Iм- PROVEMENTS IN THE MANUFACTURE OF IRON AND STEEL
Year: 1879

page_text: LETTERS PATENT to Matthew Wilks, of No. 96, King Street, in the City of
Manchester, Merchant, and Richard Howson, of Exchange Place, Middlesborough
on Tees, in the County of York, Civil Engineer, for the Invention of "Iм-
PROVEMENTS IN THE MANUFACTURE OF IRON AND STEEL."
Sealed the 30th May 1879, and dated the 17th March 1879.
PROVISIONAL SPECIFICATION left by the said Matthew Wilks and
Richard Howson at the Office of the Commissioners of Patents on the 17th
March 1879.
MATHEW WILKS, of No. 96, King Street, in the City of Manchester, Merchant,
and RICHARD Howson, of Exchange Place, Middlesborough on Tees, in the County
of York, Civil Engineer. "IMPROVEMENTS IN THE MANUFACTURE OF IRON AND
STEEL."
Our Invention relates to an improved mode of treating iron whereby it is refined
in the manner and by means of the apparatus, hereinafter described adopted in
what is usually called the Bessemer or pneumatic process, or by the process usually
called the open hearth process, those processes being combined with a method of
injecting hydrocarbóns into the molten metal as hereinafter described.
In carrying out our Invention we proceed as follows:-We take a vessel similar
for example to a Bessemer converter; we line it with a basic lining with the object
of assisting in the refining of the metal. Into the vessel we introduce a charge of
We add to the charge
iron, which may be run in molten or melted in the vessel.
when requisite the necessary basic materials with the object of removing the
phosphorus from the charge under treatment, and also of preserving the lining of
the vessel.
.
In order to maintain the charge at a sufficiently high temperature for the purpose
of preserving its fluidity, we introduce into it with the blast petroleum or any other
bydro-carbon.
This is effected in a convenient manner by a coke tower fitted with tanks. These
tanks are to contain the petroleum or other hydro-carbon which is allowed to trickle
therefrom into the body of the coke tower, or the hydro-carbon is forced by the
blast into the body of the coke through the lower part of the tower, whereby its
particles are taken up.

page_text: :
The currents of air having passed through the saturated coke carry forward the
petroleum or other hydro-carbon in the form of spray, and in this state the bydro-
carbon is introduced into the charge under treatment, and thereby raises the heat
of the molten metal and maintains it at the required temperature.
The molten metal having been treated with the impregnated blast for a sufficient
time is then tapped.
By means of our Invention it will be found that the fluidity of the charge
which would otherwise become viscid by the introduction of the basic materials
necessary for the elimination of the phosphorus can be maintained at a sufficiently
high temperature for teeming it from the vessel after the silicon and natural heat
giving elements contained in the iron have been burnt off.
Another advantage secured by our Invention is that it will be found that
descriptions of iron which otherwise could not be blown on account of the low per
centage of carbon and silicon contained therein can be advantageously used, the
absence of these calorific elements being supplied to the petroleum or other hydro-
carbon adopted.
Modifications in detail of our Invention may be adopted for example instead of
a Bessemer converter; our Invention can be applied to forms of furnace known as
open hearth furnaces, also to any furnace in which iron or steel is melted or manu-
factured, or whether the blast used be what is commonly known as high pressure
or low pressure.
:
In addition to the method previously described we sometimes employ for the
purpose of introducing petroleum or other hydro-carbon into the molten metal the
mechanical system known as that of the injector, by which a small stream of hydro-
carbon can be injected into the current of air and carried along with it in the form
of spray, as is well understood. .
The form of the vessel or generator previously described may also be modified
in many ways, and for coke may be substituted pumice stone or other porous
materials.
Our Invention can be applied as well to the production of refined iron as to
malleable iron and steel, and the time of submitting the metal to the impregnated
blast is regulated by the description of the product required, whether it be refined
iron, malleable iron, or steel.
By basic lining we mean a lining formed from lime-stone, or magnesian lime-
stone, or chalk, or bauxite, or such other materials as are preferably of an aluminous
character, but very low in silica.
"
☑
By basic additions we mean oxide of iron, or lime, or mixtures of both, and these
may be applied cold, or heated previously to being introduced into the bath of
nietal.

