US243774A - Manufacture of ingot iron and steel - Google Patents

Description

u e nv h s nu e .n s 2 E T R O W S N I A H W d. d o M 0 /N\ MANUFAoURE 0F INGOT IRON AND. STEEL. 774

Patented July 5, 1881.

(No Model.) Sheets-Sheet 2.

W. HAINSWORTH.

MANUPAGTURE 0F INGOT IRON AND STEEL. I No. 243,774. y Patented July 5,1881.

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UNITED STATES PATENT OFFICE.

WILLIAM HAINSVVORTH, OF PITTSBURG, PENNSYLVANIA.

MANUFACTPURE OF lNGOT IRON AND STEIEL.A

SPECIFICATION forming part of Letters Patent No. 243,774, dated July 5, 1881.

Application filed January 10, 1881.

Pennsylvania, have invented or discovered a` new and useful Improvement in Manufacture of Ingot Iron and Steel; and I do hereby declare the following to be a full, clear, concise,

'and exact description thereof', reference being had to the accompanying drawings, making a part of this specification, in which-like letters indicating like parts- Figure 1, Sheet 1, is a plan view, showing the main appliances required in carrying out my present invention. Fig. 2, Sheet 2, is a sectional elevation in the plane of the line x a: of Fig. 1,but with the upper end of slidingbox case sectionedin the line 002, Fig. l. Fig. 3 is a sectional view in the plane of the line fr x of Fig. 2. Fig. 4 is a perspective view of the movable Hue box or case, showing the flue-port openings which come opposite the converter-mouth; and Fig. 5 is a detached side view of the pouring end of the converter,

Bessemer Vand Siemens-'Martin or open-hearth processes, with reference to securing from 'the Bessemer or a similar converter the variable products or qualities of product heretofore obtained from the open hearth.

In carrying out this part of my invention I employ the ordinary or any suitable form of Bessemer converter, provided with an airblast, means of rotation, and other appliances such as are usual or necessary, and in the usual way of working the air-blast or Bessemer process I bring the charge to such stage or degree of purification as, being attainable by that process, may be desired, and ordinarily7 I prefer to continue the blowing until all, or nearly all, the carbon is eliminated. Heretofore it has been usual, after this stage of treatment has been reached, to rotate the converter to a horizontal, or nearly horizontal, position and recarbonize the molten charge till it possesses the desired percentage of carbon, or till (No model.)

its quality or constituent elements were otherwise changed by the introduction of spiegel,

ferro-manganese, or other metals or metallic variety, as well as greater purity, of product,`

and this is largely due to the fact that the metal can be keptin a molten state as long as may be necessary without any such destructive .or wasteful 4action thereonof the heat employed as in the Bessemer process would result from a continuance of the blowing opertion. This facility possessed by the openhearthl process ofkeepingthe metal in a molten condition indefinitely without deleterious results and with positive benet gives to this process a decided advantage over the Bessemer, since it enables the manufacturer to charge and recharge as often as he may desire into the molten metal such other metal or metallic alloy or mixture of the same as he may wish with reference to getting such quality of product as he may desire, or one quality of product from or after one or more such charging operations and another quality from or after one or more such other' charging operations, so that from the original charge of metal in the converter two or more different qualities of product may be obtained. Also, by treating Bessemer metal or product by the open-hearth process I secure results which are practically unattainable by the Bessemer process alone in the elimination of phosphorus and the oxidation of silicon. Phosphorus is oxidized with rapidity at a lower temperature than can be got in the blowing operation; but by a prolonged exposure in the open-hearth process after the blowing ceases it may be largely oxidized, so as to go into the slag. And another advantage appertainingvto the open-hearth process, and also arising from the ability to keep the charge in a fluid state for a considerable time,is that the manufacturer can Work into the charge a largel percentage of scrap, so as to utilize the same, and, so far as I am aware, this is the cheapest and best IOO process known for converting scrap into merchant iron or steel; and, furthermore, the combination of the two processes enables me to use a commoner kind of cast-iron, with perhaps a large percentage of vphosphorus, than has heretofore been practicable with the airblast process alone, and still get an equally good product as in the basic process and at a much less expense.

