A New Process and Apparatus for the Direct Production of Iron and other Metals from their Ores.
Year: 1896

page_text: Date of Application, 20th Mar., 1890
Complete Specification Left. 22nd Dec.. 1896-Accented. 25th May 1807
GULI
mar., Toyo
Complete Specification Left. 22nd Dec.. 1896-Accepted 25th May 1807
FRUTACIONAL DE PUIFICATION.
A New Process and Apparatus for the Direct Production of Iron
and other Metals from their Ores.
We, ALEXANDER KARYSCHEFF, Imperial Russian State Councillor, and
SERGEI DEMMENIE, Imperial Russian College Assessor both of St. Petersburg,
Russia, do hereby declare the nature of this invention to be as follows:-
This invention relates to a new pyrochemical process capable of industrial
application for producing iron, chromium, and analogous metals, such as cobalt,
nickel, manganese, wolfram, molybdenum, uranium &c. from their combinations
with oxygen, sulphur, arsenic, and the like; in other words, a new metallurgical
process for obtaining the said metals and alloys thereof direct from the natural
ores and from the waste products of factories, without its being necessary to resort
to the production of any intermediate compound or alloy.
The said process also involves the construction of a new description of
metallurgical furnace.
The study of pyrochemical solutions, that is to say, solutions in which a body is
dissolved in another rendered liquid by heat, leads to the conviction that the bodies
contained therein, whether of a chemically simple or of a compound nature, will
have assumed a gas like nature, that is, they have become greatly rarified. The
measure of such rarification can be increased in three different ways, namely:-
Firstly, by increase of the temperature of the solution, Secondly, by the action of
chemical reagents, and, Thirdly, by the joint action of electricity. Of course these
agents can be employed either separately or in conjunction with each other. Thus
for example the reduction of oxide of iron (or other soluble oxides) dissolved in
molten silicates, can be effected by raising the temperature to the point of
dissociation; but the same result can be obtained at a much lower temperature if
certain chemical reagents or electricity are employed, or if all three agents are
employed simultaneously.
The essential feature of the present invention consists in effecting the decom-
position or reduction of the metallic compounds by converting these into the
condition of pyrochemical solutions which are then further subjected to the action
either of heat energy, or of chemical energy, or of electrical energy, or to the
combined action of all these.
It is to be observed that the action of chemical reagents is much more intense if
these reagents are at the same time in a pyrochemically dissolved or gas like
condition, on this account, in the processes proposed by us all reagents employed
for the reduction of the metal are used as pyrochemical solutions.
Our pyrochemical process can be applied to all metals and alloys. For the sake
of clearness we will in the following, describe its application to the production of
metallic iron.
From the above it will be seen how indispensable it is, for reducing iron by our
said process to introduce into the furnace charge materials of such a nature that
all the inert gangue or other bodies combined with the oxide or other compounds
of the iron shall be thereby made to form during the melting process a compound,
which, together, with the other materials introduced with the ore, shall constitute
a body in which metallic mixture contained in the ore can be dissolved. It is

page_text: obvious that in preparing the charge of ore regard must be had to the acid or basic
nature of the furnace walls and bed, that is, to the lining of the furnace within
which the chemical reactions are to take place.
It will also be obvious that in forming the mass to be treated care must be taken
to choose such materials that are, on the one hand, cheap, and that, on the other
hand will form easily fusible compounds or slags in the furnace.
For a basic furnace, for instance, the charge is so arranged as to produce
pyroxenes which will readily dissolve oxide of iron (Fe2O3). The most readily
fusible pyroxene is hedenbergite (Ca, Fe) O, SiO,; if however the slags are to be
applied to other purposes, such, for example, as for ornamentation, the translucent
green or yellow diopside (Ca, Mg) 0, SiO,, can be used, or augite (Ca, Mg, Fe)
O, SiO2, which is also translucent and black or dark green.
A fine appearance is also possessed by diolog, distinguished by strongly irridescent
mother-of-pearl lustre, its laminated structure, and greenish grey enamel produced
on being rapidly cooled; its composition is :-SiO, 50-2 p.c.; Al2O3:
= 3.8 p.c.;
CaO = 20-26 pc.; MgO = 164 p.c.; FeO = 84 p.c. If Al,O, predominates in
the ore, there are formed, by the addition of CaO, calcium aluminates which also
dissolve the iron oxide (FeO3).
If on the other hand the furnace lining is of an acid nature, the SiO, contained
in the ore is converted by an addition of suitable substances into Na₂O, 8 CaO,
33 SiO,.
If the ore contains phosphorus compounds, which deteriorate the value of the
metal, dolomite is added to the charge in order to produce so called "Thomas"
slags, which have the known effect of improving the product, or other vitreous
compounds containing phosphorous are employed such as libenite, (FeCaO, P,O,
HO) which contains about 30 p.c. phosphoric acid; or phosphorecalcite, con-
taining 20 p.c. phosphoric acid, or any other similar compound.
With a proper preparation of the charge it is easy to convert all deleterious
admixtures into slags, and obtain metals of excellent qualities. As the composition
of the ore is very varied, the charge must also be correspondingly varied in its
composition; we will therefore limit ourselves to the above general explanations
which may serve as guides for the preparation of the charges.
We have explained above, that for the complete decomposition of the dissolved
bodies, heat-energy alone will suffice if the temperature of the furnace is raised.
to the dissociation limit. As these conditions are however not easily attained in
practice, it is necessary to assist the heat energy by the application of chemical
energy. From the chemical point of view our process consists:-
1. In the conversion of the compound to be treated into a dissolved condition.
2. The conversion also of the reagents into a dissolved or gas like condition.
3. The final reaction producing reduced metal.
The production of the reagents constitutes the principal part of the process; it
can be varied according to the special circumstances of each particular case; in
most cases however carbon in gaseous form, will constitute the reagent. We will
therefore here consider exclusively the production of this material as reagent,
which will sufficiently explain the general bearing of the process.
The charge employed with the reagent used in our furnace is prepared as
follows: The various metallic ores, together with their fluxes and with the
addition of a small quantity of carbon (in form of charcoal &c.) are made up
in the following proportions; according to the furnace temperature, the charge
requires an addition of carbon to the extent of from th to th the quantity
required for the conversion of the oxygen contained in the metallic oxides into
carbon di-oxide.
The higher the furnace temperature is, the smaller is the necessary proportion
of added carbon; as if it were possible to attain the dissociation temperature then,
as above explained, no addition of carbon would be necessary.
In addition, there must always remain from the previous operation, on the furnace
bed a small quantity of metals saturated with carbon.

