IMPROVEMENTS IN THE MANNER OF REDUCING AND REFINING METALLIC ORES, MORE PARTICULARLY ORES OF IRON, & IN CONVERTING IRON INTO STEEL, AND IN APPARATUS TO BE USED IN CONVECTION THEREWITH
Year: 1867

page_text: LETTERS PATENT to Silas Covell Salisbury, of the City and State of New
York, United States of America, Civil Engineer, for the Invention of
"IMPROVEMENTS IN THE MANNER OF REDUCING AND REFINING METALLIC
ORES, MORE PARTICULARLY ORES OF IRON, & IN CONVERTING IRON INTO STEEL,
AND IN APPARATUS TO BE USED IN CONVECTION THEREWITH."
ealed the 3rd September 1867, and dated the 7th March 1867.
PROVISIONAL SPECIFICATION left by the said Silas Covell Salisbury
at the Office of the Commissioners of Patents, with his Petition, on the
7th March 1867.
I, SILAS COVELL SALISBURY, of the City and State of New York, United
States of America, Civil Engineer, do hereby declare the nature of the said
Invention for "IMPROVEMENTS IN THE MANNER OF REDUCING AND REFINING
METALLIC ORES, MORE PARTICULARLY ORES OF IRON, & IN CONVERTING IRON INTO
STEEL, AND IN APPARATUS TO BE USED IN CONNECTION THEREWITH," to be as
follows:-
My Invention consists in a method or process by which metallic ores or oxides
are reduced much more rapidly and economically than by ordinary processes,
and by which when iron ores are reduced the metal obtained therefrom is
made soft iron in the same furnace in which the ores are reduced, and is also
CDQ71

page_text: refined to a great extent while the ores are being reduced and the metal pro-
duced therefrom. And my Invention consists also in a method of converting
iron into steel while in a fluid state and as it is delivered from the furnace
in which the ores are reduced; and also in apparatus for applying such
processes. In blast furnaces combustion is imperfect, the heat above the
boshes being only about sufficient to disengage the gases from the ores,
lime, and fuel, and set them free without utilization; the lighter gases
escape from the top, and the heavier ones fall and produce carbonic acid,
which absorbs a great amount of latent heat so essential for rapid con-
version and liquefaction of ores not fully prepared and roasted; such ores
consequently retain most of their impurities, and the metal produced there-
from is also full of such impurities. I overcome these defects by introducing
into the furnace hydrogen and oxygen gases, or steam heated to a temperature
from 700° to 800°, or thereabouts, Fahrenheit, thereby greatly increasing the
temperature of the furnace, and by also introducing with such gases and the
air blast hydrocarbon gas wholly free from sulphur, phosphorus, ammonia,
and other impurities, and causing these gases to penetrate and pervade the
whole mass of the ore. The air blast is prepared in the usual manner, and
supplied to the furnace by blowing engines as in ordinary cases. The carbon
gas is obtained from oils or hydrocarbons wholly free from sulphur, phos-
phorus, ammonia, or like impurities which are vaporized, and the vapour
passed through a highly heated retort to convert it into a fixed gas. The
hydrogen and oxygen gases may be prepared separately, but are more con-
veniently obtained from water or steam passed through a retort heated so as
to nearly or actually decompose the steam, and resolve it into its hydrogen
and oxygen. In such retort the steam or gases are also subjected to a
pressure of from 15 to 20 pounds per square inch, or sufficient to cause them to
enter the furnace with greater pressure than does the air blast, and not be forced
back by it. The tuyere by which these several gases are furnished to the fur-
nace is made of a central and two concentric tubes, so that the different gases
and air blast will enter different chambers, the steam or hydrogen and oxygen
entering the central part, the hydrocarbon gas the middle, and the air blast
the outer one. The steam or hydrogen and oxygen being subjected to pressure
in the retort in which they are heated, are thereby forced into the furnace, and
carry along the hydrocarbon gas, and also assist in forcing the air blast, thereby
rendering unnecessary large and powerful blowing engines as are usually
required, and also rendering necessary not more than one-half as much air
blast as in ordinary cases. The quantity of hydrogen and oxygen and hydro-
carbon gases will vary somewhat according to the character of the ores, but

