Improvements in Converters.
Year: 1889

page_text: Date of Application, 25th June, 1889
Complete Specification Left, 21st Feb., 1890-Accepted, 5th Apr., 1890
TRUVIDIONAL DI MUIPTICATION
Improvements in Converters.
A communication from JOHN WESLEY BOOKWALTER, residing at Springfield, Ohio,
United States of America, Manufacturer.
I, ALFRED JULIUS BOULT of 323 High Holborn in the County of Middlesex, M.I.M.E.,
do hereby declare the nature of this invention to be as follows:-
In the ordinary rapid process of converting crude iron into malleable iron or
steel, where the air is forced into the metal under pressure, especially in the form
of jets, there is a tendency to produce local currents or vortices in portions of the
mass of metal which thus acquire a rapid movement apart from the other portions of
the metal, so that the moving portions are brought more intimately under the action
of the blast, and subjected thereto for a longer period of time than the other portions
which do not acquire so rapid a movement.
This action is attended with several
injurious results.
First, the portion of metal to which the rapid movement has been imparted is liable
to be over-blown or over-converted.
Second, the impurities eliminated in the process of conversion tend to remain within
the body of the metal within the vortices of the local current, so that their ready
escape therefrom is prevented, and they cannot accumulate upon the surface as they
should in a state of separation from the metal.
Third, the continuous circulation of the scoria in local bodies or portions of the
metal mixes them so intimately therewith as to render their removal difficult.
My correspondent has discovered that the difficulties to which I have alluded may
be overcome and the best grade of malleable iron or steel may be produced by securing
a uniformity of contact of the air with every portion of the metal, and that this is
essential in order that the decarbonization, desiliconization or conversion of the iron
may be uniform throughout the entire mass.
Having ascertained that the tendency to form local currents or vortices is much
greater when the air blasts enter the metal near the surface than when they enter at
a greater depth below the surface my correspondent has devised means whereby to
secure a continuously uniform action of the air upon limited uniform quantities of
the metal at one time, feeding the metal gradually to the air within a fixed or limited
space. By this means small portions of the metal as they are fed to the air are
driven thereby out of the zone of violent agitation of the air and metal, and there-
after are thrown back towards the greater body of metal, while a new portion of the
latter is being brought under the influence of the air, that portion of the metal which
is submitted to the action of the air being the purest portion of the body, that is
having combined with it less scoria than any other portion, and the greater body
of the metal which is not under the direct influence of the air being comparatively
stationary and free from currents or vortices.
The means which my correspondent has devised for effecting the above described
results consists in dividing the converter or that portion thereof which holds the
molten metal into two portions or chambers, one of which is much larger than the
other and contains the main body of the molten metal, and into the smaller of said
chambers, which is termed the "converting chamber," the metal is fed at a limited
uniform rate so as to meet a blast of air or other aeriform agent, by which the
inflowing stream of metal is forced outward through the converting chamber and
through the space or chamber above the body of molten metal and onto the surface of
the latter, this operation being continuous as the metal flows into the conversion
chamber and meets the continuous blast of air and the operation being continued until
'

page_text: every portion of the metal has been so acted upon as to effect the desired conversion,
which will be uniform throughout the mass.
In addition to the beneficial results issuing from insuring the contact of every portion
of the body of metal uniformly with the converting agent, my correspondent also
by this means prevents the intermingling of the scoria with the purer portion of the
metal, inasmuch as the scoria owing to its specific gravity remains upon the surface
of the larger body of the metal in separation therefrom, and as the body of metal is
free from active currents or movements tending to disturb the scoria, the latter remains
in its position so that by this division of the converter into two chambers the metal to
be acted on by the converting blast is drawn from the lowest part of the bath the
farthest from the scoria and the purest portion of the metal is therefore subjected to
the action the converting agent, and is again and again returned to the blast while the
scoria remains undisturbed at the surface.
The apparatus may be constructed in different ways so as to constitute two chambers
and secure the desired uniform intermingling of the metal and the air blast, and I
will now proceed to describe some of these.
