IMPROVE- MENTS IN THE MANUFACTURE OF MALLEABLE IRON AND STEEL, AND IN THE MACHINERY OR APPARATUS EMPLOYED IN BUCH MANUFACTURE
Year: 1861

page_text: LETTERS PATENT to Henry Bessemer, of Queen Street Place, New
Cannon Street, in the City of London, for the Invention of "IMPROVE-
MENTS IN THE MANUFACTURE OF MALLEABLE IRON AND STEEL, AND IN THE
MACHINERY OR APPARATUS EMPLOYED IN BUCH MANUFACTURE."
Sealed the 30th July 1801, and dated the 1st February 1861.
PROVISIONAL SPECIFICATION left by the said Henry Bessemer at the
Office of the Commissioners of Patent, with his Petition, on the 1st
February 1861.
I, HENRY BESSEMER, of Queen Street Place, New Cannon Street, in the
City of London, do hereby declare the nature of the Invention for "IMPROVE
MENTS IN THE MANUFACTURE OF MALLEABLE IRON AND STEEL, AND IN THE MACHINERY
OR APPARATUS EMPLOYED IN SUCH MANUFACTURE," to be as follows:-
In the manufacture of malleable iron and steel by forcing atmospheric
air beneath the surface of molten, crude, or pig iron, it has been found
that the powerful heat generated at or near to the orifices of the tuyeres,
together with the chemical action of the slags or oxides of iron and silicium
has the effect of enlarging these orifices, and in a short time rendering the
tuyeres unfit for further use; the tuyeres when thus worn have to be
Faire 1

page_text: eplaced by new ones.
"
The fitting in of these new tuyeres by the plan
at present practised renders it necessary first to knock out the old ones, and
then to cool down the converting vessel, after which the new tuyeres may be
inserted in their places, and the spaces around them filled up with a plastic
matter or "grout," which is generally composed of powdered "ganister
mixed with water. After this is done a fire is lighted in the converting vessel,
and the wet parts thereby properly dried, and the interior of the vessel again
highly heated before the process of conversion can be repeated, the change of
tuyeres thus rendering the apparatus incapable of being used for several
hours.
Now, the object of the first part of my Invention is to construct the tuyere
or tuyeres in such a manner that they shall be capable of being replaced by
others rapidly and with little labor as soon as they are worn out, this change
of the tuyeres taking place after the conversion of one or more charges of
crude iron, or during the process of conversion should it be rendered necessary
by the wearing out of the tuyere before the converting process is completed.
My improved tuyere consists of a number of rings or discs of fire-clay,
Cornish clay, plumbago and fire-clay, "silica clay," silicate of magnesia, or
other suitable refractory substance; these rings have a central hole in them
through which a stout steel or iron rod passes. There are also several other
holes made through them at a small distance from the central one, which
holes are for the purpose of allowing air to pass through each ring, or circular
brick is put on to the iron rod, and some fire-clay or other "lute
" or plastic
matter is put between them so as to make a tight joint. The surfaces of each
disc may be ground flat, or they may be moulded with concentric grooves, and
with correspoding raised rings or ridges alternately so as to fit closely and
assist in holding each other together. A long column is thus to be built up
upon the rod, the air passages in each piece being so placed as to form con-
tinuous tubes throughout the whole length of the column or tuyere. At the
lower end a larger ring is put on, having other holes around its periphery
communicating with those before mentioned, the upper part of the column or
tuyere being surmounted with a disc larger in diameter than the rest for the
purpose of filling up the orifice in the vessel, through which the tuvere is
inserted. The upper end of the iron end on which the tuyere is built passes
into a metal cap so made as to be readily fixed to, and form a close joint with
the blast pipe; the different pieces constituting the tuyere are pressed together
by a powerful spiral spring, which allows the necessary expansion of the rod
and its rings. While they are firmly held together under a regulated pressure,