page_text: The atmosphere of that section of the furnace in which the reagent is prepared
must be of a reducing nature; if it is not, the charge must be protected against the
exidizing flame by means of an isolating covering. Under these conditions the
production of the reagent takes place rapidly and energetically.
The dissolved metallic compounds act at the high temperature employed
energetically upon the gaseous carbon of the alloy containing carbon on the bed
of the furnace; they become reduced and are saturated with carbon on coming in
contact herewith, thus nequiring the property of acting in a reducing manner upon
the next following portions of the ore. In proportion as the quantity of metal
saturated with carbon increases, the reaction becomes more and more energetic;
the reduced metals collect on the bottom of the bed and the slugs, perfectly free
from metal, float on the top thereof. The reaction continues uninterruptedly if
the metals saturated with carbon flow off continuously towards the middle part of
the furnace, the excess of slag being uninterruptedly discharged from the furnace,
and new quantities of the charge being fed forward.
Our reagent consists therefore of nothing else than the metals to be worked
themselves or of other metals, but which are reduced, saturated with carbon, and
melted, that is to say, which contain carbon in gaseous form.
It would be wrong
to imagine that this reagent was cast iron; it is an alloy of iron and other metals,
which serves the purpose of dissolving a maximum quantity of carbon, the
metals of the reagent being regarded as useful addition to the article of
manufacture.
Thus for instance for iron the reagent can contain considerable quantities of
manganese chromium or wolfram, which increase the good properties of the iron
and also favour the formation of alloys rich in carbon. The obtaining of the
definite product is effected with the assistance of this reagent in a very effective
and rapid manner, as the metallic compounds contained in the solution in a gaslike
condition act energetically upon the carbon also in gaseous condition, of the
reagent, being themselves subject to the reduction process and freeing the reagent
from its carbon.
With this reaction the temperature rises considerably and the overheated metal
being very liquid can be readily cast in moulds. The quality of the metal can be
casily regulated as this results from the reciprocal reaction of two liquids of known
composition.
In
As already stated, electrical energy may also be employed in addition to chemical
energy for more easily effecting the reduction of the metals by thermal energy.
this case the part played by the electrical energy is somewhat different from that
of electrolysis; in the latter case the complete decomposition of a chemical solution
is effected by the passing of a current of electricity through it, whereas in the
present case the substance treated is already, owing to the high temperature, in a
state of tension, so that it only requires a comparatively small additional action to
effect the dissociation.
This assistance is rendered by the application of electrical energy.
In the present case the electricity can be applied not only in the dynamic form,
but also in the static condition. In practice it is advantageous to employ
transformers of very high tension, the anodes being put in connection with the
slag and the cathodes with the furnace bed, which for this purpose is made of an
electrical conductor such as graphite.
The current generated in the transformer is so regulated that from the one side
of the electrodes there issues an electrical discharge and from the other side a dark
discharge.
For this purpose suitable resistances are introduced into the circuit which
prevent the development of the return induction current (closing current) of less
high tension, an extraordinary great number of interruptions per second being
effected by means of an interrupter. By this means only the direct or opening
current is made to circulate through the circuit, which offers all the characteristics
of polarity and high tension,

page_text: asca, WI Cerca alterations, any
kind of smelting furnace provided that it can produce a sufficiently high
temperature.
But for more readily carrying out the process, we employ a furnace of special
construction, such as is shewn on the accompanying drawings, which as will be
presently described allows of the process and the manipulations for carrying it out
to be varied according to necessity.
Figure 1 shews a vertical section of the furnace on line 1-1 Figure 5.
Figure 2 is a horizontal section on line 2-2 Figures 3 and 6.
Figure 3 is a vertical section on line 3-3 Figure 5.
Figure 4 is a vertical section on line 4-4 Figure 2.
Figure 5 is a horizontal section on line 5-5 Figure 1.
Figure 6 is a vertical section on line 6-6-6 Figure 5.
Figure 7 is a front view of the furnace.
Figure 8 a plan of one half thereof.
Figure 9 a side view of the furnace.
The same parts are indicated by the same letters of reference in all the figures;.
the direction of the gases are indicated by the feathered arrows, and the direction
of the air by the non-feathered arrows.
The furnace is constructed on the regenerative system.
It consists of five chambers namely three large ones 'K. L. K', which are
separated from each other at their upper parts by two smaller ones M M' which
are always quite full of carbonaceous material but the beds of the three large
chambers all communicate with each other.
A A' are gas producers worked with wood, coal, or coke. B B' B' and B' B* B°
are gas regenerators, CC air regenerators.
The regenerators C C contain retorts D, D, D', D1, Figures 2 and 6 of cast iron
or refractory material, which have a grating-like bottom and are closed at top by
a cover with pipes d d', passing through the wall of the regenerators.
The retorts are filled with compounds generating oxygen, to be presently
described. E E1 Figure 4 are reversing valves, the first one for gas and the
second for air; by reversing the positions of these valves the direction of the
gaseous currents can be reversed. e el are flues for the gases and ee flues for
the air; these four flues establish, by means of the valves E E' a communication
between the regenerators and the chimney.
The dampers ffff" serve for regulating the draught through the air and gas
regenerators.
From the regenerators the gas passes through the flues g, gl alternately into the
two large lateral chambers K K', the air enters through openings h h between the
double arches of the middle large chamber L. F F are cast iron apparatus
cooled by water which enables the gas regenerators B B to be put in communica-
tion at will either with the producers A A' or with the regenerators B B, by
means of the channels a a¹ or bb. The openings i Figures 2 and 7 serve
for the introduction of an injector or a pipe for supplying naphtha to the
regenerators B B³.
The gas producers A. A' are supplied with fuel through the feed hopper k k'.
The gas enters through the channels Figure 6 from the producers into the
brick uptakes G G₁ from which it passes through the channels m m' into the
regenerators B B³.
The uptakes G G communicate with each other by means of the iron pipes H
which on the other hand are connected by the pipe I with the gas valve E. The
channels and m m' can be hermetically closed by the dampers n n¹ and o o'.
In the communicating pipe H for the gas are provided valves p p by means of
which the gas producers can be separated from each other, and a slide q Figures 1.
4. 7 and also enables the communication between the producers and the
apparatus E to be cut off.
In the middle chamber L the definite product is prepared, which flows off from

page_text: the direction of the gases, the first generator A¹, which was cooled, is now supplied
with air, while the second A is supplied with superheated steam. In this way both
producers alternately supply water gas and ordinary producer gas, while a mixture
of both passes continuously into the furnace.

