| Date : June 2001 Experiment : 1 Location : L'Anse Aux Meadows NF Team : Parks Canada Consultants (1) Furnace : Norse boxed bowl - stone slab sides, clay sealed, sod backed - no tap arch Size : 35 cm x 30 x 50 H (square) Source : based on LAM (theoretical) Tuyere : 25 mm ID steel pipe Placement : 5 cm above floor - 3 cm in from wall - angle slightly up Bellows : standard Norse double chamber Air : (E) 2 L per stroke - (E) 120 L per minute Charcoal : 8 kg broken hardwood Consumption : Ore : LAM bog ore - 5 kg (roasted) Sequence : ore added as one large charge Duration : about 2 hours (plus preheat) Result : small slag mass - some small iron 'prills' (total 100 gm) - test as high carbon (cast iron) Notes : a number of basic errors, consider equipment test : - charcoal allowed to burn down to half way - ore placed on raft of bark - air flow not constant (cycles temperature) - low pressure / poor penetration of air - sequence too short |
Date : May 2002 Experiment : 2 / D1 Location : Wareham ON Team : DARC (2) + Dr. Kevin Smith Furnace: Norse boxed bowl - stone slab sides, clay sealed, sod backed - no tap arch Size : 30 cm x 30 x 40 H (square) Source : based on LAM (theoretical) Tuyere : 25 mm ID steel pipe Placement : angle slightly up Bellows : standard Norse double chamber Air : (EE) 1.2 L per stroke - (EE) 120 - 72 L per minute Charcoal : 22 kg broken hardwood Consumption : Ore : St Lunaire bog ore - 6 kg (roasted) - mix of 2.8 ore / 2.5 scale / .7 sand Sequence : ore added as three large charges Duration : about 8 hours (plus preheat) Result : 2 kg slag mass - total 4.3 kg magnetic slag recovered Notes : a number of basic errors - use of large amount forge scale - extremely low air volume - low pressure / poor penetration of air - air flow not constant (cycles temperature) |
| Date : June 2003 Experiment : 3 / D2 Location : Wareham ON Team : DARC Furnace : Early Medieval Medium Shaft - cylindrical cob with refractory liner - tap arch - fire brick base Size : 27 cm taper to 24 x 90 H Source : suggested by Sauder & Williams Tuyere : 25 mm ID steel pipe Placement : (E) about 20 cm from base - about 5 cm in from wall - angle at 15 down Bellows: vacuum blower Air : Charcoal : (E) 50 kg broken hardwood Consumption : about 1.5 kg charcoal every 12-15 minutes Ore : Virginia rock ore - 8 kg (roasted) Sequence : ore added as 6 x 1.5 kg charges Duration : about 4 1/2 hours (plus preheat) Result : - initial liquid slag (faylite) tapped - burn through crashes sequence Notes : Generally sequence is closer to correct - slag bowl forms too high - slightly reduced air volume - incorrect tuyere angle |
Date: June 2004 Experiment : 4 / D3 Location : Wareham ON Team : DARC + Mike McCarthy / Mark Pilgrim Furnace : Norse Boxed Short Shaft - cylindrical cob backed with stone slab and sand - no tap arch Size : 25 cm tapers to 20 x 50 H Source : suggested by Crew Tuyere : 25 mm ID steel pipe Placement : 2 cm from base - about 5 cm in from wall - angle at 15 down Bellows : initial Norse double bag / various Air : initial 2.2 per stroke / at 130 per minute / various Charcoal : (E) 19 kg broken hardwood Consumption : about 1.5 kg charcoal every 12-15 minutes Ore : Virginia rock ore - 7 kg (roasted) Sequence : ore added as 7 x 1 kg charges Duration : about 6 hours (plus preheat) Result : slag masses only Notes: - Clay slumps during smelter construction - moves tuyere to incorrect position, too close to floor and shallow angle. This 'drowns' air flow. - Air system failures lead to fluctuating temperatures - Attempt to cut new tuyere unsuccessful |
