IMPROVEMENTS IN THE MANUFACTURE OF AND MODE OF TREATING IRON AND IN APPARATIS EMPLOYED TENDERAR
Year: 1874

page_text: LETTERS PATENT to Robert Stone, of Liverpool, in the County of
Lancaster, for the Invention of "IMPROVEMENTS IN THE MANUFACTURE
OF AND MODE OF TREATING IRON AND IN APPARATIS EMPLOYED TENDERAR "

page_text: cupolas or furnaces are filled with layers of pig iron, or iron ore and fuel
alternately, and, upon melting, the moulten iron finds its way to the
bottom of the cupola, and all the foreign matter to a certain extent floats
on the top, but there is still a large proportion of foreign matter retained
in the moulten metal, and it is especially the object of this Invention to
rid the moulten metal of all foreign matters. With this object in view
it is essential that the moulten metal shall be stirred or sifted so that all
foreign matters will rise to the surface, and leave the metal at the bottom
pure for withdrawal. To obtain this object I construct a cupola furnace
of the usual form, but having at intervals from the bottom loose grids or
sieves of terra cotta, fire-clay, or other suitable non-combustible material
placed between the layers of fuel and the pig iron, so that, upon melting,
the moulten metal will fall through to the bottom of the cupola, and the
foreign matter be sifted or sustained by the terra cotta grids or sieves.
In some instances I employ a vertical shaft in the cupola made of
suitable non-combustible material, and fitted with arms or provisions so
arranged that when the shaft is rotated they will agitate the moulten
metal, and by this means free the metal from all foreign matters. This
shaft and the agitators may be suspended above the cupola and inserted
thercinto when the metal is in a moulten state, and able by being agitated
to give off its impurities.
In some instances the cupolas or furnaces can be fitted with a piston
and rod working into the cupola like a pump, and so arranged that it
will lift up all the impurities and deposit them on the sieves. The
moulten metal, upon being withdrawn from the cupola for making
castings and being run into moulds, will be found of very superior
quality.
In running the moulten metal into moulds from the cupola I prefer
that where possible such moulds should be left open on their top surface,
and I use a heavy roller running on rails, so that it will bring its weight
to bear on the metal in the moulds as the metal cools, thereby driving
all air from the metal, and setting it firmly down free from all blown
holes. The roller may be provided with collars or grooves of any suitable
pattern, so as to impress the metal therewith, as will be understood..
Further, the moulten metal can be run into dics or moulds. These
moulds or dies can be formed of cement, stone, or any other material
that will answer the purpose of forming the different shapes of the

page_text: castings. The top half of these moulds can be removed when the liquid
is formed into shape, and, while yet red and soft, the heavy rollers are
shaped, the form of the top half already removed, and are rolled over until
the metal cools, thereby producing iron of a very hard durable texture.
The pressure power on the metal while in a soft partially liquid state
causes every particle to bind close in one united body, being far preferable
to the ordinary way of rolling iron, as no splits, shakes, or holes can
ever result in iron treated under this process, and in some instances
where the roller cannot be properly applied I use leverage to force the
metal into a close body.
I consider the before described treatment of iron far superior to the
ordinary way of rolling out iron, inasmuch as in the ordinary way the
rollers can only deal with the iron while hot. In this way the rollers
can deal their weight on the iron while all the iron is in a liquid state.
Further, I propose to run the moulten metal direct from the blast
furnace where the iron is first separated from the ore, thus saving the
heavy expense of running it into pigs. This I propose to accomplish by
placing the blast furnace beside or over the cupola, which mixes and
blends the iron as it pours down the cupola from one separating sieve to
another. These sieves can revolve round, blending it into a mellow pure
liquid as it passes the different stages.
Where iron is required of a very high, fine, tough, rigid nature, I
propose to have a greater number of sieves or separators of the liquid
metal, as thereby the oftener the metal passes from one stage to another
it tends to anncal and bring down the hard nature of the metal.
In some instances I may find it necessary to partially cool down some
of the sections of the moulten metal. This can be done by always having
a sufficient stock of moulten metal ready for use in the bottom sections
of the cupola, or by having an extra number of cupolas. In carrying
out this process it may be necessary to have cast or wrought iron cupolas
lined inside with fire-brick, terra cotta, or any other indestructible
material. Round these cupolas there may be a blast flue to assist to
heat the metal inside. Thus, while the iron midway in the cupola might
be partially cool, that at the bottom would be in a hot liquid state. These
hot blasts or flues can be so arranged round the cupola as to graduate
the heat of the iron from the bottom to the top of the cupola from one

