Improvements in the Manufacture of Steel,
Year: 1897

page_text: Date of Application, 14th Sept., 1897
Complete Specification Left. 6th June 1898-Accepted 10th Sent
180x
apprivation, but, fo
Complete Specification Left. 6th June 1898-Accepted 10th Sent
180x
PROVISIONAL SPECIFICATION.
Improvements in the Manufacture of Steel,
We, THOMAS JAMES HESKETT (Engineer and Steel Manufacturer) and HENRY
JONES, Engineer and Ironfounder, both of 50, North Terrace and Victoria Street,
Adelaide, in the Province of South Australia, do hereby declare the nature of our
invention for "Improvements in the Manufacture of Steel" to be as follows:
This invention is for the purpose of more conveniently and with greater
economy manufacturing steel of any desired temper from iron or from suitable
ores or metals.
By our improved process, pig iron, steel scrap, wrought iron scrap or any
suitable mixture of these metals may be manufactured into steel of desired
temper for steel castings or produced in ingots to be afterwards rolled or forged.
In the Bessemer process-which is very largely employed in steel manufac-
ture a given quantity or charge of pig iron is melted and conveyed to an open
converter which is separate and apart from the melting furnace or cupola and
the charge is converted into steel by the forcing of air currents through the metal
until the contained carbon has been reduced to the required percentage. During
the operation the combustible gases formed pass off at a very high temperature
and burn at the mouth of the converter doing no useful work. At the same time
a considerable percentage of the metal in a finely divided state is ejected from
the converter along with the gases owing to the very violent ebullition which
takes place.
In our process of producing steel the converter is connected with the cupola
and is covered during the operation by which means we obtain the following
advantages namely, The heat of combustion and the combustible gases given
off in the conversion of the molten iron to steel instead of being wasted as in
open converters are utilised in the melting down of the contents of the cupola
the operations of melting down and converting both being continuously and
simultaneously carried on, and so that the metal in the converter is constantly
being supplied with additional heat in the form of highly carburized metal going
down from the smelting zone of the cupola and the heat of the steel in the con-
verter is kept at a uniform temperature high enough for the oxygen from the
blast to combine with the carbon in the metal at once on its falling into the
converter.
The foregoing results are rendered possible by providing a brick lined channel
or flue connecting the cupola and converter which lining is kept very hot by
the waste heat from the converter gases escaping into the cupola and the flue
allowing the metal to run from the cupola into the converter without loss of heat
by exposure to the atmosphere or contact with material at a lower temperature
than itself.
Another advantage of our process is that variable quantities and variable
qualities of steel can be tapped out of the converter without suspending the
operation and chemical action.

page_text: Another advantage of our process is that the particles of metal which are
necessarily ejected and lost in an open converter are by our method saved and
returned to be utilised.
In operation the cupola is charged with the metal to be operated upon in the
same way as if it were being charged with iron for smelting only, the blast being
delivered into it through tuyeres. The molten metal runs down through the
pussage from the cupola into the converter where a blast is applied through the
converter tuyeres of sufficient quantity and strength until the contents have
been reduced by the expulsion of the carbon to the required composition when
the metal is drawn off through a suitable taphole into ladles or moulds. The
rate of conversion of the molten iron into steel is constant because the blast
pressure is constant the pipe being in open communication with the blower. The
rate of melting down is capable of variation in the cupola, being regulated at
will by a valve or valves which intercept and control the blast passing into the
cupola tuyeres. By this means the reduction of metal can be hastened or retarded
and steel with greater or less percentage of carbon produced accordingly in the
couverter.
Our improved process as above described whilst suitable for steel manufacture
from ore or metal on a large scale is particularly adapted for foundry purposes
as a given quantity of molten steel can be tapped out of the converter without
interfering with the working of the converter consequently the operations of
melting down and converting go on simultaneously and continuously. The
steel after ascertaining by sample that it is of the desired quality is taken off in
any desired quantity from the converter to the moulds at its highest temperature
thus avoiding loss through skulls in the ladles.
Fuel is economised in melting by making use of the heat of combustion and
the combustible gases given off at the converter. As the gases are combustible
and at a high temperature they pass from the converter through the opening
and burn at the melting down tuyeres of the cupola giving off an intense heat.
It will be seen that from the time the metal is charged into the cupola it is
subjected to a constantly increasing temperature until it is tapped into the ladle.
Metal is economised and saved by having the converter covered and closed in
except the small slag hole so that practically the particles of metal that in an
open converter are thrown off and lost are by our process carried with the pro-
ducts of combustion into the cupola and then intercepted and returned to the
converter along with the down flowing metal.
Plant is economised in foundries because an ordinary iron foundry plant can
be adapted at slight expense for producing steel according to our invention. The
cupola furnace can also be used for ordinary iron casting purposes by closing
temporarily the converter tuyere holes with sand or by blocking up the brick-
lined channel and making a tapping hole at the raking out door at the bottom
of the cupola.
It will be obvious that for large operations two or more converters may be
advantageously connected with one cupola to enable repairs to be effected in the
converters at the same time that the smelting operations are proceeding. The
invention may be applied to the manufacture of steel direct from the ore by
charging the ore, fuel, and fluxes into the cupola furnace in the usual way.
We have ascertained by trials that with our process we can obtain more heat
than is required in producing steel with one per cent. of silicon, whereas under
other process 2% to 3% is required, and at the same time our process enables us
to use a much greater proportion of scrap than can be used in the Bessemer
process.
D
1 ...

