CERTAIN IMPROVEMENTS IN THE. PRODUCTION OF METALS OR METALLIC ALLOYS, AND IN THE PROCESS EMPLOYED THEREFOR."
Year: 1876

page_text: LETTERS PATENT to John Hollway, of the Firm of Hollway, Brothers,
7, Jeffrey's Square, in the City of London, for the Invention of "CERTAIN
IMPROVEMENTS IN THE. PRODUCTION OF METALS OR METALLIC ALLOYS, AND IN
THE PROCESS EMPLOYED THEREFOR."
PROVISIONAL SPECIFICATION left by the said John Hollway at the Office
of the Commissioners of Patents on the 23rd August 1876.
JOHN HOLLWAY, of the Firm of Hollway, Brothers, of 7, Jeffrey's Square, in the
City of London "CERTAIN IMPROVEMENTS IN THE PRODUCTION OF METALS OR
METALLIC ALLOYS, AND IN THE PROCESS EMPLOYED THEREFOR."
This Invention relates to improvements in the production of metals and metallic
alloys, and has for its object the further developinent.and extension of an Invention
for which Letters Patent were granted to me on the 5th day of April 1876,
No. 1446, which Invention was for the "Manufacture of Spiegel Eisen or Ferro-
manganese by Smelting or otherwise Reducing Compound Metallic Coke formed by
Mixing Ferro-manganiferous Manganese and Iron Ores, or any thereof, with Coal
or other Carbonaceous Materials, and the Fluxes and Bitumen that may be con-
sidered Advisable, and Coking such Mixture in Ordinary Coke Ovens."
This present Invention relates to the production of metallic coke by a similar
process to that described in the Specification of the Patent above referred to, but
inasmuch as the production of the coke forming the subject of this Invention is
intended for the manufacture of metals or alloys other than spiegel eison or ferro-
manganese, I will describe, as embraced by these present improvements, the pro-
duction of compound coke out of various kinds of ores or other substances containing
metals, berein-after more particularly referred to, amalgamated with carboniferous
and other substances, which when smelted in the blast furnace or by other means
of reduction will produce a metallic "pig" from the constituents of the material
coked.
My primary object in the development of this Invention is the formation of a
compound metallic coke containing as one of its principal metallic ingredients a
substance known in commerce as "blue billy" or "purple ore," which coke will
when smelted produce pig iron without the difficulties which have hitherto formed

page_text: an obstacle to the smelting of the said "purple ore." These obstacles are the
following:
--
First. This substance being in the form of powder renders it unsuitable for reduc-
tion by the ordinary operation of the blast furnace.
Second. A residue of the copper and sulphur contained in the pyrites from which
the "purple ore" is produced remains therein.
Third It does not possess in sufficient quantities the ingredients for a good slag,
silica, lime, alumina, and other suitable components being deficient.
To overcome these obstacles and so produce ordinary iron take this "purple ore,"
adding thereto iron slag if desired with the fluxes necessary, also manganese ore or
substances containing that metal (to assist in eliminating the sulphur), together
with the coal and pitch necessary for forming a sound coke, the whole of which
ingredients are to be pulverized or disintegrated and well mixed. This mixture is
to be coked in coke ovens in the ordinary manner, and the coke produced will be
capable of yielding when reduced in the furnace iron at a moderate cost.
When a better quality of iron may be required, add to the mixture iron sand or
other combinations of iron equally pure, and an increased quantity of manganese.
The foregoing will form an illustration of the manner in which by the same
process other residuums or substances containing metals, and especially those of
small commercial value, may be utilized in an economical manner by their admix-
ture with coal or other carbonaceous material, and pitch if required, and other
substances, as herein-before described, in the form of compound metallic coke,
including in such admixtures the substances requisite for neutialising or eliminating
any objectionable constituents or for improving the quality of the product; and by
forming the materials into coke the mechanical difficulty of using same in a
powdered form is overcome.
.