page_text: the use of about thirty gallons of water to two of hydrocaroon on 101 men
production has been found satisfactory. These gases being introduced under
pressure penetrate and pervade the whole ore mass, and by their own high
temperature greatly increase the heat of the furnace. by means of which with
the additional supply of carbon from the hydrocarbon gas the carbonic acid is
converted into carbonic oxide, and the gases introduced mixed with the gases
of the furnace, and form with them a complete combustion, and thus utilize
them, such combustion also increasing the heat, and more effectually and
rapidly reducing the ores. Such gases also having a greater affinity for the
sulphur, phosphorus, and other impurities than the roasted or melted ores
have these impurities are to a very great degree carried off, and the ores are
thus desulphurized, and the metal refined as the ores are reduced. By having
control over the quantity and quality of the gases introduced hard or soft iron
The character
may be produced, or its character be changed, as desired.
of the iron will also be improved by introducing into the furnace as the ores
are being reduced about one per cent. of the oxide or peroxide of manganese,
which I prefer to introduce in connection with the hydrocarbon gas.
In the conversion of iron into steel the metal is received as it is delivered
from the blast or reducing furnace into any suitable vessel, and while in such
fluid or liquid state is subjected to the action of the air blast, and of currents
or blasts of steam or hydrogen and oxygen heated to about the same degree,
and under pressure as herein-before described, and afterwards to the action of
the same currents or blast of highly heated steam or hydrogen and oxygen
in combination with hydrocarbon gas either with or without manganese.
The air blast and the oxygen decarbonize the metal, and the hydrogen by its
greater aflinity for the sulphur and other impurities derived from the ores
and from the coal or fuel used in the furnace takes up and carries off such
impurities. After the fluid metal has been thus decarbonized and refined the
air blast is discontinued, and in place thereof a blast or current of hydrocarbon
gas derived from some hydrocarbon wholly free from sulphur, phosphorus, or
like impurities is caused to pass through the fluid metal in combination with
the hydrogen and oxygen, or steam blast, until the metal is carbonized suffi-
ciently for the purposes required. By having entire control over the gases so
passed through the melted iron, steel with different proportions of carbon can be
produced at pleasure. There may also be introduced into the fluid metal either
mechanically mixed therewith, or introduced in the form of a powder with
the currents of the gases, about one per cent. in weight of manganese.
It has been heretofore attempted to decarbonize and purify fluid iron by
passing steam through it in connection with the air blast, but the steam so

page_text: used has been of such a temperature as to cool the metal, the air blast being
used in connection therewith to again increase the temperature. By heating the
steam before it is forced through the metal to a temperature of from 700° to
800° Fahrenheit, or thereabouts, such cooling is effectually prevented, and
the mass continually kept at a high temperature, and the processes of decar-
bonizing and purifying the mass more rapidly effected. Manganese has
also been made use of in converting iron into steel, and sometimes in connec-
tion with a hydrocarbon, but it has been introduced either into the cupola
furnace or in the smelting crucibles, or in the cementing process, and when
used with any hydrocarbon has been used in connection with coal tar or similar
hydrocarbon containing sulphur or other impurities, which have injured the
metal more than the manganese could improve it. Manganese is also one of
the ingredients of speigel eisen or prepared iron prepared for mixing with iron
to convert it into steel, but in such case it is very difficult to obtain a complete
and uniform mixture, and the iron with which it is mixed should be wholly free
from sulphur, which is rarely the case unless specially refined. By introducing
the manganese directly into the fluid metal and in combination with hydro-
carbon gas wholly free from sulphur, phosphorus, &c., and with the hydrogen
and oxygen a much more uniform and perfect mixture is secured, the hydrogen
also removing any sulphur, and a more rapid conversion of iron into steel is
produced. The introduction into the fluid iron either in a solid form or in a
powdered state of a small proportion of lead is also found very effective in
removing therefrom any sulphur or phosphorus, and thereby more completely
purifying the metal. Any suitable apparatus may be used for heating the
steam, or hydrogen and oxygen, and for giving it the required pressure. For
mixing with such gases the hydrocarbon gas and the air blast, and forcing
them through the fluid iron combine with such heating apparatus an exhaust,
or vacuum chamber, so called, into which the heated hydrogen and oxygen or
steam is admitted, and which also is provided with pipes to take in the hydro-
carbon gas and air blast, and also with a common discharge pipe. The pipe
conveying the heated steam under pressure, extends into such exhaust chamber,
and terminates near to or within the mouth of the discharge pipe, so that the
steam as it passes through will create a vacuum therein, and thus cause the
hydrocarbon gas and the air blast to enter such chamber, and be carried out
with the hydrogen and oxygen to the blast furnace, or for use in converting
iron into steel.

