It is not especially difficult to make iron if you have the ore, a
charcoal fire in a little oven of stones, and a pair of bellows. Put
on layers of charcoal alternating with layers of ore, blow the
bellows, and by and by you will have a lump of iron. It is not really
melted, but it can be pounded and worked. This is called the "Catalan
method," because the people of Catalonia in Spain made iron in this
way. It is still used by the natives of the interior of Africa. But if
all the iron was made by this method, it would be far more costly than
gold. The man who makes iron in these days must have an immense "blast
furnace," perhaps one hundred feet high, a real "pillar of fire." Into
this furnace are dropped masses of ore, and with it coke to make it
hotter and limestone to carry off the silica slag, or worthless part.
To increase the heat, blasts of hot air are blown into the bottom of
the furnace. This air is heated by passing it through great steel
cylinders as high as the furnace. The fuel used is nothing more than
the gases which come out at the top of the furnace.
The slag is so much lighter than iron that when the ore is melted the
slag floats on top just as oil floats on water, and can be drained out
of the furnace through a higher opening than that through which the
iron flows. The slag tap is open most of the time, but the iron tap is
opened only once in about six hours. It is a magnificent sight when a
furnace is "tapped" and the stream of iron drawn off. Imagine a great
shed, dark and gloomy, with many workmen hurrying about to make ready
for what is to come. The floor is of sand and slopes down from the
furnace. Through the center of this floor runs a long ditch straight
from the furnace to the end of the shed. Opening from it on both sides
are many smaller ditches; and connecting with these are little
gravelike depressions two or three feet long and as close together as
can be. These are called "pigs." When the time has come, the workmen
gather about the furnace, and with a long bar they drill into the
hard-baked clay of the tapping hole. Suddenly it breaks, and with a
rush and a roar the crimson flood of molten iron gushes out. It flows
down the trench into the ditches, then into the pigs, till their whole
pattern is marked out in glowing iron. Now the blast begins to drive
great beautiful sparks through the tapping hole. This means that the
molten iron is exhausted. The blast is turned off, and the "mud-gun"
is brought into position and shoots balls of clay into the tapping
hole to close it for another melting, or "drive." The crimson pigs
become rose-red, darken, and turn gray. The men play streams of water
over them and the building is filled with vapor. As soon as the pigs
are cool enough, they are carted away and piled up outside the
building.
Public-domain text, read in full here on John Shaqi.
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