page_text: the lower enlarged ring in which the tuyere orifices are formed may be per-
forated with numerous small holes, or with a lesser number of holes of a larger
size, or in lieu thereof the air may be made to escape between flat or grooved
discs, or from a hollow or bell-shaped cavity formed beneath the centre of the
tuyere, but I prefer to employ circular orifices of inch to of an inch in
diameter, inore or less. For charges of two tons of cru-le metal forty of the
former or twenty of the latter sized orifices will be found sufficientwhen using
blast at 7 or 8 lbs. pressure on the square inch. As a general rule, I prefer
in this form of tuyere to direct the jets of hair horizontally, or at a slight
angle downwards, but the openings may be so made as to direct the jets in
any other direction either upward or downward, or at a tangent to the axis of
the tuyere so as to cause a rotation of the metal in the vessel. In lieu of
the several air passages formed around the iron rod one large central hole
may be employed with the rod passing also down it, or several rods may
pass through separate holes in the rings instead of one in the centre.
In one form or modification of the improved tuyere I employ an iron pipe
in lieu of the solid iron rod, the pipe not only serves to hold the various parts of
the tuyere together, but to convey the air to the lower part of it, and thereby
render unnecessary the several air passages before described. In order to
defend the tuyere from the sudden action of heat thereon, I prefer to "loam
up" the outside of it with any suitable plastic matter, such as fire-clay and
sand, or what is known as " silica clay," the outside of the tuyere bricks being
scored or roughened to facilitate the adhesion of this coating. The several
rings before-mentioned may be made of plastic clay or other material, but I
prefer to make them of dry materials, by means of powerful pressure in suit-
able moulds, after which they are to be baked or burned. I prefer to employ
a spherical vessel mounted on axes for the conversion of crude iron with my
improved tuyeres, and to make, in addition to the usual chimney or outlet of
the vessel, a circular opening on the top of it, through which the tuyere may
be lowered down into the fluid metal, and be again raised up vertically from
it. Whenever it may be deemed necessary to do so, the metal cup on the
top of the tuyere being attached to the hollow arm or jib of a hydraulic
crane, the ram of which moves vertically and parallel with the blast pipe
leading from the blowing engine, the pipe sliding up and down through a
suitable stuffing-box, so that the connection of the blast with the tuyere will
not be interrupted by any motion of the tuyere and crane arm upward or
downward, nor by the movement of the crane on its vertical axis; thus
great facility is afforded for the rapid removal and change of the tuyere.

page_text: It also admits of the raising or lowering of the orifices of the tuyere into or
out of the metal more or less at different stages of the process.
On the upper side of the blast pipe, and in a position vertically over the
air passages of the tuyere, I fix a small globular vessel, provided with two
cocks, one communicating with the blast pipe, and the other with the
external air; this vessel is for the purpose of holding any fluid, granular or
powdery matter, such as nitrate of soda, fluor spar, metallic oxides, or any
other flux or matter intended to be forced by the blast into the molten metal,
either for the purpose of improving or purifying the metal, or for rendering
the slags more fusible and easily run off.
Within the range or sweep of the hydraulic crane I construct a furnace
having several compartments or chambers of a size suitable for holding a
tuyere, and thus affording a convenient mode of heating up the tuyeres
gradually,and retaining their heat until they may be required. The chambers
may be constructed of fire-bricks or of simple cylinders of fire-clay, or in
lieu thereof cast-iron vessels or retorts may be inserted in a vertical position
in the furnace to receive and heat the tuyeres.
My Invention also consist in giving motion to the converting vessel by
means of a hydraulic ram or plunger, moving vertically in a cylinder, and
placed below the axis of the vessel, the ram or plunger being raised by the
pressure of water from any elevated tank or vessel under pressure, and again
lowered by allowing the water to escape from beneath it; this motion of the
ram is communicated to the axis of the converting vessel by means of a wire
rope attached to the ram, and passing round a grooved pulley keyed on to the
axis of the vessel, a second wire rope suspends a counterbalance weight on the
opposite side of the pulley; this weight may be about equal to one half of
the weight of the ram or plunger, so that whenever the ram is raised the
lowering of the counterweight will cause the vessel to turn round while the
lowering of the ram will raise the counterweight, and turn the vessel in
the opposite direction; these movements will be under the control of the
work man who admits or discharges the water from the apparatus bya suitable
valve an i handle. The vessel may thus at any time be made to discharge its
contents, or be put into a position suitable for running in a charge of crude
metal. In pouring out the fluid iron or steel from the converting vessel the
spout or opening from which the metal flows is moved (as the pouring
proceeds) away from the spot where the pouring first commenced. I there-
fore find it advantageous to provide the hydraulic casting crane with a suit-
able sliding motion, whereby the casting ladle may be moved horizontallyin a