page_text: SPECIFICATION in pursuance of the conditions of the Letters Patent, filed
by the said Silas Covell Salisbury in the Great Seal Patent Office on
the 6th September 1867.
TO ALL TO WHOM THESE PRESENTS SHALL COME, I, SILAS
COVELL SALISBURY. of the City and State of New York, United States of
America, Civil Engineer, send greeting.
WHEREAS Her most Excellent Majesty Queen Victoria, by Her Letters
Patent, bearing date the Seventh day of March, in the year of our Lord One
thousand eight hundred and sixty-seven, in the thirtieth year of Her reign,
did, for Herself, Her heirs and successors, give and grant unto me, the said
Silas Covell Salisbury, Her special licence that [, the said Silas Covell
Salisbury, my executors, administrators, and assigns, or such others as I,
the said Silas Covell Salisbury, my executors, administrators, and assigns,
should at any time agree with, and no others, from time to time, and at all
times thereafter 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 "Ix-
PROVEMENTS IN THE MANNER OF REDUCING AND REFINING METALLIC ORES, MORE
PARTICULARLY ORES OF IRON, AND IN CONVERTING IRON INTO STEEL AND IN APPA
RATUS TO BE USED IN CONNECTION THEREWITH," upon the condition (amongst
others) that I, the said Silas Covell Salisbury, my executors or administrators,
by an instrument in writing under my, 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
immediately after the date of the said Letters Patent.
NOW KNOW YE, that I, the said Silas Covell Salisbury, do hereby declare
the nature of my said Invention, and in what manner the same is to be per-
formed, to be particularly described ascertained in and by the following
statement:-
My Invention consists in a hew and improved method or process for
reducing metallic ores or oxides, by which such ores are reduced much more
rapidly and economically than by the ordinary processes, and by which when
iron ores are reduced the metal obtained therefrom is made soft iron in the
same furnace in which the ores are reduced without being first carbonized as
in ordinary blast furnaces, and then decarbonized by an after process, and is
also refined to a great extent while such ores are being so reduced and the
metal obtained therefrom; and in an improved process of converting iron

page_text: into steel while in a fluid state, and as it is produced and delivered from the
furnace in which the ores are reduced; and also in the construction of appa-
ratus for applying such processes or Invention.
In describing that part of my Invention relating to the reducing and
refining metallic ores I show its application to the reduction of iron ores in
the common blast furnace, but I do not intend to limit its application to such
furnaces. The common ores of iron are oxides, with which are found mixed
carbon, sulphur, phosphorus, and other metals or substances: and such ores
are ordinarily smelted and reduced to a metallic state by being exposed, mixed
with carbon in the form of coal, coke, or wood charcoal to a high heat in a
blast furnace. By such operation the ores become deoxidized, or their oxygen
is removed by combustion with the carbon or fuel in the furnace, and the
melted iron then descends or gravitates to the bottom or lower part of the
furnace in the form of cast iron, or iron surcharged with carbon and mixed
also with many or most of the impurities found in the ore.
This operation
The cast iron
requires a large amount of fuel and also consumes much time.
thus produced being highly charged with carbon has afterwards to be decar-
bonized and converted into soft iron by puddling or some similar process.
These processes or modes of treatment arc, in fact, the opposite of each other,
the ore which is an oxide being first deoxidized, the metal derived from it
becoming charged with carbon in the blast furnace, and then afterwards the
metal thus carbonized being decarbonized by the application of oxygen, so as
to convert the cast or hard iron into soft iron adapted to be applied to the
various uses for which suitable.
My Invention enables me to produce malleable or soft iron in the same
furnace in which the ores are reduced, and while they are being reduced at the
same time also refining the ores from sulphur and other impurities; and also
to reduce the ore and convert it into soft iron in a less time and at less expense
than has heretofore been required to convert it into cast iron.
It is essential to the perfect working and operation of a blast or other
furnace used for reducing metallic ores that the ores should arrive at the
boshes or place of conversion completely reduced or calcined and freed to as
great a degree as possible from the impurities found in the ores, and also that
the temperature of the furnace should be sufficiently great and supplied with
a sufficient amount of carbon to convert the carbonic acid into carbonic oxide
and to utilize the gases produced in the furnace. The great difficulty that
exists in ordinary blast furnaces is that the combustion therein is imperfect,
the heat produced from the coal and blasts of the furnace being only just
about sufficient above the boshes to disengage the gases from the ores and

