How to fiLL a Blast Purnace.
Address, WEIMER MACHINE WORKS, Limited, LEBANON, PA.How to fill a Blast Furnace.Times Printing House, 735 Chestnut Street, Philadelphia.HOW TO FILL A BLAST FURNACE.
The condition of the stock charged into a blast furnace, and the way it is charged, are factors in the operation of a plant which have not until late years received the attention they deserved; and the value of the gases produced by the chemical action in the furnace, were for a long time but poorly appreciated.
During the last decade much patient investigation has been bestowed upon various devices for closing the tunnel-head, and controlling the flow of gases to boilers and hot-blast stoves. Efforts have also been directed to secure a more even distribution of the material charged.
While these improvements have been partially successful, and considerable advance has been made in blast-furnace practice, we must admit, that too little attention has been given to the tunnel-head generally, and to the importance of securing a positive, uniform distribution, independent of the integrity and intelligence of the “ top-filler,” as well as an uninterrupted supply of gas while the furnace is in operation.
In constructing a blast furnace, great care is ordinarily exercised in proportioning the crucible, and boshes ; dams, tymps, tuyeres or cinder blocks are set very exactly to specified heights or at particular angles, and the slope of the boshes is maintained to a predetermined inclination. But when the inwall is built, and the tunnel-head constructed, it is not presumed that such a nicety of detail is needed, or that great care in proportion is essential. A good stack is well built throughout, and the proportions of the top and arrangements of its detail should be as carefully studied as the diameter of hearth or position of tuyeres.
3There is no better paying work about a blast furnace than the thorough preparation of stock; but the money expended in roasters, crushers, separators and pickers, or in the necessary manual labor; brings no adequate return, if the stock is improperly charged into the furnace ; and the care used in the disposition of tuyeres so as to obtain a uniform combustion of the fuel employed will amount to little if the ore, flux and fuel is placed at the mercy of the “ top-filler,” or charged through a badly contrived tunnel-head fixture.
The older charcoal furnaces were built with so small an opening in the top that the stock had to arrrange itself with considerable regularity, which was improved by the attendant’s ravel or shovel. When larger furnaces came into use, and tunnel-heads of greater diameter employed, the workmen were protected from the intense heat of the large volume of escaping gases by brick chimneys; in which a series of doors were made, so that the barrows could discharge at intervals all around the throat with a view of obtaining a more thorough distribution of the stock. In some instances cars with drop bottoms are run on tracks, over the centre of the tunnel-heads, and a hanging bell is suspended in the furnace to obtain a more uniform filling. In other cases to accomplish the same result, the receptacles for the stock are provided with bell-shaped bottoms, and are carried by overhead railways to the opening in the top plates, when the bottom is dropped and the stock falls into the furnace.
In order to secure a seal for the top of the stack, and force the gases to the boilers and hot-blast stoves, the “ cup and cone” or “ bell and hopper” was introduced, but it was found necessary to combine the feature of a distributor as well as a seal with this arrangement. Much has been written upon the proper shape and proportion of bells, and numerous experimental forms tried. They have been made single, double, or in series, in order to obtain as equal division of the materials as possible in the shaft
4Plate 1.
A- CAST IRON TOPPER
The old way of
trying TO Fill A FURNACEPlate 2
THE NEW WAY OF filling a furnace
A Brick hopper Patent no. 223670
B CENTRE DROP Patent No. 212415of the furnace; but no form of bell, or series of bells, can thoroughly distribute, except from a hopper which has received the stock so as to be evenly scattered in it, and to have at least an approximate even flow from it; and any method of placing the stock on the bell which is dependent upon the integrity of manual labor, must run all the risks incident to the variety of persons employed.
To perfect a device securing uniform and regular methods of filling furnaces, so that a practically equal proportion of each of the ores, and of the flux and fuels charged, will be directed over the entire area of the throat, the apparatus illustrated was designed.
5DESCRIPTION.
Plate 1 shows in cross-section the ordinary arrangement of a tunnel-head. A cast-iron hopper rests upon the inwall, and supports a lip-ring, against which the bell closes, sealing the top of the furnace, except when the bell is lowered to drop the charge placed in the hopper. The "top-fillers” ar t supposed to dump successive barroius of the mixture of ores, fuel and flux at various points around the hopper, so that the charge is practically uniform; but it is evident that even with the most careful attention considerable irregularity must exist, particularly when several ores are used, and each filled into separate barrows. The illustration shows the approximate position of the stock falling upon and lying in the hopper as usually arranged. In such a fixture it is evident that unless the amount of each of the component parts of the “ charge ” is sufficient to form a regular layer all around the bell, no approach to a uniformity of flow from it is possible.
