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ITP Metal Casting: Advanced Melting Technologies
Advanced Melting Technologies: Energy Saving Concepts and Opportunities for the Metal Casting Industry November 2005 BCS, Incorporated 5550 Sterrett Place, Suite 306 Columbia, MD 21044 www.bcs-hq.com Advanced Melting Technologies: Energy Saving Concepts and Opportunities for the Metal Casting Industry Prepared for ITP Metal Casting by BCS, Incorporated November 2005 Acknowledgments This study was a collaborative effort by a team of researchers from University of Missouri–Rolla, Case Western Reserve University, and Carnegie Mellon University with BCS, Incorporated as the project coordinator and lead. The research findings for the nonferrous casting industry were contributed by Dr. Jack Wallace and Dr. David Schwam, while the ferrous melting technologies were addressed by Dr. Kent Peaslee and Dr. Richard Fruehan. BCS, Incorporated researched independently to provide an overview of the melting process and the U.S. metal casting industry. The final report was prepared by Robert D. Naranjo, Ji-Yea Kwon, Rajita Majumdar, and William T. Choate of BCS, Incorporated. We also gratefully acknowledge the support of the U.S. Department of Energy and Cast Metal Coalition (CMC) in conducting this study. Disclaimer This report was prepared as an account of work sponsored by an Agency of the United States Government. Neither the United States Government nor any Agency thereof, nor any of their employees, makes any warranty, expressed or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any Agency thereof. -
5. Sirhowy Ironworks
Great Archaeological Sites in Blaenau Gwent 5. SIRHOWY IRONWORKS There were a number of ironworks in the area now covered by Blaenau Gwent County Borough, which provided all the raw materials they needed – iron ore, limestone and fuel, charcoal at first but later coal to make coke. The Sirhowy ironworks (SO14301010) are the only one where there is still something to see. The works were opened in 1778 with one blast furnace. Although it was originally blown by water power, in 1799 the owners invested in a Boulton and Watt steam engine. This gave them enough power to blow a second furnace, which started production in 1802. In the early years of the 19th century, the pig iron produced at Sirhowy was sent to the Tredegar works a little further down the valley where it was refined, until 1818 when the Sirhowy works were sold and started to send its pig iron to Ebbw Vale. A third furnace was added in 1826 and a fourth in 1839. But by the 1870s iron smelting at Sirhowy was no longer profitable, and the works finally closed in 1882. Like all ironworks in South Wales, the furnaces were built against a steep bank which enabled the ironworkers to load the charge of iron ore, limestone and coke or charcoal fuel more easily at the top of the furnace. All that is now left now are the remains of a bank of blast furnaces with the arches that would originally have linked them to the casting houses in front, and the building that originally housed the waterwheel. -
ANTHRACITE Downloaded from COAL CANALS and the ROOTS of AMERICAN FOSSIL FUEL DEPENDENCE, 1820–1860 Envhis.Oxfordjournals.Org
CHRISTOPHER F. JONES a landscape of energy abundance: ANTHRACITE Downloaded from COAL CANALS AND THE ROOTS OF AMERICAN FOSSIL FUEL DEPENDENCE, 1820–1860 envhis.oxfordjournals.org ABSTRACT Between 1820 and 1860, the construction of a network of coal-carrying canals transformed the society, economy, and environment of the eastern mid- Atlantic. Artificial waterways created a new built environment for the region, an energy landscape in which anthracite coal could be transported cheaply, reliably, at Harvard University Library on October 26, 2010 and in ever-increasing quantities. Flush with fossil fuel energy for the first time, mid-Atlantic residents experimented with new uses of coal in homes, iron forges, steam engines, and factories. Their efforts exceeded practically all expec- tations. Over the course of four decades, shipments of anthracite coal increased exponentially, helping turn a rural and commercial economy into an urban and industrial one. This article examines the development of coal canals in the ante- bellum period to provide new insights into how and why Americans came to adopt fossil fuels, when and where this happened, and the social consequences of these developments. IN THE FIRST DECADES of the nineteenth century, Philadelphians had little use for anthracite coal.1 It was expensive, difficult to light, and considered more trouble than it was worth. When William Turnbull sold a few tons of anthracite to the city’s waterworks in 1806, the coal was tossed into the streets to be used as gravel because it would not ignite.2 In 1820, the delivery © 2010 The Author. Published by Oxford University Press on behalf of the American Society for Environmental History and the Forest History Society. -
Three Hundred Years of Assaying American Iron and Iron Ores
