| Time | Event | Measures | |||||||||
| Relative | Absolute | Total | |||||||||
| Relative | Elapsed | Charcoal | Ore | ||||||||
| 0:00 | 0 | addition rough charcoal, gentle air blast | |||||||||
| 0:15 | Smelter Corn put on | ||||||||||
| 0:20 | Smelter Corn readt for eating | ||||||||||
| 0:40 | Start of graded Charcoal | ||||||||||
| 0:45 | 5 | first measured charcoal | 1 | 4 lbs* | 4 lbs | ||||||
| 0:54 | 9 | charcoal | 2 | 8 lbs | |||||||
| 1:02 | 8 | charcoal | 3 | 12 lbs | |||||||
| 1:05 | Start heating first charge | ||||||||||
| 1:10 | 8 | Charcoal | 4 | 16 lbs | |||||||
| 1:11 | Ore | 1 | .75 lbs* | .75 lbs | |||||||
| 1:19 | 9 | charcoal | 5 | 20 lbs | |||||||
| 1:22 | 5 | Ore | 2 | .75 lbs | 1.5 lbs | ||||||
| 1:30 | 11 | charcoal | 6 | 24 lbs | |||||||
| 1:33 | 11 | Ore | 3 | .75 lbs | 2.25 lbs | ||||||
| 1:38 | 8 | charcoal | 7 | 28 lbs | |||||||
| 1:45 | 12 | Ore | 4 | .75 lbs | 3 lbs | ||||||
| 7 | charcoal | 8 | 32 lbs | ||||||||
| 1:52 | 7 | Ore | 5 | .75 lbs | 3.75 lbs | ||||||
| 1:55 | 10 | charcoal | 9 | 36 lbs | |||||||
| 2:02 | 10 | Ore | 6 | .75 lbs | 4.5 lbs | ||||||
| 2:04 | 9 | charcoal | 10 | 40 lbs | |||||||
| 2:12 | 10 | Ore | 7 | .75 lbs | 5.25 lbs | ||||||
| 2:14 | 10 | charcoal | 11 | 44 lbs | |||||||
| 2:22 | 10 | Ore | 8 | .75 lbs | 6 lbs | ||||||
| 2:24 | 10 | charcoal | 12 | 48 lbs | |||||||
| 2:31 | 9 | Ore | 9 | .75 lbs | 6.75 lbs | ||||||
| 2:35 | 11 | charcoal | 13 | 52 lbs | |||||||
| 2:46 | 11 | charcoal | 14 | 56 lbs | |||||||
| Ore | 10 | .75 lbs | 7.5 lbs | ||||||||
| 2:53 | 7 | charcoal | 15 | 60 lbs | |||||||
| 2:56 | 10 | Ore | 11 | .75 lbs | 8.25 lbs | ||||||
| 3:05 | 12 | charcoal | 16 | 64 lbs | |||||||
| 9 | Ore | 12 | .75 lbs | 9 lbs | |||||||
| 3:12 | 7 | Ore | 13 | .75 lbs | 9.75 lbs | ||||||
| 3:14 | Turned Air up to C+ | ||||||||||
| 3:15 | 10 | charcoal | 17 | 68 lbs | |||||||
| 3:24 | 9 | charcoal | 18 | 72 lbs | |||||||
| 12 | Ore | 14 | .75 lbs | 10.5 lbs | |||||||
| 3:35 | 9 | charcoal | 19 | 76 lbs | |||||||
| 3:36 | Turned Air up to D | ||||||||||
| 3:47 | 12 | charcoal | 20 | 80 lbs | |||||||
| 23 | Ore | 15 | .75 lbs | 11.25 lbs | |||||||
| 3:48 | Optical Pyrometer measurements (2400-2800F) | ||||||||||
| 3:56 | 9 | charcoal | 21 | 84 lbs | |||||||
| Ore | 16 | .75 lbs | 12 lbs | ||||||||
| 4:03 | 7 | Ore | 17 | .75 lbs | 84 lbs | 12.75 lbs | |||||
| 4:05 | 9 | charcoal | 22 | 88 lbs | |||||||
| 4:14 | 9 | Ore | 18 | .75 lbs | 13.5 lbs | ||||||
| charcoal | 23 | 92 lbs | |||||||||
| 4:24 | 10 | Ore | 19 | .75 lbs | 14.25 lbs | ||||||
| charcoal | 24 | 96 lbs | |||||||||
| 4:33 | 9 | Ore | 20 | .75 lbs | 15 lbs | ||||||
| charcoal | 25 | 100 lbs | |||||||||