page_text: stage to another, so that a supply of hot liquid metal could be always in
stock ready for use.
Further, I propose, in order to make iron of a very superior quality, to
have hot furnaces and blasts under the moulds to keep up the heat in
the iron for as long a time as thought proper to run the rollers or power
over it; besides, the roller may be heated from inside. By this mode of
making iron it prevents contraction in the iron.
Further, it may be necessary to have up-and-down draughts in the
cupolas, which can be arranged by air pipes. These draughts will carry
off all sulphur and impurities, and cause a stronger blast.
Further, it may be necessary to cause the cupolas to revolve by means
of a shaft or otherwise.
The amalgamating system to which this Invention relates can be
applied to the utilization of the "waste" of ores, or mine refuse, or
mine dust. Such "waste" refuse or dust can be formed into blocks by
mixing with chemicals or oils, tar, petroleum, or other like liquids that
will assist in heating or bringing down the harsh nature of the metal
to a pliable yielding nature. These blocks of ore and fuel can be
treated and sifted in the cupola or furnace in manner as herein-before
described.
SPECIFICATION in pursuance of the conditions of the Letters Patent,
filed by the said Robert Stone in the Great Seal Patent Office
on the 22nd August 1874.
TO ALL TO WHOM THESE PRESENTS SHALL COME, I, ROBERT
STONE, of Liverpool, in the County of Lancaster, send greeting.
2
WHEREAS Her most Excellent Majesty Queen Victoria, by Her
Letters Patent, bearing date the Twenty-fifth day of February, in the
year of our Lord One thousand eight hundred and seventy-four, in 3
the thirty-seventh year of Her reign, did, for Herself, Her heirs and
successors, give and grant unto me, the said Robert Stone, Her

page_text: special licence that I, the said Robert Stone, my executors, admi-
nistrators, and assigns, or such others as I, the said Robert Stone,
my executors, administrators, and assigns, should at any time agree
with, and no others, from time to time and at all times there-
after during the term therein expressed, should and lawfully might
make, use, exercise, and vend, within the United Kingdom of Great
Britain and Ireland, the Channel Islands, and Isle of Man, an
Invention for "IMPROVEMENTS IN THE MANUFACTURE OF AND MODE or
TREATING IRON, AND IN APPARATUS EMPLOYED THEREFOR," upon the condition
(amongst others) that I, the said Robert Stone, my executors or
administrators, by an instrument in writing under mỹ, or their,
or one of their hands and seals, should particularly describe and
ascertain the nature of the said Invention, 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.imme-
diately after the date of the said Letters Patent.
NOW KNOW YE, that I, the said Robert Stone, do hereby declare the
nature of my said Invention, and in what manner the same is to be
performed, to be particularly described and ascertained in and by the
following statement :-
This Invention relates to improvements in manufacturing iron and in
the mode of treating the same when the iron is used for forming castings.
or to be run into moulds.
:
In the melting or reducing of pig iron or iron ore into a liquid state;
so that it may be run into moulds, cupolas or furnaces are used. These
cupolas or furnaces are filled with layers of pig iron, or iron ore and fuel
alternately, and, upon melting, the moulten iron finds its way to the
bottom of the cupola, and all foreign matter to a certain extent floats
on the top, but there is still a large proportion of foreign matter retained
in the moulten metal, and it is especially the object of this Invention to
rid the moulten metal of all foreign matters. With this object in view.
it is essential that the moulten metal shall be stirred or sifted so that all
foreign matters will rise to the surface, and leave the metal at the bottom
pure for withdrawal. To obtain this object I construct a cupola furnace
of the usual form, but having at intervals from the bottom loose grids or
sieves of terra cotta, fire-clay, or other suitable non-combustible material
placed between the layers of fuel and the pig iron, so that, upon melting,
the moulten metal will fall through to the bottom of the cupola, and