page_text: SPECIFICATION in pursuance of the conditions of the Letters Patent filed by
the said Matthew Wilks and Richard Howson in the Great Seal Patent Office
on the 2nd September 1879.
MATTHEW WILKS, of No. 96, King Street, in the City of Manchester, Merchant,
and RICHARD HOWSON, of Exchange Place, Middlesborough on Tees, in the County
of York, Civil Engineer. "IMPROVEMENTS IN THE MANUFACTURE OF IRON AND
STEEL."
Our Invention relates to an improved mode of refining iron adopted in what is
usually called the Bessemer or pneumatic process, or by the process usually called
the open hearth process, those processes according to our Invention being combined
with a method of injecting hydrocarbons into the molten metal as hereinafter
described.
In carrying out our Invention we proceed as follows:-We take a vessel similar
for example to a Bessemer converter, and of a size sufficient to treat a charge of up
to 8 tons or even a larger quantity.
When we desire to operate upon qualities of iron which contain any considerable
proportion of phosphorus, we line the vessel or hearth with a basic lining, such as
has been heretofore proposed to be used for similar vessels, by which lining we
mean a lining formed from limestone or magnesian limestone, or chalk or bauxite,
or such other materials as are preferably of an aluminous character, but very low in
silica.
We apply this basic lining to the vessel intended to hold the charge, either by
ramming in the ordinary way in which ganister linings are now generally rammed,
or by means of basic bricks moulded in forms suitable to the shape of the vessel.
We prefer to form the lining by means of basic bricks, by which we mean bricks
formed from highly magnesian limestone, having a small per centage of alumina and
silica; this material is ground very finely in a mortar mill, then mixed with water
and made into bricks of the required size and shape so as to secure the closest
joints possible; these bricks are then carefully dried and afterwards burnt in a kiln
at a very high temperature. The bricks are set with a cement composed of the same
material of which they are formed, mixed with petroleum or other hydro-carbon.
Into the vessel we introduce a charge of pig or cast iron which may be run in
molten, or it may be melted in the vessel. We add to the charge basic materials
by which we mean oxide of iron or lime, or mixtures of both in such a quantity as
to secure the slag being highly basic. These materials are thrown into the vessel,
and when the charge is run in molten, they may be introduced partly before
running in the charge, and partly during the blowing of the charge.
The quantity of the basic materials required will be not less than from 10 to 20
per cent. of the weight of the charge under treatment, the quantity required being
in a direct ratio to the amount of silicon originally contained in the iron under
treatment.
The object of the basic lining to the vessel and the addition of the basic materials
is to remove the phosphorus from the charge under treatment, as has before been
proposed to be done, and we make no claim to the use of such basic lining or basic
materials as forming part of our Invention.
It has been found in practice that the addition of basic materials, whether applied
cold or heated, has the effect of injuriously lowering the temperature of the charge,
and thereby great difficulty is created in effecting a complete treatment of the
metal on its removal from the vessel for further treatment or manipulation.

page_text: To avoid this difficulty, and to maintain the charge at a sufficiently high tem-
perature for the purpose of preserving its fluidity, and at the same time to secure
a means of readily purifying the iron by the use of the basic additions to the
charge, we introduce into it with the blast petroleum or any other hydro-carbon.
One mode of effecting this is by. means of a coke tower fitted with tanks to
contain the petroleum or other suitable hydro carbon.
Such coke tower may be made in a cylindrical form of wrought iron plates
which should be not less than 3/ths of an inch in thickness, and properly rivetted
together. A convenient size for the coke tower is 16 feet high by 4 feet diameter;
other sizes may be adopted, but these proportions of height to size should be
maintained.
A chamber is formed at its bottom part by placing about 1 foot 6 inches from
the bottom a perforated grating. This chamber forms the blast chamber.
Above the grating the tower is filled to the height of about 12 feet with coke,
pumice stone, or other suitable porous materials.
Around the upper part of the tower are placed two or more cylindrical tanks or
compartments for holding the petroleum or other hydro-carbon.
These tanks are filled with petroleum or other hydro-carbon, and are connected
with the coke tower by a pipe placed in the bottom of each tank, and fitted with
the requisite tap. The pipe enters the tower towards the upper surface of the coke
or other material employed as a substitute, and serves to introduce or force under
pressure if necessary the petroleum or other hydro-carbon into the tower, and
among the coke or other material. The necessary force may be supplied by con-
necting by means of a pipe the tops of the tanks containing the petroleum or other
hydro-carbon with the blast pipe. Each tank is fitted with a glass registering
guage. The form of the vessel or coke tower above described may be modified in
many ways. One form of tower which may be usefully employed is shewn in the
Drawing, No. 1, heretó annexed.
The introduction of the petroleum or other hydro-carbon into the charge is con-
veniently effected by forming a bye pass on the blast pipe which leads to the
furnace or vessel containing such charge; such bye pass leads into the blast chamber
of the coke tower, and the blast is thereby passed through such blast chamber,
thence through the grating, into the coke, where it takes up the petroleum or other
hydro-carbon, and delivers it in a minutely divided or vaporous condition through
the blast pipe, and thence to the furnace or vessel containing the charge.
By the methods hereinbefore described for introducing petroleum or other hydro-
carbons the heat of the metal is raised to and maintained at the required tempera-
ture so as to preserve the requisite fluidity.
In addition to the method previously described for the purpose of introducing
petroleum or other hydro-carbons into the molten metal, the mechanical system
known as that of the injector may be adopted, by means of which a small stream
of hydro-carbon can be injected into the blast and carried along with it in the form
of spray into the melting or molten metal.
Since the Letters Patent above mentioned were applied for it has been ascer-
tained that still greater advantages may be obtained from the use of hydro-carbons,
both as regards the materials to which they are applied and the products obtained
therefrom, and as regards the form in which the hydro-carbons may be most suc:
cessfully used, and which are in fact further developments of the improvements, the
subject of the said application, Letters Patent were respectively applied for on
June 27th, 1879, in the names of Millis Coventry and the said Matthew Wilks, and
on August 6th, 1879, also in the names of the said Millis Coventry and Matthew
Wilks, for those further improvements of which full descriptions will be found in
the respective Specifications of the said Letters Patent. It is therefore sufficient
here to state that the best form in which hydro-carbons can be used, as proposed
according to our Invention, will be found to be in the form of vapour. In that form