page_text: lime and fuel and set them free without utilization.
The lighter gases arc
carried off from the top of the furnace, and the heavier ones fall and produce
carbonic acid, which absorbs a large amount of the latent heat so essential for
the rapid conversion and liquefaction of the ores not previously fully prepared
and roasted, and such ores consequently retain a large proportion of their
impurities, as sulphur, phosphorus. &c., which as they are disengaged con-
tinue their affinity for the liquid ores, the iron produced is thus full of
impurities derived both from the minerals and the coal. By my process I
overcome and remove these defects or imperfections by greatly increasing the
temperature of the furnace by introducing therein hydrogen and oxygen
heated to a temperature of from 700° to 800° or more Fahrenheit, and under
pressure and by introducing along with such hydrogen and oxygen and the
air blast hydrocarbon gas wholly free from sulphur. phosphorus, or ammonia.
and causing these several gases to penetrate and pervade the whole mass of
the ore.
The Drawings illustrate the application of my process to an ordinary blast
furnace.
Fig.
represents an ordinary blast furnace in connection with a furnace
& retorts for preparing and supplying the hydrogen and oxygen and
hydrocarbon gases in combination with the air blast.
2 is an enlarged view of the compound tuyere for supplying such
gases to the blast furnace.
The air blast may be heated in any convenient manner. The Drawings
show a retort A in a furnace B, designed for such purpose, from which retort
the air passes by a pipe a to the outer chamber or division b of the tuyere C.
In actual operations the air blast after being heated will first pass to the
blowing engines, and from them he delivered to the tuyere and into the
furnace. The carbon gas is to be obtained from oils or hydrocarbons which
are wholly free from sulphur, phosphorus, ammonia, or like impurities. Such
oils are first vaporized in a suitable vaporizer D, from which the vapor is con-
veyed to a highly heated retort E, in passing through which such vapor is
converted into a fixed gas and also highly heated, and is then conveyed by a
pipe c to the chamber d of the tuyere. The hydrogen and oxygen gases may
be prepared separately, but are usually obtained from water or steam passed
through a retort F, the heating surface of which may be increased by
diaphragms of perforated metal or their equivalent, which retort is heated
sufficiently so that the steam is nearly or actually decomposed and resolved
into its hydrogen and oxygen gases; such gases before they pass from such
retort are also to be subjected to a pressure of from 15 to 20 pounds the

