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. |
|
|
|
|
|