The size of the pieces of the material employed prevents the intimate mixture of the particles of iron with the particles of carbon, and hence we would, on theoretical grounds, anticipate just what practice has proved, viz., that the reduction is incomplete, and the resulting metal being charged with oxides is red-short.  In practice, blooms made by this process have been so red-short that they could not be hammered at all.

It would be impracticable in this process to employ ore and carbon in as fine particles as Wilson does, as a very large portion of the charge would be carried off by the draught, and a sticking of the material to the sides of the rotating furnace could scarcely be avoided.  I do not imagine that a division of the material into anything like the supposed size of molecules is necessary; we know that the graphitic carbon in the pig-iron employed in puddling is not so finely divided, but it is much smaller particles than bean or pea size, and by approximating the size of the graphite particles in pig iron, Wilson has succeeded in obtaining good results.

If we examine the utilization of the heat developed by the combustion of a given quantity of coal in this process, and compare it with the result of the combustion of an equivalent amount of fuel in a blast furnace, we shall soon see the theoretical economy of the process.  The coal is burned on the grate of the puddling-furnace, to carbonic acid, and the flame is more fully utilized than in an ordinary puddling-furnace, for besides the ordinary hearth there is the second or rear hearth, where additional heat is taken up, and then the products of combustion are further utilized in heating the retorts in which the ore is partly reduced.  After this the heat is still further utilized by passing it under the boilers for the generation of steam, and the heat lost in the gases, when they finally escape, is very small.  In a blast furnace the carbon is at first burned only to carbonic oxide, and the products of combustion issue mainly in this form from the top of the furnace.  Then a portion of the heat resulting from the subsequent burning of these gases is pretty well utilized in making steam to supply the power required about the works, but the rest of the gas can only be utilized for heating the blast, and here there is an enormous waste, the amount of heat returned to the furnace by the heated blast being very small in proportion to the amount generated by the burning of that portion of carbonic oxide expended in heating it, and the gases escape from both the hot-blast and the boilers at a high temperature.

In the direct process under consideration the fuel burned is more completely utilized than in the puddling process, to which the cast iron from the blast furnace is subjected to convert it into wrought iron.