coke dust, and the mixture fed into upright retorts
placed in the chimney of the puddling furnace.
By exposure for 24 hours to the heat of the waste
gases from the furnace, in the presence of solid carbon,
a considerable portion of the oxygen of the ore is
removed, but little or no metallic iron is formed.
The ore is then drawn from the deoxidizer into the
rear or second hearth of the puddling furnace, situated
below it, where it is exposed for 20 minutes to a
much higher temperature than that of the deoxidizer.
Here the presence of the solid carbon, mixed with
the ore, prevents any oxidizing action, and the temperature
of the mass is raised to a point at which the cinder
begins to form. Then the charge is carried forward
by the workmen to the front hearth, in which the temperature
of a puddling furnace prevails. Here the cinder
melts, and at the same time the solid carbon reacts
on the oxygen remaining combined with the ore, and
forms metallic iron; but by this time the molten cinder
is present to prevent undue oxidation of the metal
formed, and solid carbon is still present in the mixture
to play the same role, of reducing protoxide of iron
from the cinder, as the carbon of the cast iron does
in the ordinary puddling process. I have said
that the cast iron used as the material for puddling
contains about 3 per cent. of carbon; but in this
process sufficient carbon is added to effect the reduction
of the ore to a metallic state, and leave enough in
the mass to play the part of the carbon of the cast
iron when the metallic stage has been reached.
It would be interesting to compare the Wilson with
the numerous other direct processes to which allusion
has already been made, but there have been so many
of them, and the data concerning them are so incomplete,
that this is impossible. Two processes, however,
the Blair and the Siemens, have attracted sufficient
attention, and are sufficiently modern to deserve
notice. In the Blair process a metallic iron
sponge was made from the ore in a closed retort, this
sponge cooled down in receptacles from which the air
was excluded, to the temperature of the atmosphere,
then charged into a puddling furnace and heated for
working. In this way (and the same plan essentially
has been followed by other inventors), the metallic
iron, in the finest possible state of subdivision,
is subjected to the more or less oxidizing influences
of the flame, without liquid slag to save it from
oxidation, and with no carbon present to again reduce
the iron oxides from the cinder after it is formed.
The loss of metal is consequently very large, but
oxides of iron being left in the metal the blooms are
invariably “red short.”
In the Siemens process pieces of ore of the size of
beans or peas, mixed with lime or other fluxing material,
form the charge, which is introduced into a rotating
furnace; and when this charge has become heated to
a bright-red heat, small coal of uniform size is added
in sufficient quantity to effect the reduction of
the ore.