page_text: In place of the ordinary producer gases, acetylene can be generated in the
producers from calcium carbide in the following manner.
We close the openings 6 b', and the valves of the apparatus F F¹ receive the
position shewn for F' on the drawing.
The combustion products, after passing through the regenerators, are made to
enter the producer A through the channels and m, and to pass from the ash pit
thereof into the regenerator B2, and thence to the chimney.
The producer is not filled with ordinary fuel but with small blocks formed of a
compressed mixture of lime and carbon powder. When heated by the combustion
gases passing through, this mixture will produce calcium carbide. At the same
time the calcium carbide generated in the other producer in the same manner is
decomposed by means of superheated steam, which, after passing through the
regenerator B and the apparatus F into the ash pit of the producer, enters
through the apparatus E; by the decomposition of the calcium carbide, acetylene
is obtained which enters the furnace through the regenerators B, and B.
11
The caustic lime produced by this reaction will trickle through the grate
openings of the producers and serves again for the manufacture of the before
mentioned small blocks serving for the production of the calcium carbide.
Consequently the lime is nct used up but serves solely for producing acetylene
directly from carbon and steam.
With regard to this heating combination, the following must be observed :-
1. For the production of calcium carbide a very high temperature is required
(about 3500° C.) but the temperature of the gases escaping from our furnace in
the sixth heating combination, and in using air having a large percentage of oxygen
mixed with it, will be more than sufficient for producing such a degree of heat,
and consequently the production of acetylene will be effectually carried out, of
course under the assumption that the producers are placed in the neighbourhood of
the point where the combustion gases issue.
2. At the temperature of the gases issuing from the furnace the calcium carbide
is not only formed but also melted, and in dropping down upon the still unmelted
carbon and lime blocks, it offers a large surface to the following reaction of the
steam, whereby the production of the acetylene is considerably facilitated.
3. The degree of heat produced by the combustion of acetylene is so great that
in order to utilise it, it is very advantageous to introduce into the furnace also a
portion of the hot combustion gases containing dioxide. The latter will then be
decomposed and the carbon mono-oxide produced will form a supplemental heating
medium, while the liberated oxygen will assist in the combustion of the acetylene.
SEVENTH HEATING COMBINATION.
It is very easy to lead half of the combustion gases from the furnace under the
grates of the gas producers, in order to again convert them into producer gases at
the expense of the fuel, and of the heat contained in them.
If the channels u u¹ are closed, and a communication be established between the
ash pits of the producers, and a steam jet exhauster of refractory material be
arranged in the openings b b1, the combustion products can be drawn from the
regenerator B, and forced into the producers, the gas evolved in the producers
being delivered through the channels into the common gas main, and from
there they pass through the channel m into the regenerator B3 B and thence into
the furnace, channel in being closed.
The other half of the combustion products pass away to the chimney through
the air regenerators in the usual manner.

page_text: EIGHTH HEATING COMBINATION.
Each of the openings serves to receive a pipe which supplies naptha from
a reservoir or from an injector. If naptha be injected without air supply, into the
regenerator through which, at the time, the producer gas is passing to the furnace
as above described, the naptha will not only be readily volatilised, but it is also
converted into naptha gas at the cost of some of the large quantity of heat stored
in the regenerator.
It is evident that such a heating process affords the possibility of regulating the
working of the furnace within the widest limits and if necessary, to produce an
extraordinarily high temperature in the furnace (which could not possibly be
produced in ordinary furnaces) by the exclusive use of oxygen and a mixture of
water gas and acetylene or naptha gas.
In addition as will be seen from the above description the utilization of the heat
of the furnace is much more perfect than in ordinary furnaces, as all the heat '
which is ordinarily lost, is utilised for heating air and gas for the furnace and air
or steam for the producers, as also for the production of oxygen and acetylene and
the decomposition of naptha.
From the above description of the circulation of the gases it will be seen that
the lateral furnace chambers K K' are always filled with reducing gases, the one
chamber being alternately always filled with the gases that pass from the producer
into the middle chamber L while the other one will be filled with the combustion
gases from the chamber L, which in passing through the carbon of the intermediate
chamber M or M' will have become decomposed.
The central chamber L in which combustion takes place, and in which the
highest temperature is reached, has an oxidyzing atmosphere.
The temperature of the side furnace-chambers K K', which depends on the
degree to which the gases in the regenerators are heated, may also be highly
increased or intensified, without any difficulty according to requirement, by means
of the partial combustion of the gas traversing the same, said combustion being
effected by means of the air which is to be introduced as desired through the
openings in the roof.
In the side chambers the ores are reduced at the expense of the reducing gases
of these furnaces and of the carbon that has been added to the charge, in the
presence also of the molten carbonaceous alloys as has already been explained
hereinbefore.
The reduced and carburetted or carburized ("saturated with carbon") alloys
(reagents) produced in the side furnace chambers, flow, in the same measure as
they are formed, through the openings v, v¹ into the cavity of the chambers M M',
said cavity being still filled with carbon. Here, in the said cavity and in direct
contact with the incandescent carbon, the said alloys combine with said incandescent
carbon up to the point of saturation (if this point has not been previously
completely reached, or if said alloys have already again lost a part of their
carbon) and flow continuously through the window-openings u u¹ into the central
chamber.
On account of its smaller specific gravity the slag formed in the side chambers K K',
cannot pass into the central chamber; it accumulates up to a certain level, and
when this level is reached, the slag is tapped or removed through special openings
provided in the wall of the furnace for this purpose.
The charge introduced into the central chamber L melts, and the metallic
compounds that are contained in a dissolved gaseous state in the slag, act upon the
gaseous carbon of the reagent which is flowing from out of the side chambers,
with the result that the former are reduced, and the latter are decarburized.
As the temperature of all the chambers can be easily regulated, no difficulty
whatever will be experienced in effecting the reduction and the other reactions
under the very most favourable conditions for this purpose.