The converter may be of any desired form and may be either a stationary converter
or supported and swing upon trunnions. The lower portion of the converter which
holds the body of the molten metal is divided into two chambers by means of a tubular
partition of refractory material projecting upward from the bottom of the converter
and vertically adjustable by any suitable appliance as for instance by a rod extending
through the top of the converter and provided with a rack engaging with an elevating
pinion by means of which the rod and the tube can be raised and lowered. The
lifting of the tube leaves between it and the bottom of the converter a channel through
which the molten metal from one chamber may flow into the other chamber and oy
elevating or lowering the tube the dimensions of the channels may be changed to
regulate the flow of metal into the conversion chamber. Communicating with the
conversion chamber is an air pipe terminating in a tuyere or tuyeres or nozzle through
which the blast or jets of air may be directed longitudinally through the tube to meet
and carry with it the inflowing current of metal. This air pipe may project into
the chamber to any desired height that may be found best or it may stop short and
merely blow into the chamber. When the blast constitutes the converting, agent, it
acts directly upon the small body that flows into the conversion chamber, but when
the blast is not the converting agent it serves to throw the metal as fed into the con-
version chamber into the converting agent, which in such case is introduced into the
converter in any suitable manner and in any suitable form, as for instance in the form
of a gas in the converter above the molten metal. The small body of metal acted on
by the blast may be thrown from the conversion chamber either in a small stream or
divided into a spray according to the speed of the feed. The feed may be regulated
by tilting the converter to a greater or less extent as well as by varying the size of
the feed channel, or the strength, volume, or force of the blast may be varied and
effect a like result.
A different form of device for controlling the flow through the channel or channels
may be so arranged that a valve carried by a rod is moved to obstruct the channel to
a greater or less extent. Thus the arm which carries the valve is pivotted at the upper
end and is moved by a screw or equivalent so as to carry the valve into or away from
the channel.
By rendering adjustable the tube or partition which separates the chambers the
dimensions of the orifices may be regulated as described so as to regulate the flow of
the metal and properly proportion the same to the quantity of air which is admitted
to the conversion chamber, and by arranging the orifices or channels at the bottom of
the chamber the purest portion of the body of the metal is subjected to the action of the
air, which would not be the result if the metal was admitted into the conversion
chamber from a point nearer the surface.
The quantity of metal admitted into the conversion chamber may be varied also by
varying the pressure of the blast for by increasing the pressure there is a greater

page_text: tendency to form a vacuum and therefore a larger quantity or metal is drawn into the
chamber.
The converter may be divided into two chambers by means of a partition so that
the contents of the conversion chamber are thrown diagonally across the converter.
This partition may consist of two three or more tubes arranged side by side. Or there
may be only one continuous diaphragm extending across the converter thus dividing
the same into two chambers there being in this case a series of tuyeres or nozzles.
There may be one or more channels.
In another construction the converter is divided into two chambers by a transverse
partition which preferably projects above the surface of the metal and is inclined at
one side across which the air blast at any suitable angle is directed to meet the stream
of metal flowing through the channel formed by arranging the partition a short
distance above the bottom of the converter. By placing the partition at one side of
the converter the conversion chamber is rendered smaller than the other chamber so
that the metal which flows therein will never exceed in amount the proportion the
air blast can force out of the compartment onto the surface of the metal in the
larger chamber.
By dividing the bath into two connected sections as described it is practicable
to greatly increase the depth of the bath without materially interfering with the
rapidity, certainty, and thoroughness of the conversion. Thus the converter may
extend to an unusual degree below the tuyeres with a long partition forming one
large and one small chamber, the air acting on the metal at the top of the latter
chamber, and the metal flowing from the larger to smaller chamber as before
described.
In all cases where the tuyere or nozzle is at one side of the converter it may be
placed at any desired depth below the top of the conversion chamber formed by the
partition and it may be inclined to any angle or it may be adjustable to any angle
that will give the best converting effect to the blast and impart the most effective
carrying or elevating action to the blast in operating upon the molten metal to
carry it from the conversion chamber onto the surface of the metal in the larger
chamber.
In any of the forms described the size of the channel may be regulated in any
suitable manner. The nozzle or nozzles may be arranged at any desired height
as regards the partition and to vary the angle as may be required each nozzle may
be adjustable; thus it may extend through a ball bearing fitting a socket in the
converter wall.
