IMPROVEMENTS IN THE CONSTRUCTION OF FURNACES AND APPARATUS EMPLOYED IN THE MANUFACTURE OF MALLEABLE IRON AND STEEL AND IN THE MODE OF WORKING THEM to bo as follows
Year: 1884

page_text: WC JOSEPH BURCH of Adswood Grove Stockport in the County of Chester,
Consulting Mechanician and RUSSELL ALLEN of Overbrook Kersal Manchester
in the County of Lancaster, Gentleman do hereby declare the nature of our
Invention for IMPROVEMENTS IN THE CONSTRUCTION OF FURNACES AND APPARATUS
EMPLOYED IN THE MANUFACTURE OF MALLEABLE IRON AND STEEL AND IN THE
MODE OF WORKING THEM to bo as follows;—
These improvements are supplementary to our former invention relating to
puddling and refining furnaces for which Letters Patent No 3250 A D 1882 were
granted to us s-They have been devised with a view to perfect our system of
continuous puddling and refining metals, our main object at the present time being
to simplify the construction of the floor or hearth of the refinery chamber of our
furnaces, re-arrange the several parts generally and thereby improve the mode of
working described in the Specification of our said foriner Patent a concise outline
of which invention it will be necessary to give here in order that our present
improvements thereon may more readily be understood.
The principal foatures of our said former invention comprise three sections
(viz) a main furnace grate combined a reverberatory rocking hearth chamber of
unusual length, and a balling cylinder which rotates-The Specification describes
our new system of continuous puddling or refining metals, and which consists in
feeding or introducing a fresh charge of molten metal into the fore end of the
furnace every time the refinery chamber thereof rocks to-and-fro and the charges
in succession by the rocking motion are caused to follow each other throughout the
whole length of the refining chamber into the balling cylinder, from the far end of
which the several charges in rotation are delivered in the form of puddle balls-
The floor of the refinery chamber is furnished with a multiplex series of narrow
hearths or channels from side to side crosswise, and severally communicating, the
after end of one hearth with the fore end of the next, and so on alternately at the
sides throughout the whole length of the Chamber by means of junction inclines,
so that a continuous channel crossing and recrossing the hearth chamber is formed

page_text: from its fore to its after end and along this channel the separate charges follow
cach other and gradually reach in regular rotation the after end of the Chamber,
whence they pass along with the flaming gases through a fixed flue piece into the
balling cylinder through which by means of an internal spiral they are gradually
transferred to the furthermost end, where they are discharged in the shape of
puddle balls, the extreme end of the balling cylinder being in open communication
with the furnace chimney-We also describe a modification in which we shew a
series of shorter fornaces each having a main fire grate and a refining chamber
furnished with narrow hearths forming a continuous channel-The short furnaces
are so arranged that the separate charges of molten metal being fed in succession
into the fore end of the first furnace, are caused to follow each other throughout
the whole series, that is to say, by the combined motion of the furnaces rocking in
concert, the charges after they pass through the first are made to flow into the fore
end of the second furnace and passing through it are delivered in rotation into the
fore end of the third furnace, and so on to the last, whence they are discharged
into either a balling cylinder or into moulds.
Now as an opinion has been expressed that we shall have much difficulty in
finding a sufficiently refractory and lasting material of which to construct the
narrow hearths and divisional fences of our refinery chambers, such as must
effectually withstand the constant attrition of the flowing molten metal as it runs
over them, and further that we must provide means for subjecting the puddle balls
in the balling cylinder to what is denominated a final heat" we have devised our
present improvements with a view to render our new system of continuous
puddling and refining metal as complete and perfect as possible, and to this end our
present improvements consist as follows―
"
First Instead of constructing on the floors of our hearths chambers a multiplex
crosswise arrangement of narrow hearths communicating by junction inclines and
thereby fortuing a continuous channel crossing and recrossing the climber
throughout its whole length, we in one inodification make the centre of the floor
a perfect plane from end to end, and we introduce in relief thereon along each side
upon the floor of the chamber a series of obliquo guides, so formed as to cause the
successive charges of metal every time they flow across tho chamber as the furnace
rocks from side to side, to move forward towards the delivery end of the Chamber,
and reaching there in rotation are delivered direct into the balling cylinder-ln a
second modification we omit the oblique guides and make the floor of the refinery
chamber entirely plain from end to end, excepting that along the sides we in some
cases form shallow recesses that serve to keep the successive charges equable in
quantity, and there is one oblique guide placed at the delivery end of the chamber
which regulates the quantity of metal discharged into the balling cylinder every
time the chamber rocks to the delivery side In order to ensure the onward flow
of the metal towards the delivery end of the refinery chamber, we in both
modifications give to the chamber from its fore to its after end, an adjustable
downward inclination more or less according to the time required by the special
quality and nature of the metal in process, and by this means as the metal flows
from side to side, it acquires a tendency to gravitate towards the lowest or delivery
end of the chamber, its movement in that direction being regulated (more especially
in the second modification) by the amount of inclination given-In all cases
however the metal which is kept in a state of ebullition whilst passing through
the chamber must be discharged into the balling cylinder before it " "falls or
thickens, and therefore it is important that the means are at hand either to
accelerate or retard its onward movement through the chamber at the same time
that it flows from side to side, so that it can be timed and regulated to a nicety-
The heating of the refinery chamber is effected as formerly by a main furnace grate
at its fore-end, and the requisite degree of heat is maintained and regulated
throughout the whole length of the chamber, by the combustion of heating gas
burning internally, or by small auxiliar fire grates adapted externally at intervals
to the sides..