page_text: As already hereinbefore stated, the floors and walls of the furnaces may be
basic or acid according to requirement. It is however preferable to employ a
neutral material for these, such as graphite, which, when it is protected from
direct contact with air, behaves entirely neutral. A hearth composed of graphite-
mass is extremely durable.
As our side chambers K K' are constantly filled up to a certain level with charge
and slag, that is to say, are constantly protected from contact with or the entrance
of air, we construct these furnaces with their internal surface lined or coated with
slabs or plates of graphite up to the said level.
The central chamber L is lined with dolomite which is supported on a foundation
of chrome-iron rock or ore.
Generally, any fire resisting material can be employed in the construction of
our furnace, but it must be of a very good quality in view of the very high
temperatures which it will have to withstand.
With respect to the arrangement and working of the furnace, we think it well
to add the following:-
1. The drawings show merely the general type or idea of our furnace which
differs by its construction and arrangement very essentially from other metallurgical
furnaces. The details of the construction of the same may be modified. Many
of such modifications may be readily foreshadowed, and may be specially mentioned
here. Thus, for instance, instead of the flaps F. F and of the dampers n, 1, 0, o¹,
an apparatus, common to all might very easily be provided. It would be easy to
arrange the generators, not on the side of the outflow, but on the opposite side;
this would be an advantage in certain cases. The charging hoppers in the roof
might be arranged to operate automatically; and so on.
Unimportant modifications of details might be effected without end; but the
general type or idea of the whole apparatus, and its essential parts will remain
unaltered. Thus it is for that reason that we have illustrated the essential features
of the apparatus in the drawings, and have not thought it necessary to show in the
same the less important modifications of details that we have had in mind and
intend to make.
2. With respect to an essential part of our furnace, namely, of the side
chambers K K, whose atmosphere acts with a reducing effect, we think that it is
absolutely necessary to add the following:-
These chambers are shewn in the drawings as of small height, although in some
cases, dependent on the local conditions, the properties of the ores and metals to
be treated, the force of the draught or of the suction &c., the height of the
chambers may be increased until they become actual shaft furnaces. This
Inodification would be a very important one, although it would not nevertheless be
a departure from the principle of our furnace, for which reason we have not
annexed hereto any drawings on this point, as we are of opinion that what has
been said here is sufficient.
3. It would be easy to combine two of our furnaces longitudinally so as to form
one common furnace with two parallel rows of chambers K, L, K', and each having
a tap hole ou opposite sides.
A modification of this kind of our construction would be very suitable in many
cases, because with greater compactness, the apparatus is less costly, and the
efficiency is increased.
Dated this 26th day of March 1896.
ABEL & IMRAY,
Agents for the Applicants.

page_text: A New Process and Apparatus for the Direct Production of Iron and
other Metals from their Ores.
We, ALEXANDER KARYSCHEFF, Imperial Russian State Councillor, and
SERGEI DEMMENIE, Imperial Russian College Assessor, both of St. Petersburgh,
Russia, do hereby declare the nature of this 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 relates to a new pyrochemical process capable of industrial
application for producing iron, chromium, and analogous metals, such as cobalt,
nickel, manganese, wolfram, molybdenium, uranium &c. from their combinations
with oxygen, sulphur, arsenic, and the like, in other words, a new metallurgical
process for obtaining the said metals and alloys thereof direct from the natural ores
and from the waste products of factories, without its being necessary to resort to the
production of any intermediate compound or alloy.
The said process also involves the construction of a new description of
metallurgical furnace.
The study of pyrochemical solutions, that is to say, solutions in which a body
is dissolved in another rendered liquid by heat, leads to the conviction that the
bodies contained therein, whether of a chemically simple or of a compound nature,
will have assumed a gas like nature, that is, they have become greatly rarified.
The measure of such rarification can be increased in three different ways, namely:
Firstly, by increase of the temperature of the solution, secondly, by the action of
chemical reagents, and, thirdly, by the joint action of electricity. Of course
these agents can be employed either separately or in conjunction with each other.
Thus for example the reduction of oxide of iron (or other soluble oxides) dissolved
in molten silicates, can be effected by raising the temperature to the point of
dissociation; but the same result cau be obtained at a much lower temperature if
certain chemical reagents or electricity are employed, or if all three agents are
employed simultaneously.
. The essential feature of the present invention consists in effecting the decom-
position or reduction of the metallic compounds by converting these into the
condition of pyrochemical solutions which are then further subjected to the action
either of heat energy, or of chemical energy, or of electrical energy, or to the
combined action of all these.
It is to be observed that the action of chemical reagents is much more intense
if these reagents are at the same time in a pyrochemically dissolved or gas like
condition, on this account, in the processes proposed by us all reagents employed
for the reduction of the metal are used as pyrochemical solutions.
Our pyrochemical process can be applied to all metals and alloys. For the sake
of clearness we will in the following, describe its application to the production of
metallic iron.
From the above it will be seen how indispensable it is, for reducing iron by our
said process to introduce into the furnace charge materials, of euch a nature that
all the inert gangue or other bodies combined with the oxide or other compounds
of the iron shall be thereby made to form during the melting process a compound,
which, together with the other materials introduced with the ore, shall constitute
a body in which metallic mixture contained in the ore can be dissolved. It is
obvious that in preparing the charge of ore regard must be had to the acid or basic
nature of the furnace walls and bed, that is, to the lining of the furnace within
which the chemical reactions are to take place.