| 4:42 | 9 | Ore | 21 | .75 lbs | 15.75 lbs | ||||||
| charcoal | 26 | 104 lbs | |||||||||
| 4:50 | 8 | Ore | 22 | .75 lbs | 16.5 lbs | ||||||
| charcoal | 27 | 108 lbs | |||||||||
| 4:58 | 8 | Ore | 23 | .75 lbs | 17.25 lbs | ||||||
| charcoal | 28 | 112 lbs | |||||||||
| 5:06 | 8 | Ore | 24 | .75 lbs | 18 lbs | ||||||
| charcoal | 29 | 116 lbs | |||||||||
| 5:14 | 8 | Ore | 25 | .75 lbs | 18.75 lbs | ||||||
| charcoal | 30 | 120 lbs | |||||||||
| 5:23 | 9 | Ore | 26 | .75 lbs | 19.5 lbs | ||||||
| charcoal | 31 | 124 lbs | |||||||||
| 5:32 | 9 | Ore | 27 | .75 lbs | 20.25 lbs | ||||||
| charcoal | 32 | 128 lbs | |||||||||
| 5:39 | 7 | Ore | 28 | .75 lbs | 21 lbs | ||||||
| charcoal | 33 | 132 lbs | |||||||||
| 5:46 | 7 | Ore | 29 | .75 lbs | 21.75 lbs | ||||||
| charcoal | 34 | 136 lbs | |||||||||
| 5:54 | 8 | Ore | 30 | .75 lbs | 22.5 lbs | ||||||
| charcoal | 35 | 140 lbs | |||||||||
| 5:59 | 5 | Ore | 31 | .75 lbs | 23.25 lbs | ||||||
| 6:03 | 4 | Ore | 32 | .75 lbs | 24 lbs | ||||||
| 9 | charcoal | 36 | 144 lbs | ||||||||
| 6:07 | 4 | Ore | 33 | .75 lbs | 24.75 lbs | ||||||
| 6:12 | 5 | Ore | 34 | .75 lbs | 25.5 lbs | ||||||
| 9 | charcoal | 37 | 148 lbs | ||||||||
| 6:15 | 3 | Ore | 35 | .75 lbs | 26.25 lbs | ||||||
| 6:20 | 5 | Ore | 36 | .75 lbs | 27 lbs | ||||||
| 8 | charcoal | 38 | 152 lbs | ||||||||
| 6:24 | 4 | Ore | 37 | .75 lbs | 27.75 lbs | ||||||
| 6:26 | 2 | Ore | 38 | .75 lbs | 28.5 lbs | ||||||
| 6:29 | 3 | Ore | 39 | .75 lbs | 29.25 lbs | ||||||
| 9 | charcoal | 39 | 156 lbs | ||||||||
| 6:34 | 5 | Ore | 40 | .75 lbs | 30 lbs | ||||||
| 6:36 | 7 | charcoal | 40 | 160 lbs | |||||||
| 6:39 | 5 | Ore | 41 | .75 lbs | 30.75 lbs | ||||||
| 6:42 | 3 | Ore | 42 | .75 lbs | 31.5 lbs | ||||||
| 6:44 | 2 | Ore | 43 | .75 lbs | 32.25 lbs | ||||||
| 8 | charcoal | 41 | 164 lbs | ||||||||
| 6:48 | 4 | Ore | 44 | .75 lbs | 33 lbs | ||||||
| 6:50 | 2 | Ore | 45 | .75 lbs | 33.75 lbs | ||||||
| 6:52 | 2 | Ore | 46 | .75 lbs | 34.5 lbs | ||||||
| 8 | charcoal | 42 | 168 lbs | ||||||||
| 6:54 | Gromp | 1 | nodule | ||||||||
| 6:56 | 4 | Ore | 47 | .75 lbs | 35.25 lbs | ||||||
| 6:58 | 2 | Ore | 48 | .75 lbs | 36 lbs | ||||||
| 4 | Gromp | 2 | |||||||||
| 7:00 | 8 | charcoal - switch to rough crushed | 43 | 172 lbs | |||||||
| 2 | Ore | 49 | .75 lbs | 36.75 lbs | |||||||
| Gromp | 3 | ||||||||||
| 7:02 | 2 | Gromp | 4 | ||||||||
| 7:04 | 4 | Ore | 50 | .75 lbs | 37.5 lbs | ||||||
| 2 | Gromp | 5 | |||||||||
| 7:08 | 4 | Ore | 51 | .75 lbs | 38.25 lbs | ||||||
| Gromp | 6 | ||||||||||
| 7:10 | 10 | charcoal | 44 | 176 lbs | |||||||
| 2 | Ore | 52 | .75 lbs | 39 lbs | |||||||
| Gromp | 7 | 3.75 lbs | |||||||||
| 7:19 | charcoal | 45 | 180 lbs | ||||||||