page_text: straight line further from the rain or axis of the crane as the pouring proceeds,
and thus insure the ladle being at all times beneath the opening from which
the metal flows.
"
When large armour plates" or other large flat masses of malleable iron
or steel are required, I prefer to cast such masses in shallow ingot noulds, so
proportioned that the top surface of the ingot shall form one of the large
planes or surfaces of the plate or slab after it is hammered or rolled; and
when desirable, I make such ingots of distinct layers of steel of different
qualities, or of steel and malleable iron, by pouring into the mould molten
steel or molten malleable iron, one after the other, so that an union of the
different qualities of metal may be effected at or near their point of junction,
but nevertheless so that the different qualities of metal shall for the most part
bo distinct from each other, forming layers or strata of hard and soft metal.
The action of the air upon the upper exposed surface of the ingot may be
lessened or entirely prevented by strewing thereon powdered glass of borax or
other readily fusible flux, silicate, or saline matter. In making ingots or
castings in large shallow moulds, I find it advantageous to elongatethetubular
fire-clay orifice through which the mo'ten metal flows from the casting ladle,
so that the clay tube may dip into the fluid metal in the mould, and thus
prevent the flowing stream of metal from taking down air with it into the
fluid mass below.
Both cast steel and malleable iron when in a molten state frequently
disengage gases so rapidly as to flow or boil over the tops of the moulds in
which they are poured, and thus form ingots or castings containing numerous
cells; now 1 have found that this tendency of the metal to disengage gases
and boil spontaneously is counteracted by the employment of a very small
quantity of the metal silicium, 1 pound in weight of which is sufficient when
diffused through two thousand pounds of molten steel to destroy thistendency
to ebulition, and cause the metal to lie quietly in the mould.
About the year 1839 it was discovered by Josiah Marshall Heath that
metallic manganese also had a powerful effect on molten steel if alloyed
therewith to the extent of one per cent. ; he found that it conferred on the
steel so alloyed the property of welding and working more soundly under the
hammer than steel not so alloyed. The result of this discovery by Heath has
been the almost universal application of manganese to the manufacture of
cast steel. It however happens that both the metals silicium and manganese
are difficult of reduction in such quantities as are required for commercial
purposes, and when found naturally alloyed with iron, the latter metal is in

page_text: such excess as to cause many disadvantages in its use as a means of alloying
steel with those metals. But I have found that the metals manganese and
silicium may be readily reduced in combination with so small a quantity of
iron as to facilitate their application instead of causing an inconvenience by
any excess of iron or carbon present as in the natural alloys of these metals
with pig iron. For the purpose of making an alloy easy of reduction, and
especially suitable as an alloying metal, I take, by preference, from 30 to 70
parts of pure hematite or magnetic iron ore, and 50 parts of grey or black
oxide of manganese; or I take manganesian iron ore, and add to it as much
grey or black oxide of manganese as may be desired, and if silica be not
present in these oxides, I add 5 parts of powdered flint or such quantity of a
silicious iron ore as is equivalent thereto; to these materials I add about
40 parts of f pure anthracite coal, or other pure or nearly pure carbon; I then
crush these materials under edge stones, or between crushing rolls; t'e
materials thus become thoroughly mixed and incorporated, and may then be
deoxidized or cemented in fire-clay retorts, such as are used for gas making,
or in the chests of an ordinary steel-converting furnace, and after cooling
down may be sprinkled with or immersed in coal tar or other hydrocarbon
preparatory to the smelting of the metallized mass in crucibles, and which
crucibles I by preference fix in an air furnace where they may be surrounded
with coke as practised in furnaces employed to melt blister steel; or the
furnace may have tuyeres around the lower part, and be urged by a blast.
I place the crucibles on a stand which has a hole through it; the crucible has
also an opening in its lower part, so that the cemented metallic mass, as it
fuses, may flow or be tapped out, and fall into a trough or mould while more
of the materials are put in at the top, so as to render the operation continuous
like a blast furnace, so long as the crucible lasts. The preliminary process of
deoxidizing the ores in retorts or chests may be omitted if the melted crucibles
are made sufficiently high or have rings of fire-clay built up upon them to
increase their height, so that the crude materials may be put in at the top
and become gradually deoxidized as they sink down, or the materials may be
formed into masses by pressure in suitable moulds previous to the deoxidizing
or smelting process. The metallic alloy so made may be heated or melted in
other crucibles when required for use. From 30 to 50 pounds of this alloying
metal may be put into each ton of molten steel before pouring the same iuto
moulds; but when I desire to use this alloying metal (or any other similar
mixture of metals containing carbon) in the manufacture of ma'leable iron, or
in the manufacture of very mild or soft steel, I cast the said alloying metal