page_text: It will also be obvious that in forming the mass to be treated care must be
taken to choose such materials that are, on the one hand, cheap, and that, on the
other hand will form casily fusible compounds or slags in the furnace.
For a basic furnace, for instance, the charge is so arranged as to produce
pyroxenes which will readily dissolve oxide of iron (Fe2O3). The most readily
fusible pyroxene is hedenbergite (Ca, Fe) O, SiO,, if however the slags are to be
applied to other purposes, such, for example, as for ornamentation, the translucent
green or yellow diopside (Ca, Mg) O, SiO,, can be used, or augite (Ca, Mg, Fe)
O, SiO,, which is also translucent and black or dark green.
A fine appearance is also possessed by diolog, distinguished by strongly
irridescent mother-of-pearl lustre, its laminated structure, and greenish grey enamel
produced on being rapidly cooled; its composition is: SiO2 = 502 p.c.; Al,O=
3.8 p.c.; CaO = 20-26 p.c.; MgO = 16-4 p.c.; FeO 8.4 p.c. If Al,Os
predominates in the ore, there are formed, by the addition of CaO, calcium
aluminates which also dissolve the iron oxide (Fe,O).
If on the other hand the furnace lining is of an acid nature, the SiO, contained
in the ore is converted by an addition of suitable substances into Na,O,CaO,
33 SiO,.
If the ore contains phosphorus compounds which deteriorate the value of the
metal, dolomite is added to the charge in order to produce so-called "Thomas"
slags, which have the known effect of improving the product, or other vitreous
compounds containing phosphorus are employed such as libenite (FeCaO, P,O,
H,O) which contains about 30 p.c. phosphoric acid; or phosphorecalcite, con-
taining 20 p.c. phosphoric acid, or any other similar compound.
With a proper preparation of the charge it is easy to convert all deleterious
admixtures into slags, and obtain metals of excellent qualities. As the composition
of the ore is very varied, the charge must also be correspondingly varied in its
composition.
The following may be taken as an example of the charge for a basic furnace:
Taking iron ore having the composition Fe = 44.25%, Mn = 1.77%₁ SiO, =
1360o, Al,O,= 1•86, CaO = 0-13, Ph=007, H,O 17,17,, K,O +
N₂O 110% and the slags to be produced are to have a composition corre-
sponding to diopside MgO.CaO. 2 SiO, where the bases MgO and CaO are replaced
by K,O and Na,O and the SiO, by Al,O, and P,O,, then in order to obtain such
a slag it will be necessary to use for each 100 parts (by weight) of said ore, 25 parts
of dolomite of the following composition CO₂ = 46-40% SiO, = 0.85%, A1,0,
+ FeO, = 140%, CaO = 3200%, MgO 19.40%. This charge gives a rather
refractory slag which can be made more fusible by replacing a portion of the
dolomite by CaCO.
=
Our experiments have shown that with the indicated amount of SiO2, the most
advantageous proportion between MgO and CaO in the charge is obtained if 10 parts
(by weight) of the dolomite are replaced by an equal amount of limestone having
the following composition CaO = 52.58% Mg = 1.58%, Fe = 0.51%, A1,0₁
= 0.12%, SiO=0.17%, CO, = 43.06%
If the reaction takes place quickly owing to the rapid formation of hot fluid
solvents, (as is the case of the artificial diopside mentioned as well as in other
modifications of the very large pyroxene group) it is advisable to replace a portion
of the SiO, by oxide of aluminium and a portion of the CaO and MgO by a small
quantity of KO and Na,O or preferably by Na,O,SiO,. This latter is produced
automatically in the furnace if NaCl is added in the presence of steam and of the
SO, contained in the charge.
We have explained above, that for the complete decomposition of the dissolved
bodies, heat-energy alone will suffice if the temperature of the furnace is raised to
the dissociation limit. As these conditions are however not easily attained in
practice, it is necessary to assist the heat energy by the application of chemical.
energy. From the chemical point of view our process consists:-
1. In the conversion of the compound to be treated into a dissolved condition.

page_text: 2. The conversion also of the reagents into a dissolved or gas like condition.
3. The final reaction producing reduced metal.
The production of the reagents constitutes the principal part of the process; it
can be varied according to the special circumstances of each particular case; in
most cases however carbon in gaseous form, will constitute the reagent. We will
therefore here consider exclusively the production of this material as reagent, which
will sufficiently explain the general bearing of the process.
The charge employed with the reagent used in our furnace is prepared as
follows: The various metallic ores, together with their fluxes and with the
addition of a small quantity of carbon (in form of charcoal &c.) are made up in the
following proportions; according to the furnace temperature, the charge requires
an addition of carbon to the extent of from th to Toth the quantity required for
the conversion of the oxygen contained in the metallic oxides into carbon di-oxide.
The higher the furnace temperature is, the smaller is the necessary proportion
of added carbon; as if it were. possible to attain the dissociation temperature
then, as above explained, no addition of carbon would be necessary.
In addition, there must always remain from the previous operation, on the
furnace bed a small quantity of metals saturated with carbon.
The atmosphere of that section of the furnace in which the reagent is prepared
must be of a reducing nature; if it is not, the charge must be protected against
the oxidizing flame by means of an isolating covering. Under these conditions
the production of the reagent takes place rapidly and energetically.
The dissolved metallic compounds act at the high temperature employed
energetically upon the gaseous carbon of the alloy containing carbon on the
bed of the furnace they become reduced and are saturated with carbon on
coming in contact herewith, thus acquiring the property of acting in a reducing
manner upon the next following portions of the ore. In proportion as the quantity
of metal saturated with carbon increases, the reaction becomes more and more
energetic; the reduced metals collect on the bottom of the bed and the slags,
preferably free from metal, float on the top thereof. The reaction continues
uninterruptedly if the metals saturated with carbon flow off continuously towards
the middle part of the furnace, the excess of slag being uninterruptedly discharged
from the furnace, and new quantities of the charge being fed forward.
Our reagent consists therefore of nothing else than the metals to be worked
themselves or of other metals, but which are reduced, saturated with carbon, and
melted, that is to say, which contain carbon in gaseous form. It would be wrong
to imagine that this reagent was cast iron; it is an alloy of iron and other metals,
which serves the purpose of dissolving a maximum quantity of carbon, the
metals of the reagent being regarded as useful addition to the article of
manufacture.
Thus for instance for iron the reagent can contain considerable quantities of
manganese chromium or wolfram, which increase the good properties of the iron
and also favour the formation of alloys rich in carbon. The obtaining of the
definite product is effected with the assistance of this reagent in a very effective
and rapid mauner, as the metallic compounds contained in the solution in a gas
like condition act energetically upon the carbon also in gaseous condition, of the
reagent, being themselves subject to the reduction process and freeing the reagent
from its carbon.
With this reaction the temperature rises considerably and the overheated metal
being very liquid can be readily cast in moulds. The quality of the metal can be
easily regulated as this results from the reciprocal reaction of two liquids of known
composition.
As already stated, electrical energy may also be employed in addition to
chemical energy for more easily effecting the reduction of the metals by thermal
energy. In this case the part played by the electrical energy somewhat different
from that of electrolysis; in the latter case the complete decomposition of a
chemical solution is effected by the passing of a current of electricity, through it,

