Non-technical chats on iron and steel, and their application to modern industrySpring, La Verne W. (La Verne Ward)
History
Non-technical chats on iron and steel, and their application to modern industry
Spring, La Verne W. (La Verne Ward)
Iron; Steel
The two processes are practically the same except that by the basic
process the phosphorus as well as the silicon, manganese, and carbon are
reduced or eliminated. In order to take out the phosphorus, additions of
lime (i. e., calcium oxide or calcium carbonate) are made just as
occurred with the basic Bessemer process.
Should we use lime in a furnace having an acid lining, much of the lime,
which is a “base,” would react with the “acid” (silica) bricks of the
lining, and, becoming neutralized, would not do its work. So, as in the
basic Bessemer process, we here have to use either “basic” or “neutral”
lining.
The material generally used is burnt magnesium carbonate which is known
as “magnesite.” Dolomite, which is a combination of the carbonates of
calcium and magnesium, is sometimes used. Chrome bricks, the usual
neutral material, are rather too expensive for extensive use. The best
magnesite comes from Austria and is usually not very cheap. As acid
materials (those of silica or clay) are cheaper and mechanically
stronger, a compromise is ofttimes effected by using basic materials for
the furnace bottom and acid bricks for the sidewalls and roof. A few
rows of chrome bricks may be put in to form a neutral dividing line just
at and above the edge of the bath where the action of the slag is the
most severe. It also serves to keep the basic and acid materials apart
and from reacting with each other.
At the commencement of charging, limestone or sometimes burnt lime is
shoveled in upon the bottom or “hearth” of the white-hot furnace.
When cold metal is charged, the pigs of iron are conveyed into the
furnace by the melter and his helpers by means of long handled flat iron
tools called “peels.” This is followed by charging some or all of the
scrap or iron which is to be made a part of the charge.
Even in the smaller 15 or 25–ton furnaces hand charging takes a great
deal of time, sometimes as much as six or eight hours, and the labor
cost as well as the heat loss is therefore excessive. Modern machine
charging which requires not more than an hour is therefore highly
desirable.
[Illustration:
ROW OF OPEN-HEARTH FURNACES SHOWING PIT OR TAPPING SIDE
]
During the melting down of the pig iron with the scrap that has been
charged, the air and flame burn out about half of the silicon and
manganese of the metal. To remove the remainder of these and the carbon
of the charge, additions are made from time to time of sufficient ore to
keep the bath “boiling.” This phenomenon results from the giving off of
carbon monoxide gas formed from the oxygen of the iron ore and the
carbon of the metal, just as happened when the puddler in the
manufacture of wrought iron used iron ore in his furnace. The covering
of slag which forms and protects the bath from the flame undoubtedly
transfers oxygen from the furnace gases to the bath and this helps to
burn out the carbon.
Public-domain text, read in full here on John Shaqi.
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