page_text: into thin plates, or I granulate or "shot" it.after which it is to be decarbonized
or partially decarbonized by cementation in boxes or chambers containing
oxides of iron or zinc, so that the iron present in the alloy may be converted
into malleable iron, and be thus prevented from recarburetting the malleable
iron or mild steel. into which it is put in a solid though highly heated state.
I desire it to be understood that the proportions 1 have given of the several
matters combined to form the alloy or alloying metal,and the quantity of such
alloying metal to be used for each ton of malleable iron or steel, may be
considerably varied, but I have given a medium proportion which I believe
will be found most advantageous, observing, however, as a general rule, that a
larger quantity of silicium and a less quantity of manganese may be employed
for castings than for forgings.
SPECIFICATION in pursuance of the conditions of the Letters Patent, filed
by the said Henry Bessemer in the Great Seal Patent Office on the
1st August 1861.
TO ALL TO WHOM THESE PRESENTS SHALL COME, I, HENRY
BESSEMER, of Queen Street Place, New Cannon Street, in the City of London,
send greeting.
WHEREAS Her most Excellent Majesty Queen Victoria, by Her Letters
Patent, bearing date the First day of February, in the year of our Lord
One thousand eight hundred and sixty-one, in the twenty-fourth year of
Her reign, did, for Herself, Her heirs and successors, give and grant
unto me, the said Henry Bessemer, Her special licence that I, the said
Henry Bessemer, my executors, administrators, and assigns, or such others
as I, the said Henry Bessemer, my executors, administrators, and assigns,
should at any time agree with, and no others, from time to time and
at all times thereafter during the term therein expressed, should and lawfully
might make, use, exercise, and vend, within the United Kingdom of Great
Britain and Ireland, the Channel Islands, aud Isle of Man, an Invention
for "IMPROVEMENTS IN THE MANUFACTURE OF MALLEABLE IRON AND STEEL, AND
IN THE MACHINERY OR APPARATUS EMPLOYED IN SUCH MANUFACTURE," upon the
conditions (amongst others) that I, the said Heury Bessemer, my executors or
administrators, by an instrument in writing under my, or their, or one of
their hands and seals, should particularly describe and ascertain the nature
of the said Invention, and in what manner the same was to be performed,

page_text: and cause the same to be filed in the Great Seal Patent Office within
six calendar months next and immediately after the date of the said Letters
Patent.
NOW KNOW YE, that I, the said Henry Bessemer, do hereby declare
the nature of the said Invention, and in what manner the same is to be
performed, to be particularly described and ascertained in and by the fol-
lowing statement thereof, that is to say :-
In the manufacture of malleable iron and steel by forcing atmospheric air
beneath the surface of molten, crude, or pig iron, it has been found that the
powerful heat generated at or near to the orifices of the tuyeres, together with
the chemical action of the slags or oxides of iron and silicium, has the effect of
enlarging these orifices, and in a short time rendering the tuyeres unfit for
further use; the tuyeres when thus worn have to be replaced by new ones.
The fitting in of these new tuyeres by the plan at present practised renders it
necessary, first to knock out the old ones, and then to cool down the con-
verting vessel, after which the new tuyeres may be inserted in their places,
and the spaces around them filled up with a plastic matier or "grout," which
is generally composed of powdered "ganister" mixed with water; after this
is done a fire is lighted in the converting vessel, and the wet parts thereby
properly dried, and the interior of the vessel again highly heated before the
process of conversion can be repeated, the change of tuyeres thus rendering
the apparatus incapable of being used for several hours.
Now the object of the first part of my Invention is to construct the tuyere
or tuyeres in such a manner that they shall be capable of being replaced by
others rapidly and with little labor as soon as they are worn out, this change
of the tuyeres taking place after the conversion of one or more charges of
crude iron or during the process of conversion,should it be rendered necessary
by the wearing out of the tuyere before the converting process is completed.
In order that the improvements forming the first part of my said Invention
may be fully understood I have represented the same on the Sheet of Drawings
hereunto annexed, where Figure 1 is a plan, on an enlarged scale, of one of
the circular bricks forming the tuyere; Figure 2 a section through the centre
of the same; Figure 3 a cross section on the line A, B, of Figure 4; Figure 4
being an elevation of the tuyere when built up; and Figure 5 a vertical
section of the same; Figure 6 is also a vertical section of another modification
of the improved tuyere, in which the air passage is formed by a wrought-iron
pipe passing down the centre of the tuyere; Figure 7 and Figure 8 also shew
the lower portion of two other modifications of my improved tuyere, which