Now, by my present invention, after I have worked the Bessemer process as above stated, I rotate the converter to a horizontal, or nearly horizontal7 position, so that the level of the metal in the converter shall be below the level of the tuyere-openings, and having shut off lthe air-blast, I apply to the metal a flame or lheat such as is employed in the open-hearth process, and while the metal is thereby kept in a iiuid condition, and also further purified, I introduce iron and steel scrap, spiegel, ferromanganese, cast-iron, or other metal or metallic alloy, or mixture of the same, substantially as practiced in the open-hearth-process, with reference either to increasing the quantity of the molten metal or to varying its quality, or both.

If I nd by testing that I have added toov much of one or more metals or alloys, I neutralize the same, or so much of them as may be desirable, by adding the proper ingredient or .ingredients for the purpose; or if I desire one quality7 or product for one purpose and another quality for another purpose, and desire to take both from the same charge, I iirst, by adding the proper metal or alloy or mixture, bring the charge to one of the desired qualities, pour off whatever may be required, then by the use of some other metal or alloy or mixture bring the charge to the other of the desired qualities, or make other desired variations in treatment, all as practiced in connection with the open-hearth process, and during all this time, except while the pouring is being done, I provide for keeping up the action of the heat or dame on the surface of the metal, so as to preserve irs fluidity and perfect its quality while the treatment referred to is in progress.

In working this combined air-blast or Bessemer and open-hearth process I make use of apparatus some of which is old and some of which I believe to be new.

B represents a converter of the ordinary Bessemer form and construction, and which, with its attachments and co-operative appliances-such as tuyere-box z, blast-pipe z', tiltingmechanism z2, and its manner of workingare so well known that they need not be further described. In such or a similar converter I treat the metal by the air-blast in the usual way till it is free, or practically free, of carbon, or arresting the process sooner, if so desired. I then rotate the converter to a position hori- Zontal, or nearly so, so as to bring the level of the molten metal below the tuyere-openings, cut oif the blast, and introduce into the converter-mouth what is sometimes called an oxidining heat or iiame.77

The apparatus employed in this part of the operation I will next describe.

P represents a top view of a gas-producer of any suitable construction, and which may be arranged at any convenient point out of the way of other operations which have to be carried on with rapidity. As shown, it is outside the pit p, in which the pouring or casting is to be done. The iiue a' goes over and down into an underground flue, a. (Shown by dotted lines in Fig. l and partly by dotted and partly by full lines in Fig. 3.) This fine opens at a2, Fig. 2, into a chamber, a3, built in the masonry or abutment A. Directly opposite this abutment A, and at a little distance therefrom, I build a like abutment, A', and make therein a chamber, a, Fig. 3, which leads down and opens into a iiue, a5, Fig. 2, which latter is carried back alongside of the iiue. a to the stack P.

The abutments A A are inclined, as represented in Fig. 2, and their inner faces are made with a slight incline or bevel, as illustrated by the lines s sin Fig. 3. Also, the flue-chambers a3 a4 are`open on their inner or adjacent sides, so that a3 shall open into a flue, c, which opens directly into the convertermouth when the latter is rotated to a horizontal position, and another line, c', leading from the converter-mouth, opens at its other end'into the other flue-chamber, a4.

The tlues c c are made in a box or case, C, which is made movable, so that when the pouring is to be done no obstruction shall be in the way. It may be moved into and out of position in front of the converter-mouth in anyT suitable way-as, for example, it may be raised and lowered by a crane from above; but I believe it better 1o arrange it on an incline, b, in a suitable pit, b', and slide it up and down on suitable guides or ways, b2. Its lower end is made of a wedge shape, such that it will fit neatly in bet'ween the abutments A A and bring the communicating ports into line, as clearly illustrated in Fig. 3. As a device for moving it into and out of position with its upper end opposite the converter-mouth, I prefer to use a hydraulic cylinder, D, the piston-stem d of which is connected directly to the box C.

