Earth and Sky Every Child Should Know / Easy studies of the earth and the stars for any time and place

by Julia Ellen Rogers

Man was pretty well along on the road to civilization before he learned where iron could be found in beds, and how it could be purified for his use. We now know that certain very minute plants, which live in quiet water, cause iron brought into that water to be precipitated, and to accumulate in the bottom of these boggy pools. In ancient days these bog deposits of iron often alternated with coal layers. Millions of years have passed since these two useful substances were laid down. To-day the coal is dug, along with the bog iron. The coal is burned to melt the iron ore and prepare it for use. It is a fortunate region that produces both coal and iron.

Bituminous coal is plentiful, and scattered all over the country, while anthracite is scarce. The cheapest iron is made in Alabama, which has its ore in rich deposits in hillsides, and coal measures close by, furnishing the raw material for coke. The result is that the region of Birmingham has become the centre of great wealth through the development of iron and coal mines.

Where water flows over limestone rock, and percolates through layers of this very common mineral, it causes the iron, gathered in these rock masses, to be deposited in pockets. All along the Appalachian Mountains the iron has been gathered in beds which are being mined. These beds of ore are usually mixed with clay and other earthy substances from which the metal can be separated only by melting. The ore is thrown into a furnace where the metal melts and trickles down, leaving behind the non-metallic impurities. It is drawn off and run into moulds, where it cools in the form of "pig" iron.

The first fuel used in the making of pig iron from the ore was charcoal. In America the early settlers had no difficulty in finding plenty of wood. Indeed, the forests were weeds that had to be cut down and burned to make room for fields of grain. The finding of iron ore always started a small industry in a colony. If there was a blacksmith, or any one else among the small company who understood working in iron, he was put in charge.

To make the charcoal, wood was cut and piled closely in a dome-shaped heap, which was tightly covered with sods, except for a small opening near the ground. In this a fire was built, and smothered, but kept going until all the wood within the oven was charred.

This fuel burned readily, with an intense heat, and without ashes. Sticks of charcoal have the form of the wood, and they are stiff enough to hold up the ore of iron so that it cannot crush out the fire. For a long time American iron was supplied by little smelters, scattered here and there. The workmen beat the melted metal on the forge, freeing it from impurities, and shaping the pure metal into useful articles. Sometimes they made it into steel, by a process learned in the Old World.

The American iron industry, which now is one of the greatest in the world, centres in Pittsburg, near which great deposits of iron and coal lie close together. The making of coke from coal has replaced the burning of charcoal for fuel. When the forests were cut away by lumbermen, the supply of charcoal threatened to give out, and experiments were made in charring coal, which resulted in the successful making of coke, a fuel made from coal by a process similar to the making of charcoal from wood. The story of the making of coke out of hard and soft coal is a long one, for it began as far back as the beginning of the nineteenth century.

In 1812 the first boat-load of anthracite coal was sent to Philadelphia from a little settlement along the Lehigh River. A mine had been opened, the owner of which believed that the black, shiny "rocks" would burn. His neighbours laughed at him, for they had tried building fires with them, and concluded that it could not be done. In Philadelphia, the owners of some coke furnaces gave the new fuel a trial, in spite of the disgust of the stokers, who thought they were putting out their fires with a pile of stones. After a little, however, the new fuel began to burn with the peculiar pale flame and intense heat that we know so well, and the stokers were convinced that here was a new fuel, with possibilities in it.

But it was hard for people to be patient with the slow starting of this hard coal. Not until 1840 did it come into general favour, following the discovery that if hot air was supplied at the draught, instead of cold, anthracite coal became a perfect fuel.

At Connellsville, Pennsylvania, a vein of coal was discovered which made coke of the very finest quality. Around this remarkable centre, coke ovens were built, and iron ore was shipped in, even from the rich beds of the Lake Superior country. But it was plain to see that Connellsville coal would become exhausted; and so experiments in coke-making from other coals were still made. When soft coal burns, a waxy tar oozes out of it, which tends to smother the fire. Early experiments with coal in melting iron ore indicated that soft coal was useless as a substitute for charcoal and coke; but later experiments proved that coke of fine quality can be made out of this bituminous soft coal, by drawing off the tar which makes the trouble. New processes were invented by which valuable gas and coal tar are taken out of bituminous coal, leaving, as a residue, coke that is equal in quality to that made from the Connellsville coal. Fortunes have been made out of the separation of the elements of the once despised soft coal. For the coke and each of its by-products, coal tar and coal gas, are commercial necessities of life.