"

page_text: In the construction of the roof of our improved refinery chambers we mako
certain parts or sections capable of being lifted or removed, so that if required the
chamber may be opened for repairs or otherwise; and we also make eye-holes and
openings at intervals at the sides.
We also adapt the present improvements to the floors or hearth chambers of our
furnaces that rock and work together in combination as formerly described.
Second This part of our present invention relates to the fitting up of the
rotating balling cylinder, to which at its further most end we now adapt a main
furnace grate, whereby we obtain a "final heat" in the cylinder in the best possible
manner, and instead of mounting the cylinder in a level position and in a line with
the refinery chamber, we dispose it at an angle thereto, in order that tho
successive charges of metal as they are discharged from the chamber may flow into
it direct from the delivery port, which is now placed at the side-Wo also give to
the Cylinder a downward inclination from the end contiguous to the refinery
chamber which end is the highest, and above the level of the fire grate at its
furthermost or lowest end-The several charges of metal become pasty and
colerent as they are moved along or through the cylinder by the internal spiral,
and as they gradually approach the fire grate the heat increases and the liquid
cinder which escapes gradually through orifices opened and closed automatically is
reduced by the increasing heat to a highly fluid state, so that it readily separates
from the puddle balls, which as they in succession or apparatus provided for
conveying them to the shingling haminers.
Third This part of our improvements rolates to the position of the chimney,
which we now build at or contiguous to the after or lowest end of the refinery
chamber in place of the fixed fluo piece which according to our present
arrangements is not now required-By this means we are enabled to discharge
the spent gases and products of combustion from the delivery end of the chamber
either direct into the chimney or previously into the flues of a steam boiler, and
by the same chimney the fiery draught from the new firegrate that heats and
passes through the balling cylinder, is also carried off, after having when necessary.
been further utilized in generating steam-Tho flue passages from both sections
(viz) the Refinery hearth chamber and the balling cylinder are provided with
suitable dampers to regulate the fire draughts from their respective furnaces.
The refinery hearth chambers and their furnace grates are mounted-as heretofore
on rockers, the parts resting on rollers or slides to facilitate expansion and
contraction without friction, and the rocking motion as formerly described may be
effected by cams, or it may be produced by cranks acting on levers and connecting
rods, or by other known mechanism.
The fluxes, oxidising agents, refining and other matters used in the process of
puddling, are to be introduced to commingle with the fluid metal as it flows,
preferably in the same manner and by apparatus similar to that described in the
Specification of our said former Patent.

page_text: We JOSEPH BURCH of Adswood Grove, Stockport in the County of Chester,
Consulting Mechanician, and RUSSELL ALLEN of Overbrook Kersal Manchester in
the County of Lancaster, Gentleman, do hereby declare the nature of our said
Invention for "IMPROVEMENTS IN THE CONSTRUCTION OF FURNACES AND APPARATUS
EMPLOYED IN THE MANUFACTURE OF MALLEABLE IRON AND STEEL, AND IN THE
MODE OF WORKING THEM," and in what manner the same is to be performed, to
be particularly described and ascertained in and by the following stateinent :-
These improvements aro supplementary to our former invention relating to
puddling and refining furnaces, for which Letters Patent N° 3250 A.D. 1882 were
granted to us. They have been devised with a view to perfect our systein of
continuous puddling or refining metals, our main object at the present time being
to simplify the construction of the floor or hearth of the refinery chamber of our
furnaces, rearrange the several parts generally and thereby improve the mode of
working described in the Specification of our said former l'atent, a concise outline
of which invention it will be necessary to give here, in order that our present
improvements thereon may be more readily understood.
