight manner that the two eye openings or peep holcs
can be brought opposite to cach other when required to allow an eye
view of the particular part of the furnace within its range. Several of
the adjustable slides are intended to be applied at different parts of the
furnace to enable the operator to inspect the progress of the work, but
in each case the slide must be fitted to sustain the powerful pressure of
the blast.
The insulated vessel, Figures 10 and 11, is a portable deep cylindrical
receiver J supported upon a glass insulated plate in any suitable hot-
chamber. It is lined with fire-brick material and has an outlet 2
provided with a sliding stop plato 3 of fire-brick, so that the fluid
contents of the vessel can be run out as occasion may require. A small
torpedo 4 is enclosed in clay and connected to two separated wires 5, 5,
which enter the sides of the vessel J and connect with the torpedo in
the lower end of the said vessel, so that an electric spark may be pro-
duced within the torpedo to explode it, and thus allow a current of the
electric fluid to pass up through the melted malleable iron in the vessel,

page_text: so long as the action of the electric fluid may be required to act on the
said metal. A disk 6 of compacted clay and carbon, say equal parts,
and a like disk of porous burnt brick saturated or impregnated either
with water, hydrocarbons, acid or alkaline fluids, are intended to be
prepared beforehand, and the required one securely fixed on or near
the bottom of the inside of the purifying vessel J, so that when the
melted malleable iron is run into the said heated vessel, the intense
heat will gradually liberate the carbon from the clay in the one case,
and the hydrocarbons, water, alkaline or acid properties of the burnt
clay disk in the other case, as either disk may require to be placed in
the vessel.
After the iron has been purified, refined, or recarbonized in the
vessel J, it is intended to be either run out and conveyed to the usual
squeezer, and then to the rolls and elongated into bars, or in a more
highly heated or liquified condition run directly into molds, which will
form it into solid ingots of the T, H, L, U, or V shape, or into the cross
heads for engines, or other complicated solid forms before named, or
into hollow conical frusta, in order to facilitate by said cast forms the
production of railway rails, or hollow shafts or bars by elongation
between rolls, or the production of cross heads for engines and other
complicated masses of malleable iron or steel, ready for the planer or
file without the aid of the forge hammer.
The hollow conical ingot and the mold for casting it is shown in
Figure 13 in vertical central section, K being the hollow ingot; k¹, the
outside shell of the mold; ", the central core, and ", the removable
base of the mold. When the ingot has become sufficiently set the core
can be readily knocked out and the ingot K released by separating the
two vertically divided halves of the mold.
The portable pouring vessel, Figure 14, is a hollow vessel L, resembling
in shape a bullock's horn with the smaller end cut off so as to produce
an open way entirely through it. It is intended to be made of boiler
plate iron lined with clay and supported upon a bottom rim , so as to
keep its two open ends upward when resting thercon. It has two hollow
or tubular bearings 2, 3, fixed transversely upon its concave or upper
side, whereby it can be suspended by chains and tackle blocks from a
travelling crane, so as to be readily tilted in the operation of pouring
melted metal from its interior through its smaller end as occasion may

page_text: require. The smaller end may be provided with a stopper 4 which can
be readily removed before pouring.
The object of the peculiar construction described and shown is to
produce a pouring vessel that will discharge the metal from its lowered
end and allow the scoria to float to its larger or higher end, and thus
prevent any of the latter from entering the flask.
The apparatus for interrupting the flow of the hot air or gas into the
refining or puddling pool e" in the chamber E, see Figures 1, 3, 4, so
as to produce the air gun like shots for kneading the metal automatically
is shewn in Figures 15 and 16. A, B, is a frame which may be of any
suitable materials or construction, through the lower part of which the
series of tuyère pipes F, F, (the bore of which is about 3/8ths to 3/4ths of
an inch diameter), pass in connection with suitable enlargements or
bosses having a smooth cylindrical or otherwise shaped hole, cutting the
said bore of the tuyère pipe transversely. Into each of these transverse
openings a stem f¹ having a hole 2 corresponding with the bore of the
tuyère pipe is adjusted to slide so that the passage way for the hot air or
gas, to be forced by blast pressure through the respective pipes F, F,
may be suddenly closed and opened alternately by the movements of the
said stems f'. The required movements of the said stems are effected
by means of a rotating cylinder C provided with a series of transversely
arranged grooves c', c', corresponding in number with the pipes F, and
in each groove a friction wheel 3 rolls as the said cylinder rotates, the
axis of the roller being in the end of a lever 4 of the first class, which
is supported upon its fulcrum 5, and has its weight end articulated to
the stem f¹, which works in the boss of the tuyere pipe. Each of the
grooves c'in the cylinder C is varied in depth so as to produce an
excentric, which will cause the stem f¹ to be moved, so that its hole 2
will be periodically and suddenly brought into juxtaposition with the
bore of its tuyere pipe F, and thus open and close alternately the passage
way for the hot air or gas blast through, the tuyere into the poole con-
taining the fluid metal to be operated upon thereby, the opening and
closing of the tuyere being in accordance with the velocity of the
rotary motion of the cylinder, and the force with which the hot air or
gas blast strikes and drives through the metal in the pool, being in
accordance with the degree of pressure under which the main blast is.
driven for the purpose.