page_text: square inch, or such that they will pass into the tuyere with greater force or
pressure than does the air blast, so that they will not be forced back
by such blast. Such gases enter the central division e of the tuyere by means
of a pipe f. It is not necessary, however, that the steam should be actually
decomposed before it enters the furnace, as it will be resolved into its gases
immediately after it enters therein; but if not actually decomposed before
entering the furnace it should be heated from 700° to 800° or more Fahrenheit,
so that it will enter the furnace at a temperature but little below the point of
decomposition. The tuyere, as will be apparent from the foregoing description,
instead of being a single tube or pipe as heretofore constructed is a compound
instrument composed of a central and two concentric or external tubes or
pipes so that different gases or blasts can be supplied to its different chambers.
Such construction of tuyere is shown more plainly in Figure 2. In order
also to deliver if desired several gases into the furnace at varying points the
several tubes of the fuyere may project unequally into the furnace, as also
shown in Figure 2. The hydrogen and oxygen gases being subjected to a
very considerable pressure before they leave the retort are thereby forced
through the tuyere and into the furnace, and carry along with them the hydro-
carbon gas, and also assist in forcing the air blast into the furnace, thereby ren-
dering unnecessary as large and powerful blowing engines as are usually re-
quired. A much less quantity of air blast is also required when such gases are
used in connection therewith, not more than one-half as much being necessary
as when used by itself; such hydrogen and oxygen and hydrocarbon gases
may be prepared in any convenient manner, and the quantity and proportion of
such gases will vary somewhat according to the character and purity of the
ores to be reduced; but the use of about thirty gallons of water to about two
gallons of hydrocarbon oil for the production of such gases has been found to be
very satisfactory; the proper supply and quantity of these gases is regulated
and controlled by suitable valve cocks. By introducing these gases into the
furnace under pressure, as mentioned, they are caused to penetrate to the very
centre of and pervade the whole or mass, and by their high temperature they
increase greatly the heat of the furnace, by reason of which increased tempera-
ture, together with the additional supply of carbon from the hydrocarbon gas,
which is many times more dense and rich than the coal gases, the carbonic
acid in the furnace is converted into carbonic oxide, and the gases introduced
ascending and mixing with the gases of the furnace form with them a complete
combustion, and thus utilize such gases, such combustion also increasing the
heat and more effectually and rapidly reducing the ores and preparing them
for immediate and rapid conversion to liquefaction; such gases having also a

page_text: greater affinity for the sulphur, phosphorus, ammonia, &c. contained in the coals
and ores than the roasted or liquified ore have; these impurities are consumed
or carried off and the metal thereby freed therefrom; the ores are thus both
more rapidly reduced and also desulphurized or refined at the same time. By
having an entire control over the quantity and quality of the several gases
used I am able to produce either harder or softer iron, or to change its cha-
racter, as desired. By the use of such gases magnetic sulphurous ores, which
are of but little value when smelted in the ordinary manner, can be converted
into the finest quality of pig iron; and even from ordinary or medium ores
there is obtained that quality of iron being free from sulphur, phosphorus,
and like impurities, which is so much desired for the manufacture of steel.
Scrap iron, unfit even for the most ordinary kind of cast. iron, has been found
to produce, when subjected to the action of such gases, castings equal to those
obtained from the best pig iron, as prepared in common furnaces, and the use
or mixture of Scotch pig iron to improve the character of the metal obtained
from common ores can also be dispensed with. By the use of such gases there
is produced a free and easy flow of the slag, thereby preventing any accumu-
lation of it or other matter on the inner surface of the furnace; the previous
roasting, calcining, or desulphurizing of the ores before they are supplied to
the furnace is unnecessary; the quality of the metals is improved by the
increase of temperature, whereas in the ordinary furnaces if the temperature
is increased beyond a certain degree the metals are injured, less air blast is
required, and less power to force it into the furnace; less fuel is consumed,
there is an increased production and an improved quality of metal; scrap and
debris burnt iron, that is now almost wholly useless, can be rendered of use
and value; and accidents, such as arise from the cooling of the furnace, are
prevented or rendered impossible, as by increasing the quantity of the gases
the temperature can be so increased as to effectually prevent their occurrence.
The character of the iron will also be improved by introducing into the furnace
as the ores are being reduced, and the metal derived therefrom purified, a
small quantity of the oxide or peroxide of manganese about one per cent. of
the quantity of metal to be produced. I consider it most preferable to intro-
duce such manganese in connection with the hydrocarbon gas, with which it
can be introduced in the form of powder. In the conversion of iron into steel,
as usually effected, the iron as produced by the ordinary blast furnaces is
decarbonized by puddling or some equivalent process and converted into soft
iron, and then afterwards by a further process carbonized sufficiently to form
steel. The conversion of iron into steel is thus a succession of processes which
require much time and large expense in their complete performance.