page_text: whereas in the present case the surostance
temperature, in a state of tension, so that it only requires a comparatively small
additional action to effect the dissociation.
This assistance is rendered by the application of electrical energy.
In the present case the electricity can be applied not only in the dynamic form,
but also in the static condition. In practice it is advantageous to employ trans-
formers of very high tension, the anodes being put in connection with the slag
and the cathodes with the furnace bed, which for this purpose is made of an
electrical conductor such as graphite.
The current generated in the transformer is so regulated that from the one side
of the electrodes there issues an electrical discharge and from the other side a
dark discharge.
For this purpose suitable resistances are introduced into the circuit which
prevent the development of the return induction current (closing current) of less
high tension, an extraordinary great number of interruptions per second being
effected by means of an interrupter. By this means only the direct or opening
current is made to circulate through the circuit, which offers all the characteristics
of polarity and high tension.
For carrying out our said process may be used, with certain alterations, any
kind of smelting furnace provided that it can produce a sufficiently high
temperature.
But for more readily carrying out the process, we employ a furnace of special
construction, such as is shewn on the drawings accompanying our Provisional
Specification, which as will be presently described allows of the process and the
manipulations for carrying it out to be varied according to necessity.
Figure 1 shews a vertical section of the furnace on line 1-1 Figure 5.
Figure 2 is a horizontal section on line 2-2 Figures 3 and 6.
Figure 3 is a vertical section on line 3-3 Figure 5.
Figure 4 is a vertical section on line 4-4 Figure 2.
Figure 5 is a horizontal section on line 5-5 Figure 1.
Figure 6 is a vertical section on line 6-6-6 Figure 5.
Figure 7 is a front view of the furnace.
Figure 8 a plan of one half thereof.
Figure 9 a side view of the furnace.
The same parts are indicated by the same letters of reference in all the figures.
the direction of the gases are indicated by the feathered arrows, and the direction
of the air by the non-feathered arrows.
The furnace is constructed on the regenerative system.
It consists of five chambers namely three large ones K, L, K', which are separated
from each other at their upper parts by two smaller ones M M which are always
quite full of carbonaceous material but the beds of the three large chambers all
communicate with each other.
A A' are gas producers worked with wood, coal, or coke. B, B1, B2 and
B B B are gas regenerators, C C' air regenerators.
The regenerators C C contain retorts D, D, D', D', Figures 2 and 6 of cast
iron or retractory material, which have a grating-like bottom and are closed at top
by a cover with pipes d d', passing through the wall of the regenerators.
The retorts are filled with compounds generating oxygen, to be presently
described. E, E Figure 4 are reversing valves, the first one for gas and the
second for air; by reversing the positions of these valves the direction of the
gaseous currents can be reversed. e e¹ are flues for the gases and ee Hues for
the air; these four flues establish, by means of the valves E E¹ a communication
between the regenerators and the chimney.
The dampers f¹ƒ ƒ serve for regulating the draught through the air and gas
regenerators.
From the regenerators the gas passes through the flues go alternately into the
two large lateral chambers K K₁, the air enters through openings between

page_text: the double arches of the middle large chamber L. F F are cast iron apparatus
cooled by water which enables the gas regencretors B2 B3 to be put in communica-
tion at will either with the producers A A¹ or with the regenerators B B by
means of the channels a a¹ or bb. The openings i Figures 2 and 7 serve
for the introduction of an injector or a pipe for supplying naptha to the
regenerators B B
The gas producers A A' are supplied with fuel through the feed hopper kk.
The gas enters through the channels Figure 6 from the producers into the
brick uptakes G G from which it passes through the channels m m' into the
regenerators B B³.
The uptakes G G communicate with each other by means of the iron pipes H
which on the other hand are connected by the pipe I with the gas valve E. The
channels and m,m' can be hermetically closed by the dampers a n' and oo'.
In the communicating pipe H for the gas are provided valves p p by means of
which the gas producers can be separated from each other, and a slide g Figures 1, 4,
7 and 9 also enables the communication between the producers and the apparatus E
to be cut off.
In the middle chamber L the definite product is prepared, which flows off from
the furnace through the tap hole and shoot N; in the two lateral large
chambers K K are produced the reagents.
The introduction of the charges into the three large chambers KL K' is effected
through the openings 00'0' in the roofs thereof; the charging of the
chambers M M with carbon is effected through the openings P P.
The doors QQ Q allow of access to the furnace when the bed requires to be
reliued, ne also generally for repairs, &c.
The air spaces between the superposed arches of the lateral chambers K K' du
not communicate with the air regenerators but directly with the atmosphere and
through the openings as also with the chambers K K
Within the furnace the gases flow from one compartment into the other through
the channels and ww, while the reagents from the lateral chambers K K³ pass
into the middle one L through the openings vv.
The space R below the furnace bed serves to receive any metal that may escape
through the bed, and to protect the regenerators.
The reversing valves E E' are so arranged that the gases are made to flow in
the direction of the arrows.
The regulating valves, of the apparatus remain open.
The following eight heating combinations serve to illustrate the different
operations that may be carried out with the same construction of furnace and are
not intended to form successive steps of a continuous process.
FIRST HEATING COMBINATION.
The producers communicate with each other and are closed to the gas valve E
(the slide g being closed). Air enters through the two reversing valves.
From the apparatus E the air passes through the regenerators C' into the
furuace into which it enters from the opening A' in the roof.
From the apparatus E the air, after having passed through the regenerator B
and become heated, passes into the closed ash pit of the gas producers A A' from
the apparatus F. The ashpits are connected together by means of pipe not
shewn in the drawings. In this way the producers work with a heated air supply,
in consequence of which, as is known, the quantity of carbon dioxide in the
producer gas is reduced. From the producers the gas flows into the regenerator B
(the slide o' is open, the slide o is closed) the slides n n remain always open, and
from thence into the furnace.
The combustion of the gas will only begin to take place in the middle chamber L
where the gas comes into contact with the air entering through the opening 4.
The products of combustion will partly pass from the furnace through the opening 4,

