By the introduction in 1879, however, of the "Thomas-Gilchrist" or "basic" process, these difficulties were very largely overcome, and the employment of even such impure irons as the Cleveland (containing comparatively a large percentage of phosphorus) was rendered possible, and the price of steel consequently generally very much reduced. The process consists of submitting the molten pig-iron to a very great heat in a pear-shaped vessel (known technically as the "converter"). This is open at the top, and is supported on hinges, which permit of its being moved so as to pour off the scum which rises to the surface at the end of the operation, and which, we may explain, consists of "basic slag." In the original process the sides of the "converter" were lined with fire-bricks, consisting largely of silica. This process was known as the "acid" process. In the "Thomas-Gilchrist" process, however, the sides of the "converter" are lined with lime (dolomitic limestone being largely used), lime being also added to the pig-iron. An air-blast is injected through the molten mass, and the impurities are burnt, or oxidised as it is chemically termed. The phosphorus in the iron is thus converted into phosphoric acid, and, uniting with the lime, forms phosphate of lime, which rises, as we have already said, to the surface in the form of a scum, and is separated from the steel by being poured off.
Not at first used.
This, then, is how the Thomas-slag is obtained. It did not seem, however, for some years after the introduction of this ingenious process, to have struck any one that this rich phosphatic bye-product might prove a valuable addition to our artificial fertilisers. The result was, that the Thomas-slag was treated as another of the only too numerous valueless bye-products which seem to be necessarily incidental to most of our chemical and other manufactures, and was allowed to accumulate in large quantities without being used for any purpose.
Discovery of its Value.
In 1883 some short articles published in Germany on the subject were the means of first drawing the attention of the public to its importance as a manure. During the years 1884 and 1885 numerous experiments were carried out on the subject in the same country; and from then up till the present hour it has become more and more extensively used in Germany, till in 1887, as already stated, its consumption amounted to nearly 300,000 tons.
It consists mainly of phosphate of lime, silicate of lime, free lime, free magnesia, and oxides of iron and manganese. Its composition, of course, naturally varies; but the following may be taken as an average analysis:[233]—
| Per cent. | ||
| * | Phosphoric acid | 17 |
| Lime in combination with phosphoric, silicic, sulphuric, and carbonic acids | 40 | |
| Free lime | 15 | |
| Oxides of iron | 12 | |
| * | Equal to tricalcic phosphate | 37 |
As a rule, the phosphoric acid varies considerably, ranging from 10 to 20 per cent—that is, from 22 to 44 per cent tricalcic phosphate. This is owing to the difference in the percentage of phosphorus in the raw material and the quantity of lime added. Attempts have been made in Germany during the last two or three years to obtain a slag richer in phosphoric acid than that obtained heretofore, and a process for this purpose has been patented by Professor Scheibler. This consists of a slight modification in the ordinary process. Instead of treating the pig-iron with an excessive quantity of lime, the amount added is not sufficient to effect the complete dephosphorisation of the iron. The resulting slag is very rich in phosphoric acid, and is correspondingly poor in iron. The iron is then again treated with fresh lime, and the phosphorus completely removed, while the same lime may be used over again. Such slag forms a very much more concentrated phosphatic manure than the ordinary slag, and is known as patent phosphate meal.
A point which not only renders the slag a product of peculiar interest from a chemical point of view, but has a most important bearing on its value as a manure, is the nature of the compound formed by the union of the lime with the phosphoric acid.