IMPROVEMENTS IN THE MANUFACTURE OF IRON AND STEEL AND IN APPARATUS AND MATERIALS EMPLOYED THEREFOR."
Year: 1881

page_text: LETTERS PATENT to John Coley Bromfield, of Brighton, in the County of
Sussex, Sanitary Engineer, for an Invention of "IMPROVEMENTS IN THE
MANUFACTURE OF IRON AND STEEL AND IN APPARATUS AND MATERIALS
EMPLOYED THEREFOR."
PROVISIONAL SPECIFICATION left by the said John Coley Bromfield at
the Office of the Commissioners of Patents on the 23rd November 1881.
JOHN COLEY BROMFIELD, of Brighton, in the County of Sussex, Sanitary
Engineer. "IMPROVEMENTS IN THE MANUFACTURE OF IRON AND STEEL AND IN
APPARATUS AND MATERIALS EMPLOYED THEREFOR."
My Invention refers to the manufacture of iron or steel, and specially to that
of a fuel or composition to be used in the smelting of iron or steel.
" bluo
I grind coal or coal dust and iron ore or a material technically known as
billy," or a combination of these, to a powder, in proportion of say 2 tons of coal
to 1 ton of iron, but 1 do not limit myself to these proportions, then I take
seaweed and obtain a mucilage therefrom by steaming same in a close jacketted
boiler or other apparatus suitable for the purpose. The coal and iron ore powder
are then amalgamated by mixing by machine or otherwise with some of the
seaweed mucilage; this done I add to the product from 5 to 10 per cent. of some
hydraulic cement such as Portland cement; the cement, mucilage, coal and irou
dust being well amalgamated, the whole product is submitted to pressure. The
materials thus prepared are made into blocks or bricks in any convenient way,
but preferably by a brick making machine in which the bricks are submitted to
excessive pressure. The bricks thus made are dried artificially or otherwise.
The Invention further consists in treating tho bricks or blocks thus prepared by
coking them in a retort, such as the retort hereafter described, whereby the whole
of the sulphur and phosphorus contained in them is eliminated from the said bricks
or blocks while the whole of the materials of which they are composed are
thoroughly amalgamated. Bricks or blocks thus prepared are then suitable for
furnace use, whereby I obtain a high class of metal from which practically the

page_text: whole of the phosphorus and other injurious elements contained in the raw
material are expelled. When the blocks or bricks are only used as a fuel for iron
and steel manufacture the powdered ore is omitted from the composition.
The retort which I prefer is constructed of iron or other suitable material and
in two parts, an upper and a lower part. The upper part of the said retort projects
up through the top of the furnace, and its mouth-piece is provided with a suitable
lid or cover. The lower part is connected by a flange joint with the upper part,
and between the two parts I place a door arranged to turn upon a pivot, so that
the said upper part can be closed or shut off from the lower part when desired.
The said lower part is a continuation of the upper part and extending downwardly
below the flanged joint forming a second chamber immediately below the upper,
and is provided with a suitable lid. or door opening downwards so that the
contents of the chamber can be removed as required. The said retort is charged
or filled with the bricks or blocks before mentioned through its mouth-piece, while
the door between the two parts is closed. This charge is burned, and then the
said door is opened and the contents of the upper part descend into the lower
part; the said door may then again be closed, and a fresh charge supplied to the
upper part of the retort. While the second charge is being burned the first charge
is cooling in the lower part, and when sufficiently cool can be removed from the
same. The second charge is then admitted to the lower part of the retort, a fresh
charge supplied to the upper part, and so on.