| Date : October 2004 Experiment : 5 Location : Cooperstown NY (Early Iron 1) Team : Michael Mahoney / Millard Wyman Paul Burdon / Elizabeth Hendrix Furnace : Norse Short Shaft - cylindrical cob set in earth trench - no tap arch Size : 28 cm x 60 H Source : suggested by earlier experiments Tuyere : 25 mm ID steel pipe Placement : 15 cm from base - about 3 cm in from wall - angle at 15 down Bellows : Norse double bag Air : 2.2 L per stroke - at 130 L per minute Charcoal : 100 L broken hardwood Consumption : about 6 L charcoal every 15 minutes Ore: Virginia rock ore - 8 kg (roasted) Sequence : ore added as 5 x 1.5 kg charges + .5 reduction Duration : about 4 hours (plus preheat) Result : 'pre bloom mass' Notes : Air cut during operator changes and short smelter repairs - Generally structure successful - Air flow still low - Longer sequence required to develop larger bloom |
Date : October 2004 Experiment : 6 / D4 Location : Wareham ON Team : DARC Furnace : Econo Norse - firebrick backed with sand set in earth trench - no tap arch Size : 30 cm x 70 H Source : suggested by earlier experiments Tuyere : 25 mm ID steel pipe Placement : 20 cm from base - about 3 cm in from wall - angle at 20 down Bellows : vacuum blower Air : 550 L per minute Charcoal : 110 L broken hardwood Consumption : about 6 L charcoal every 12 - 15 minutes Ore : Virginia rock ore - (EE) 8 kg (roasted) Sequence : ore added as 8 x 1 kg (E) charges Duration : about 5 1/2 hours (10 hours total) Result : 2 kg bloom - high carbon (cast iron) Yield : EE 25% Notes : Air cut (electrical problems) at pre-heat only - Successful creation of small bloom - Air flow still a bit low - Longer sequence required to develop larger bloom |
Date : February 2005 Experiment : 7 Location : Lexington VA (Smeltfest 05) Team : Gangue aux Fer (3) Furnace : Econo Norse - firebrick backed with sand set on plinth - tap arch Size : 25 cm x 60 H Source : DARC 10/04 Tuyere : 25 mm ID 1/8" formed copper Placement : 18 cm from base - about 5 cm in from wall - angle at 20 down Bellows : vacuum blower Air : 815 L per minute Charcoal : 85 kg broken hardwood Consumption : about 2 kg charcoal every 10 minutes Ore : Virginia rock ore - about 35 kg (roasted) Sequence : ore added about every 10 minutes as small charges .5 - 2 kg Duration : about 7 hours (not including preheat) Result : 6.5 kg bloom - (not tested) Yield : 18 % Notes : - Successful creation of mid sized bloom - tap slag recycled |
Date : February 2005 Experiment : 8 Location : Lexington VA (Smeltfest 05) Team : Vince Petty / Vandy Simpson Furnace : Econo Norse - firebrick backed with sand set on plinth - tap arch Size : 25 cm x 60 H Source : DARC 10/04 Tuyere : 25 mm ID 1/8" formed copper Placement : 18 cm from base - about 5 cm in from wall - angle at 20 down Bellows : vacuum blower Air : 815 L per minute Charcoal : 85 kg broken hardwood Consumption : about 2 kg charcoal every 10 minutes Ore : Virginia rock ore - 28 kg (roasted) Sequence : ore added about every 10 minutes as small charges .5 - 2 kg Duration : about 7 hours (not including preheat) Result : 7.5 kg bloom - (not tested) Yield : 27 % Notes : - Successful creation of mid sized bloom - tap slag recycled |
Date : May 2005 Experiment : 9 Location : Wareham, ON Team : OABA / Neil Peterson / John Burton Furnace : Econo Norse - firebrick backed with sand, set on plinth - tap arch Size: 25 cm x 60 H Source : DARC 10/04 Tuyere : 25 mm ID schedule 40 pipe Placement : 20 cm from base - about 5 cm in from wall - angle at 20 down Bellows : electric blowers / rotary hand Air : inconsistent flow Charcoal : 67 kg broken hardwood Consumption : about 2 kg charcoal every 10 minutes Ore : Stelco taconite - 3 kg (roasted) Sequence : ore added about every 12 minutes as small charges .75 - 3 lbs Duration : about 7 hours (not including preheat) Result : 9.5 kg bloom - (estimated) Yield : 45 % E Notes : - Successful creation of mid sized bloom - tap slag recycled |
Date : June 2005 Experiment : 10 / D5 Location : Wareham, ON Team : DARC smelt demo team Furnace : Norse Short Shaft - clay cob with stone slab support - tap arch Size : 25 cm x 60 H Source : suggested by earlier experiments Tuyere : 25 mm ID schedule 40 pipe Placement : 16 cm from base - about 5 cm in from wall - angle at 20 down Bellows : large double bellows / electric blower Air : 600 l / min (estimated) Charcoal : 38 kg broken hardwood Consumption : about 2 kg charcoal every 10 minutes Ore : Stelco taconite - 9 kg (roasted) Sequence : ore added in variable sequence (10 - 20 min) as small charges .75 - 2.25 lbs Duration : about 7 hours (not including preheat) Result : 3 kg bloom - (estimated) Yield : 28 % E Notes : - Successful creation of historic sized bloom - extreme hot weather limits use of bellows |