Pipe and ports for supplying and exhausting water-pressure are represented at d; but other forms or constructions of hydraulic or fluid-pressure apparatus may be substituted for that shown. As soon as the converter is turned down, as above stated, the box or case C is run up to position, as shown.

The gas from producer I? passes by fines a a, chamber a3, and line c into the converter, where it is ignited in connection with an air jet or supply, introduced as presently to be described. The flame and heat pass around the inside of the converter, on or just above the level or surface of the molten metal therein, in a kind of a swivel, and perform substantially the same function as in the open-hearth IOS IIO

furnace, and, more particularly, keep up and preserve the fluidity of the metal without damage or material waste, and perhaps cooperate in improving its quality. Waste heat 5 and gases pass out by the flue c', chamber a4,

and tlue a5 to the stack; but in doing so they impart a considera-ble percentage ot' their heat to the walls of the tlues a c, and particularly to the partition-walls, so that the ingoing gases 1o passing through a and c shall, hy taking up heat therefrom, be raised to the desired high temperature before reaching the point of igni- 'tion and combustion.

In this manner I apply the principle ofthe 1 5 regenerator-furnace to the heating of the gases employed in the converter; and while I prefer this mode of using the regenerator principle simply because it is a cheap, easy, and convenient way of utilizing the waste heat of the ze converter for the purpose specified, I do not in this part of my invention limit myself thereto, but includeas the equivalent thereof any suitable form of regenerator apparatus arranged in the lne of communication between z 5 the gas-producer and the converter, whereby the ingoing gases shall be artificially raised in temperature above what they possess on leaving the producer.

l will next describe the apparatus for heat- 3o ing and introducing the heated air.

In an application already tiled I have shown and claimed a pipe for carrying off the waste products of the Bessemer blowing operation,

as the-same pass off or are blown oft' while' the blowing is in progress.

This pipe I showed as having (when in position) its open end directly over the converter-month, the latter being vertical or in a blowing position. Such pipe then passes over in a goose-neck form to aoapoint out of the way, thence beneath the surface of the ground, and oft' to any desired point where the waste heat and gases could be utilized; but such utilization was not claimed there, nor is it claimed here, except as it is -used for heating a column or flow of air, which 5o the tilting motion ofthe converter.

A matter of a separate application.

At suitable points-say at thejunctions of sections B with B2 and of B2 with BS-I arrange a damper device, such that the pipes may be closed or opened at pleasure. Dampers suita- 6o ble for the purpose are common, and hence I have merely shown damper-cases n n in which to operate the ordinary form of sliding damper, the handles of which are represented at u2. These dampers being open and the swing-section B' being over the converter-mouth while the blowing, is in progress, waste heat, gases,

sparks, &c., will be conducted oft' and discharged; but after the blowing operation is finished and the converter is tilted preparatory to the further treatment of the metal, as described, I close both dampers.

To the section B2, at or near the end farthest from the converter, is connected an air-pipe, c, .which leads from any suitable blowing apparatus or device, by the use ot' which a blast ot' air can be driven into or along the heated pipesection B2. From a point at or near the other end o f said section B2, I take a pipe, c', over and lead it into the gas-flue c at or near the point where the latter opens into the convertermouth, as illust-rated in Fig. 2, so that a blast or jet ot' heated air will be supplied to the gas at or about the proper point for the intermixture of the two preliminary to their ignition and combustion, and so as to secure the proper action of the heat or flame so generated in the converter, as already described. The outgoing waste heat and gas given o' in the blowing opera-tion will have heated the section B2 to a high temperature, so that the air, on being driven or forced through it, will be raised to the proper temperature lfor doing its work. Also, the blowing action should be sufficient in amount or degree so that the escaping air shall create and keep up the proper draft in the ilues a c, so as to bring the gas forward from the producer.

It will thus be seen that I also employ the regenerator principle in the heating of the air, using for that purpose the waste heat of the blowing operation; but in this case also, as in the case of the gas, while I believe this to bel the easiest, cheapest, and simplest way ot' doing the work described, I do not limit myself thereto, but include herein like modifications and substitutes as in the heating of the gas.