The principal features of our said former invention comprise three sections (viz³)
a main firegrate combined with a reverberatory rocking hearth chamber of unusual
length, and a balling cylinder which rotates. The specification describes our new
system of continuous puddling or refining metals, which consists in feeding or
introducing a fresh charge of molten metal into the fore end of the furnace every
time the refinery or hearth chamber rocks to-and-fro, and the charges in succession
are by the rocking motion caused to follow each other throughout the whole length
of the refinery chamber into the balling cylinder from the far end of which the
several charges in rotation are delivered in the form of puddle balls.-The floor of
the Refinery chamber is furnished with a series of narrow hearths or channels
arranged crosswise side by side and severally communicating, the after end of one
hearth with the fore end of the next alternately at the sides of the chamber
throughout its whole length, by means of junction inclines, so that a continuous
channel crossing and re-crossing the hearth chamber, is formed from its fore to its
after end, and along this channel the separate charges are by the rocking motion
caused to follow each other, and they gradually reach in regular rotation the after
end of the chamber, whence they pass along with the flaming gases through a fixed
flue piece into the balling cylinder, through which by means of an internal spiral
they are gradually transferred to the furthermost end of the cylinder, its extreme
end being in open communication with the chimney. We also described a
modification in which we shew a series of shorter rocking furnaces, cach having
a main firegrate and a refining chamber furnished with narrow hearths forming
a continuous channel through cach.
These furnaces are so arranged that the separate charges of molten metal, which
are fed singly into the receiver at the fore end of the first furnace are caused to
follow each other through the whole series, that is to say, by the combined motion
of the furnaces rocking in concert one with another, the charges as they are
delivered from the after end of the first are caused to flow into the Receiver at the
fore end of the second furnace, and passing through it are delivered in regular

page_text: rotation to the fore end of the thiru furnace, and so on to the last furnace of tho
series, whence they are discharged either into a balling cylinder, or into moulds, or
otherwise.
Now as an opinion has been expressed that we shall have much difficulty in
providing a sufficiently refractory and lasting material wherewith to construct the
narrow hearths and divisional fences of the Refinery chambers such as must be
capable of effectually withstanding the constant attrition of the flowing metal as
it runs to-and-fro over them, and further that we must find means for subjecting
the puddle balls to what in hand puddling is denominated the "final hont," we
have in order to meet these requirements, dovised our present improvements,
hoping thereby to render our new system of continuous puddling as complete and
perfect as possible; and to this end the main features of our invention consist as
follows viz., In simplifying the construction of the floor or hearth of our
refinery chambers, to which for the purposes hereinafter explained we give a
downward inclination from its fore end adjoining the main fire grate, to its after
end where the refined metal is discharged: In improving and re-arranging the
parts whereon the refinery chamber rests and rocks:-In the addition of a main
firegrate to the delivery end of the balling cylinder :-in the use of a grid for the
purpose of separating the melted cinder from the puddle balls, and in improving
the internal form of the spiral gutter: also in so placing the chimney in an
intermediate position that it may receive and carry off the spent gasos and
products of combustion from the two main firegrates, namely of the refinery
chamber, and of the balling cylinder:-and in other minor details.
First. Instead of forming by means of narrow hearths and junction inclines a
continuous channel on the floor or hearth of our Refinery chamber A, we (as
exhibited in the modification shown by Fig: 1 on the drawing hereto annexed)
make the hearth A' a perfect plane from end to end, and we construct in relief
thereon along both sides of the chamber, a series of oblique guides A", so formed
as to assist in causing the successivo charges of metal every time they flow across
the hearth alternately from side to side, to move forward in the direction of the
lowest or delivery end of the chamber, and reaching there in regular succession
are, by means of the delivery spout A3 and the inclining gutter A' delivered direct
into the balling cylinder C, which may be disposed as formerly described (see
Fig 4.) in a line with the refinery chamber, or as shewn by the plan Fig: 1, at a
right angle thereto, or otherwise as may be most convenient-A³ marks eyeholes
or openings along the sides of the chamber, and A is the receiver, into which a
fresh charge of molten metal is fed every time the chamber rocks over to the
feeding side. B marks the main furnace grate; and B' the furnace bridge.