page_text: b
consists of a number of rings or discs of fire-clay, Cornish clay, plumbago and
fire-clay, "silica clay," silicate of magnesia, or other suitable refractory sub-
stance; these rings a have a central hole in them, through which a stout steel
or iron rod 6 passes, there are also several other holes c made through them
at a small distance from the central one, which holes are for the purpose of
allowing air to pass through; each ring or circular brick is put on to the iron
rod b, and some fire-clay or other "lute" or plastic matter is put between
them, so as to make a tight joint. The surfaces of each disc may be ground
flat, or they may be moulded with concentric grooves, and with corresponding
raised rings or ridges alternating, as shewn at a, Figures 1 and 2, so as to fit
closely and assist in holding each other together. A long column or tuyere
is thus to be built up upon the rod, the air passages in each piece being so
placed as to form continuous tubes throughout the whole length of the column
or tuyere; at the lower end a larger ring a' is put on, having other holes a²
around its periphery communicating with those before mentioned, the upper
part of the column or tuyere being surmounted with a disc a³ larger in
diameter than the rest of the circular pieces, for the purpose of filling up the
orifice in the vessel through which the tuyere is inserted, the upper end of the
iron rod b, on which the tuyere is built, passes into a metal cap f so made as
to be readily fixed to and form a close joint with the blast pipe; the different
pieces constituting the tuyere are pressed together by a powerful spiral spring
, which allows the necessary expansion of the rod and its rings, while they
are firmly held together under a regulated pressure; the lower enlarged ring
a', in which the tuyere orifices are formed, may be perforated with numerous
small holes, or with a lesser number of holes of a larger size, or in lieu thereof
the air may be made to escape between flat or grooved discs, as shewn in
Figure 7, or from a hollow or bell-shaped cavity formed beneath the centre of
the tuyere, as shewn in Figure 8; but I prefer to employ circular orifices of
inch to of an inch in diameter, more or less, as shewn at a³, Figures 3, 4,
and 5 For charges of two tons of crude metal forty of the former or twenty
of the latter sized orifices will be found sufficient when using blast at 7 or
S lbs. pressure on the square inch. As a general rule I prefer, in this form
of tuyere, to direct the jets of air horizontally, or at a slight angle, downwards;
but the openings may be so made as to direct the jets in any other direction,
either upward or downward, or at a tangent to the axis of the buyere, so as to
cause a rotation of the metal in the vessel. In lieu of the several air passages
formed around the iron rod one large central hole d may be employed with
the rod passing also down it, as shewn in Figure 7, or several rods may pass

page_text: through separate holes in the rings instead of one in the centre. In one form
or modification of the improved tuyere I employ an iron pipe i, as shewn in
Figure 6, in lieu of the solid iron rod; the pipe not only serves to hold the
various parts of the tuyère together, but to convey the air to the lower part of
it, and thereby render unnecessary the several air passages before described.
The pipe has a plug k screwed into its lower end, a washer under the head
of the plug secures the lower perforated circular brick j in its place, and thus
holds the several parts of the tuyere together; the air which passes down the
pipe i passes throught slots formed near the bottom of it, and escapes into the
metal through radial perforations 7 formed in the lower part of the tuyere,
the top end of the pipe i passing through a metal cap and spring m is secured
by a screwed nut n, and thus the whole may be held together under a pressure
equal to the force of the spring m. On reference to Figure 5 it will also be
seen that the central rod 6 has its lower end also screwed by a nut and washer
p, which are contained in a recess formed in the centre of the lower circular
brick a; after screwing on this nut the recess is filled with clay or loam to
prevent the metal from having access to it, this precaution being taken in
every modification of these improved tuyeres. In order to defend the tuyere
from the sudden action of the heat thereon I prefer to "loam up" the outside
of it with any suitable plastic matter, such as fire-clay and sand, or what is
known as "silica clay," the outside of the tuyere bricks being scored or
roughened to facilitate the adhesion of this coating. The several rings
before-mentioned may be made of plastic clay or other material, but I
prefer to make them of dry materials, by means of powerful pressure in
suitable moulds, in a manner well understood and practised in making
bricks, tiles, and other articles in dry powdered clay or china earth,
after which they are to be baked or burned.
Having described the nature of my improved tuyeres, I will now proceed to
shew in what manner they are to be employed in the manufacture of malleable
iron and steel. For this purpose I have on the Sheet of Drawings, hereunto
annexed, shewn at Figure 9 a vertical section of the converting apparatus
and its appliances, and at Figure 10 an elevation of the converting vessel
and the hydraulic apparatus employed to give motion to it.
I prefer to employ a spherical vessel A, mounted on axes C, for the con-
version of crude iron with my improved tuyeres, and to make in addition to
the usual chimney or outlet 1) of the vessel a circular opening B on the top of
it through which the tuyere a may be lowered down into the fluid metal, and
be again raised up vertically from it whenever it may be deemed necessary to