Bull. Hist. Chem, 17/18 (1995) 41 THREE HUNDRED YEARS OF ASSAYING AMERICAN IRON AND IRON ORES Kvn K. Oln, WthArt It can reasonably be argued that of all of the industries factors were behind this development; increased pro- that made the modern world possible, iron and steel cess sophistication, a better understanding of how im- making holds a pivotal place. Without ferrous metals purities affected iron quality, increased capital costs, and technology, much of the modem world simply would a generation of chemically trained metallurgists enter- not exist. As the American iron industry grew from the ing the industry. This paper describes the major advances isolated iron plantations of the colonial era to the com- in analytical development. It also describes how the plex steel mills of today, the science of assaying played 19th century iron industry serves as a model for the way a critical role. The assayer gave the iron maker valu- an expanding industry comes to rely on analytical data able guidance in the quest for ever improving quality for process control. and by 1900 had laid down a theoretical foundation for the triumphs of steel in our own century. 1500's to 1800 Yet little is known about the assayer and how his By the mid 1500's the operating principles of assay labo- abilities were used by industry. Much has been written ratories were understood and set forth in the metallurgi- about the ironmaster and the furnace workers. Docents cal literature. Agricola's Mtll (1556), in period dress host historic ironmaking sites and inter- Biringuccio's rthn (1540), and the pret the lives of housewives, miners, molders, clerks, rbrbühln (Assaying Booklet, anon. -
Henry Bessemer and the Mass Production of Steel
Henry Bessemer and the Mass Production of Steel Englishmen, Sir Henry Bessemer (1813-1898) invented the first process for mass-producing steel inexpensively, essential to the development of skyscrapers. Modern steel is made using technology based on Bessemer's process. Bessemer was knighted in 1879 for his contribution to science. The "Bessemer Process" for mass-producing steel, was named after Bessemer. Bessemer's famous one-step process for producing cheap, high-quality steel made it possible for engineers to envision transcontinental railroads, sky-scraping office towers, bay- spanning bridges, unsinkable ships, and mass-produced horseless carriages. The key principle is removal of impurities from the iron by oxidation with air being blown through the molten iron. The oxidation also raises the temperature of the iron mass and keeps it molten. In the U.S., where natural resources and risk-taking investors were abundant, giant Bessemer steel mills sprung up to drive the expanding nation's rise as a dominant world economic and industrial leader. Why Steel? Steel is the most widely used of all metals, with uses ranging from concrete reinforcement in highways and in high-rise buildings to automobiles, aircraft, and vehicles in space. Steel is more ductile (able to deform without breakage) and durable than cast iron and is generally forged, rolled, or drawn into various shapes. The Bessemer process revolutionized steel manufacture by decreasing its cost. The process also decreased the labor requirements for steel-making. Prior to its introduction, steel was far too expensive to make bridges or the framework for buildings and thus wrought iron had been used throughout the Industrial Revolution. -
Hopewell Village
IRONMAKING IN EARLY AMERICA the Revolutionary armies, is representative of (such as Valley Forge) to be made into the tougher the hundreds of ironmaking communities that and less brittle wrought iron. This was used to Hopewell In the early days of colonial America, iron tools supplied the iron needs of the growing nation. make tools, hardware, and horseshoes. and household items were brought over from Europe by the settlers or imported at a high cost. Until surpassed by more modern methods, cold- HOPEWELL FURNACE Village The colonists, early recognizing the need to manu blast charcoal-burning furnaces, such as that NATIONAL HISTORIC SITE • PENNSYLVANIA facture their own iron, set up a number of iron at Hopewell, supplied all the iron. These furnaces In an age when most businesses were operated by works, notably at Falling Creek, Va., and Saugus, consumed about 1 acre of trees a day for fuel, one or two men in a shop, Hopewell employed at Mass. Operations gradually spread throughout so they had to be located in rural areas close to least 65 men, with some responsible for two or the colonies, and by the end of the 1700's, south a timber supply. more jobs. As the nearest town was many miles eastern Pennsylvania had become the industry's away, the ironmaster built a store to supply his center. Hopewell Village, founded by Mark Bird Since the pig iron produced by these furnaces workers, many of whom lived in company-owned in 1770 in time to supply cannon and shot for had a limited use, much of it was sent to forges homes. -
Global Technology Roadmap for CCS in Industry Steel Sectoral Report