page_text: Improvements in the Manufacture of Steel.
We, THOMAS JAMES HESKETT (Engineer and Steel Manufacturer) and HENRY
JONES (Engineer and Ironfounder), both of 50, North Terrace and Victoria Street,
Adelaide, do hereby declare the nature of our 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 is for the purpose of more conveniently and with greater
economy manufacturing Bessemer steel of any desired temper from iron or from
suitable ores or metals.
By our improved process, pig iron, steel scrap, wrought iron scrap, or any
suitable mixture of these metals may be manufactured into steel of desired
temper for steel castings or produced in ingots to be afterwards rolled or forged.
In the Bessemer process which is very largely employed in steel manufac-
ture a given quantity or charge of pig iron is melted and conveyed to an open
converter which is separate and apart from the melting furnace or cupola and
the charge is converted into steel by the forcing of air currents through the metal
until the contained carbon has been reduced to the required percentage. During
the operation the combustible gases formed pass off at a very high temperature
and burn at the mouth of the converter doing no useful work. At the same time
a considerable percentage of the metal in a finely divided state is ejected from
the converter along with the gases owing to the very violent ebullition which
takes place.
In our process of producing steel the converter is connected by a short enclosed
brick lined channel with the cupola and is covered during the operation by which
means we obtain the following result namely:-The heat of combustion and
the combustible gases given off in the conversion of the molten iron to steel
instead of being wasted as in open converters are continuously utilised in the
melting down of the contents of the cupola the operations of melting down and
converting both being continuously and simultaneously carried on, and so that
a bath of steel is maintained in the converter and is constantly being supplied
with additional heat in the form of highly carburized metal going down from
the smelting zone of the cupola and the heat of the steel in the converter is kept
at a uniform temperature high enough for the oxygen from the blast to combine
with the carbon in the metal at once on its falling into the converter.
The foregoing results are rendered possible by providing a short covered fire-
brick lined channel or flue connecting the cupola and converter which lining is
kept very hot by the waste heat from the converter gases escaping into the cupola
and the flue allowing the metal to run from the cupola into the converter without
loss of heat by exposure to the atmosphere or contact with material at a lower
temperature than itself.
Another advantage of our process is that variable quantities and variable
qualities of steel can be tapped out of the converter without suspending the
operation and chemical action.
Another advantage of our process is that the particles of metal which are
necessarily ejected and lost in an open converter are by our method saved and
returned to be utilised.
In order that our invention may be clearly understood we will now describe the
same with reference to the apparatus which we prefer to employ, but we wish
it to be clearly understood that we do not bind ourselves to that particular
apparatus, modifications of which may be made without departing from our
invention.
:

page_text: Figure 1 is a central vertical section and
Figure 2 is a vertical section on line a b of Figure 1.
As before stated our invention is based upon the principle of having the con-
verter connected and combined with the cupola by a short covered fire proof
channel. In the drawings A is a cupola with feed opening A' in which the
ore or metal is melted. B is the converter and C a flue lined with fire brick or
fire resisting material connecting the cupola with the converter. D is a blast
box with a number of small tuyere holes D' arranged to deliver the blast into
the converter below the surface of the molten metal. E is a blast pipe connected
with a Roots or other blower or a blowing engine. F is a valve which regulates
the quantify of blast which it is desired to pass through the cupola tuyeres G.
H is a brick lined removable cover so that the converter lining can be repaired
and renewed. K is a slag hole through which an iron rod is inserted to take
a sample of the molten steel also for the overflow of slag.
In operation the cupola is charged with the metal to be operated upon and
carbonaceous fuel in the same way as if it were being charged with iron for
smelting only, the blast being delivered into it through the tuyeres G. The
molten metal runs down through the passage C into the converter B where a
blast is applied through the tuyeres D¹ of sufficient quantity and strength until
the contents have been reduced by the expulsion of the carbon to the required"
composition. The rate of conversion of the molten iron into steel is constant
because the blast pressure is constant the pipe D being in open communication
with the blower. The rate of melting down is capable of variation in the cupola
being regulated at will by a valve or valves such as F which intercept and control
the blast passing into the cupola tuyeres. By this means the reduction of metal
can be hastened or retarded and steel with greater or less percentage of carbon
produced accordingly in the converter. M is the tap hole for drawing off molten
steel to suitable ladles or moulds.
Our improved process as above described whilst suitable for steel manufacture
from ore or metal on a large scale is particularly adapted for foundry purposes
as a given quantity of molten steel can be tapped out of the converter into ladles
or moulds without interfering with the working of the converter consequently
the operations of melting down and converting go on simultaneously and con-
tinuously. The steel after ascertaining by sample that it is of the desired quality
is taken off in any desired quantity from the converter to the moulds at its highest
temperature thus avoiding loss through skulls in the ladles.
Fuel is economised in melting by making use of the heat of combustion and
the combustible gases given off at the converter. As the gases are combustible
and at a high temperature they pass through the opening C and burn at the
melting down tuyeres G giving off an intense heat. It will be seen that from
the time the metal is charged into the cupola it is subjected to a constantly
increasing temperature until it is tapped into the ladle.
Metal is economised and saved by having the converter covered and closed in
except the small slag hole so that practically the particles of metal that in an
open converter are thrown off and lost are by our process carried with the pro-
ducts of combustion through the opening C and then intercepted and returned
to the converter along with the down flowing metal.
Plant is economised in foundries because an ordinary foundry plant can be
adapted at slight expense for producing steel according to our invention. The
cupola furnace can also be used for ordinary iron casting purposes by closing
temporarily the converter tuyere holes with sand or by blocking up the brick
lined channel C and making a tapping hole at the raking out door at the bottom
of the cupola.
It will be obvious that for large operations two or more converters
may be
advantageously connected with one cupola to enable repairs to be effected in the
converters at the same time that the smelting operations are proceeding. The

page_text: invention may be applied to the manufacture of steel direct from the ore by
charging the ore, fuel, and fluxes into the cupola furnace in the usual way.
We have ascertained by trial that with our process we can obtain more heat
than is required in producing steel with one per cent. of silicon, whereas under
other processes 2% to 3% is required, and at the same time our process enables
us to use a much greater proportion of scrap than can be used in the Bessemer
process, as hitherto practised.
We are aware that the waste heat from the converter has been utilized to assist
in melting down the charge, and that the melting down and conversion have
been carried on simultaneously without utilizing the waste heat, also, that the
waste heat from a reverberatory furnace has been utilized, but no process has
been adopted, so far as we are aware, which contains the combination of essential
steps and features producing the economical results attained by our process and
apparatus.
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:-
In the conversion of iron to steel by Bessemer methods-
1. The continuous utilisation of the waste heat of combustion and the com-
bustible gases given off in the conversion of molten iron to steel by the connection
of the converter with the cupola in which the melting down takes place sub-
stantially as described and set forth.
2. The herein described continuous utilisation of the waste heat of combustion
and the combustible gases given off in the conversion of molten iron to Bessemer
steel by the connection of the converter with the cupola such connection being
established preferably by a short covered fire-brick lined channel or flue so that
the operations of melting down and converting are both continuously and simul-
taneously carried on and the metal in the converter is constantly being supplied
with additional heat in the form of highly carburized metal going down from
the smelting zone of the cupola as and for the purposes set forth.
3. The herein described process for, in a combined cupola and Bessemer con-
verter continuously and simultaneously melting down iron or suitable ore or
metal and converting the same into Bessemer steel without exposing the charge
to the atmosphere or other cooling material.
4. The herein described method of collecting and saving the particles of metal
ejected by the blast in the conversion by Bessemer methods of iron to steel by
conveying them to the melting furnace or cupola and returning them to the
converter along with the down flowing metal as described and set forth.
Dated this 6th day of June 1898
A. M. & WM. CLARK,
Chartered Patent Agents, 53, Chancery Lane, London.
A. M. & WM. CLARK,
Chartered Patent Agents, 53, Chancery Lane, London.