| Date : September 2005 Experiment : 11 / D6 Location : Annapolois Royal NS Team : DARC smelt demo team + Mark Pilgrim Furnace : Norse Short Shaft - commercial clay cob with stone slab support - tap arch Size : 25 cm x 60 H Source : suggested by earlier experiments Tuyere : 25 mm ID schedule 40 pipe Placement : 24 cm from base - about 5 cm in from wall - angle at 20 down Bellows : large double bellows / electric blower Air : no data Charcoal : 47 kg broken hardwood Consumption : about 2 kg charcoal every 10 minutes Ore : Stelco taconite -9 kg (roasted) Sequence : ore added in variable sequence (10 - 20 min) as small charges .75 - 2.25 lbs shift to forced air at Duration : about 7 hours (not including preheat) Result : cast iron mass 2 kg? no data available on size Notes : use of high purity taconite means no silica - use of high temperature clay means no silica - no silica means no carbon control - exit valves required on bellows ?? |
Date : September 2005 Experiment : 12 Location : Copperstown NY (Early Iron 2) Team : Elizabeth Hendrix / Toby Bashaw Furnace : Flue Tyle - commercial tile reinforced with wire - tap arch Size : 25 cm square x 60 H Source : developed by Sauder & Williams Tuyere : 25 mm ID forged copper Placement : about 24 cm from base - 5 cm in from wall - angle at 20 down Bellows : electric blower Air : plus 1000 L/min? Charcoal : 110 lbs primary sequence / no data for balance* Consumption : about 5 lbs charcoal every 10 minutes Ore : Virginia Rock Ore - about 35 lbs * Sequence : ore added in variable sequence (8 - 12 min) as small charges .75 - 2.25 lbs Duration : about 7 1/2 hours * (not including preheat) Result : Two bloom masses Secondary at 3.4 KG Notes : Main smelt sequence abandoned at 6 1/2 hours Smelt assumed, produced secondary 'salvage bloom' * no clear records kept for secondary sequence |
| Date : October 2005 Experiment :13 / D7 Location : Wareham, ON Team : DARC Furnace: Norse Short Shaft - clay cob with stone slab support - tap arch Note - reuse of furnace from June 05 Size : 25 cm x 60 H Source : suggested by earlier experiments Tuyere : 25 mm ID ceramic kiln support Placement : 16 cm from base - about 5 cm in from wall - angle at 20 down Bellows : vacuum blower Air : 600 l / min (estimated) Charcoal : 79.5 kg broken hardwood Consumption : about 2 kg charcoal every 10 minutes Ore : Stelco taconite + Virginia Rock Ore 17 kg (roasted) Sequence : ore added in variable sequence (7 - 10 min) as small charges .75 - 2.25 lbs Duration : about 6 1/4 hours (not including preheat) Result : 4.3 kg bloom Yield : 22 % Notes : - Successful creation of historic sized bloom - Success in patching and re-firing smelt |
Date: February
2006 Experiment: 14 Location: Black Rock Forge, Traverse City MN Team: (demonstration) Brent Cole, Ken Chambers Furnace: Econo Norse firebrick backed with sand set on plinth tap arch (disassemble to extract) Size: 25 cm x 60 H Source: DARC 10/04 Tuyere: 25 mm ceramic tube Placement: 20 cm from base about 5 cm in from wall angle at 22.5 down Bellows: electric blower Air: 775 L per minute Charcoal: 107 kg broken hardwood Consumption: about 2 kg charcoal every 9 minutes Ore: Michigan taconite 45.5 kg (roasted) Sequence: ore added about every 9 minutes charges range from .45 to 2.2 kg each Duration: about 7 1/4 hours (not including preheat) Result: 13.5 kg bloom - good workable iron Notes: - Successful creation of mid sized bloom - small amount of tap slag recycled |