The illustration shows the bell operated from a beam, supported on a column, and worked by a steam or air cylinder, it being held in place by means of a latch when the bell is closed.
Plate 2 is an illustration of the improved method of filling a furnace. The cast-iron hopper is dispensed with, and the hp ring placed in the throat of the furnace, resting on a ring-plate supported upon the inwalls, the lip-ring being held by key-bolts passing through lugs on the ring-plate. A vertical circular wall of red brick of sufficient interior diameter to permit of the removal of the lip-ring is constructed so as to form a hopper. The top is provided with a covering plate having an opening in it so proportioned that when the wheels of the charging barrows are run against an adjustable guard, the stock from the barrow will fall on the apex of the bell, and thus be uniformly distributed over the lip-ring, and consequently over the
6A BRICK HOPPER PAT. N4 223.8*0 Q CENTRE DROP PAT. MU 212.41 S p FRICTION WINCH flVX.Nl MAS
Plate 3.Plate 4.
PL WEIMERS , BRICK HOPPER and CENTRE DROP CHARGING APPARATUSsurface of the throat of the furnace, placing the charging beyond the risk of carelessness of the “ top-fillers,” and ensuring a delivery of the stock such as will be conducive to regularity of working, thereby materially lessening the personal labors of the manager, economizing fuel, increasing the output, and maintaining a uniformity of operation and of product not otherwise to be secured.
The illustration shows the top of a furnace in section, and similar operating gear to that on Plate i. This arrangement is a good one, but it necessitates the consignment of an apparatus of great power (a steam cylinder) to the control, in many cases, of uneducated labor. The position of “ top-filler” is not generally given to persons of mechanical ability, and therefore the apparatus committed to their care should be as simple and as free from risks of disarrangement as possible. Although any laborer cannot intelligently manage a steam or air operating cylinder, the most obtuse navvy can turn a crank; and to obtain an arrangement which could be placed in charge of any unskilled person, if necessary, the apparatus illustrated on Plate 3 is designed. Ibis cut shows the tunnel-head of a blast-furnace in section similar to that on Plate 2 ; but instead of operating the bell by a steam or air cylinder, motion to the beam is given by rack and pinion worked by a hand-crank and controlled by a friction-brake. The charge having been dropped through the opening upon the apex of the bell, and thereby distributed, the “top-filler” steps to the friction-winch, grasps the small brake lever, and, throwing out the latch, allows the weight of the charge to carry the bell down at an easy rate, by a slight pressure on the brake. The counterweights in the box at the end of the beam are so proportioned that the bell weighs slightly in excess of them and therefore there is but little power required to move it. By simply turning the hand-crank—the gear-wheel operating on the rack (which is connected to the beam by means of a suitable rod), the bell is readily raised into position against the lip-ring, and the top of the furnace closed. In this apparatus a
7cast-iron framework, forming a fulcrum for the wrought-iron beam, and for the operating gear, is substituted for the column shown on Plates I and 2.
The value of perfect regularity in the various details of furnace operation is becoming more appreciated by those having them in charge.
In dropping the bell, the gases of the furnace find a free vent through an opening necessarily of great area ; and as this operation is repeated many times throughout the day, the aggregate of even a few seconds at a time amounts to an equivalent of exposing this large area for escape of gases for many minutes in each twenty-four hours, and a consequent waste of much heat-producing power. The opening ot this area draws the gases from the hot-blast stoves and boilers, thereby creating an irregularity in operation which, to say the least, is undesirable. In many instances coal fires are maintained to secure ignition of the gases after each dropping of the bell.