page_text: SPECIFICATION in pursuance of the conditions of the Letters Patent filed
by the said John Coley Bromfield in the Great Seal Patent Office on the
23rd May 1882.
JOHN COLEY BRONFIELD, of Brighton, in the County of Sussex, Sanitary
Engineer. "IMPROVEMENTS IN THE MANUFACTURE OF IRON AND STEEL AND IN
APPARATUS AND MATERIALS EMPLOYED THEREFOR.'
"J
My Invention refers to the manufacture of iron or steel, and to the apparatus
therefore.
I grind coal or coal dust and iron ore, or a material technically known as "blue
billy," or a combination of these, to a powder, in proportion of, say, 2 tons of coal
to 1 ton of iron ore, but I do not confine myself to these proportions, as much depends
upon the quality of coal used; in many cases half the quantity will be found
sufficient to mix with a ton of crushed iron ore. Alumina may be added with
calcium oxide or carbonate of lime when much silica is found to be present in the
ore. Then I take seaweed and obtain a mucilage therefrom by steaming same in
a close jacketted boiler or other apparatus suitable for the purpose, extracting the
mucilage by hydraulic pressure. The coal and iron ore powder are then thoroughly
mixed and incorporated by machinery or otherwise with some of the seaweed
mucilage; this done, I add to the product from 5 to 20 per cent. of some hydraulic
cement, such as Portland cement, carbonate of lime, magnesian lime, or calcium
oxide, according to the nature of the iron ore to be treated, the cement, mucilage,
coal dust, and iron ore powder being well amalgamated or mixed and incorpo-
rated; the mixture is then submitted to pressure; the fibrous portion of the pressed
sea weed may also be added after it has been carbonized.
The materials thus prepared are made into blocks or bricks in any convenient
way, but preferably by a brick making or drain pipe machine, in which the bricks,
cylinders, cylindrical balls, or other forms are submitted to excessive pressure.
The bricks or moulds thus made are dried artificially or otherwise. Silica may bo
added during the process of mixing where it is required to produce oxygen in tho
retort.
The Invention further consists in treating the bricks or moulds thus prepared
by coking them in a retort, such as the retort hereafter described, whereby prac-
tically the whole of the sulphur and phosphorus contained in them is eliminated
from the said bricks or moulds, while the whole of the materials of which they are
composed are thoroughly united; bricks or moulds thus prepared are then suitable
for furnace use, whereby I obtain a high class of metal, from which practically the
whole of the phosphorus and other injurious and impure elements contained in the
raw material or crushed pig iron are expelled. When the bricks or moulds are
only used as a fuel for iron and steel manufacture the powdered iron ore is
omitted from the composition. The retort which I prefer is constructed of iron
or other suitable material, and in two parts, an upper and a lower part. The upper
part of the said retort, which I prefer to make of fire clay, which may be com-
bined with lime (magnesian lime by preference), projects up through the top of the
furnace, and its mouth piece is provided with a suitable lid or cover. The lower
part, which I prefer to be made in wrought iron, is a continuation of the upper
part, and extending downwardly below the joint or juncture, forming a second
chamber immediately below the upper, and is provided with a suitable lid or door
opening sideways near the bottoni, so that the contents of the chamber can be
removed as required.
The said retort I make taper from the top, so that the bottom end is wider than
the top for the more easily allowing the material when coked to fall to the bottom:

page_text: The said retort is charged or filled with the bricks or moulds before mentioned
through its mouth piece, while the door nt the bottom of the two parts is closed.
The charge is coked, and then the said door is opened and the contents of the
lower part are drawn off to allow the contents of the upper part to descend into
the lower part; the said door may then again be closed, and a fresh charge supplied
to the upper part of the retort. Previously to filling up the upper part I first
charge the lower part with cold coko on the furnace being lighted. While tho
second charge is being coked the first charge is cooling in the lower part, and when
sufficiently cool can be removed from the same. The second chargo is then admitted
to the lower part of the retort to be drawn out of the side door at the bottom as
a fresh chargo is supplied to the upper part, and so on as long as the furnace is
alight.
The accompanying Drawings illustrate the manner in which I prefer to carry
this part of my Invention into effect. Figure 1 is a front elevation of so much of
n furnace and retort as will be necessary to illustrate this part of my Invention;
and Figure 2 is a longitudinal vertical section of same.
A is the retort proper, which I prefer to make of fire clay, with or without lime
composition, and of a somowhat conical shape, as shown; B is the cold coke chamber
below the retort, preferably made of wrought iron; C is a lid or door, whereby the
coko is removed from the chamber B; E is the mouth piece or feeding portion
of the retort A, which is bolted and secured thereto, as shown; L is the retort lid,
and 1, 2, 3, 4 the deflecting plates thereon for throwing back the products, which
arise and come against the same into the retort A. The retort lid is secured to
the mouthpiece by cotter appliances, as shown; F is draught or sight door in
furnace to regulate the draught and to examine the state of the retort; G, G, are
draught poles; H is the furnace door; 1, 1, shows the position of the furnace bars;
J is the ash pit; N is pipe leading from the mouth piece of the retort to the
water tank D; the bell mouth M of the pipe N dipping into the water in the
tank D; K is the hydraulic main; and O is the gas servico pipe leading from
the main K to the underside of furnace bars for leading the gas thereto to be burnt
if required in the furnace; P is the brickwork or wrought iron furnace; Qis a tap
in the top portion of retort for the purpose of ascertaining the nature of the gas
or gases being evolved, and also when the material being coked is exhausted of its
gases; and R is tap in wrought iron coke chamber to enable oxygen, if it be
required, to be introduced to the retort through the coke in the lower chamber B,
and also to allow the carbon vapours to be discharged before the door C is removed.
The action is as follows:-The wrought iron chamber B is first filled with ordinary
coke, the conical portion A of retort is filled with blocks or pieces of material
prepared in the manner before described, and this is effected by removing the retort
lid L; the lid being replaced, the operation is free to commence. The furnace is
fired either from gas ready at hand from the gas holders or by coals from the
furnace, and the coking in the retort proceeds. The gas which is generated in
the retort escapes by the ascension pipe N through the water tank D, where it
may be stored in main K, or utilized as described, being conveyed by the pipe O
back to the furnace to be consumed in the shape of fuel for the furnace. The gas
not consumed is utilized in any other desired manner for illuminating or other
purposes as required. The material in the retort A being sufficiently coked (which
when this is effected can be ascertained by the state of the gases therein through
the tap Q), the coke in vessel B is drawn, the door C thereof is immediately closed,
and the coked material from the retort A falls into the empty coke chamber below;
the retort is then recharged as before and so on continuously; it is only necessary
at starting to charge tho chamber B with coke, for after the first discharge the
coked material itself from the retort fills the chamber B, and forms a base for the
material in the retort to rest upon during the coking operation. The diagrams,
Figure 3, show a series of furnaces and retorts from which the gases are led and
disposed of as desired, whether for lighting purposes or otherwise, as well as
securing and utilizing the several products usually obtained in gas making, also for

page_text: convoying off the noxious vapours generated in the furnaces; S is a safety valve,
which may lead into a flue from main K if more gas is being made than could be
burnt under furnace, or it may be led off to an ordinary gas purifier and condenser
for treatment prior to being stored in a gas holder for use in various ways, the bye
products being in this manner saved and rendered commercially valuable. Little
explanation is needed on my part to point out the high commercial value of the
results to be obtained by economising and utilizing the products contained in the
materials that are placed in the retorts, but which under present usage are allowed
to escape in waste; these products will repay many times over the cost of
preparing the iron ore for the smelting furnace, even if the economy of fuel did
not recommend my process as a valuable one, in addition to the fact that I
eliminate all injurious ingredients which form so considerable a drawback in many.
descriptions of iron ores.
Having now described the nature of my said Invention, and in what manner the
same is to be performed, I declare that I am aware it has been proposed to employ
some of the ingredients before referred to in the manufacture of iron and steel, it
has also been proposed to employ them in a powdered state; it has also been
proposed to coko the materials, but I am not aware that the coking has been
suggested to be applied to the combination of materials which I employ, neither
am I aware that the same or similar combinations of material which I employ have
ever before been employed, or suggested to be employed, in the manufacture of
iron and steel, but I claim as my Improvements in the Manufacture of Iron and
Steel, and in Apparatus and Materials Employed therefor,"-
First. The preparation and combination of coal dust, crushed or powdered iron
ore, and seaweed mucilage, with cement or lime, and its subsequent treatment by
pressure into blocks, bricks, cylinders, or other forms, and then the coking thereof,
whereby the impurities are eliminated from the metal, which metal in a pure
or practically pure state is left in the coke ready for the smelting furnace, all
substantially as herein before described.
Second. The construction and arrangement of retorts and furnaces for the coking
of preparations or combinations of materials, substantially as and for the purposes
set forth.
In witness whereof, I, the said John Coley Bromfield, have hereunto set my
band and seal, this Twenty second day of May, in the year of our Lord