'Africa' Smelt - March 2011 (Smeltfest)

Jake Keen - Smelt Master
TIME ELAPSED EVENT CHARCOAL   ORE  
      added total added total
14:20   start wood fire in core        
    added small wood splits 8 buckets      
15:10   adding small wood pieces        
15:30   jake starts fitting plugs to tuyeres        
16:10   all tuyeres plugged        
16:13   open one tuyere in each quadrent        
16:15   finish adding small wood pieces 20 buckets      
16:30   temperatures @ west bottom tuyere        
    in about 6" = 975 C        
16:45   open three tuyere in each quadrent        
16:53 2:33 end of wood only pre-heat phase        
             
16:53   addition first rough charcoal / main sequence starts        
17:00   touch off exhaust flame        
    close off all tuyeres        
17:30   open three tuyeres in each quadrent 1 bag 40    
17:43   temperature @west bottom tuyere        
    about centre = 1170 C        
17:57   added rough charcoal 2 bags 120    
18:07   added rough charcoal 1 bag 160    
18:16   added rough charcoal - fill to charge door 3/4 bag 190    
19:18 2:25 end of charcoal pre-heat phase        
             
19:18   first ore addition - as slug     2 lbs 2
19:20   temperature @ west centre = 1150 C        
?   top up rough charcoal - ore addition ?   3 lbs 5
19:45   briefing        
19:55   add balance of rough charocal 1/4 bag 200    
20:13   rough ore added as slug, topped w graded charcoal 1 bucket 205 1 measure 10
20:28 0:15 glowing cherry red chimney 1 210 1 15
20:39 0:11 S/W/E tuyeres show white hot 1 215 1 20
20:50 0:11 double charcoal to bring to charge door 2 225 2 30
21:03 0:13   2 235 2 40
21:18 0:15 level allowed to drop to top of 'bell' 1 240 1 45
21:31 0:13 tuyeres tapped 1 245 1 50
21:40 0:09   1 250 1 55
21:51 0:11 tuyeres poked clear 1 255 1 60
    S / E tuyeres show 'little cooler'        
    N / W tuyeres show white heat        
22:03 0:12 add last of rough ore 1 260 1 65
22:13 0:10 added graded ore 1 265 1 70
22:18 0:05 noticably hotter 1 270 1 75
22:27 0:09 poked tuyeres - mass felt 1 275 1 80
22:43 0:16   1 280 1 85
22:57 0:14 mass closer to W tuyeres 1 285 1 90
23:18 0:21 charcoal only added 1 290    
23:24 0:06 ore charges resumed 1 295 1 95
23:34 0:10   1 300 1 100
23:44 0:10   1 305 1 105
23:55 0:11 N /W / S tyeres 'had a bit of slag' 1 310 1 110
0:04 0:09   1 315 1 115
0:12   top tuyeres closed all quadrants        
0:22 0:18   1 320    
0:33 0:11   1 325 1 120
0:44 0:11 open all top tuyeres        
0:55 0:22   1 330 1 125
1:04 0:09   1 335    
1:15 0:11 charcoal jammed in shaft - poked down to free 1 340    
1:38 0:23 ore charges resumed with smaller additions 1 345 3 lbs 128
1:47 0:09   1 350 3 lbs 131
1:56 0:09   1 355 3 lbs 134
2:08 0:12   1 360 3 lbs 137
2:25 0:17   1 365 3 lbs 140
2:42 0:17 slag at N / S / W tuyeres - ore charges increased 1 370 4 lbs 144
2:56 0:14 bubbling heard, sparks seen 1 375 4 lbs 148
3:05 0:09   1 380 4 lbs 152
3:16 0:11   1 385 4 lbs 156
3:30 0:14 slag formation continues - full ore charges resume 1 390 1 161
3:40 0:10   1 395 1 166
3:56 0:16   1 400 1 171
4:06 0:10   1 405 1 176
4:18 0:12   1 410 1 181
4:37 0:19   1 415 1 186
4:48 0:11   1 420 1 191
5:15 0:27 furnace left to burn down on its own 1 425 2 200
  9:57 end of main smelt sequence        
             
10:45 5:30 approximate opening of furnace        
             
    TOTALS        
             
  Time Preheat (start to first ore charge) 5 hours      
    Main Smelt Sequence (not including burn down) 10 hours      
    Burn Down (approximate) 5 1/2 hours      
    Total Elapsed Time 20 1/2 hours      
             
  Fuels Preheat wood 28 buckets      
    Rough Charcoal 200 lbs      
    Graded Charcoal 225 lbs      
    Total Charcoal 425 lbs      
             
  Ore Total Added 200 lbs      

Last Updated on 4/1/11
By Darrell Markewitz