page_text: do so, the metal capf on the top of the tuyere being attached to the hollow
arm or jib E of a hydraulic crane, the ram G of which moves vertically and
parallel with the blast pipe H leading from the blowing engine, the pipe
sliding up and down through a suitable stuffing box I formed on the vertical
pipe I, so that the connection of the blast with the tuyere will not be
interrupted by any motion of the tuyere and crane arm upward or downward,
nor by the movement of the crane on its vertical axis, thus great facility is
afforded for the rapid removal and change of the tuyere, it also admits of the
raising or lowering of the orifices of the tuyere into or out of the metal more
or less at different stages of the process. On the upper side of the blast pipe,and
in a position vertically over the air passages of the tuyere, I sometimes fix a
small globular vessel provided with two cocks, one communicating with the
blast pipe and the other with the external air; this vessel is for the purpose of
holding any fluid, granular or powdery matter, such as nitrate of soda, fluor
spar, metallic oxides, or any other flux or matter intended to be forced by the
blast into the molten metal either for the purpose of improving or purifying
the metal, or for rendering the slags more fusible and easily run off.
Within the range or sweep of the hydraulic crane arm E, I construct a
furnace K, having several compartments or chambers each of a size suitable
for holding a tuyere, and thus affording a convenient mode of heating up the
tuyeres gradually and retaining their heat until they may be required. One
of these chambers L is shewn in section in Figure 9. They may be con-
structed of fire-bricks, or of simple cylinders of fire-clay, or in lieu thereof
cast-iron vessels or retorts may be inserted in a vertical position in the
furnace K to receive and heat the tuyeres.
Whenever the apparatus lastly described is to be put in operation a tuyere
is attached by the flange f* of the metal cap f to a corresponding flange,
which forms the extreme end of the tubular crane arm E; as soon as it is so
fixed, water under pressure is allowed to enter the hydraulic cylinder N by a
suitable valve, and by its pressure raise the ram G and the crane arm E, with
the tuyere attached thereto. The arm E is then turned round until the
tuyere comes vertically over one of the retorts or chambers L, the ram is then
lowered by allowing the water to flow out, and the tuyere deposited in the
retort as shewn by dots at P. This process may be repeated until the retorts
are each filled. A gentle fire is then to be made in the furnace K, and as
soon as the tuyeres acquire a red heat they will be fit for use, but may remain
there in readiness for any convenient period of time. The interior of the con-
verting vessel A having been heated by burning fuel in the interior thereof

page_text: will also be in readiness for use as soon as the whole of the unconsumed fuel is
discharged therefrom by turning the vessel upside down. A charge of molten
crude iron having been run into the vessel A, and one of the heated tuyeres
having been attached to the crane arm, the latter is to be raised so as to lift
the tuyere from the chamber L; the arm is then to be turned into the position
shewn by dots at Q, and the tuyere lowered vertically through the opening B
into vessel A. The air from the blast engine is conveyed into the lower part
of the pipe 1*, and passes through the pipe H into the upper part of the
ram G, the stuffing box G* allowing the ram to move freely round the
pipe H, so that the tubular arm E may at all times be in connection with the
blast I. Before lowering the tuyere into the molten metal the blast cock
must be opened, and the air allowed to pass out of the orifices of the tuyeres,
which may then be allowed to descend below the surface of the metal, and
thus effect its conversion into steel or malleable iron in a manner now well
understood. As soon as the conversion is effected, the crane arm and tuyere
are to be again raised into the position shewn by dots at Q; the malleable
metal may then be discharged from the vessel by turning it round on its axis
by means of an hydraulic apparatus herein-after described. While the vessel
is still in a highly heated state another charge of crude iron may berun in and
the tuyere again caused to descend into the fluid metal as before. When by
this means the tuyere becomes too much worn away to act properly it may be
withdrawn and placed down on the floor and another one inserted in its place,
and so on continuously so long as the lining of the converting vessel lasts,
thus avoiding the loss of time and the cooling of the vessel caused by the
insertion of tuyeres into the body of the lining of the vessel by the running
in of wet ganister in the manner herein-before described.
R
My Inventionalso consistsin giving motion to the converting vessel by means
of a hydraulic ram or plunger moving vertically in a cylinder and placed
below the axis of the vessel, the ram or plunger being raised by the pressure
of water from any elevated tank or vessel under pressure, and again lowered
by allowing the water to escape from beneath it, this motion of the ram is
communicated to the axis of the converting vessel by means of a wire rope
attached to the ram U, and passing round and attached to a grooved
pulley S keyed on to the axis of the vessel, a second wire rope T suspends
a counterbalance weight V on the opposite side of the pulley, this weight
may be about equal to one half of the weight of the ram or plunger, so
that whenever the ram is raised, the lowering of the counterweight will
cause the vessel to turn round, while the lowering of the ram will raise the