| 7:30 | charcoal | 46 | 184 lbs | ||||||||
| 7:31 | Shock Charge - ore | 53 | .75 lbs | 39.75 lbs | |||||||
| 7:37 | charcoal | 47 | 188 lbs | ||||||||
| 7:49 | charcoal | 48 | 192 lbs | ||||||||
| 7:55 | Turn air down to C | ||||||||||
| Scoop out charcoal | |||||||||||
| 7:59 | Turn air down to A | ||||||||||
| 8:02 | Compacting the bloom | ||||||||||
| 8:06 | Extraction | ||||||||||
| 8:12 | Removed Tap arch | ||||||||||
| NOTES: | |||||||||||
| Charge times recorded at END of unit addtition | |||||||||||
| * All charcoal charges are based on a 'standard pail' - weight of 4 lbs | |||||||||||
| All ore charges are based on a 'standard scoop' - weight of 3/4 lbs | |||||||||||
| An ore scoop was weighed as 410g ( 0.9 lbs), then bags of 10Kg of ore were scooped out and the number of scoops counted - this averaged out to 363g ( 0.8 lbs) | |||||||||||
| Estimated from known marks | |||||||||||
| Air flow rates were check at the end of the experiment and confirmed to match previous readings. | |||||||||||
| YIELD: 8.1 Kg ( 17.8 lbs) in various types | |||||||||||
| Two small blooms were recovered 900g and 650g. These seem to be masses with mild steel and cast iron. | |||||||||||
| An additional 3.75 Kg in a single Cast Iron / Slag mass | |||||||||||
| 600 g of magnetic bits were screened from the ash | |||||||||||
| 1.3 Kg of cast iron were recovered | |||||||||||
| 900 g of loosly sintered material was also pulled from the smelter | |||||||||||
| This smelt did not work as expected. Usually around 2.5 hours into the smelt the reaction "takes off". The time to burn down a bucket of charcoal drops below 8 minutes. To counter this more ore is added to each bucket of charcoal. This time this did not happen. The burn rate stayed at around 8 minutes. We checked the air flow, which was as expected. We used the optical pyrometer to check the inside temperature. 6 different readings were tken by various people all in the expected range. Yet the only difference between this smelt and the previous one was that this smelter was cut into the bank. | |||||||||||
| Around 6 hours into the smelt it was decided to try increasing the amount of ore in a bucket. We expected that this would slow down the burn time but we did want to see what would happen. In a strange twist the burn time stayed at 8 minutes.... so we added more ore, and the burn time stayed at 8 minutes. Given this strange behaviour we finished the smelt as we normally would have. When the bloom was pulled it was found to be mostly cast iron. This makes sense as the ore/charcoal ratio in this smelt was much smaller than usual, the ore spent more time in contact with the carbon then would normally happen. | |||||||||||