IMPROVEMENTS IN THE MANUFACTURE OF STEEL, AND IN THE REFINEMENT OF IRON
Year: 1878

page_text: LETTERS PATENT to John Perry Downing, of Swalwell, in the County of
Durham, Sole Executor of John Perry Downing, of The Tyne Steel Works,
Redheugh, Gateshead, in the County of Durham, Steel Manufacturer, deceased,
for the Invention of "IMPROVEMENTS IN THE MANUFACTURE OF STEEL, AND IN
THE REFINEMENT OF IRON."
Sealed the 28th December 1878, in pursuance of an Order of the Lord Chancellor,
and dated the 12th June 1878.
PROVISIONAL SPECIFICATION left by the said John Perry Downing at the
Office of the Commissioners of Patents on the 12th June 1878.
JOHN PERRY DOWNING, of The Tyne Steel Works, Redheugh, Gateshead, in the
County of Durham, Steel Manufacturer. " IMPROVEMENTS IN THE MANUFACTURE
OF STEEL, AND IN THE REFINEMENT OF IRON."
The Invention relates to the production of steel directly from pig iron or other
iron, or iron ore, by one direct process; also to the purification of iron from dele-
terious matters in one furnace operation. These improvements are effected by the
employment of a high and varied degree of temperature during the direct process.
The proportions of matter employed for the manufacture of steel by this direct
process will vary with the quality or character of the iron under operation, as well
as the quality of steel to be produced; but supposing the iron to be treated to be of
the character of that known as Cleveland pig iron, that is to say, iron of low
quality, and the steel desired to be produced to be of a fine quality, then for each
ton of the iron under operation I combine 1 to 3 per cent. of tap cinder, 1 to 3 per
cent. of oxide of iron or other iron ore, 1 to 2 pounds of black oxide of manganese
or other manganese possessing similar properties, 1, pound of sal ammoniac, 1 cwt.
of Spiegel esen. To these I add 1 cwt. of either sponge iron or scrap iron.
The method I find to answer well is first to place the iron to be treated in a
suitable furnace, such as an air or gas or a puddling furnace or cupola, from 1 to 3
per cent. of tap cinder, about 1 cwt. of either sponge iron or scrap iron being added
...

page_text: at the same time. The furnace employed is then run with the iron and other
matters referred to for about half an hour after melting time to a very high degree
of heat, such as the highest cast-steel heat. After melting time I run the furnace
for about half an hour at or about such temperature; the cinder refuse or other
impure matter is then tapped off, when I add the oxide of iron or ores, varying the
quantities according to the quality of steel required to be obtained; I at the same
time stir the matters if desired; I then add the manganese and the sal ammoniac.
I then run the furnace again for about half an hour to a higher temperature, when
I add the Speigel esen; and if other portions of the ingredients referred to should
then be required such may now be added. I then stir the molten matter once or
twice round with a rabble or other suitable tool, but I take care not to puddle or
boil, as the product (steel) should leave the furnace in a liquid state at the highest
degree of temperature, and be run into ingots to be subsequently hammered,
squeezed, or rolled, as desired.
For other qualities of steel suitable for bars, plates, rails, sheets, or ordinary
purposes, the quantities of the respective ingredients employed will be reduced or
increased in proportion to the quality of steel required.
In operating with higher qualities of iron than such as Cleveland pig iron the
quantities of the ingredients referred to will be varied in proportion to the quality
of steel desired to be obtained.
The furnace employed for this direct process must be capable of resisting the
highest degrees of cast steel heats.
The results are, for their success by this direct process, mainly dependent on the
employment of high and varying degrees of heat, raising or diminishing the heat
according to whether a harder or softer degree of steel is desired to be obtained.
Corresponding results may be obtained when a combination of different irons or
ores is adopted, as, for instance, say 1 ton of Cleveland pig iron or other iron, and
from 1 cwt. to 5 cwt. of Indian, Greek, or other iron of similar nature, with the
other ingredients, as above stated, but somewhat less or inore in quantity in
proportion to the quality of iron used with the process, as before described.
The quantity of Indian, Greek, or other iron of similar nature to be used in
combination with the Cleveland or other iron referred to will be regulated by the
quality of steel desired to be produced.
For the production of refined iron I combine about 1 ton of Cleveland or other
iron, and from 1 cwt. to 3 cwt. of Indian, Greek, or other iron of a similar nature,
and I melt them together to a high temperature, say to a cast steel heat, and after
the iron has been reduced to a liquid state the heat is increased and the liquid
allowed to remain in the furnace for from one and a half to two hours, as may be
desired. It is then run off into ingots to be subsequently hammered, squeezed,
rolled, or used for castings, as desired.