Figs 2 and 5, are side views of the refinery chamber A, which is seen to incline
downwards throughout its whole length from the furnace bridge B¹ to the delivery
spout A³, in order to insure the onward flow of the molten metal, and Fig 3 is a
transverse section of the refinery chamber, showing the improved arrangement of
the parts whereon the chamber rests and rocks, and the provision made to permit
of its longitudinal expansion and contraction without any appreciable amount of
friction or strain. E marks the improved rocker carriages which are free to move
on the antifriction rollers F: these rollers are disposed on the surface beds G. which
are rigidly fixed to the cross frames H that are secured to the foundations.-Cast
upon the ends of one of the cross frames are the bearings I, which receive and
support the cam shafts J, whereon are fixed the lifting cans K which, as the shafts
revolve, lift the sides of the refinery chamber alternately by means of the cam
rollers L, that are free to rotate in the carrier bearings M. which are secured to the
bottom of the refinery chamber. The strong tooth gearing N, formed between
the level bearing surfaces at the underside of the chamber, by engaging with
corresponding gearing formed between the curved bearing surfaces of the rocker
carriages E, secure the chamber against all risk of slipping sidewise, when the sides
are alternately raised by the lifting cams K, as shewn by Fig: 6 which exhibits

page_text: the refinery chamber A rocked over to one side. Figs 7 exhibit a side view and
plan of the rocker, carriages E, and Figs 8 shew a side view and plan of the surfaco
beds G.
In the modification shewn by the plan Fig: 4 the oblique guides are omitted,
and the hearth of the refinery chamber is seen to be entirely plain throughout its
whole length, with the exception of the two oblique guides A2 one of which is
placed at the feeding end to prevent the too sudden spreading of the charges as
the metal flows in from the receiver and the other is placed by the delivery port to
regulate the quantity of refined metal discharged by the delivery spout A³ and
conveyed into the balling cylinder C, by means of the straight gutter A*, one
charge every time the refinery chamber rocks over to the delivery side.
In order to ensure a regular longitudinal onward flow of the molten metal
towards the delivery end of the chamber combined with its movements from side
to side, we in both modifications (and especially in the latter) give to the refinery
chamber from its main firegrate, to its after or delivery end, a downward inclination,
more or less according to the nature of the metal in process, and by this means,
whilst the metal is flowing from side to side alternately, it also acquires a tendency
to gravitate towards the lowest or delivery end of the chamber, its movement in
that direction, as indicated by the curved dotted lines (a) in both of the figs 1
and 4 being regulated by the amount of inclination given. In all cases the charges
of metal, which is kept in a state of ebullition whilst passing through the chamber,
must be discharged into the balling cylinder before it "falls" and begins to thicken,
and therefore it is important that means are at hand either to accelerate or retard
its movement through the chamber, whilst at the same time it is kept Bowing
froin side to side. These results may be accomplished by either increasing or
diminishing the speed of the rocking motion, or the incline of the hearth may be
made adjustable by mounting the parts that support the refinery chamber on a
long trusty girder, capable of being raised at one end either by an hydraulic lift,
or by suitable serews, or otherwise. When however the exact required gradient is
ascertained, in all probability an alteration of the rocking speed will be found
sufficient, so that the furnace and refinery chamber may at once be placed on rigid
foundations, and resting on the rocker carriages.
The heating of the refinery chamber is to be effected as formerly described by a
main furnace grate at its fore end, and the requisite degree of heat is to be
maintained and regulated throughout the mid and after end or section of the
chamber, either by the combustion of heating gas, or by small auxiliary fire grates,
adapted as formerly described, at intervals to the sides.
In constructing the roof of the refinery chamber, we propose in some cases to
make certain parts or sections capable of being lifted or temporarily removed; so
that when required, the chamber may be opened for repairs, and in addition to tho
eye holes A through which the attendants will be able to watch the refining
process as the work goes on, or introduce a narrow instrument suitable for
removing any dross or scoria found adhering to the hearth, some of the side panels
may also be inade capable of removal.