| Date: March 2006 Experiment: 15 Location: Smeltfest - Lexington VI Team: Dick Sargent (Gangue aux Fer) Furnace: Norse Medium Shaft - "Yormungand' clay cob set on plinth tap arch (bottom extraction) Size: 35 to 30 cm x 85 H Source: ongoing research, details suggested by Williams Tuyere: 25 mm ID ceramic tube Placement: 15 cm from base about 6 cm in from wall (wall is angled) angle at 22.5 down Bellows: electric blower Air: 740 l/m Charcoal: 84 kg broken hardwood Consumption: about 2 kg charcoal every 7 minutes Ore: hematite grit (commercial) 45.5 kg Sequence: ore added about every 7 minutes increasing from .5 to 2.8 kg Duration: about 4 3/4 hours (not including preheat) Result: 22 kg bloom - high carbon 'steel' Notes: - Successful creation of large carbon rich bloom - test of spit wood form - test of commercial hematite blasting grit ore |
Date: March 2006 Experiment: 16 Location: Smeltfest - Lexington VI Team: Dick Sargent (Gangue aux Fer) Furnace: Norse Short Shaft - "Yormungand' clay cob set on plinth tap arch (bottom extraction) second firing of furnace Size: 35 to 30 cm x 60 H Source: ongoing research, details suggested by Williams Tuyere: 25 mm ID ceramic tube Placement: 15 cm from base about 6 cm in from wall (wall is angled) angle at 22.5 down Bellows: electric blower Air: 740 l/m Charcoal: 68 kg broken hardwood Consumption: about 2 kg charcoal every 7 minutes Ore: hematite grit (commercial) 45.5 kg Sequence: ore added about every 7 minutes increasing from .5 to 2.8 kg Duration: about 4 3/4 hours (not including preheat) Result: 2o kg bloom - high carbon 'steel' Notes: - Successful creation of large carbon rich bloom - damaged top of previous smelter removed - clear duplication of earlier sequence |
| Date: June 2005 Experiment: 17 / D8 Location: Wareham, ON Team: DARC - Leaders Dave Cox & Kevin Jarbeau Furnace: Norse Short Shaft clay cob half dug into earth bank small tap arch (top extraction) Size: 25 cm x 65 H Source: suggested by earlier experiments Tuyere: 25 mm ID ceramic tube Placement: 7 cm from base about 5 cm in from wall angle at 22.5 down Bellows: electric blower Air: 970* l / min (re-calculated) Charcoal: 87 kg broken hardwood Consumption: about 2 kg charcoal every 10 minutes Ore: Virginia rock ore 18 kg (roasted) Sequence: ore added in smaller charges for most of smelt considerable re-cycle of tap slag Duration: about 8 hours (not including preheat) Result: 1.5 kg bloom - cast iron Notes: - first smelt controlled by Dave and Kevin - slow addition of ore resulted in excess carbon |
Date: September
2006 Experiment: 18 / D9 Location: Bonfield ON (Baron's Howe SCA) Team: DARC - Nick West (with labour from observers) Furnace: Norse Short Shaft clay cob with stone slab support small tap arch Size: 28 to 18 cm x 60 H Source: suggested by earlier experiments Tuyere: 25 mm ID ceramic tube Placement: no information on base about 5 cm in from wall angle at 22.5 down Bellows: large double bellows Air: no data Charcoal: 59 kg broken hardwood Consumption: about 2 kg charcoal every 15 minutes Ore: Virginia rock ore 10.5 kg (roasted) Sequence: ore added in variable sequence (10 - 20 min) as small charges .75 - 2.25 lbs Duration: about 6 1/4 hours (not including preheat) Result: small cast iron mass - no data available on size Notes: demonstration smelt with high audience content Irregular bellows control from many operators smelter set up to replicate LAM arrangement |
| Date: October
2006 Experiment: 19 Location: Peter's Valley NJ - Early Iron 3 Team: none (demonstration smelt) Furnace: Small diameter Norse short shaft - "Loki' clay cob set small tap arch (top extraction) Size: 20 cm x 65 H Source: ongoing research Tuyere: 25 mm ID ceramic tube Placement: 7 cm from base about 5 cm in from wall angle at 22.5 down Bellows: electric blower Air: 700 * l/m (based on recalculated rates) Charcoal: 36 kg broken hardwood Consumption: about 2 kg charcoal every 14 minutes considerable variation (from 9 - 20 min) Ore: Minden Bog 8.9 kg Sequence: ore added about every 14 minutes (see above) increasing from .5 to 1 kg Duration: about 4 3/4 hours (not including preheat) Result: .7 kg small lumps of clean cast iron Notes: - Successful test of small diameter furnace - test of (questionable) Minden 'ooze' |