page_text: alkalies. If a current of atmospheric air be passed through this mass, the substances
contained therein, form some higher oxygen compounds which in their turn, on
treatment with super-heated steam, give off free oxygen, which is then led into the
furnace.
The retorts containing the said mixture are for this purpose heated by the
combustion gases from the furnace to the necessary temperature of about 350° C.
Air entering through the pipes d d passes simultaneously through the retorts,
which air gives up its oxygen to the mixture therein, while the nitrogen escapes
with the products of combustion to the chimney. Super-heated steam is then made
to enter the retorts D D, the charges of which are saturated with oxygen, so that
such oxygen passes off therefrom and enters the furnace through the regenerator C.
The air can be admitted through the valve E or can he entirely cut off, according
as a supply of oxygen-alone-or of air rich in oxygen is desired. In consequence of
the continuous alternation of taking up and giving off oxygen, the above mentioned
mixture will remain effective for a considerable length of time.
The degree to which the retorts are heated is observed through sight holes e in
the wall of the regenerator, the regulation of such heating is effected by regulating
the quantity of air supplied thereto and also by increasing and decreasing the
chimner draught by means of the slides ££1
In place of the ordinary producer gases, acetylene can be generated in the
producers from calcium carbide in the following manner :-
We close the openings 6 b', and the valves of the apparatus F F¹ receive the
position shewn for F on the drawing.
The combustion products, after passing through the regenerators, are made to
enter the producer A through the channels and m, and to pass from the ash pit
thereof into the regenerator B2, and thence to the chimney.
The producer is not filled with ordinary fuel but with small blocks formed of a
compressed mixture of lime and carbon powder. When heated by the combustion
gases passing through, this mixture will produce calcium carbide. At the same
time the calcium carbide generated in the other producer in the same manner is
decomposed by means of superheated steam, which after passing through the
regenerator B and the apparatus F' into the ash pit of the producer, enters
through the apparatus E, by the decomposition of the calcium carbide, acetylene
is obtained which enters the furnace through the regenerators B and B³.
The caustic lime produced by this reaction will trickle through the grate openings
of the producers and serves again for the manufacture of the before mentioned
small blocks serving for the production of the calcium carbide (consequently the
lime is not used up but serves solely for producing acetylene directly from carbon
and steam.
With regard to this heating combination the following must be observed.
1. For the production of calcium carbide a very high temperature is required
(about 3500° C.) but the temperature of the gases escaping from our furnace in the
sixth heating combination, and in using air having a large percentage of oxygen
mixed with it, will be more than sufficient for producing such a degree of heat, and
consequently the production of acetylene will be effectually carried out, of course
under the assumption that the producers are placed in the neighbourhood of the
point where the combustion gases issue.
2. At the temperature of the gases issuing from the furnace the calcium carbide
is not only formed but also melted, and in dropping down upon the still unmelted
carbon and lime blocks, it offers a large surface to the following reaction of the
steam, whereby the production of the acetylene is considerably facilitated.
3. The degree of heat produced by the combustion of acetylene is so great that
in order to utilise it, it is very advantageous to introduce into the furnace also a

page_text: portion of the hot combustion gases containing dioxide. The latter will then be
decomposed and the carbon mono-oxide produced will form a supplemental heating
medium, while the liberated oxygen will assist in the combustion of the acetylene.
SEVENTH HEATING COMBINATION.
It is very easy to lead half of the combustion gases from the furnace under the
grates of the gas producers in order to again convert them into producer gases at
the expense of the fuel, and of the heat contained in them.
If the channels u u¹ are closed, and a communication be established between the
ash pits of the producers, and a steam jet exhauster of refractory material be
arranged in the openings b', the combustion products can be drawn from the
regenerator B, and forced into the producers, the gas evolved in the producers
being delivered the channels into the common gas main, and from there they
pass through the channel m into the regenerator B³ B and thence into the furnace,
channel m being closed.
The other half of the combustion products pass away to the chimney through the
air regenerators in the usual manner.
EIGHTH HEATING COMBINATION.
Each of the openings i¹ serves to receive a pipe which supplies naptha from a
reservoir or from an injector. If naptha be injected without air supply, into the
regenerator through which, at the time, the producer gas is passing to the furnace
as above described, the naptha will not only be readily volatilised, but it is also
converted into naptha gas at the cost of some of the large quantity of beat stored
in the regenerator.
It is evident that such a heating process affords the possibility of regulating the
working of the furnace within the widest limits and if necessary, to produce an
extraordinarily high temperature in the furnace (which could not possibly be
produced in ordinary furnaces) by the exclusive use of oxygen and a mixture of
water gas and acetylene or naptha gas.
In addition as will be seen from the above description the utilization of the
heat of the furnace is much more perfect than in ordinary furnaces, as all the heat
which is ordinarily lost, is utilised for heating air and gas for the furnace and air
or steam for the producers, as also for the production of oxygen and acetylene and
the decomposition of naptha.
From the above description of the circulation of the gases it will be seen
that the lateral furnace chambers K K are always filled with reducing gases,
the one chamber being alternately always filled with the gases that pass from the
producer into the middle chamber L while the other one will be filled with
the combustion gases from the chamber L, which in passing through the carbon of
the intermediate chamber M or M' will have become decomposed.
The central chamber L in which combustion takes place, and in which the highest
temperature is reached, has an oxidyzing atmosphere.
The temperature of the side furnace,-chambers K K' which depends on the
degree to which the gases in the regenerators are heated, may also be highly
increased or intensified without any difficulty according to requirement by means of
the partial combustion of the gas traversing the same, said combustion being
effected by means of the air which is to be introduced as desired through the
openings ss in the roof.
In the side chambers the ores are reduced at the expense of the reducing gases
of these furnaces and of the carbon that has been added to the charge, in the
presence also of the molten carbonaceous alleys as has already been explained
hereinbefore.
The reduced and carburetted or carburized ("saturated with carbon") alloys
(reagents) produced in the side furnace chambers flow, in the same measure as they