This process is peculiarly adapted for the production of metallic compounds or
alloys, such as iron in combination with chromium, titanium, or other metals, as
the substances containing the metals can be thereby very easily classified and
arranged.
In addition to these advantages the intimate and close mixture of the metallic
with the carbonaceous and other substances would facilitate the smelting, especially
in the case of metals which are difficult of reduction.
Further, the ingredients being in a pulverized state any objectionable constituents
can be more easily removed therefrom by washing or other purifying process.
I consider it unnecessary further to explain in detail the process, as this is fully
done in the Specification of my previous Patent, herein-before referred to.
SPECIFICATION in pursuance of the conditions of the Letters Patent filed by
the said John Hollway in the Great Seal Patent Office on the 23rd February
1877.
JOHN HOLLWAY, of the Firm of Hollway, Brothers, of 7, Jeffrey's Square, in the
City of London. "CERTAIN IMPROVEMENTS IN THE PRODUCTION OF METALS OR
METALLIC ALLOYS, AND IN THE PROCESS EMPLOYED THEREFOR."
This Invention relates to improvements in the production of metals and metallic
alloys other than ferro-manganese and spiegel eisen, and has for its object the
further development and extension of an Invention for which Letters Patent were
granted to me on the Fifth day of April One thousand eight hundred and seventy-
six, No. 1446, which Invention related to the "Manufacture of Spiegel Eisen or
Ferro-manganese by Smelting or otherwise Reducing Compound Metallic Coke.
The Coke is formed by Mixing Ferro-manganiferous Manganese and Iron Ores and
other Manganiferous or Ferreous Substances, or any thereof, with Coal or other
Carbonaceous Materials, and the Fluxes and Bitumen that be considered Advisable,
and Coking such Mixture in the Ordinary Manner."

page_text: My present Invention relates to the production of metallic coke of the character
herein-after described by a similar process to that described in the Specification of
the Patent above referred to, and my primary object in the development of this
Invention is the formation of a compound metallic coke containing as one of its
principal metallic ingredients a substance known in commerce as "blue billy" or
'purple ore." This coke when smelted will produce pig iron without the difficulties
which have been hitherto experienced in smelting the said "purple ore."
"
To overcome these difficulties and to produce iron I take "blue billy," and add
thereto iron slag if desired with the fluxes necessary, also manganese ore or sub-
stances containing that inetal in order to assist in eliminating the sulphur, together
with sufficient coal and bitumen if necessary, using the materials and the quantities
(having regard to the character of the materials) which will make a sound coke.
Persons acquainted with the manufacture of iron and coke will have no difficulty
after a few trials in choosing the materials, and using them in the required pro-
portions. I pulverise or disintegrate such of these ingredients as require to be so
treated, well mix the whole together, and coke same. The metallic coke when
reduced in the furnace with iron ore in order to utilise the excess of carbon con-
tained therein will be found to yield good iron successfully at a moderate cost.
When a better quality of iron is required I add to the mixture iron sand or oxides
of iron equally pure, and an increased quantity of manganese.
"Blue billy" may in some cases be employed in making the metallic coke withont
the addition of any manganiferous or other ferreous substances.
The ingredients should be varied according to the different characters of the
various ores to be smelted with the metallic coke.
The intimate and close admixture of the metallic with the carbonaceous and other
substances facilitates the smelting, and enables it to be effected with less expenditure
of carbon than is necessary for reduction of the same quantity of oxides of iron con-
tained in ordinary ores.
The following is an example of the process of producing such metallic coke froin
"blue billy" and Paloinare's iron ore, the latter being an ore containing by analysis
about fifty per cent. of metallic iron and about ten per cent. of metallic man-
ganese-For the production of a coke containing about thirty per cent. of metallic
iron and about forty-eight per cent. of carbon I take the following ingredients in
about the proportions indicated --Twenty tons of "blue billy," fifteen tons of
Palomare's ore, forty tons of coal, and eight tons of pitch Such of these ingredients
as are not in a sufficiently powdered form are to be pulverized or disintegrated, and
the whole well mixed. This mixture should be then coked. When this operation
is completed, the metallic coke produced is suitable for smelting with ordinary iron
ores, and with or without ordinary coke, as may be found most suitable and
economical.