Date: October
2006 Experiment: 20 Location: Peter's Valley NJ - Early Iron 3 Team: Dick Sargent (Gangue aux Fer) Furnace: Flue Tyle standard clay tile set on block plinth bottom extraction Size: 28 cm x 60 H Source: Developed by Sauder & Williams Tuyere: 25 mm ID ceramic tube Placement: 15 cm from base (?) about 3 cm in from wall angle at 20 down Bellows: Rock Bridge blower Air: approx 1000 l/m E Charcoal: 60 kg broken charcoal Consumption: about 2 kg charcoal every 8 minutes Ore: Virginia rock ore 45.5 kg (roasted) Sequence: started at 1.7 increasing to 2.4 kg Duration: about 5 hours (plus preheat) Result: 8.2 kg dense bloom of workable iron Notes: - use of large charges suggested by McCarthy - furnace ran hot and predictably - 1/3 forged into Norse reproduction anvil |
| Date: November
2006 Experiment: 21 / D10 Location: Wareham, ON Team: DARC Furnace: Norse Short / Medium Shaft clay cob half dug into earth bank (reuse of 6/06) small tap arch (top extraction) Size: 25 cm x 65 H metal cylinder extends top 30 cm Source: suggested by earlier experiments Tuyere: 25 mm ID ceramic tube Placement: 10 cm from base (light ash only) about 5 cm in from wall angle at 22.5 down Bellows: electric blower Air: 1060* l / min (re-calculated) Charcoal: 29 kg broken hardwood Consumption: about 2 kg charcoal every 6 minutes Ore: Virginia rock ore 21 kg (roasted) Sequence: all charges at 2 kg each Duration: about 2.3 hours (not including preheat) Result: large volume of high iron content slag no recognizable bloom Notes: - attempt to duplicate 'fast charge' method - reuse of earlier cobb smelter - no solid base lowers material below sinter zone |
Date: November
2006 Experiment: 22 Location: Wareham, ON Team: none Furnace: Norse Short / Medium Shaft clay cob half dug into earth bank (reuse of 6/06) small tap arch (top planned, bottom used) Size: 25 cm x 65 H metal cylinder extends top 30 cm Source: suggested by earlier experiments Tuyere: 25 mm ID ceramic tube Placement: 10 cm from base about 5 cm in from wall angle at 22.5 down Bellows: electric blower Air: 1060* l / min (re-calculated) Charcoal: 51 kg broken hardwood Consumption: about 2 kg charcoal every 6 minutes Ore: Virginia rock ore plus gangue from previous smelt 8.8 kg (roasted) plus 10.2 kg Sequence: ore added first as 1.4 kg each 6 minutes gangue added last as 1.1 kg each 7 minutes Duration: about 2.3 hours (not including preheat) Result: 6.8 kg dense workable iron Notes: - 'Redemption Smelt' to re-smelt gangue material - attempt to duplicate 'fast charge' method - reuse of earlier cobb smelter |
| Date: June 2007 Experiment: 23 Location: Wareham ON Team: (course) Steve Mikaff, Colin Paddin Furnace: Econo Norse firebrick backed with sand set on plinth tap arch (disassemble to extract) Size: 25 cm x 60 H Source: DARC 10/04 Tuyere: 25 mm ceramic tube Placement: 23 cm from base about 5 cm in from wall angle at 22.5 down Bellows: electric blower Air: 800 L per minute Charcoal: 63.5 kg broken hardwood Consumption: about 2 kg charcoal every 8 minutes Ore: commercial hematite grit 22.5 kg (roasted) Sequence: ore added about every 8 - 3 minutes charges range from .45 to 1.5 kg each Duration: about 4 hours (not including preheat) Result: 12.5 kg bloom - good workable medium carbon Notes: - textbook smelt as course |
Date: June 2007 Experiment: 24 / D11 Location: Wareham ON Team: Neil Peterson, Darrell Markewitz, Ron Ross Furnace: short shaft (half banked) clay cobb tap arch (top extraction) Size: 22.5 cm x 60 (+ 15 collar) H Source: ongoing research, Tuyere: 25 mm ID ceramic tube Placement: 14 cm from base about 5cm in from wall (wall is angled) angle at 15 down Bellows: electric blower Air: 900 l/m Charcoal: 56.5 kg broken hardwood Consumption: about 2 kg charcoal every 7 minutes Ore: Virginia Rock (poor) 23.3 kg Sequence: ore added about every 8 minutes increasing from .45 Duration: about 5 hours (not including preheat) Result: .9 kg bloom – good workable iron Notes: - low yield expected from poor ore first phase of 'hot swap' double smelt |