To obtain greater uniformity of operation, prevent the waste of the large volume of gases, and make the top of the furnace more comfortable to those whose duty calls them there, the apparatus shown in Plates 4 to 7 was designed. Vibrating on the same fulcrum as the bell-beam is a double lever, one end being supplied with a counter-weight and a knuckle-jointed operating rod, the other end having two connecting rods, which are attached to it, and to a cast-iron seal sliding on the bell-rod as a guide, and neatly covering the opening in the top plates. When the charge is being placed in the hopper, the seal is raised sufficiently high not to interfere with the barrows, by bending the knuckle-jointed rod, which brings down the double lever, and raises the seal as shown on Plate 4 in section, and on Plate 5 in elevation, the counterweight being placed on the beam so as to keep the seal in this position. When the charge is completed, the
8Plate 5.n-IRU YWOPP«&-PAlN«33J.i10 E-CMFRE OROP- »	-	ill-41 J
C-JFAL COVER- «	*	M/-SOR
<;-£RJCIU)N WHICH-- - Hi-4iD-
Plate 6.knuckle-jointed rod is brought into a vertical position, thus throwing the weighted end of the double lever up, and bringing the seal down On to the top plates, covering the opening as on Plates 6 and 7, the former being in section and the latter in elevation, the rod acting as a brace sufficient to hold the seal in position, but sensitive to sudden jars, as from explosions, so that the seal can, in such case, leave its seat. When the opening is closed,]the bell is dropped by the brake and raised by turning the winch, the only escape of gas being a volume equal to that which can be contained in the hopper and lip-ring.
The value of uniformity of operation obtained by keeping a constant flow of gases from the furnace to the hot-blast stoves and boilers has been demonstrated by the arrangement which has been in successful use for six years, shown in perspective on Plates 8 and 9. I his apparatus consists of a conical top having two or more openings in it which are closed by sliding doors operating from a revolving head, which receives motion from a horizontal steam or air cylinder, forming part of the casting carrying the beam. The beam is moved by a vertical cylinder as shown ; the doors are hinged to relieve any explosions which may occur. Plate 8 shows the doors open in the position they are kept while the stock is being dropped on the bell; and Plate 9 shows the door closed while the bell is being lowered in the furnace, thus preventing the escape of gases. This arrangement has proved of great benefit to the furnaces using them, and was, prior to the introduction of centre-drop, and friction-charging apparatus, unequaled by any other. As this apparatus cannot be employed in connection with the centre drop, is very expensive, more liable to disarrangement, composed of numerous parts, and requiring steam or compressed air to operate it, the arrangements as shown on Plates 3 to 7 were designed as being more efficient, less costly, and less liable to accident, and we now offer it to the furnace proprietors and managers as a valuable and indispensable feature to secure uniformity of operation, independent of skill or integrity of manual labor.
9The cut on front of cover shows an adaptation of the centre drop and seal, to a furnace operating the bell by means of a steam or air cylinder. All the illustrations herein given are taken from different arrangements of tunnel-heads in practical operation.
For the brick-hopper, centre-drop and seal, the following advantages are claimed:
First. By dispensing with a cast-iron hopper and constructing it of brick, a saving in first cost and maintenance is effected
Second. As the gases are not permitted to escape while the bell is dropped, a constant flow is maintained, whereby the deposition of dust is lessened, and a regular heat can be kept in combustion chambers of hot-ovens and boilers, and no gas is wasted.
I bird. Being simple in construction, the apparatus is inexpensive, and ordinary labor can operate it without risk of damage through ignorance or neglect.
Fourth. The stock all dropping on the apex of the bell secures a uniformity of distribution in the hopper, and consequently in the furnace, which is not affected by inattention on the part of the “top-filler."
Fifth. Equal distribution at the stock line encourages a uniform flow of stock; which secures greater regularity of operation, resulting in saving of fuel and labor, and in reliability of product.
Propositions for furnishing the apparatus herein described complete ready to put into place, or for the right to construct and use the same, furnished on application to
P. L. WEIMER,
LEBANON, PA.,
AND
152 South Fourth Street, Philadelphia.
10Plate 7.The various arrangements above described are in use at a large number of furnaces scattered throughout the country, and are employed in connection with plants using charcoal, coke, raw bituminous coal, anthracite coal, and mixed fuels.
A few testimonials will suffice to show how the apparatus is appreciated by those who have it in use .
Office of Pottstown Ikon Company, Pottstown, Pa., August 4, 1880.
P. L. WEIMER, Fsq.
Dear Sir: We have had in use at our two blast furnaces, for nearly six months, your centre dump bells. Both of them have worked very satisfactorily, and, as far as we can judge, this is an important feature in their construction.