The metal and alloys used or usable in the open-hearth process for increasing the quantit-y ofthe charge, as well as for varying its quality, are so many and various, but at the same time so well known, that I do not deem it necessary to describe them.

In my present invention I use or propose to use any or all of them,and in like manner, but under the conditions herein prescribed,forthe purpose of increasing thequantity or varying the quality of a blown Bessemer charge while still retained in the converter, as the same have been used or are usable on,in, or in connection with a charge of metal on the open hearth; and the described process has the very great advantage .of combining the quickness and cheapness ofthe Bessemer process with the variable capacity and accuracy of result which appertain to the open-hearth process. This process also provides conditions for the partial elimination from Bessemer lnetal or product of phosphorus, and for the more complete oxidation of silicon, on account of the long exposure ot' the bath to oxygen and of the sepa- Vration of the oxides so formed from the metal,

the same going into the slag. Also, grades or IOO IIC

qualities of metal which heretofore could not be worked by theBessem er or air-blast process may by this process be made to give aproduct equally as good as by the open-hearth process alone or by thebasic process.

Since the box C covers the converter-mouth while such subsequent treatment is in progress, I provide in the side or wall ofthe converter, preferably at or near its mouth, a door, fi, of suitable size for the introduction of such metals, alloys, or chemicals as may be desired, and this door, preferably of conical or pyramidal forin, may be opened and closed, and when closed be fastened by any suitable devices, such as are known in the art for such purposes, as by a hinge, t', and pivoted lockin g-bar, t2, engaging suitable catches, t3, Fig. 5.

For turning` on and shutting off the flow of gas and air, any suitable arrangement of cock, valves, dam'pers, or gates may be added.

I do not deem it absolutely necessary to the working of the described process that the waste gases leave the converter by its mouth, as it would be practicable to remove the tuyerebox after each blowing and make the wastetlue connection at that end of the converter.

The process thus described is valuable, not only for making various grades or qualities of ingot iron or of steel in ingot form, but also it is of value in the preparation of metals or materials to be run oft' directly to the molds for the making of all sorts of cast ingot-iron or caststeel castings, and such, among other uses, I include herein.

The making of cast-steel castings is already a well-known branch of the art, and this invention is designed, ir. part, as a more effect.- ive, cheaper, and more certain method of and apparatus for preparing material from castiron for the making of such castings.

I am aware that, broadly speaking, it is not new, after treating a charge of metalin a converter by the Bessemer process, to rotate 'the converter to a horizontal' position and inject gas through a tuyere above the surface ofthe charge; and also that it is not new to employ the outgoing waste heat of an ordinary fixed furnace-chamber to heat the in going gases, and hence I make no claim to such features of construction by themselves considered.

I am also aware that a rocking basin-shaped con Vertin g-chamber or hearth havin glateral or end heat-supply and waste-ports has been combined with an arrangement of gas and air dues for treating the metal with air and gas, injected sometimes beneath and sometimes above the surface of the metal; but I am not aware of any prior combination with a Besse mer converter of gas and air flues such that, after the metal has been treated to the desired extent by the air-blast while in an upright or vertical position, and the converter has been turned down to a horizontal position, or one substantially horizontal, a combined stream of air and gas can be turned onto the metal through the open mouth of the converter, with provision for carrying oi' the waste gases through the converter-mouth, and such combination is included herein, whether the fluebox be movable or stationary.

I claim herein as my inventionl. In combination with an air-blast converter, a movable tine-box, C, having gas and air conduits or ports opening unitedlyinto the converter-mouth, and a gas-escape conduit, suhstantially as set forth.

2. rIhe combination of an air-blast converter, a gas producer and regenerator, au airblast and air-regenerator, and a movable fluebox C, which, when in position for work, brings the gas, air, and waste ues unitedly at the converters mouth, substantially as set forth.

3. The abutments A A', arranged and chambered as described, in combination with movable flue-box C and piston and cylinder for moving the same, substantially as set forth.

4. In combination with an air-blast converter, a movable due-box, C, and a cylinder and piston for moving the same into and out of position relative to the converters mouth when in a tiltedposition, substantially as set forth.

and to carry off the waste gas, heat, Svc., also,

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