| Date: June 2007 Experiment: 25 / D12 Location: Wareham ON Team: Dave Cox, Kevin Jarbeau Ken Cook Furnace: short shaft (half banked) clay cobb tap arch (top extraction) Size: 22.5 cm x 60 (+ 15 collar) H Source: ongoing research, Tuyere: 25 mm ID ceramic tube Placement: 14 cm from base about 5cm in from wall (wall is angled) angle at 15 down Bellows: electric blower Air: 900 l/m Charcoal: 42 kg broken hardwood Consumption: about 2 kg charcoal every 9 minutes Ore: 50/50 hematite grit + Virginia Rock (poor) 23.9 kg Sequence: ore added about every 8 minutes increasing from .45 – 1.5 kg Duration: about 3.25 hours (no preheat) Result: 3.1 kg bloom – good workable iron Notes: - lower yield expected from poor ore second phase of 'hot swap' double smelt significant burn through with extended smelt time |
Date: October 2007 Experiment: 26 Location: Wareham, ON Team: Darrell Markewitz, Neil Peterson Furnace: Norse Short Shaft clay slabs half dug into earth bank with stone above tuyere small tap arch (top extraction) Size: 20 x 24 cm x 62 H Source: suggested by LAM Tuyere: 25 mm ID ceramic tube Placement: 15 cm from base (no set base) about 5 cm in from wall angle at 22.5 down Bellows: electric blower Air: start at about 500 – finish at 800 l / min Charcoal: 54 kg broken hardwood Consumption: about 2 kg charcoal every 7 minutes Ore: Stelco taconite 12.3 kg (roasted) Sequence: ore added in smaller charges for most of smelt considerable re-cycle of tap slag Duration: about 5:45 hours (not including 1:30 preheat) Result: 6 kg bloom – workable iron Notes: - test of stone plate above tuyere - test of simple 'blow hole' set up - start with lower air delivery |
| Date: October 2007 Experiment: 27 / D13 Location: Wareham ON Team: DARC – Neil Peterson, Ken Cook, Darrell Markewitz Furnace: Norse Short Shaft stone slabs with clay fill small tap arch (top extraction ) Size: 25 x 35 cm x 63 H Source: suggested by LAM Tuyere: 25 mm ID ceramic tube Placement: no information on base about flush with wall angle start at 25 down, repositioned to 10 down Bellows: vacuum blower Air: 410 l/m Charcoal: 153 l / 41 kg broken hardwood Consumption: about 2 kg charcoal every 22 minutes Ore: hematite grit with 2.3 kg Virginia rock (poor) as seed 12.3 kg total Sequence: ore added as small charges .5 to 1 kg Duration: about 4 3⁄4 hours (not including preheat) Result: about 2 kg badly sintered high carbon (not forgeable) Notes: proof of concept on stone slab construction large amount (+ 3 kg) unsintered iron fragments recovered results as expected with low volume air |
Date: November 2007 Experiment: 28 Location: Wareham ON Team: (course) Peter Martin, Shawn, Scott Pond Furnace: Norse short shaft clay cob set on low plinth small tap arch (top extraction) Size: 25cm x 72 H (+ 15 cm collar) Source: ongoing research Tuyere: 25 mm ID ceramic tube Placement: 10 cm from base about 5 cm in from wall angle at 22.5 down Bellows: vacuum blower Air: 750 l/m Charcoal: 60 kg broken hardwood Consumption: about 2 kg charcoal every 7 minutes Ore: Stelco taconite (seed of poor Virginia rock) 18.2 kg Sequence: ore added about every 7 minutes increasing from .5 to 2 kg Duration: about 4 1⁄2 hours (not including preheat) extra long (2 hour ) split wood preheat Result: 5.5 kg workable bloom with slight carbon Notes: - text book smelt for teaching |
| Date: March 13, 2008 Experiment: 29 Location: Smeltfest 08, Lexington VA Team: Skip Williams, Jake Keen Furnace: Medium Shaft clay cobb tap arch (bottom extraction) bellows plate with blow hole Size: 30 cm x 105 H Source: based on Williams' observations at Eindhoven Tuyere: tapered copper to 2.7 cm ID 3 cm dia. blow hole Placement: natural set base about 6 cm set back to tuyere tip Bellows: electric blower Air: not measured Charcoal: 45 kg broken hardwood Consumption: about 2 kg charcoal every 8 minutes Ore: Virginia Rock 23 kg (roasted) Sequence: ore added about every 12 minutes charges range from .5 to 2.3 kg each Duration: about 4 1/2 hours (not including preheat) Result: 5.5 kg bloom - soft iron with some carbon Notes: - bloom has pronounced crescent shape |