Second-This part of our improvements relates to the fitting up of the rotating
balling cylinder C, to which at its furthermost end we adapt a main fire grate O,
whereby we obtain in the best possible manner the means for subjecting the
puddle balls to a "final heat" in the cylinder which, as shown by Fig: 1, can bo
disposed at a right or other angle to the refinery chamber, or as shown by tho
Figs and 5, placed in a line therewith, so that the successive charges of the then
refined metal in either case, may flow direct into the cylinder as they are
discharged from the end of the chambers by their respective delivery spouts A³,
which in Fig: 1 is shown at the end of the chamber and in Fig: 4 is placed at the
side. We also give to the balling cylinder a downword inclination from the end
contiguous to the refinery chamber, which end is the highest, and above the level
of the firegrate O; see Figs 1 and 9 which is placed at its furthermost or lowest

page_text: end, (see Fig: 5): The several charges of metal gradually become pasty and
coherent or as 'tis said "como to nature" as by the rotations of the cylinder they
are caused to move along the spiral gutter C which (see Figs 1 & 4) has now tho
form of a hollow curve instead of being made square with objectionable angles as
heretofore; by this means all the charges in the cylinder are made to advanco
one, turn of the spiral every time the cylinder rotates, and by degrees they
become solid masses which, as they accumulate, are gradually rolled in the curved
gutter into the form of puddle balls and which, as they slowly approach tho firo
grate at the end of the cylinder, are exposed to the increasing "final heat," and the
combined metal slag, cinnerary and other foreign matters, is reduced thereby to a
highly fluid state, so that it readily separates from the puddle balls, as the latter
in succession roll out of the end of the cylinder and down the sloping grid P, and
are received upon the carriages that convey them to the shingling hammers, whilo
the melted cinder falls through the bars of the grid into a closed receptacle beneath
containing water, so that instead of forming a solid mass, it cools in separate pieces
which, as they accumulate may be removed by any convenient means. The firo
grate O, is divided into two parts by the sloping grid P, each part having a
separate bridge inarked O',-C marks the annular surfaces that rest on the
supporting rollers C³, and C marks the annular genring which rotates the cylinder
when engaged by the tooth wheels Q, that are fixed on the driving shaft R, which
also imparts notion to the cam shafts J, (sco Fig. 2) by means of the small bevel
wheels S, which are also fixed on the driving shaft R, and engage with the large
bevel wheels T, of which there are two, one being mounted on the end of each of
the cam shafts J, whereby the latter are caused to revolve in contrary directions,
as indicated by the arrows in the Figs. 3 and 6. D is the wall plate that receives
the end of the balling cylinder when the latter is expanded by the heat.
Third This part of our improvements relates to the altered position of the
chimney U, which we now erect at or continguous to the lowest or delivery end of
the refinery chamber, the fixed flue formerly described being, according to our
present arrangements, not required. V marks the flue way from the refinery
chamber, and W, the flue way from the balling cylinder. Before however the
fiery draughts from either or from both sections are allowed to enter the chimney,
they may be further utilised in generating steam, and suitable dampers will be
provided for regulating the fire draught from each section of the apparatus.
The fluxes, oxidising agents, refining and other matters and ingredients used in
the process of puddling are generally to be introduced to commingle with the molten
metal as it boils and Hows, and preferably but not necessarily in the same manner
and by apparatus similar to that described in the Specification of our said former
Patent.
Having now particularly described and ascertained the nature of our said
invention, and in what manner the same is to be performed, we declare that what
we claim is
First We claim the use in the refinery chambers of our puddling furnaces, of
plain hearths constructed either with or without oblique guides, and so disposing
the chambers that they incline downwards from the feeding end, for the purpose of
causing the metal in process whilst it is flowing from side to side, also to gradually
gravitate to the lowest or delivery end; all after the manner and for the purposes
herein shown and described.
Second; We claim the improved mode of mounting the refinery chamber on
rocker carriages that are free to move on anti-friction rollers disposed ou flat beds
or surfaces, in order that longitudinal expansion or construction of the chamber
may take place freely without strain or friction.
Third; We claim the addition to the bailing cylinder of a fire grate at its
delivery end; also the use of a grid for the purpose of separating the melted cinder
from the puddle balls; also the improved internal curved form of the spiral gutter;

page_text: and so disposing the supporting rollers whereon the cylinder rotates, that the
cylinder is made to incline downwards in the direction of the new fire grate.
Fourth; We claim the disposing of the improved refinery chamber and the
balling cylinder either in a line with each other or at an angle relatively, and
building the chimney in an intermediate position, so that it may serve to carry off
the spent gases and products of combustion from their respective furnace grates.
Dated this Sixteenth day of Sentember 1884.