page_text: My Invention has for its object the conversion of the iron into steel while
the iron is in a fluid state and as it is delivered from the furnace in which the
ores are reduced, and can be applied to the conversion of such metal when
produced in furnaces in which the ores are reduced in the ordinary manner, or
when produced from furnaces in which the ores have been reduced by the
process herein-before described.
My process consists in first subjecting the fluid metal, after having been
received from the furnace, into suitable tanks or vessels to the action of
currents or blasts of steam or hydrogen and oxygen very highly heated and
under considerable pressure, in combination or connection with the ordinary
air blast, and afterwards subjecting the same metal to the action of currents
or blasts of like highly heated steam or hydrogen and oxygen in combination
with hydrocarbon gas and manganese.
The fluid iron as it is discharged
from furnaces in which it has been reduced in the ordinary manner is generally
not only very highly carbonized but also retains to a very great extent the
various impurities which existed in the ore. By forcing through the fluid
mass and subjecting it to the action of steam or hydrogen and oxygen and the
air blast such metal is decarbonised and also at the same time purified, the
air blast and the oxygen decarbonizing the metal, and the hydrogen by its
greater affinity for the sulphur and other impurities derived from the ores and
from the coal or fuel used in the blast furnace taking up and carrying off such
impurities from the metal. The currents or blasts of such gases and of the air
are passed through the metal until the mass is thoroughly decarbonized and
purified. The relative proportion of such gases or steam and air blast used
for such purposes is about 60 to 70 per cent. of steam or hydrogen and oxygen,
and 30 or 40 per cent. of the air blast. When the iron has been reduced and
refined by the process first herein-before described the use of the blasts of the
gases and the air will be required for a much shorter time than when reduced
in the ordinary blast furnaces. After the metal has thus been decarbonized
and refined the air blast is discontinued, and in place thereof a blast or current
of hydrocarbon gas derived from some hydrocarbon which is wholly free from
sulphur, phosphorus or like impurity is caused to pass through the fluid metal
in combination with the hydrogen and oxygen or steam blast, the use of which
is continued; the metal is subjected to the action of such gases until it is
sufficiently carbonized for the purposes required. To improve the steel there
is also introduced in the fluid metal about one per cent. in weight of man-
ganese, which may be mechanically mixed with the mass, or carried in in the
form of powder in connection with the currents or blasts of the gases.
The Drawings, Figures 3, 4, 5, represent a convenient apparatus for highly

page_text: heating the steam or hydrogen and oxygen and giving it any desired pressure.
and also for forcing such gases or steam with the air blast or hydrocarbon gas
through the melted mass of metal.
Fig. 3 is a general view of such apparatus; Fig. 4 is a detached view of
the gas generator; Fig. 5 is a vertical section of Fig. 4.
The steam generator or heater A' is so constructed as to give or secure a
broad flat surface for evaporation, and has space for but a small body of
water which is constantly being supplied; such generator consists of a metallic
plate a of any size required, having a large flat evaporating surface b¹, to and
over which is fixed with steam-tight joints another metallic plate c', and
between which is a shallow space for the introduction of the water or liquid;
such plates also are made thick and strong enough to bear any pressure
desired; into the shallow space between such plates the water or liquid is
forced by a pump or its equivalent; the water or liquid, however, instead of
being forced directly into the evaporating chamber is first delivered into a con-
duit or passage d extending along one side of the evaporating or heating cham-
ber, and connecting therewith by numerous small orifices shown in Figure 4,
and in section in Figure 5, by means of which the water or liquid is forced over
the whole surface of the evaporating chamber, and a rapid evaporation con-
stantly secured; such orifices should be quite small so as to finely divide the
liquid, and near together so as to distribute it over the evaporating surface,
A continuous narrow opening will be found equally effective for the purposes
mentioned as a series of such orifices. The steam or gases after being pro-
duced are subjected to any pressure desired in the evaporating chamber and
then are taken therefrom by a pipe e¹.
Experiments prove that water will evaporate upon a flat plate or surface
many times faster than heat can be imparted to such a plate from a fire or
furnace underneath it; such a plate, therefore, cannot be kept hot enough to
keep up constant evaporation. To supply heat more rapidly to such an
evaporating surface it becomes necessary to greatly increase in some way its
fire surface; this I accomplish by means of ribs or projections 1, 2, 3, placed
on the under side of the plate; these ribs for a plate having from fifteen to
twenty square feet are generally about half an inch thick at their lower ends.
and extend down and into the fire or furnace about five or six inches; such
form of construction of the evaporating plate secures a very large fire surface
directly under the evaporating surface, and thus supplies or imparts to such
surface all required heat, and as rapidly as it is demanded for evaporating.
The water or evaporating surface being wholly on the upper surface of the
plate a' and not extending down into the ribs 1, 2, 3, the destruction or