Global Technology Roadmap for CCS in Industry Steel Sectoral Report JP. Birat, ArcelorMittal Global R and D, Maizières-lès-Metz, France Steel sectoral report Contribution to the UNIDO roadmap on CCS1 - fifth draft JP. Birat, ArcelorMittal Global R and D, Maizières-lès-Metz, France Abstract What is the status of CCS today in the Steel sector as a tool for mitigation CO2 emis- sions? How mature is CCS as a solution against other approaches? What is the level of emissions to be handled, today and in the temporality of climate Change, i.e. 2050 at least? Are there gaps in the technology and barriers to its implementation in the sector? Does the level of development of a country have any incidence on the issue? These are the main questions tackled in this sectoral report for Steel. Today, CCS has not quite reached the level of being a technology in the Steel sector, as it is still a concept that needs to be fleshed out and validated at a credible scale. Open questions are related to the kind of capture that can be applied in the sector as the players speak of CCS in roadmaps but are still working out how this general con- cept can be turned into a practical technology. The main trend is to develop a sector- specific concept called "in-process" capture that can be applied to the mainstream process routes (blast furnace or direct reduction, for example) with the expected benefit of improving energy needs and productivity of equipment compared to the benchmark best practice of today. -
American Iron and Steel Institute Photographs and Audiovisual Materials 1986.268
American Iron and Steel Institute photographs and audiovisual materials 1986.268 This finding aid was produced using ArchivesSpace on September 14, 2021. Description is written in: English. Describing Archives: A Content Standard Audiovisual Collections PO Box 3630 Wilmington, Delaware 19807 [email protected] URL: http://www.hagley.org/library American Iron and Steel Institute photographs and audiovisual materials 1986.268 Table of Contents Summary Information .................................................................................................................................... 3 Historical Note ............................................................................................................................................... 4 Scope and Content ......................................................................................................................................... 5 Arrangement ................................................................................................................................................... 8 Administrative Information ............................................................................................................................ 8 Related Materials ........................................................................................................................................... 8 Controlled Access Headings .......................................................................................................................... 9 Collection -
The History of Modern Iron Manufacture
Drew Beinhaker Anthropology 377 5/19/94 The History of Modern Iron Manufacture To Virginia, the first of the English settlements in America, belongs the honor of inaugurating within their limits as a colony that most important industry, iron manufacture. -R.A. Brock, 18851 Among the vast spectrum of metallic elements found in the earth’s crust, iron ore, because of its abundance and accessibility, has proved to be nature’s greatest gift to mankind. Although rarely found in a pure state, the presence of iron makes up nearly one-fifth of the earth’s total mass. Due to its solubility in water, iron is much more prevalent deep in the earth’s core than it is in the surface layers. Limestone is the… 1 Robert Alonzo Brock, “Early Iron Manufacture in Virginia: 1619-1776,” in Proceedings of the United States National Museum, 1885, 8(Washington, 1886): 77. quoted in A History of Metals in Colonial America, (p.55). most common agent attributed to the deposits of iron in water. The available nature of this metal and the many uses of its finished product has lead to the development of one of the most fundamental industries known to man, iron manufacture. The beginning of modern iron making can be traced back to sixteenth century Europe with the operation of the Catalan forge in Catalonia, Spain. The forge contained an air blast system which was triggered by the pressure of a waterfall through the use of a device known as a trompe. Water and air bubbles would flow through a pipe into an airtight receptacle allowing for the necessary pressure to accumulate in order to initiate the process. -