page_text: counterweightand turn the vessel in the opposite direction, these movements
will be under the control of the workman who admits or discharges the
water from the apparatus by a suitable valve and handle, the converting vessel
may thus at any time be made to discharge its contents, or be put into a
position suitable for running in a charge of crude metal. In pouring out the
fluid iron or steel from the converting vessel, the spout or opening from which
the metal flows is moved (as the pouring proceeds) away from the spot where
the pouring first commenced, I therefore find it advantageous to provide the
hydraulic casting crane with a suitable sliding motion, whereby the casting
ladle may be moved horizontally in a straight line further from the ram or
axis of the crane as the pouring proceeds, and thus insure the ladle being
at all times beneath the opening from which the metal flows.
When large "armour plates" or other large flat masses of malleable iron or
steel are required, I prefer to cast such masses in shallow ingot moulds, so
proportioned that the top surface of the ingot shall form one of the large
planes or surfaces of the plate or slab after it is hammered or rolled, and
when desirable, I make such ingots of distinct layers of steel of different
qualities, or of steel and malleable iron, by pouring into the mould molten
steel or molten malleable iron one after the other, so that au union of the
different qualities of metal may be effected at or near their point of junction,
but nevertheless so that the different qualities of metal shall, for the most
part, be distinct from each other, forming layers or strata of hard and soft
metal, the action of the air upon the upper exposed surface of the ingot may
be lessened or entirely prevented by strewing thereon powdered glass of borax,
or other readily fusible flux, silicate, or saline matter. In making ingots or
castings in large shallow moulds, I find it advantageous to elongatethe tubular
fire-clay orifice through which the molten metal flows fromthecastingladle,so
that the clay tube may dip into the fluid metal in the mould, and thus provent
the flowing stream of metal from taking down air with it into the fluid mass
below, this improvement in the casting ladle, and in the nodeof casting ingots
is shewn at Figure 11 on the annexed Sheet of Drawings. Figure 11 is a
vertical section of the lower part of the casting ladle and the mould into which
the fluid malleable iron or steel is being run. The iron ladle 1 is lined with
loam, as shewn at 2, a conical metal tube 3 is secured by a flange to the under
side of the ladle, a piece of well baked tube of fire-clay, or of fire-clay and
plumbago 4 is inserted in the lower end of the iron tube 3, so as to project
therefrom as shewn, the rest of the tube 3 may be lined with loam, and the
upper part of the tube may be formed into a valve seating, as already

page_text: practised in ladles employed for casting steel, so that the fluid metal is
admitted to the vertical tube only at such times and in such quantities as may
be desired; when casting with this improved ladle the nozzle 4 should be
made red-hot over the fire, and then be lowered nearly to the bottom of tho
mould 5, the valve may then be raised, and the fluid metal be allowed to flow
out, it will soon rise above the orifice of the nozzle 4, and thus prevent the
air from being taken down into the metal, air so introduced acts both
chemically and mechanically in producing the cellular condition so common
in cast steel. As the metal rises in the mould the ladle should also be steadily
raised, so as to keep the nozzle only a small distance below the surface of
the fluid metal, independently of the bubbles produced in pouring.
Both cast steel and malleable iron, when in a molten state, frequently
disengage gases so rapidly as to flow or boil over the tops of the moulds in
which they are poured, and thus formingots or castings containing numerous
cells. Now I have found that this tendency of the metal to disengage gases
and boil spontaneously is counteracted by the employment of a very small
quantity of the metal silicium, one pound in weight of which is sufficient when
diffused through two thousand pounds of molten steel to destroy this
tendency to ebullition, and cause the metal to lie quietly in the mould.
About the year 1839, it was discovered by Josiah Marshall Heath, that
metallic manganese also had a powerful effect on molten steel if alloyed there-
with to the extent of one per cent.; he found that it conferred on the steel so
alloyed the property of welding and working more soundlyunder the hammer
than steel not so alloyed, the result of this discovery by Heath has been the
almost universal application of manganese to the manufacture of cast stecl.
It however happens, that both the metals silicium and manganese are difficult
of reduction in such quantities as are required for commercial purposes, and
when found naturally alloyed with iron, the latter metal is in suchexcessasto
cause many disadvantages in its use as a means of alloying steel with those
metals. But I have found that the metals manganese and silicium may be
readily reduced in combination with so small a quantity of iron as to facilitate
their application instead of causing an inconvenience by anyexcess of iron or
carbon present, as in the natural alloys of these metals with pig iron. For
the purpose of making an alloy easy of reduction from its ores or oxides, and
especially suitable as an alloying metal, I take by preference from 30 to 70
parts of pure hematite or magnetic iron ore, and 50 parts of grey or black
oxide of manganese; or I take mangauesium iron ore and add to it as much
grey or black oxide of manganese as may be desired, and if silica be not

