Iron, which is the most valuable of all our metals, may fitly head our list. So many useful articles are made of it, that without consideration any one can name twenty. The arts of peace and the glories of war are all produced with the assistance of iron, and its occurrence with coal has rendered us the greatest service, and placed us at the head of nations. It occurs native in meteoric stones.
Iron is obtained from certain ores in England and Sweden, and these contain oxygen and iron (see [Mineralogy]). We have thus to drive away the former to obtain the latter. This is done by putting the ores in small pieces into a blast furnace (fig. 402) mixed with limestone and coal. The process of severing the metal from its ores is termed smelting, the air supplied to the furnace being warmed, and termed the “hot blast.” The “cold blast” is sometimes used. The ores when dug from the mine are generally stamped into powder, then “roasted,”—that is, made hot, and kept so for some time to drive off water, sulphur, or arsenic, which would prevent the “fluxes” acting properly. The fluxes are substances which will mix with, melt, and separate the matters to be got rid of, the chief being charcoal, coke, and limestone. The ore is then mixed with the flux, and the whole raised to a great heat; as the metal is separated it melts, runs to the bottom of the “smelting furnace,” and is drawn off into moulds made of sand; it is thus cast into short thick bars called “pigs,” so we hear of pig-iron, and pig-lead. Iron is smelted from “ironstone,” which is mixed with coke and limestone. The heat required to smelt iron is so very great, that a steam-engine is now generally employed to blow the furnace. (Before the invention of the steam-engine, water-mills were used for the same purpose.) The smelting is conducted in what is called a blast furnace. When the metal has all been “reduced,” or melted, and run down to the bottom of the furnace, a hole is made, out of which it runs into the moulds; this is called “tapping the furnace.”
Fig. 402.—Blast furnace.
Smelting is often confounded with melting, as the names are somewhat alike, but the processes are entirely different; in melting, the metal is simply liquefied, in smelting, the metal has to be produced from ores which often have no appearance of containing any, as in the case of ironstone, which looks like brown clay.
The cone of the furnace, A, is lined with fire-bricks, i i, which is encased by a lining, l l; outside are more fire-bricks, and then masonry, m n; C is the throat of the furnace; D the chimney. The lower part, B, is called the boshes. As soon as the ore in the furnace has become ignited the carbon and oxygen unite and form carbonic acid, which escapes, and the metal fuses at last and runs away. The coal and ore are continually added year after year. The glassy scum called “slag “ protects the molten iron from oxidation.
Fig. 403.—General foundry, Woolwich Arsenal.
The metal drawn from the blast furnace is “pig iron,” or “cast” iron, and contains carbon. This kind of iron is used for casting operations, and runs into sand-moulds. It contracts very little when cooling. It is hard and brittle.