Yours Truly,
WILLIAM H. MORRIS,
Treasurer.
Etna Iron Works, Ironton, Ohio, October 13, 1877.
P. L. WEIMER, Esq.
Dear Sir: It affords me satisfaction, and a real pleasure, to be able to state that the large charging apparatus furnished us in 1875, an^ which has been in almost constant use since, gives us perfect and entire satisfaction ; have had no repairs to make, and it is ready at all times to perform its duty, and meets more than my most sanguine expectations.
Very Respectfully,
GEORGE WILLARD,
President.
11Sheridan Furnaces, Sheridan, Pa., October 19, 1877.
P. L. WEIMER, Esq.
Dear Sir: In reply to your favor, would state that your charging apparatus, on Nos. 1 and 2 Furnaces, are giving the best of satisfaction. The one on our No. 2 Furnace is in constant use since July, 1875, during which time we have expended nothing for repairs, etc., being the best arrangement for a closed top furnace that we have met with.
Yours Truly,
WILLIAM M. KAUFMAN & CO.
Phoenix Iron Works, Phoenixville, August 3, 1880.
P. L. WEIMER. Esq.
Dear Sir : The centre drop charging apparatus which you supplied for our No. 1 and No. 2 Furnaces has given such satisfaction as a stock distributor, that we would be doing ourselves and the furnaces injustice were we to omit it from No. 3 Furnace, which is now being repaired.
Respectfully,
CHARLES INN RADER, Manager Blast Furnace Department.
Office of the Warwick Iron Company, Pottstown, Pa., August 4, 1880.
P. L. WEIMER, Esq.
Dear Sir: Our experience with your furnace top has been very satisfactory, enabling us to obtain a better distribution of stock, with more certainty than was previously possible. We also find an advantage in the use of the gas seal, both as to the comfort of our men, and in the better control of the gas.
Very Truly,
EDGAR S. COOK, Manager Warwick Iron Company.
12Plate 9-WEIMER’S PATENT CHARGING BARROWS.
The barrows illustrated on Plates i, 2, 3 and 4 are the Weimer patent charging barrow, and are shown enlarged and more in detail on Plate 10. These barrows are made of various sizes suitable for the requirements of furnaces using different fuels, and are entirely of iron, except wooden guards, against which the barrows strike when dumped, and which can be removed and renewed at pleasure. The bodies are of plate iron, riveted to angles at joints, and braced on top and sides by flat iron ; the handles and legs are wrought-iron, riveted to the body. The wheels consist of wrought-iron spokes and felloes and cast hubs, the hub being cast about the spokes after they are inserted in the tire, when the nuts on the spokes (which are provided with screwed ends) are brought up against the tire, making the wheel rigid and firm. F.ach wheel is secured to an independent axle working in bearings, pivoted to the body of the barrow so that the vehicle can be turned in a short space with ease. The bearings are long, and closed to keep out dust, thus insuring a freedom of motion necessitating but small power to propel them even when fully loaded.
When a number of these barrows are supplied, they are balanced so as to be of uniform weight, to guarantee correct charging of the stock. The shape and proportion of the barrows is the result of careful study of the requirements of such appliances, and are presented to the trade as the strongest, most convenient, durable, and easiest running barrow ever put into service.
13A feature of these barrows is that, being made from templates, all parts of each size (three sizes are made) are interchangeable, and any damage occurring to one of them can be readily repaired.
When desired, the patent wheels and axles can be furnished to parties wishing to manufacture their own barrows.
P. L. WEIMER,
Lebanon, Penna.
162 SOUTH FOURTH STREET.
PHILADELPHIA
14Plate 10.THE WEIMER PATENT BLOWING ENGINE
is now in use at more than forty Blast Furnaces, and is giving universal satisfaction.
It has a greater capacity for its size than any blowing engine built, and is, therefore, most economical in cost.
It uses steam to better advantage than other forms of blast engines.
Its air valves accomodate themselves to any speed desired, and are simple and not liable to wear out.
It saves expensive foundations and buildings.
Each engine is set up and operated to satisfaction of purchaser before leaving the works.
Twenty-one sizes are now made.
Price-lists on application to
P. L. WEIMER,
15a South Fourth Street,	LEBANON,	PA.
Philadelphia.P. L. WEIMER, Lebanon, Pa.
[Patented April 20,1880.]