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Decarbonisation of steel production by electrification Bruxelles, 2019 December 4th Decarbonisation of steel production by electrification • Steel production • 1 808 Mt of crude steel. • 71% primary steel. • 2 167 Mt of iron ore. • Fe = 18 x Al, in tonnage. • Fe = 84 x Cu, in tonnage. • Iron ore: second raw material transported by shipping. WorldSteel statistics, USGS Page 2 © ArcelorMittal 2019 - All rights reserved for all countries 2019_12_04 Cannot be disclosed, used, or reproduced without prior written specific authorization by ArcelorMittal SET Plan Action 6, Bruxelles CONFIDENTIAL - Privileged Information - ArcelorMittal proprietary information Decarbonisation of steel production by electrification • Steel use 10 t/capita Nobuhiko TakamaTsu, Kimitoshi Yonezawa, Hironori ueno, Wakana Tamaki and Seiichi HaYasHi D. Müller et al. Patterns of Iron Use in Societal Evolution (2011) Tetsu-to-Hagané Vol. 100 (2014) No. 6 Page 3 © ArcelorMittal 2019 - All rights reserved for all countries 2019_12_04 Cannot be disclosed, used, or reproduced without prior written specific authorization by ArcelorMittal SET Plan Action 6, Bruxelles CONFIDENTIAL - Privileged Information - ArcelorMittal proprietary information Decarbonisation of steel production by electrification • CO2 emissions Use of reducing agents in the blast furnace in Germany ~600 kgCarbon 20 GJ or 5.5 MWh per tSteel 2 tCO2 WorldSteel A Steel Roadmap for a Low Carbon Europe Eurofer (2013) The steel industry generates between 7 and 9% of direct emissions from the global use of fossil fuel. Page 4 © ArcelorMittal 2019 - All rights reserved for all countries 2019_12_04 Cannot be disclosed, used, or reproduced without prior written specific authorization by ArcelorMittal SET Plan Action 6, Bruxelles CONFIDENTIAL - Privileged Information - ArcelorMittal proprietary information Decarbonisation of steel production by electrification • Climate neutral Europe by 2050 ‒ The goal is to reach net-zero emissions by 2050. -
Chapter 1, the Nature of Ironmaking
Chapter 1 The Nature of Ironmaking D. H. Wakelin, Manager-Development Engineering, Primary, LTV Steel Co. J. A. Ricketts, Senior Staff Engineer, Ironmaking Technology, Ispat-Inland Inc. 1.1 Introduction The term ironmaking inevitably conjures a picture of man wresting glowing liquid hot metal from a giant reactor using methods steeped in history, more art than science. Understanding of the processes taking place, however, has expanded dramatically over the past few decades, bringing science to the operation, while retaining some of the art for future explanation. Our knowledge has increased significantly even since the publication of the 10th edition of The Making, Shaping and Treating of Steel in 1985, and it is the intention of this volume to present this information, together with the previous understanding of the process.1 While the production of molten iron from the blast furnace has held the predominant position to the present day as the method of supplying virgin iron units for oxygen steelmaking, it remains dependent on the availability of suitable coals for making coke. Alternative processes have prolif- erated in recent years to take advantage of lower cost raw materials and lower capital cost for smaller scale equipment. Some are coal-based, some are gas-based. Some use lump iron ore, some use iron ore fines. All are properly included in this volume on ironmaking, which presents the basic principles, operating practices and equipment used in separating iron from its naturally occurring oxide state. 1.2 Structure of this Volume This introductory chapter is largely devoted to the history of ironmaking, bringing the reader from the earliest records to present day developments in blast furnace technology and equipment. -
Thermal Analysis of a Conventional Cupola Furnace with Effects of Excess Air on the Flue Gases Specific Heat !
Journal(of(Materials(and(( J. Mater. Environ. Sci., 2021, Volume 12, Issue 02, Page 192-204 Environmental(Science( ISSN(:(2028;2508( CODEN(:(JMESCN( http://www.jmaterenvironsci.com! Copyright(©(2021,( University(of(Mohammed(Premier(((((( Oujda(Morocco( Thermal Analysis of a Conventional Cupola Furnace with Effects of Excess Air on the Flue Gases Specific Heat ! Stephen A. Ajah1,2, Donald Idorenyin 1, Uchenna C. Nwokenkwo2, Uzoma S. Nwigwe2, Benjamin O. Ezurike2 1Applied Renewable & Sustainable Energy Research Group, Department of Mechanical Engineering, University of Nigeria, Nsukka, Nigeria 2Department of Mechanical Engineering, Alex Ekwueme Federal University Ndufu-Alike, Ebonyi State, Nigeria *Corresponding author, Email address: [email protected] **Corresponding author, Email address: [email protected] Received 29 Dec 2020, Abstract Revised 16 Feb 2021, A thermal analysis was carried out on a 6.5 m tall and 0.65 m diameter conventional cupola Accepted 17 Feb 2021 furnace at the Nigeria Railway Corporation, Enugu. This study tries to solve metallurgical problem of the furnace wall due to gases dissociation from unbalance excess air and Keywords undefined adiabatic flame temperature used during the operation. A combustion and ! Cupola furnace, thermal analysis of the fuel (coke) used for its operation has been carried out and the ! Thermal analysis, adiabatic combustion temperature of the fuel has been determined to be 2,175.93K. The ! Combustion, stoichiometric and actual air-fuel ratio of the furnace were found to be 10.97 and 12.08 ! Excess air, respectively. The percentage of flue gases difference for wet and dry case were also ! Adiabatic temperature. investigated against the percentage excess air.