If desired the blast may be directed through a single tuyere or line of tuyeres,
each circular in form so that the only action which is produced as regards the heating
of the metal results from the combustion at or directly to the adjacent surface of the
metal.
I
In order to secure the advantages of the combustion of carbonic oxide with the air
may make use of a construction in which the blast is practically in two portions one
directed upon the metal and the other above the metal, the air in the lower portion of
the blast, which is in direct contact with the metal developing at least a portion of
carbonic oxide and the air from the upper portion after passing into the converter
co-mingling with the carbonic oxide with a resultant combustion that produces an
intense heat within the converter and speedily heats the bath to a high temperature.
In order to secure the division of the blast into two portions my correspondent
either makes use of two series of tuyeres, or of a single series of tuyeres elongated
vertically so that the lower portion of the blast from each tuyere will come directly
in contact with the metal to strip off, atomize and convert or partially convert the
same, while the upper portion will carry the necessary amount of oxygen to mingle
with the carbonic oxide and effect the combustion required.
As the larger portion of air admitted into the converter should be brought to act
directly upon the metal, the blast should be heavier at the lower than at the upper
portion, and my correspondent therefore prefers to make the elongated tuyeres larger
at the lower ends, or the lower set of tuyeres larger in diameter than the upper.

page_text: In virtue of the conversion of the metal and the elimination from the same of the
constituents of the crude material as well as of the impurities contained in the metal,
the volume of the metal is reduced and the level of the surface of the metal tends to
become lower during the process of conversion and therefore to preserve the proper
relation of the blast and the surface of the inetal, means must be employed for
maintaining this relation, as by the addition of other metal, or by displacing a portion
of the metal by introducing blocks into the path, my correspondent prefers however
to employ a tilting converter suspended upon trunnions and to tilt the converter on its
axis to bring the surface of the metal towards the tuyeres from time to time as may
be desired.
My correspondent is thus enabled by tilting the converter not only to bring the
1.nyeres to their proper place in relation to the surface of the metal, but also to vary
the quantity of metal that is caused to flow into the conversion chamber from the lowest
portion of the bath.
The arrangement of the tuyeres in relation to the converting chamber may be
varied to a great extent. Thus they may be at an angle thereto near the top or near
the bottom, or nearly horizontal near the top or vertical at the bottom.
By operating upon the metal as herein before set forth by means of a blast in two
portions a high heat is developed by the combustion of carbonic oxide and ordinary
atmospheric air, successive limited portions of the bath are operated upon and a proper
circulation of the metal is secured and maintained.
Dated this 25th day of June 1889.
W. P. THOMPSON & BOULT,
Agents.
COMPLETE SPECIFICATION.
Improvements in Converters.
A communication from JOHN WESLEY BOOK WALTER, residing at Springfield, Ohio,
United States of America, Manufacturer.
I, ALFRED JULIUS BOULT of 323 High Holborn in the County of Middlesex,
M.I.M.E., 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 :-
-
In the ordinary rapid process of converting crude iron into malleable iron or steel,
where the air is forced into the metal under pressure, especially in the form of jets,
there is a tendency to produce local currents or vortices in portions of the mass of
metal which thus acquire a rapid movement apart from the other portions of the metal,
so that the moving portions are brought more intimately under the action of the blast,
and subjected thereto for a longer period of time than the other portions which do not
acquire so rapid a movement. This action is attended with several injurious results.
First, the portion of metal to which the rapid movement has been imparted is liable
to be over-blown or over-converted.
Second, the impurities eliminated in the process of conversion tend to remain within
the body of the metal within the vortices of the local current, so that their ready
escape therefrom is prevented, and they cannot accumulate upon the surfaces as they
should in a state of separation from the metal.
Third, the continuous circulation of the scoria in local bodies or portions of the
metal mixes them so intimately therewith as to render their removal difficult.
My correspondent has discovered that the difficulties to which I have alluded may
be overcome and the best grade of malleable iron or steel may be produced by securing
a uniformity of contact of the air with every portion of the metal, and that this is
essential in order that the decarbonization, desiliconization or conversion of the iron
may be uniform throughout the entire mass.