Date: March 16, 2008 Experiment: 30 Location: Smeltfest 08, Lexington VA Team: Jake Keen Furnace: Medium Shaft clay cobb tap arch (bottom extraction) bellows plate with blow hole Size: 30 cm x 105 H Source: based on Williams' observations at Eindhoven Tuyere: tapered copper to 2.7 cm ID 3 cm dia. blow hole Placement: natural set base about 6 cm set back to tuyere tip Bellows: electric blower Air: not measured Charcoal: 60 kg broken hardwood Consumption: 2 kg charcoal every 13 minutes (varies) Ore: DARC Dirt 1 30.2 kg Sequence: ore charges range from .1 to 2.5 kg each Duration: about 5 1/2 hours (not including preheat) Result: 1.7 kg bloom - high carbon Notes: - bloom has pronounced crescent shape |
| Date: March 17, 2008 Experiment: 31 Location: Smeltfest 08, Lexington VA Team: Jake Keen, Skip Williams Furnace: Medium Shaft clay cobb tap arch (bottom extraction) bellows plate with blow hole Size: 30 cm x 105 H Source: based on Williams' observations at Eindhoven Tuyere: tapered copper to 2.7 cm ID 4 cm dia. blow hole Placement: natural set base about 13.5 cm set back to tuyere tip set at 22 down Bellows: electric blower Air: not measured Charcoal: 68 kg broken hardwood Consumption: 2 kg charcoal every 12 minutes (varies) Ore: Virginia Rock 59.5 kg Sequence: ore charges range from 1 to 3 kg each Duration: about 5 1/2 hours (not including preheat) Result: 7.2 kg bloom - soft iron Notes: - position of the blow hole moved up over smelt results in tall, narrow bloom |
Date: April 13, 2008 Experiment: 32 / D14 Location: Wareham, ON Team: Neil Peterson, Ken Cook Furnace: Econo Norse smaller size in metal barrel frame set on plinth (bottom extraction) Size: 20 x 70 H Source: based on DARC design Tuyere: 25 mm ID ceramic tube Placement: 15 cm from base about 5 cm in from wall angle at 20 down Bellows: electric blower Air: start at about 450 – finish at 365 l / min Charcoal: 34 kg broken hardwood Consumption: about 2 kg charcoal every 14 - 17 minutes Ore: DARC Dirt 1 18 kg Sequence: ore added as 2 kg charges for most of smelt considerable re-cycle of tap slag Duration: about 4 1/2 hours (not including preheat) Result: 2 kg bloom – workable iron Notes: - full scale test of DARK Dirt 1 in standard smelter |
| Date: April 30, 2008 Experiment: 33 Location: Heltborg, Denmark Team: Arne Espelund Furnace: Norse Medium Shaft clay cobb bellows plate tap arch (bottom extraction) Size: 25 x 88 H (used) Source: test of two stage process suggested by Espelund Tuyere: 25 mm ID steel pipe (tapered) Placement: 10 cm base set just flush with bellows plate angle at 20 down Bellows: 'Danish standard' vacuum blower Charcoal: 13 kg broken hardwood Consumption: about 2 kg charcoal every 11 minutes Ore: Guldager Bog 15 kg Sequence: ore added as 1 kg charges Duration: about 2 1/2 hours (not including preheat) Result: 11.5 kg high iron content slag Notes: - test of theoretical method proposed by Espelund, stage one is producing volume of iron rich slag... |
Date: May 2, 2008 |
| Date: May 4, 2008 Experiment: 35 Location: Heltborg, Denmark Team: Furnace: Norse Medium Shaft clay cobb bellows plate tap arch (bottom extraction) Size: 25 x 113 H Source: based on past experience Tuyere: 25 mm ID steel pipe (tapered) Placement: 10 cm base set just flush with bellows plate angle at 23 down Bellows: 'Danish standard' vacuum blower Charcoal: 20 kg broken hardwood Consumption: about 2 kg charcoal every 9 minutes Ore: Heltborg / Swedish / Guldager bog ores 15.2 kg total Sequence: ore added as .8 to 1.6 kg charges Duration: about 3 1/2 hours (not including preheat) Result: 1.8 kg, fragments in slag block Notes: - demonstration smelt of standard method |