page_text: they may be used with great advantage not only for ferrugineous ores and their
metals of various kinds, but also in treating or smelting other ores and metals, such
as tin, copper, and other ores that may be treated or smelted in an analogous
manner. The hydro carbons may be vapourized by passing the pipes in which they
are conducted from the reservoir tanks through suitable heating chambers, or steam
or hot air jackets, and then mixing them with the blast, and when a hot blast is
used it is obvious that the hydro-carbon spray proposed to be used as above
mentioned would be converted into vapour before it reaches the molten metal.
Our Invention may be applied to the manufacture of steel, the iron being refined
as hereinbefore described, the manufacture of steel therefrom being carried on
according to the methods now in practice.
Our Invention may also be applied to any form of furnaces known as open
hearth furnaces, also to any furnaces in which iron or steel is melted or manufac-
tured, or whether the blast used be what is commonly known as high pressure or
low pressure.
When the metal treated consists of iron with which a large per centage of phos-
phorus is combined, and which it is desirable to have removed, it will be found
that the time required for the treatment of the molten metal with the impregnated
blast must depend amongst other things on the quantity of basic materials added,
and upon the amount of silicon or other calorific elements in the metal under
treatment. Competent persons acquainted with the manufacture of iron will be
enabled without difficulty to apply our Invention and effect their object according
to the circumstances of the case by having regard to the colors of the flames pro-
duced and the qualities and composition of the ores under treatment as above
mentioned.
Our Invention can be applied to the production of refined iron, malleable iron
and steel, and to analogous metallurgical operations where, as above explained,
high temperatures are required to be maintained in the molten substances, and the
time of submitting the metal to the impregnated blast is regulated by the descrip-
tion of the product required, whether it be refined iron, malleable iron, or steel.
Another advantage secured by our Invention is that it will be found that
descriptions of iron which otherwise could not be blown on account of the low
per centage of carbon and silicon contained therein can be advantageously used, the
absence of these calorific elements being supplied by the petroleum or other hydro-
carbon adopted.
Having described the nature of our Invention, and the manner of performing the
same, we desire to be understood that we do not claim the method of lining vessels
with a basic lining in the manner or by the means herein before described, nor do
we claim separately. the application for the purposes aforesaid of basic linings to
vessels, or of basic additions to the charge under treatment, nor do we claim
generally the use of hydro-carbons, as propositions have been made to inject streams
of hydro-carbon oils or spirits into molten metal, but such propositions have been
and would always be unsuccessful, as it was not known that the hydro-carbon oil
or spirit must be employed in sufficient quantity and also in a very finely divided
form in order to maintain the molten metal at the required high temperature and
required fluidity.
What we claim is our improved process, as herein described, of manufacturing iron
and steel by injecting hydro-carbon oils or spirits combined in a finely divided state
with the blast employed so as to maintain the molten materials at the required
temperature, and in particular we claim when treating iron or iron ores which
contain large percentages of phosphorus the use of blasts impregnated with hydro-
carbon oils or spirits in a finely divided state, as proposed by us, combined with
the use of basic furnace linings and basic additions to the charge under treat-
ment, whereby the advantages we have referred to are obtained, and at the
same time the difficulties are obviated which have hitherto attended the use

page_text: of such basic linings and basic additions, and improved qualities of iron and steel
are produced.
In witness whereof, we, the said Matthew Wilks and Richard Howson, have
hereunto set our hands and seals, this Thirtieth day of August, in the year
of our Lord One thousand eight hundred and seventy nine.
MATTHEW WILKS. (L.S.)
RICHARD HOWSON. (L.S.)