In the manufacture of coke from coal-and "blue billy" without additional bitu-
men, sufficient coal to produce a sound coke must be employed; therefore the
proportions of the two ingredients will vary according to the quality of the coal; but
as an example for the production of a coke containing about twenty per cent. of
metallic iron, take about twenty tons of "blue billy" and sixty tons of bituminous
coal, screenings or powdered coal preferred, and well mix them together. This
mixture is then coked in the usual manner When this operation is completed, a
sound coke is produced, notwithstanding that no bitumen has been used.
With a good coking coal I have made a sound coke, using only "blue billy" and
coals, the proportions being one of the former to two of the latter. The coke thus
produced contained consequently a larger per-centage of metallic iron.
I am cognizant of the fact that several attempts have been made to deal with
ferreous substances in powder by mixing them with coal, and even bitumen, and
coking them; but these have never been brought to a successful issue, because the
intention having been to smelt the mixture alone, it was considered important to
produce coke containing the largest possible per-centage of metal as compared with
the per-centage of carbon; or that the carbon contained in the coke should not be

page_text: in excess of the quantity required for the reduction of the metallic oxides also con-
'tained therein. The resulting product was therefore unfit for use in a blast furnace,
and the attempts to carry on the process have been abandoned.
I have ascertained that in order to make sound metallic coke it is necessary that
it should contain an excess of carbon beyond what is required to smelt the metallic
substances in the mixture, and to smelt it economically so as to make it a practical
success, additional metalliferous substances must be smelted therewith in order to
utilise this excess; this can be done with or without an additional quantity of
ordinary coke.
In a trial recently made where twenty-five and one-third cwt of ordinary coke
were being used to smelt fifty cwt. of iron ore, twelve and a half cwt. of the metallic
coke were substituted for six and one-third cwt. of the ordinary coke, and the
smelting was continued. The metallic coke contained twenty-four per cent. of
metallic iron to fifty-five per cent. of carbon, or the equivalent of about fifty-eight
per cent of ordinary coke. This experiment demonstrated that the oxides in the
metallic coke can be economically reduced, and the extra carbon utilised for the
reduction of an additional quantity of ore; also, that the metallic oxides contained
in the coke are reduced with a less expenditure of carbon than that necessary for
the reduction of an equivalent quantity of metallic oxides contained in ordinary
ores.
It will be understood that the reason I have not more definitely described the
quantities of the various ingredients proposed to be mixed in the production of com-
pound metallic coke is owing to the fact that the ingredients to be treated vary so
much in their components; for example, substances containing metals, the fluxes,
and even ores from the same mine, are found to differ considerably in their analyses,
and the same remark also applies to coal, therefore the proportions of such ingre-
dients must be regulated by their analyses or bituminous qualities, and by the
analyses of the ores intended to be used with the metallic coke, as will be well
understood by persons experienced in smelting metals.
I therefore claim as new and as of my Invention, the use in the manufacture of
iron of a compound metallic coke made from "blue billy" or "purple ore" mixed
with iron ores, iron sands, or other ferreous substances or manganiferous substances,
and with coal or other carbonaceous materials, and the fluxes and bitumen that may
be considered advisable, the carbonaceous materials being used in quantities large
.enough to produce a sound coke capable of being smelted, and enabling the excess
of carbon beyond the quantity required for smelting the metalliferous substances
.contained in the said coke to be utilised by smelting ordinary ores or other ferreous
substances with or without ordinary coke, all substantially as herein described
In witness whereof, I, the said John Hollway, have hereunto set my hand
and seal, this Nineteenth day of January, One thousand eight hundred and
seventy-seven.
Signed by John Hollway in the
presence of
THO®. F. FRY,
36, Hackney Terrace,
South Hackney
JAMES T. SNOW,
Waltham Villa,
Buckhurst Hill.
JOHN HOLLWAY. (LS.)