Date: June 14, 2008 Experiment: 36 / D14 Location: Wareham, ON Team: Ken Cook, Neil Peterson Furnace: Banked Short Shaft Size: 20 x 70 H Source: Viking Age - standard build Tuyere: 25 mm ID ceramic tube Placement: 11 cm from base about 3.5 cm in from wall angle at 22.5 down Bellows: electric blower Air: start at about 640 – finish at 735 l / min Charcoal: 30 kg broken hardwood Consumption: about 2 kg charcoal every 10 minutes Ore: DARC Dirt 1 20 kg Sequence: ore added as 2 kg charges Duration: about 3:20 hours (not including preheat) Result: 1.9 kg bloom as partially consolodated - workable iron Notes: - full scale test of DARK Dirt 1 in standard smelter |
| Date: September 27, 2008 Experiment: 37 Location: Troy OH Team: Ken Cook Furnace: Short Shaft set on plinth (top extraction) Size: 25 x 65 + 20 H Source: Viking Age - standard build Tuyere: 25 mm ID ceramic tube Placement: 20 cm from base about 5 cm in from wall angle at 22.5 down Bellows: electric blower Air: start at about 450 – finish at 365 l / min Charcoal: 67 kg broken hardwood Consumption: about 2 kg charcoal every 10 minutes Ore: Williamsburg Rock 35 kg Sequence: ore added as 1.1 - 2.2 charges Duration: about 6 hours (not including preheat) Result: 9.5 kg bloom – workable iron Notes: - demonstration smelt (Quad State 08) |
Date: October 12, 2008 Experiment: 38 / D16 Location: Wareham, ON Team: Neil Peterson, Ken Cook Furnace: Banked Short Shaft bellows plate with blow hole top extraction Size: 22 x 65 + 20 H Source: based on Hals, Iceland Tuyere: blow hole, later inserted - 25 mm ID ceramic tube Placement: blow hole diameter 8 cm tuyere pipe set to 15 down, about 6 cm back as insert, angle at 10 down Bellows: electric blower Air: start at about 740 – finish at 1000 (?) l / min Charcoal: 46 kg broken hardwood Consumption: about 2 kg charcoal every 13 minutes Ore: Virginia Rock (poor) mixed with Taconite (275/400) 23 kg Sequence: ore added as 1.1 kg charges for most of smelt Duration: about 6 1/2 hours (not including preheat) Result: 4.9 kg bloom – workable iron Notes: - 'work dynamic test' for proposed Hals layout - test of bellows plate / blow hole system |
| Date: November 8, 2008 Experiment: 39 D/17 Location: Wareham, ON Team: Ken Cook, Neil Peterson Furnace: Banked Short Shaft bellows plate with blow hole tuyere hung from above top extraction Size: 24 - 26 x 65 + 20 H Source: based on Hals, Iceland Tuyere: blow hole, tapered tuyere Placement: blow hole diameter 5 cm tuyere pipe set to 25 down, about 2.5 cm back Bellows: electric blower Air: start at about 740 (?) l / min Charcoal: 48 kg broken hardwood Consumption: about 2 kg charcoal every 12 minutes Ore: Virginia Rock (poor) mixed with Taconite (1/2) 24 kg Sequence: ore added as .8 increased to 1.6 kg charges Duration: about 5 hours (not including preheat) Result: 3.25 kg bloom – workable iron Notes: - 'work dynamic test' for proposed Hals layout - test of bellows plate / blow hole system - use of tapered tuyere improves air penetration - hanging air system alows access, control of smelt |
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(1) Parks Canada / L'Anse aux Meadows Mark Pilgrim Assisting Birgitta Wallace / Arne Espelund (2) Dark Ages Re-creation Company Core Team: Kevin Jarbeau / Dave Cox / Neil Peterson / Ken Cook Assisting: Marcus Burnham / Gus Gissing / Sam Falazone / David Robertson Mehgan Roberts / Anne Graham Karen Peterson / Vandy Simpson Special Guests : Dr Ron Ross / Kevin Smith (3) Gangue aux Fer Lee Sauder / Skip Williams Mike McCarthy after 2005 - Dick Sargent / Jake Keen Assisting: Elisabeth Sauder / Vandy Simpson |
Lee Sauder Mike McCarthy DARC - Iron Experiments |
June 13 & 14 - 2009
(Friday evening - all day Saturday)
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 Of interest to working blacksmiths, the student of history or those attempting to re-create the Early Medieval period. IRON SMELTING in the Viking Age - is a multi-platform CD-ROM documenting ongoing experiments re-creating both SMELTING and FORGING of the Norse metalsmiths. Contains over 600 images, working plans, experiment notes and articles. |
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