page_text: present in these oxides, I add 5 parts of powdered flint, or such quantity of a
silicious iron ore as is equivalent thereto; to these materials I add about 40
parts of pure anthracite coal, or other pure or nearly pure carbon. I then
crush these materials under edge stones, or between crushing rolls, the
materials thus become thoroughly mixed and incorporated, and may then be
deoxidized or cemented in fire-clay retorts, such as are used for gas making,
or in the chests of an ordinary steel-converting furnace, and after cooling down
may be sprinkled with or immersed in coal tar or other hydrocar bon pre-
paratory to the smelting of the metallized mass in crucibles, and which
crucibles I, by preference, fix in an air furnace, where they may be surrounded
with coke, as practised in furnaces employed to melt blister steel; or the
furnace may have tuyeres around the lower part, aud be urged by a blast. I
place the crucibles on a stand which has a hole through it, the crucible has
also an opening in its lower part, so that the cemented metallic mass as it
fuses may flow or be tapped out, and fall into a trough or mould while more
of the materials are put in at the top, so as to render the operation continuous
like a blast furnace so long as the crucible lasts; or in lieu of this mode of
treating the mixed metallic oxides, the heat of the retorts, chests, or chambers
in which they are deoxidized may be so much raised as to cause the reduced
metal to fuse and form a metallic mass at the bottom of the retort or chamber
from which it may run while still in a fluid state; or it may be retained there
until the mass has solidified, in which case it may be removed when it has
become cold whenever the melting of the alloy is intended to be effected in
the deoxidizing chamber. I prefer to line such chamber with a mixture of
plastic fire-clay and anthracite coal in the state of powder; or I employ some
other carbonaceous matter in order to protect the material of which the
chamber is constructed from the action of the inetallic oxides therein.
some cases I prefer to make two separate alloys, that is, an alloy of silicium
and iron, and an alloy of manganese and iron, which may afterwards be fused
together in any desired proportions, or each alloy may be used separately as
may be desired. The preliminary process of deoxidizing the ores in retorts or
chests may be omitted if the melting crucibles are made sufficiently high, or
have rings of fire-clay built up upon them to increase their height, so that the
crude materials may be put in at the top, and become gradually deoxidized as
they sink down; or the materials may be formed into masses by pressure in
suitable moulds previous to the deoxidizing or smelting process.
In
The metallic alloy so made may be heated or melted in other crucibles when
required for use. From 30 to 50 pounds of this alloying metal may be put

page_text: into cach ton of molten steel before pouring the same into moulds; but when
I desire to use this alloying metal (or any other similar mixture of inetals
containing carbon) in the manufacture of malleable iron, or in the manu-
facture of very mild or soft steel, I cast the said alloying metal into thin plates,
or I granulate or "shot" it, after which it is to be decarbonized, or partially
decarbonized by cementation in boxes or chambers containing oxides of iron
or zinc, so that the iron present in the alloy may be converted into malleable
iron, and be thus prevented from recarburetting the malleable iron or mild
steel into which it is put in a solid though highly heated state.
I desire it to be understood that the proportions I have given of the several
matters combined to form the alloy or alloying metal, and the quantity of such
alloying metal to be used for each ton of malleable iron or steel may be con-
siderably varied, but I have given a medium proportion, which I believe will
be found most advantageous, observing, however, as a general rule, that a
larger quantity of silicium and a less quantity of manganese may be
employed for castings than for forgings.
It will be obvious that the methods herein described of reducing metallic
oxides, and forming alloys of iron and manganese, or iron and silicium may
also be employed in forming alloys of iron with any other known metal capable
of uniting or alloying therewith, provided that such metals are of a nature to
be reduced from their oxides, acids, or salts by the action of carbon at a high
temperature; I, however, desire it to be understood that I lay no claim to
the production of any such alloys, nor to their employment or mixture with
malleable iron or steel.
Having described my Invention, and the manner in which the same may
be carried into effect, I desire it to be understood that I do not confine myself
to the precise details herein described, so long as the peculiar feature of the
several parts of my said Invention are retained; but what I do claim,
Firstly, is, the mode or modes of building up or constructing tuyeres, as
herein described, and their employment in the conversion of molten, crude
or refined pig iron into steel, or into malleable iron.
Secondly, I claim the employment of hydraulic apparatus for putting in
and removing the tuyeres from the converting vessel, in the manner herein
described.
Thirdly, I claim the employment of retorts or chambers for heating and
retaining the heat of tuyeres, and also the made herein described of putting
in and removing the tuyeres from the heating apparatus.
Fourthly, I claim the mode herein described of giving a rotatory or semi-

page_text: rotatory motion to the converting vessel by means of a hydraulic ram or
plunger and its counterweight.
Fifthly, I claim constructing the casting ladle or receptacle employed in
casting malleable iron or steel with an elongated tubular spout made to
descend into the ingot mould, as herein described.
And, lastly, I claim in the casting of ingots of malleable iron or steel the
immersion of the orifice (from which the metal flows into the mould) below
the surface of the fluid metal contained therein, and also the gradual move-
ment upward of such orifice as the level of the metal rises in the mould.
In witness whereof, I, the said Henry Bessemer, have hereunto set my
hand and seal, this Twenty-sixth day of July in the year of our
Lord One thousand eight hundred and sixty-one.
HENRY BESSEMER. (L.S.)