Having ascertained that the tendency to form local currents or vortices is much
greater when the air blasts enter the metal near the surface than when they enter at a
greater depth below the surface means have been devised to secure a continuously

page_text: uniform action of the air upon limited uniform quantities of the metal at one time,
feeding the metal gradually to the air within a fixed or limited space. By this means
small portions of the metal as they are fed to the air are driven thereby out of the zone
of violent agitation of the air and metal, and thereafter are thrown back towards the
greater body of metal, while a new portion of the latter is being brought under the
influence of the air, that portion of the metal which is submitted to the action of the
air being the purest portion of the body, that is having combined with it less scoria
than any other portion, and the greater body of the metal which is not under the
direct influence of the air being comparatively stationary and free from currents or
vortices.
The means which my correspondent has devised for effecting the above described
results consist in dividing the converter or that portion thereof which holds the molten
metal into two portions or chambers, one of which is much larger than the other and
contains the main body of the molten metal and into the smaller of which or "converting
chamber," the metal is fed at a limited uniform rate so as to meet a blast of air or
other aeriform agent, by which the inflowing stream of metal is forced outward
through the converting chamber and through the space or chamber above the body of
molten metal and onto the surface of the latter, this operation being continuous as the
metal flows into the conversion chamber and meets the continuous blast of air and the
operation being continued until every portion of the metal has been so acted upon as
to effect the desired conversion, which will be uniform throughout the mass.
In addition to the beneficial results ensuing from insuring the contact of every
portion of the body of metal uniformly with the converting agent, the intermingling
of the scoria with the purer portion of the metal is prevented inasmuch as the scoria
owing to its specific gravity remains upon the surface of the larger body of the metal
in separation, therefrom, and as the body of metal is free from active currents or
movements tending to disturb the scoria, the latter remains in its position so that by
this division of the converter into two chambers the metal to be acted on by the
converting blast is drawn from the lowest part of the bath the farthest from the
scoria and the purest portion of the metal is therefore subjected to the action of
the converting agent, and is again and again returned to the blast while the scotia
remains undisturbed at the surface.
The apparatus may be constructed in different ways so as to constitute two chambers
and secure the desired uniform intermingling of the metal and the air blast, and in
the accompanying drawings I have illustrated different constructions which I will now
proceed to describe.
Fig. 1 illustrates in section a converter A which may be of any desired form and
may be either a stationary converter or supported and swing upon trannions. The
lower portion of the converter which holds the body of the molten metal is divided
into two chambers xy by means of a tubular partition 1 of refractory material
projecting upward from the bottom of the converter and vertically adjustable by any
suitable appliance as for instance by a rod 2 extending through the top of the
converter and provided with a rack 3 engaging with an elevating pinion 4 by means
of which the rod and tube can be raised and lowered. The lifting of the tube leaves
between it and the bottom of the converter a channel 4 through which the molten
metal from the chamber may flow into the other chamber y and by elevating or
lowering the tube 1 the dimensions of the channels may be changed to regulate the
flow of metal into the conversion chamber y. Communicating with the conversion
chamber y is an air pipe 5 terminating in one or more tuyeres or nozzles 6 through
which the blast or jets of air may be directed longitudinally through the tube to meet
and carry with it the inflowing current of metal. This air pipe may project into the
chamber y to any
desired height that may be found best, or it may stop short and
merely blow into the chamber. When the blast constitutes the converting agent it
acts directly upon the small body that flows into the conversion chamber, but when
the blast is not the converting agent it serves to throw the metal as fed into the
conversion chamber into the converting agent, which in such case is introduced into
the converter in any suitable manner and in any suitable form as for instance in the

page_text: form of a gas in the converter above the molten metal. The small body of metal
acted on by the blast may be thrown from the conversion chamber either in a small
stream or divided into a spray according to the speed of the feed. The feed may be
regulated by tilting the converter to a greater or less extent as well as by varying the
size of the feed channel or the strength volume or force of the blast may be varied
and effect a like result.