page_text: are formed, through the openings into the cavity of the chambers M M', said
cavity being still filled with carbon. Here, in the said cavity and in direct contact
with the incandescent carbon, the said alloys combine with said incandescent carbon
up to the point of saturation (if this point has not been previously completely
reached, or if said alloys have already again lost a part of their carbon) and flow
continuously through the window openings u u' into the central chamber.
On account of its smaller specific gravity the slag formed in the side
chambers K K¹, cannot pass into the central chamber, it accumulates up to a
certain level, and when this level is reached, the slag is tapped or removed
through special openings provided in the wall of the furnace for this purpose.
The charge introduced into the central chamber L melts, and the metallic
compounds that are contained in a dissolved gaseous state in the slag, act upon the
gaseous carbon of the reagent which is flowing from out of the side chambers, with
the result that the former are reduced and the latter are decarburized.
As the temperature of all the chainbers can be easily regulated, no difficulty
whatever will be experienced in effecting the reduction and the other reactions
under the very most favourable conditions for this purpose.
As already hereinbefore stated the floors and walls of the furnaces may be basic
or acid according to requirement. It is however preferable to employ a neutral
material for these, such as graphite, which, when it is protected from direct contact
with air, behaves entirely neutral. A hearth composed of graphite mass is extremely
durable.
As our side chambers K K¹ are constantly filled up to a certain level with charge
and slag, that is to say are constantly protected from contact with or the entrance
of air, we construct these furnaces with their internal surface lined or coated with
slabs or plates of graphite up to the said level.
The central chamber L is lined with dolomite which is supported on a
foundation of chrome iron rock or ore.
Generally, any fire resisting material can be employed in the construction of
our furnace but it must be of a very good quality in view of the very high
temperature which it will have to withstand.
With respect to the arrangement and working of the furnace, we think it well
to add the following:-
1. The drawings show merely the general type or idea of our furnace which
differs by its construction and arrangement very essentially from other metal-
lurgical furnaces. The details of the construction of the same may be modified.
Many of such modifications may be readily foreshadowed, and may be specially
mentioned here. Thus, for instance, instead of the flaps F F and of the
dampers n n', o o' an apparatus common to all might very easily be provided.
It would be easy to arrange the generators, not on the side of the outflow but
on the opposite side; this would be an advantage in certain cases.
The charging
hoppers in the roof night be arranged to operate automatically, and so on.
Unimportant modifications of details might be effected without end; but the
general type or idea of the whole apparatus, and its essential parts will remain
unaltered.
With respect to an essential part of our furnace, namely, of the side
chambers KK, whose atmosphere acts with a reducing effect, we think that it
is absolutely necessary to add the following.
some
These chambers are shewn in the drawings as of small height, although in
cases dependent on the local conditious, the properties of the ores and
metals to be treated, the force of the draught or of the suction &c., the height
of the chambers may be increased until they become vertical shaft furnaces.
This modification would be a very important one, although it would not never-
theless be a departure from the principle of our furnace, for which reason we
have not annexed hereto any drawings on this point as we are of opinion that
what has been said here is sufficient.
3. It would be easy to combine two of our furnaces longitudinally so as to

page_text: 3
0
orm one common furnace with two parallel rows or chamocros
ach having a tap hole on opposite sides.
A modification of this kind of our construction would be very suitable in many
cases, because with greater compactness, the apparatus is less costly and the
efficiency is increased."
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 :-
1. A new process for the production of metals and their alloys directly from
their ores, such process being characterized by the conversion of the whole
charge (composed of the ores and certain suitable additions) into a molten
condition such that the metallic compounds to be treated become "pyro-
chemically" dissolved in the rest of the material substantially as described.
2. In treating iron oxides according to the process specified in the preceding
claim, a composition of the charge, such that on the same melting in the basic
furnace "pyroxines" are formed which dissolve the iron oxides substantially as
described.
3. In treating aluminous iron ores according to the process specified in
Claim 1. adding lime to the charge with the object of producing aluminates of
lime, in which the iron oxides dissolve, substantially as described.
4. In treating phosphorous iron ores introducing in the charge dolomite, or
other materials which like dolomite are capable of forming vitreous phosphorus
compounds or phosphites of lime substantially as described.
5. In the production of metals from their ores according to the method
specified in Claim 1, the use of chemical reagents in the form of pyrochemical
solutions for the purpose of aiding the thermic energy substantially as described.
6. For the purpose of preparing or forming the pyrochemical solutions referred
io in the preceding claim, introducing carbon into the charges, referred to in
Claims 1 to 5, in the proportion of th to oth of the quantity which is necessary
to convert the oxygen contained in the oxide into carbonic acid anhydride,
substantially as described.
7. The combination of the process specified in Claim 1, (the production of
metals from their ores) with the use of electric currents for aiding the thermic
energy and the chemical energy, substantially as described.
8. In the hereinbefore mentioned process, the use of electric energy in the
form of dark discharges of very high tension, which are produced by the
inclusion of suitable resistances, that serve to retard or check the return current
of the transformers, as also by means of acoustic interrupting devices which
produce alternating currents of very high tension and of extremely high frequency,
substantially as described.
9. For the purpose of carrying out the process referred to in the preceding
claims, a new metallurgical furnace which is characterised by the following
peculiarities:-
a. By the provision of a melting chamber between the regenerators, and by
the introduction of vaulted or domed roofs in the regenerator system;
b. By a combination of connecting passages between the generators and the
regenerators, such that the former can be included in the system of the
latter;
c. By the arrangement of three separate spaces divided from each other by
means of chambers containing carbon, the arrangement being such that
the two side chambers serve for the preparation of pyrochemical solutions
of the reagents, whilst the middle chamber is specially reserved for
smelting or melting out the metals, substantially as described.
10. In the furnace specified in Claim 10, the production of oxygen or of air
55 enriched with oxygen, by utilising the waste heat for the purpose of heating

page_text: the mixture (contained in the retorts of the air regenerator) of caustic alkalies
and the haloid compounds of those metals to the production of which from their
natural ores the present invention relates, substantially as described.
11. In the furnace specified in Claim 10, the production of acetylene by means
of a process of treating calcium carbide with aqueous vapour, the calcium carbide
being produced in the generator chambers by means of the waste heat from the
metallurgical furnace substantially as described.
Dated this 22nd day of December 1896.
ABEL & IMRAY,
Agents for the Applicants.