page_text: burning away of such ribs will not in any manner weaken the generator or
render it insecure; such steam generator may be furnished with safety valve f
and steam guage, the same as ordinary steam boilers. The steam is raised to
a temperature of from about 700° to 800° or more Fahrenheit, and is also
subjected in the generator to a pressure of from 15 to 20 pounds or upwards
to the square inch before they pass therefrom. After having been thus heated
under such pressure they pass by means of a pipe e' into the vacuum
chamber B', such pipe e¹ extending within such chamber opposite to the dis-
charge pipe for entering within such chamber B' into the expanded mouth
of such discharge pipe . Into the vacuum chamber B1 also enter other
pipes and h, one connecting with the retort in which the hydrocarbon gas is
heated and prepared, and the other with the air supply. The hydrocarbon is
first vaporized, and such vapor then conveyed to a highly heated retort. in
passing through which it is converted into a fixed gas. The steam or hydrogen
and oxygen being subjected to great pressure in the generator A' create as
they pass through the chamber B₁ and into the discharge pipe f¹¹ a vacuum
in such chamber, thereby causing the hydrocarbon gas or air, or other blast,
as the case may be, to flow into such chamber, where they are mixed with
the steam or other gases and discharged with them through the pipe f".
Suitable stop-cocks are placed in the pipes e', g, and h so as to regulate the
quantity of the several gases or admit to the vacuum chamber either the
carbon gas or the air blast as required. I make use of about the same
relative quantities of water and hydrocarbons oil to furnish the hydrogen and
oxygen and carbon gases, as before described, in supplying these gases to
the blast furnace. The discharge pipe f", and there may be a number of such
discharge pipes, opens into the bottom or other part of a vessel containing the
liquid metal, the pressure of the gases being sufficient to cause such gases to
pass through and pervade the metallic mass, and also prevent such metal
passing into such tubes or pipes f¹¹. By having complete and absolute control
over the quantity of the gases that are to be passed through the melted iron
and convert it into steel steel with different proportions of carbon may be
produced at pleasure.
It has been heretofore attempted to decarbonize and purify fluid iron by
passing through the mass steam in combination with an air blast, but the
steam so used has been of such a temperature as to have the effect of cooling
the fluid metal in passing through it, and the air blast has been used in con-
nection therewith to increase again its temperature. 1 prevent or avoid such
reduction of temperature by heating the steam before it is forced through the
metal to from 700° to 800° or 900° Fahrenheit, either actually decomposing

page_text: the steam and resolving it into its constituent gases, or heating it almost to
such a point so that it is decomposed and resolved into its gases as soon as it
comes in contact with the fluid metal. The metal is thus continually kept
at a high temperature, and the process of decarbonizing and purifying the
mass is thus more rapidly effected, and with greatly improved results.
I am aware that manganese has been made use of or applied in the con-
version of iron into steel, and sometimes in connection with a hydrocarbon,
but it has been introduced either in the cupola furnace or in the crucibles in
which the steel was remelted, or applied in the cementing process, and when
used with any hydrocarbon it has been in connection with coal tar or similar
cheap hydrocarbon containing sulphur and other impurities, which would
injure rather than improve the metal with which it might be brought in con-
tact. I am also aware that manganese is one of the elements or ingredients
of what is called "prepared iron or spiegel eisen. which is prepared to be
mixed with melted iron after it has been decarbonized to convert it into steel.
When so applied, however, it is very difficult to obtain a thorough and uniform
mixture of it with the entire mass of the iron, and such iron must also, in
order to properly take and receive the benefit of the manganese, be free from
sulphur which is not the case with most iron, unless specially refined. But
by introducing the manganese into the fluid metal as it is received from the
reducing furnace, and in combination with hydrocarbon gas, wholly free from
sulphur, phosphorus, and similar impurities, and with hydrogen and oxygen
gases or their equivalents, and the air blast, the metal is converted into steel
with much less expense and all danger of a too great use, or an use for a
longer time than is proper, of the oxygen or carbon gases is overcome, as the
quantity of either can be regulated according to the circumstances of any
case; all previous treatment for freeing the iron from sulphur is also unneces-
sary, the hydrogen accomplishing such. result. The introduction into the
fluid mass of a small proportion of lead is also found effectual in removing
or carrying off the sulphur and phosphorus that may still remain in the metal.
The lead may be introduced in its solid form and mechanically mixed, or in
the form of ground lead in connection with the gases.
The apparatus shewn in Figures 3, 4, & 5, may also be used for mixing the
several gases of oxygen and hydrogen and hydrocarbon with the air blast, or
other gases in combination, and supplying the same to the blast furnace, and
is peculiarly adapted and fitted for such purpose. The air blast may be
received directly into the exhaust chamber B' together with the hydrocarbon
gas, or may be supplied to the tuyere surrounding the discharge pipe f¹¹, or