A different form of device for controlling the flow through the channel or channels 4
is shown in figure 2 in which a valve 7 carried by a rod 2 is moved to obstruct the
channel to a greater or less extent. Thus the arm 2 which carries the valve is pivoted
at the upper end and is moved by a screw 8 or equivalent so as to carry the valve 7
into or away from the channel 4.
By rendering adjustable the tube or partition 1 which separates the chambers & and y
the dimensions of the orifices 4 may be regulated as described so as to regulate the
flow of the metal and properly proportion the same to the quantity of air which is
admitted to the conversion chamber, and by arranging the orifices or channels 4 at
the bottom of the chamber the purest portion of the body of the metal is subjected
to the action of the air which would not be the result if the metal was admitted into
the conversion chamber from a point nearer the surface.
The quantity of metal admitted into the conversion chamber may be varied
also by varying the pressure of the blast for by increasing the pressure there is
a greater tendency to form a vacuum and therefore a larger quantity of metal is
drawn into the chamber.
In figures 3 and 4 the converter is shown as divided into two chambers by means
of a partition 1 so that the contents of the conversion chamber are thrown diagonally
across the converter. This partition may consist of two, three or more tubes arranged
side by side. Or there may be only one continuous diaphragm extending across
the converter thus dividing the same into two chambers as shown there being in
this case a series of tuyeres or nozzles. There may be one or more channels 4 a series
being shown.
Fig. 6 shows another construction in which the converter is divided into two
chambers by a transverse partition 1 which preferably projects above the surface of
the metal and is inclined at one side across which the air blast at any suitable angle
is directed to meet the stream of metal flowing through the channel 4 formed by
arranging the partition a short distance above the bottom of the converter. By placing
the partition at one side of the converter the conversion chamber y is rendered
smaller than the other chamber so that the metal which flows therein will never exceed
in amount the proportion the air blast can force out of the compartment onto the
surface of the metal in the larger chamber.
By dividing the bath into two connected sections, as described it is practicable to
greatly increase the depth of the bath without materially interfering with the rapidity,
certainty and thoroughness of the conversion. Thus the converter may extend
to an unusual degree below the tuyeres as shown in fig. 5 with a long partition 1
forming one large and one small chamber the air acting on the metal at the top
of the latter chamber and the metal flowing from the larger to smaller chamber as
before described.
In all cases where the tuyere or nozzle is at one side of the converter it may be
placed at any desired depth below the top of the conversion chamber formed by the
partition 1 and it may be inclined to any angle or as shown in fig. 2 it may be
adjustable to any angle that will give the best converting effect to the blast and impart
the most effective carrying or elevating action to the blast in operating upon the
molten metal to carry it from the conversion chamber onto the surface of the metal
in the larger chamber a.
In any of the forms shown and described the size of the channel
may be regulated
in any suitable manner. The nozzle or nozzles may be arranged at any desired height
as regards the partition and to vary the angle as may be required each nozzle may
be adjustable; thus it may extend through a ball bearing 13 fitting a socket in the
converter wall see fig. 2.

page_text: In the construction shown in figures 1 to 5 the blast is directed through a single '
tuyere or line of tuyeres each circular in form so that the only action which is
produced as regards the heating of the metal results from the combustion at or
directly to the adjacent surface of the metal.
In order to secure the advantages of the combustion of carbonic oxide with the air
I may make use of a construction shown in figs 6 to 9 in which the blast is practically
in two portions one directed upon the metal and the other above the metal, the air in
the lower portion of the blast, which is in direct contact with the metal developing at
least a portion of carbonic oxide, and the air from the upper portion after passing
into the converter, co-mingling with the carbonic oxide, with a a resultant combustion
that produces an intense heat within the converter and speedily heats the bath to a
high temperature.
In order to secure the division of the blast into two portions my correspondent
either makes use of two series of tuyeres or of a single series of tuyeres elongated
vertically so that the lower portion of the blast from each tuyere will come directly
in contact with the metal to strip off, atomize and convert or partially convert the
same, while the upper portion will carry the necessary amount of oxygen to mingle
with the carbonic oxide and effect the combustion required.