page_text: For the purpose of keeping the friction wheels 3-3 of the levers 4-4
in close contact with the rotating cylinder C,. the power ends of the
said levers may be weighed or kept down in close contact by any
suitable spring bearing continually upon the same. The excentric
grooves care to be arranged respectively so as to open and close the
tuyere pipes of the series in succession, or two, three, or more of them
simultaneously; and in cases where the excentric would by its length
too long protract the movement of the stem f¹, two or more toes or
lifters may be substituted and the strength of the springs increased.
Any of the stems may be held out of contact with the cylinder C by
means of a tension rod o which can be hooked over the stud o¹ in
the stem.
1
. To sum up briefly, I will say that by means of the process and
apparatus herein described and set forth, castings, steel, and malleable
iron, can be produced from the ore. with greater economy of fuel; it
being a one heat process, less labor, less time, and the quantities of the
metal produced from the same kind of materials, better than can be
produced by any other process and apparatuses therefor hitherto known
or used.
Beginning at the ore-reducing furnace the melted iron and slag running
into a deep gravitating pool (kept heated by an outside furnace, as
indicated at I, Figure 9, if desirable) allows the iron and coarser slag to
separate and be drawn off for common castings, or for building blocks
of slag, as may be desired, or the iron by a suitable gutter may run into
the vessel d', see Figures 1 and 2, wherein the iron will be more
perfectly separated from any remaining slag by the gravitation of the
former towards its bottom, and the surface line of the same be indicated
by the float G therein. From this vessel d' the purified iron may be
drawn off through the outside spout for finer qualities of casting, or run
into the pool in the side chamber E, and refined by the puddling, boiling,
and kneading operation of the series of tuyere jet. pipes e', e', driving
hot air or gas in rapid air gun like shots in powerful jets through the
melted mass in the said pool, as herein-before described. After the iron
has become perfectly decarburized, the jets are to be shut off, and if
delayed the blast through the chamber still further intensified to liquify
the mass in the pool and the malleable iron then run out into the moulds
for giving the forms desired for cross heads or other articles of machinery

page_text: which can be molded for the purpose or into the ingot molds, see
Figures 5, 6, 7, provided with a pressure tube f1 for condensing or
solidifying the ingot, which when set is to be transferred to the hammer
or rolls, and clongated and finally straightened on the floor plate, thus
completing the operation by a single heat from the ore to the finished
article.
For the production of steel, the decarburizing jets of hot air through
the tubes e¹, e¹, of the pool in the chamber E, see Figure 4, are to be
suspended before the decarburization is completed or immediately after
the decarburization has been completed, a due proportion of "spiegelisen "
may be added and incorporated with the decarburized iron to recarburize
it into steel, as in Mushet's process, the intensity of the blast through the
chamber increased, and the steel run out into the ingots, and finally
hammered or rolled and straightened for the market.
Should the gravitated iron in the vessel d', see Figures 1 and 2,
contain impurities which may be eliminated by the action of the electric
fluid, the vapor of water or solutions of acid or alkaline substances in
the porous burnt clay disk in the outside vessel, see Figures 10, 11, 12,
or if it be desired to further carburize the said gravitated iron by means
of the disk of clay and carbon 6 in the said outside or portable vessel,
the said iron in the vessel d' may be run out into the portable vessel J,
and so purified or carburized, and then run back again into the vessel d',
in the furnace chamber D. The intensified blast driven through the
chamber D and furnace stack will effectually prevent "scaffolding” in
the stack, a result which sometimes occurs in stacks of the old form,
heated by a concentrated blast, in consequence generally of a deficient
proportion of carbon or coal in the charges. I would therefore recom-
mend that a furnace for superheating the blast for such stacks be
attached beforehand, so that it can be made available for removing the
scaffold, and also that in such case fuel be fed abundantly into the
tunnel head, and the superheated blast be driven downward therefrom
and cut through the hearth outlet, the top of the stack being closed.
Having thus fully described the said Invention as communicated to
me by my foreign correspondent, and shown how the same may be
conveniently and advantageously carried into practise, I claim, the
herein-described improvements in the manufacture of iron and steel,

page_text: and castings of the same, and in the apparatus employed therefor,
substantially as set forth.
In witness whereof, I, the said George Haseltine, have hereunto set
my hand and seal, this Twenty-third day of May, in the year of
our Lord One thousand eight hundred and seventy-one.
Witness,
E. C. JACKSON.
GEORGE HASELTINE. (L.S.)