page_text: SPECIFICATION in pursuance of the conditions of the Letters Patent filed by
the said John Perry Downing, sole executor of John Perry Downing, deceased,
in the Great Seal Patent Office on the 28th December 1878.
JOHN PERRY DOWNING, of Swalwell, in the County of Durham, Sole Executor of
John Perry Downing, of The Tyne Steel Works, Redheugh, Gateshead, in the
County of Durham, Steel Manufacturer, deceased. "IMPROVEMENTS IN THE MANU-
FACTURE OF STEEL, AND IN THE REFINEMENT OF IRON."
The said Invention consists in the production of steel directly from pig iron or
iron ore by one direct process; and also in the refinement of iron or purification
thereof from deleterious bodies by means of one furnace operation, and is specially
applicable to the manufacture of steel from iron obtained from what is termed
"Cleveland ore" and all other ores of a similar nature, that is to say, ores which
are either chemically or mechanically combined with phosphorus or any of its
oxides or other compounds, and which are thereby rendered unsuitable for the
manufacture of steel owing to the difficulty and expense of eliminating or rendering
innocuous the phosphorus contained therein by the processes at present employed.
The desired results are effected by the employment of high and varying degrees
of temperature during the process of smelting the pig iron or iron ore, whereby the
impure or injurious matters are more or less volatilised. During the employment
of such high and varying temperatures, and upon the addition of certain ingredients,
as herein-after described, chemical re-actions take place in the furnace, the desired
results being thus effectually and economically produced.
The proportions of the materials employed for the manufacture of steel in accord-
ance with this Invention will vary with the quality or character of the iron under
operation, as well as the quality of steel to be produced;, but supposing the iron to
be treated to be of a character of that known as "Cleveland pig iron," that is to
say, iron of low quality, and the steel desired to be produced to be of a fine quality,
then for each ton of the iron under treatment I combine from 1 to 3 per cent. of tap
cinder, 1 to 3 per cent. of oxide of iron or other iron ore, 1 to 3 pounds of black
oxide of manganese or other manganic compound possessing similar properties, half
a pound of sal ammoniac, and 1 cwt. of Spiegel eisen. To these I add 1 cwt. of
either sponge iron or scrap iron.
The method I find to answer well is first to place the iron to be treated in a
suitable furnace, such as an air, gas, or puddling furnace, cupola, or crucible, from 1
to 3 per cent. of tap cinder, about 1 cwt. of either sponge iron or scrap iron being
added at the same time. The furnace employed is then run with the iron and other
materials referred to for about half an hour after melting time to a very high
degree of heat, such as the highest cast steel heat. The cinder refuse or other
impure matter is then tapped off, when I add the oxide of iron or ores, varying the
quantities according to the quality of steel required to be obtained. At the same
time I stir the materials if desired, and I then add the manganese and the sal
ammoniac. The furnace is then run again for about half an hour to a higher
temperature, when I add the Spiegel eisen; and if other portions of the ingredients
referred to should then be required such may now be added. I then stir the molten
substances once or twice round with a rabble or other suitable tool, taking care not
to puddle or boil the substances under treatment, as the steel to be produced should
leave the furnace in a liquid state at the highest degree of temperature, and be run
into ingots to be subsequently hammered, squeezed, or rolled, as desired.
For other qualities of steel suitable for bars, plates, rails, sheets, or ordinary
purposes the quantities of the respective ingredients employed will be reduced or
increased in proportion to the quality of steel required.
In operating with higher qualities of iron than such as Cleveland pig iron the
quantities of the ingredients referred to will be varied in proportion to the quality
of steel desired to be obtained.

page_text: The furnace employed for this direct process must be capable of resisting the
highest degrees of cast steel heats.
The results sought to be obtained by the said Invention are mainly dependent on
the employment of high and varying degrees of heat, raising or diminishing the
heat according as a harder or softer degree of steel is desired to be obtained.
Corresponding results may be obtained when a combination of different varieties
of iron or iron ores is adopted, as, for instance, say 1 ton of Cleveland pig iron or
other low class iron, and from 1 cwt. to 5 cwt. of Indian, Greek, or other iron of
similar nature with the other ingredients, as above stated, but with somewhat less
or more in quantity in proportion to the quality of iron used with the process, as
before described.
The quantity of Indian, Greek, or other iron of similar nature to be used in
combination with the Cleveland or other iron referred to will be regulated by the
quality of steel desired to be produced.
For the production of refined iron I combine about 1 ton of Cleveland or other
low class iron, and from 1 cwt. to 3 cwt. of Indian, Greek, or other iron of a similar
nature, and they are melted together to a high temperature, say to a cast steel heat,
and after the iron has been reduced to a liquid state the heat is increased and the
liquid allowed to remain in the furnace for from one and a half to two hours, as
may be desired. It is then run off into ingots to be subsequently hammered,
squeezed, rolled, or used for castings, as desired.
Having thus described and ascertained the nature of the said Invention, and the
manner in which the same is to be performed, I would observe in conclusion that
what I consider novel and original, and therefore claim as constituting the Invention
secured to me by the said hercin-before in part recited Letters Patent are,-
First. The manufacture of steel by the treatment of iron and iron ores, substan-
tially as herein-before described and set forth.
And, Secondly. The refinement and purification of iron in the manner and by
the treatment substantially as herein-before described and set forth.
In witness whereof, I, the said John Perry Downing, have hereunto set my ;
hand and seal, this Twenty-fourth day of December, in the year of our
Lord One thousand eight hundred and seventy-eight..
JOHN PERRY DOWNING. (L.S.)
As sole acting executor of John Perry Downing, deceased.
Witness to the signing hereof
by the above-named John
Perry Downing,
ADOLPH MAN,
Merchant,
Newcastle-upon-Tyne.