In figures 6 and 7 the tuyers a are shown as elongated vertically the lower edges
being below the normal surface line of the metal and the upper edges considerably
above said line while in figs. 8 and 9 two sets of circular tuyeres one above the other
are illustrated.
As the larger portion of air admitted into the converter should be brought to act directly
upon the metal the blast should be heavier at the lower than at the upper portion and
my correspondent therefore prefers to make the elongated tuyeres larger at the lower
ends or the lower set of tuyeres larger in diameter than the upper.
In virtue of the conversion of the metal and the elimination from the same of the
constituents of the crude material, as well as of the impurities contained in the
metal, the volume of the metal is reduced and the level of the surface of the metal
tends to become lower during the process of conversion and therefore to preserve
the proper relation of the blast and the surface of the metal, means must be
employed for maintaining this relation, as by the addition of other metal or by
displacing a portion of the metal by introducing blocks into the bath, my corre-
spondent prefers however to employ a tilting converter suspended upon trunnions B
and to tilt the converter on its axis to bring the surface of the metal towards the
tuyeres from time to time as may be desired.
My correspondent is thus enabled by tilting the converter not only to bring the
tuyeres to their proper place in relation to the surface of the metal, but also to vary
the quantity of metal that is caused to flow into the conversion chamber from the
lowest portion of the bath.
The arrangement of the tuyeres in relation to the converting chamber may be
varied to a great extent. Thus they may be at an angle thereto near the top as
shown in fig. 5 or near the bottom as in figs. 2 and 3 or nearly horizontal near
the top as in figs. 6 and 8 or vertical at the bottom as in fig. 1 and dotted lines fig. 5.
By operating upon the metal as herein before set forth by means of a blast in
two portions a high heat is developed by the combustion of carbonic oxide and
ordinary atinospheric air successive limited portions of the bath are operated upon and
a proper circulation of the metal is secured and maintained.
Having now particularly described and ascertained the nature of the said inven¯
tion 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 ;-
1. A converter having at the bottom two chambers, one for holding the body of
metal the other communicating with the first at a point below the normal surface of
the metal and constituting a conversion chamber and a blast pipe communicating
with the conversion chamber and arranged to direct the blast upon the inflowing
current and upward from the conversion chamber substantially as set forth.

page_text: more
2. A converter having its main chamber divided near the bottom by a tra isverse
partition into two chambers of different sizes said partition having one o
channels connecting the chambers in combination with a nozzle or tuyere arra ged to
direct a blast into and from the smaller chamber substantially as set forth.
3. The combination with a converter of a partition dividing the lower portion of
the converter into two chambers, a channel connecting the said chambers means for
varying the size of said channel, and a nozzle or tuyere extending into one of the
chambers substantially as set forth.
4. The combination with a converter of a partition separating the lower portion
of the converter into two chambers a channel connecting the chambers at a point
adjacent to the bottom of the converter a valve regulating the flow through said
channel and a nozzle or tuyere communicating with one of the chambers sub-
stantially as set forth.
5. The combination with a converter of a partition dividing the lower portion of
the converter into two chambers of different sizes and having a rounded or curved
side adjacent to the larger chamber a channel connecting the two chambers near the
bottom of the converter and a nozzle or tuyere extending to the smaller chamber
substantially as set forth.
6. A converter provided with tuyeres arranged above and below the normal surface
line of the bath to project a portion of the blast into contact with the metal and a
portion above the metal substantially as and for the purpose set forth.
7. A converter provided with tuyeres arranged to project the blast above and
below the normal surface line of the metal the lower portion of the blast in greater
volume than the upper portion substantially as set forth.
8. A converter the chamber of which is divided at the lower portion into two
chambers of different sizes by a transverse partition and tuyeres constructed and
arranged to direct a portion of the blast into contact with the metal in the smaller
chamber and another portion above the metal substantially as set forth.
9. The within described method and means of converting crude metal consisting in
continuously feeding the metal from that part of the bath below the surface and
under the scoria to the converting blast without disturbing the scoria through
the medium of a converter having two chambers communicating near the bottom
substantially as set forth.
Dated this 21st day of February 1890.
W. I. THOMPSON & BOULT,
Agents for the Applicant.