page_text: part may be received into the exhaust chamber, and part supplied through the
tuyere. By the use of such vacuum chamber B' in combination with the gene-
rator A', or any vessel or boiler from which highly heated steam can be
received under pressure, I am enabled to completely mix and combine the
several gases of steam, oil and air, and in such proportions as may be desired
or necessary, and then supply them to and force them into the furnace inde-
pendant of any other power, as blowing engines, air and gas engines, thereby
greatly reducing expense and simplifying operations: such vacuum chamber
also enables me to utilize the waste gases of the furnace by mixing there-
with the heated hydrocarbon and atmospheric gases, thereby rendering un-
necessary the re-heating of such waste gases before their admission into the
furnace. Such arrangement of vacuum and mixing chamber can also be applied
to furnaces for generating steam; steam from the boiler being used to create
the vacuum and thus supply or draw in hydrocarbon and other gases, all
of which are thoroughly mixed and combined before being discharged into the
furnace.
What is claimed and is desired to be protected by Letters Patent,--
1. The application and use in blast and other like furnaces for reducing
metallic oxides of a blast of hydrogen and oxygen gases or their equivalent
when heated to a temperature of from 700° to 800° Fahrenheit, or thereabouts,
for the purposes set forth.
2. The use in such furnaces in combination with such blast of hydrogen
and oxygen gases, or their equivalent, heated as described, of carbon gas when
free from or obtained from hydrocarbons free from sulphur, phosphorus,
ammonia, &c., for the purposes set forth.
3. The use in such furnaces of such blast of hydrogen and oxygen gases,
or their equivalent, so heated, as described, and of such carbon gas free from
sulphur, phosphorus, ammonia, &c., in combination with the ordinary air blast,
for the purposes set forth.
4. In combination with blast and other furnaces used for reducing ores,
the use of a compound or divided tuyere, constructed substantially as described
for supplying to such furnaces such blasts of different character, substantially
as and for the purposes set forth.
5. The use in blast and other furnaces used for reducing ores of manganese,
substantially as and for the purposes set forth.
6. Converting iron into steel while the former is in a liquid state, and as it
is delivered from the furnace in which the ores are reduced, by the use and
application to or passing through such liquid iron, a blast of steam or hydrogen

page_text: and oxygen, heated to a temperature of from 700° to 800° Fahrenheit, or
thereabouts, in combination first with an air blast and afterwards with carbon
gas free from or obtained from hydrocarbons free from sulphur, phosphorus,
ammonia, &c., and either with or without manganese.
7. The use and application of lead in the conversion of iron into steel, sub-
stantially as and for the purposes set forth.
8. The combination of the steam generator and heater A, or its equivalent,
with an exhaust chamber and mixer B provided with suitable receiving and
discharge tubes, and operating substantially as described for generating or
heating, supplying and mixing hydrogen and oxygen gases, or their equivalent,
and carbon gas in connection with the air blast, and supplying the same either
for the purpose of converting iron into steel or for use in blast or other fur-
naces, for the purposes set forth.
In witness whereof, I, the said Silas Covell Salisbury, have hereunto set
my hand and seal, this Second day of August, in the year of our Lord
1867.
SILAS COVELL SALISBURY. (L.S.)