Improvements in Adding Metallic and Non-metallic Substances to Steel and Iron or any other Liquid Metals
Year: 1891

page_text: Date of Application, 4th Nov., 1891
Complete Specification Left, 2nd Sept., 1892-Accepted, 8th Oct., 1892
PROVISIONAL SPECIFICATION.
Improvements in Adding Metallic and Non-metallic Substances to
Steel and Iron or any other Liquid Metals.
I, JOSEPH COLLEY of 44 Wellington Road, Bilston in the County of Stafford
Steel Works Manager, do hereby declare the nature of this invention to be as
follows:-
:-
This invention consists of adding the metallic & non-metallic substances to liquid
metals, in a wooden box specially made for the purpose.
The box of wood is made ready leaving the bottom or top to be put on after the
mixture is added, the bottom is preferably narrower & left open about one third of
its area, so that a thin piece of sheet iron wood, or even strong paper is made to
cover the said opening so that when it comes in contact with the hot metal, it burns
away, allowing the additions to gradually mix with the metals.
Dated this 2nd day of November 1891
JOSEPH COLLEY.
COMPLETE SPECIFICATION.
Improvements in Adding Metallic and Non-metallic Substances to
Steel and Iron or any other Liquid Metals.
I, JOSEPH COLLEY, of 44 Wellington Road, Bilston, in the County of Stafford,
Steel Works Manager, 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 more particularly to improvements in the manufacture of
steel in the Bessemer and open-hearth steel making processes, the invention being
especially applicable when such processes are carried out in basic lined furnaces or
converters. By my process I am able to largely diminish the amount of ferro
manganese required to be added at the completion of the operation, without any
danger of having "wild or "burnt" metal, and (when basic lined furnaces and
converters are employed) I can obtain lower percentages of phosphorous and
sulphur in the resulting steel, and can at the same time carburize the bath to any
desired extent. I find also that the basic slag is obtained in a granular state, when
working by my improved way, in which condition it is very suitable for further
treatment for agricultural or other purposes. There is also less rephosphorisation
by the employment of this process than by the methods usually employed. My
process also permits of the direct carburization of the bath of metal whilst it is yet
in the furnace or converter and whilst part of the slag is still upon the surface,
thereby effecting a more uniform admixture of the carbon with the metal than in
the direct carburising processes at present in use, in which the carbon is added to
the metal when the latter is in the ladle or ingot mould.
When my invention is applied to the manufacture of steel or ingot iron I introduce
the carbon into the bath of metal, in a box made of wood, sheet iron or other
suitable material, which is filled with the necessary amount of solid carbon and
ferro-manganese.
When the bath of metal is sufficiently decarburized and dephosphorized, the
operation is stopped and the bulk of the slag removed but enough is left to cover
the metal and keep it warm. If the slag looks too thin a little lime may be added
after which the box containing the carbon, and ferro-manganese is introduced by
means of a heavy peel, or other suitable tool, and owing to its weight sinks through
the remaining slag into the bath of metal.

page_text: The box I prefer to make use of may be made most conveniently of inch board
q
rectangular in form, having a length of some 2 to 3 feet by about 9 inches in width
and 9 inches in depth. I have found that a box only 2 feet long will give good
results and also that it is very convenient to make the cross section of the box
broader at the top than at the base, the wood of which the base is made should also
be thinner than that of the sides and top so that when the box is introduced into
the bath the bottom will be the first to burn away, thereby allowing the carbon to
diffuse through the bottom of the box directly into the metal; the box being
weighted with the ferro-manganese partly sinks under the slag and the bottom of
it is directly in the metal. A wooden angle strip nailed to each side of the box
inside may be employed to support the thin bottom and keep the ferro manganese
in the box while the carbon is being diffused. In place of forming the bottom of
the box of thinner wood than the sides I may form it of a loose piece of iron plate
which quickly melts away, whilst the sides and top of the box are still only half
consumed.
The carbon used to fill the box may be either retort carbon, ground coke,
anthracite coal, graphite or wood charcoal, or any other form of carbon that
contains little residue after combustion. With the carbon the necessary amount of
ferro-manganese or other metal is mixed (preferably red hot).
I find very regular results are obtained by this method of working, both as
regards the carbon and manganese content of the resulting steel, the metal also is
invariably very quiet in the moulds. The slag which before the addition of the
box is in a thoroughly molten condition, becomes granular and can be readily
separated from the steel, and is then in a condition in which it is easily ground for
agricultural purposes.
I have found in practical working that for a charge of 8 tons of pig iron, blown
in a basic converter, there is required to give a steel containing 20 of carbon,
84 lbs. of coke and 100 lbs. of 80 % ferro-manganese. And to obtain a steel with
40% of carbon, there is required 140 lbs. of coke and 100 lbs. of 80% ferro-
manganese.
When it is desired to obtain by the basic Bessemer process extra quality and
pure steel containing lower phosphorous and sulphur than is obtained by the
ordinary method of working I modify the above described method of procedure as
follows:-
I first blow the charge in the ordinary way until it is practically finished, the
bulk of the slag is then poured off and a box of carbon weighted with hematite pig
or scrap is introduced as before described, and allowed to diffuse into the metal for
some three or four minutes. The weight of carbon thus introduced in the box
should not be less than 12 to 15 lbs. to the ton of metal.
When this addition has thoroughly diffused, the vessel is again turned up and
the blowing continued until the carbon flame just drops, by this second blowing I
find that the percentage of phosphorous and sulphur in the metal can be safely
reduced to a much greater extent than can usually be done, without fear of having
"wild" or "burnt" metal and without an undue consumption of ferro-manganese.
When the carbon flame drops (a second or two before rather than after the drop)
I stop the operation and add a second box containing the requisite amount of
carbon and ferro-manganese necessary to finish the bath of steel, and to give the
wished for percentage of carbon and manganese to the metal.
In the basic process, as carried out in the Martin-Siemens furnace, it often
happens (when the workmen have been unskilful) that the carbon has left the bath
before all the phosphorous is removed, thereby causing great difficulty in getting
rid of the remaining phosphorous. When this happens I introduce a box of carbon
into the bath as described above, which causes a gentle boil on the metal and
greatly assists in getting out the remaining phosphorous. A second box of carbon
may be added, as in the Bessemer process, just before tapping, to give the required
percentage of carbon to the steel. The usual skill required to make good steel
must be employed however or a frothy undesirable slag will be produced.

page_text: It will be evident that my invention is equally applicable for adding other
metallic substances than manganese and hematite, and other non metallic substances
than carbon to liquid metals. For instance it may be used for adding such
materials as spiegel aluminium nickel chrome iron, wrought or cast iron or the like
but as its use will probably be most general in steel and ingot iron manufacture it
has been most fully described in that connection.
Having now particularly described and ascertained the nature of my said inven-
tion and in what manner the same is to be performed I declare that what I
claim is:-
1. The improvement in the manufacture of steel or ingot iron, which consists in
adding the carbon while enclosed in a box or receptacle to the charge before it
leaves the furnace or converter substantially as described.
2. The improvement in the manufacture of steel or ingot iron, which consists in
first adding carbon as described then blowing or treating and then adding any
further amount of carbon and ferro-manganese necessary to produce the required
metal all substantially as set forth.
3. The improved means of adding metallic or non metallic substances to a bath of
liquid metal which consists in first enclosing such substances in a wooden box all
substantially as and for the purposes set forth.
Dated this 2nd day of September 1892.
PHILIP M. JUSTICE,
Chartered Patent Agent, 55 & 56, Chancery Lane, London,
For the Applicant.