page_text: the foreign matter be sifted or sustained by the terra cotta grids or
sieves.
In some instances I employ a vertical shaft in the cupola made of
suitable non-combustible material, and fitted with arms or provisions
so arranged that when the shaft is rotated they will agitate the moulten
metal, and by this means free the metal from all foreign matters. This
shaft and the agitators may be suspended above the cupola and inserted
thercinto when the metal is in a moulten state, and able by being
agitated to give off its impurities.
In some instances the cupolas or furnaces can be fitted with a piston
and rod working into the cupola like a pump, and so arranged that it
will lift up all the impurities and deposit them on the sieves. Phos-
phorus may be with great advantage mixed with the metal in tho
cupola, and will tend to materially purify the metal. The moulten
metal, upon being withdrawn from the cupola for making castings and
being run into moulds, will be found of very superior quality.
In running the moulten metal into moulds from the cupola I prefer
that where possible such moulds should be left open on their top surface,
and I use a heavy roller running on rails, so that it will bring its weight
to bear on the metal in the moulds as the metal cools, thereby driving
all air from the metal, and setting it firmly down free from all blown
holes. The roller may be provided with collars or grooves of any.
suitable pattern, so as to impress the metal therewith, as will be
understood.
Further, the moulten metal can be run into dies or moulds. These
moulds or dies can be formed of cement, stone, or any other material
that will answer the purpose of forming the different shapes of the
castings. The top half of these moulds can be removed when the liquid
is formed into shape, and, while yet red and soft, the heavy rollers are
shaped, the form of the top half already removed, and are rolled over
until the metal cools, thereby producing iron of a very hard durable
texture. The pressure power on the metal while in a soft partially liquid
state causes every particle to bind close in one united body, being far
preferable to the ordinary way of rolling iron, as no splits, shakes, or
holes can ever result in iron treated under this process, and in some
instances where the roller cannot be properly applied I use leverage to
force the metal into a close body.

page_text: I consider the before described treatment of iron far superior to tlie
ordinary way of rolling out iron, inasmuch as in the ordinary way the
rollers can only deal with the iron while hot. In this way. the rollers
can deal their weight on the iron while all the iron is in a liquid
statc.
Further, I propose to run the moulten metal direct from the blast
furnace where the iron is first separated from the ore, thus saving the
heavy expense of running it into pigs. This I propose to accomplish by
placing the blast furnace beside or over the cupola, which mixes and
blends the iron as it pours down the cupola from one separating sieve to
another. These sieves can revolve round, blending it into a mellow pure
liquid as it passes the different stages.
Where iron is required of a very high, fine, tough, rigid nature I
propose to have a greater number of sieves or separators of the liquid
metal, as thereby the oftener the metal passes from one stage to another
it tends to anneal and bring down the hard nature of the metal.
In some instances I may find it necessary to partially cool down some
of the sections of the moulten metal. This can be done by always
having a sufficient stock of moulten metal ready for use in the bottom
sections of the cupola, or by having an extra number of cupolas. In
carrying out this process it may be necessary to have cast or wrought
iron cupolas lined inside with fire-brick, terra cotta, or any other
indestructible material. Round these cupolas there may be a blast
flue to assist to heat the metal inside. Thus, while the iron midway in
the cupola might be partially cool, that at the bottom would be in a hot
liquid state. These hot blasts or flues can be so arranged round the
cupola as to graduate the heat of the iron from the bottom to the top of
the cupola from one stage to another, so that a supply of hot liquid
metal could be always in stock ready for use.
Further, I propose, in order to make iron of a very superior quality, to
have hot furnaces and blasts under the moulds to keep up the heat in
the iron for as long a time as thought proper to run the rollers or power
over it; besides, the roller may be heated from inside. By this mode of
making iron it prevents contraction in the iron.
Further, it may be necessary to have up-and-down draughts in the
cupolas, which can be arranged by air pipes. These draughts will carry
off all sulphur and impurities, and cause a stronger blast.

page_text: Further, it may be necessary to cause the cupolas to revolve by means
of a shaft or otherwise.
The amalgamating system to which this Invention relates can be
applied to the utilization of the "waste" of ores, or mine refuse, or
mine dust. Such "waste" refuse or dust can be formed into blocks by
mixing with chemicals, or oils, tar, petroleum, or other like liquids that
will assist in heating or bringing down the harsh nature of the metal
to a pliable yielding nature. These blocks of ore and fuel can be
treated and sifted in the cupola or furnace in manner as herein-before
described.
In some cases the ore itself may be ground with advantage and mixed
with chemicals, or oils, tar, petroleum, or other like liquids, and formed
into blocks and treated as aforesaid, thereby effecting great saving of
fuel and separating and producing iron at a cheaper rate.
Copper and other ores may be treated as herein-before described with
reference to iron ore.
In witness whereof, I, the said Robert Stone, have hereunto set my.
hand and seal, this Twentieth day of August, in the year of our
Lord 1874.