Heroult process the impurities of the molten iron are washed out
by treatment with suitable slags. The furnace consists of a
crucible in the form of a closed shallow iron tank, thickly lined
with dolomite and magnazite brick, with a hearth of crushed
dolomite. The electric current enters the crucible through two
massive electrodes of solid carbon, 70 inches in length and 14
inches in diameter, so mounted that they can be moved either
vertically or horizontally by the electrician in charge. These
electrodes are water-jacketed to reduce the rate of consumption.
The furnace contains an inlet for an air blast and openings in its
covering for charging the material and for the escape of the
gases. The actual process of steel-making consists of charging the
crucible with steel scrap, pig iron, iron ore, and lime of the
proper quality and in the right proportions, placing this material
on the hearth of the furnace. Combined arc and resistance heating
is applied to raise the charge to the melting point. The current
is of 120 volts or the same as that used in an ordinary
incandescent lighting circuit, but is alternating and of 4,000
amperes. This is for a three-ton furnace. As the material melts
the lime and silicates form a slag which fuses rapidly and covers
the iron and steel in the crucible, so that the molten bath is
protected from the action of the gases which are liberated and the
oxygen in the atmosphere. The next step in the process is to lower
the electrodes until they just touch beneath the surface of the
molten slag so that subsequent heating is due not to the effect of
the arc but to the resistance which the bath offers to the passage
of the current.
Air from an air blast is introduced into the crucible to oxidize
the impurities of the metal, particularly the sulphur and the
phosphorus which are carried into the slag and this is removed by
the tilting of the furnace. Fresh quantities of lime, etc., are
added, and the operation is repeated until a comparatively pure
metal remains, when an alloy high in carbon is added and whatever
other constituents are desired for the finished steel. The charge
is then tipped into the casting ladle and the part of the electric
furnace is finished. For three tons of steel eight to ten hours
are required in the Heroult crucible furnace.
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