Ironworks
Encyclopedia
Iron
Iron is a chemical element with the symbol Fe and atomic number 26. It is a metal in the first transition series. It is the most common element forming the planet Earth as a whole, forming much of Earth's outer and inner core. It is the fourth most common element in the Earth's crust...
is smelted
Smelting
Smelting is a form of extractive metallurgy; its main use is to produce a metal from its ore. This includes iron extraction from iron ore, and copper extraction and other base metals from their ores...
and where heavy iron and/or steel
Steel
Steel is an alloy that consists mostly of iron and has a carbon content between 0.2% and 2.1% by weight, depending on the grade. Carbon is the most common alloying material for iron, but various other alloying elements are used, such as manganese, chromium, vanadium, and tungsten...
products are made. The term is both singular and plural, i.e. the plural of ironworks is ironworks.
An integrated ironworks in the 19th century usually included one or more blast furnace
Blast furnace
A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals, generally iron.In a blast furnace, fuel and ore and flux are continuously supplied through the top of the furnace, while air is blown into the bottom of the chamber, so that the chemical reactions...
s and a number of puddling furnaces and/or a foundry
Foundry
A foundry is a factory that produces metal castings. Metals are cast into shapes by melting them into a liquid, pouring the metal in a mold, and removing the mold material or casting after the metal has solidified as it cools. The most common metals processed are aluminum and cast iron...
with or without other kinds of ironworks.
The processes carried at ironworks are usually described as ferrous metallurgy, but the term siderurgy is also occasionally used. This is derived from the Greek
Greek language
Greek is an independent branch of the Indo-European family of languages. Native to the southern Balkans, it has the longest documented history of any Indo-European language, spanning 34 centuries of written records. Its writing system has been the Greek alphabet for the majority of its history;...
words sideros - iron and ergon or ergos - work. This is an unusual term in English, and it is best regarded as an anglicisation
Anglicisation
Anglicisation, or anglicization , is the process of converting verbal or written elements of any other language into a form that is more comprehensible to an English speaker, or, more generally, of altering something such that it becomes English in form or character.The term most often refers to...
of a term used in French
French language
French is a Romance language spoken as a first language in France, the Romandy region in Switzerland, Wallonia and Brussels in Belgium, Monaco, the regions of Quebec and Acadia in Canada, and by various communities elsewhere. Second-language speakers of French are distributed throughout many parts...
, Spanish
Spanish language
Spanish , also known as Castilian , is a Romance language in the Ibero-Romance group that evolved from several languages and dialects in central-northern Iberia around the 9th century and gradually spread with the expansion of the Kingdom of Castile into central and southern Iberia during the...
, and other Romance languages
Romance languages
The Romance languages are a branch of the Indo-European language family, more precisely of the Italic languages subfamily, comprising all the languages that descend from Vulgar Latin, the language of ancient Rome...
.
Primary ironmaking
History of ferrous metallurgy
The history of ferrous metallurgy began far back in prehistory. The earliest surviving iron artifacts, from the 5th millennium BC in Iran and 2nd millennium BC in China, were made from meteoritic iron-nickel. It is not known when or where the smelting of iron from ores began, but by the end of the...
:
- BloomeriesBloomeryA bloomery is a type of furnace once widely used for smelting iron from its oxides. The bloomery was the earliest form of smelter capable of smelting iron. A bloomery's product is a porous mass of iron and slag called a bloom. This mix of slag and iron in the bloom is termed sponge iron, which...
— where bar ironWrought ironthumb|The [[Eiffel tower]] is constructed from [[puddle iron]], a form of wrought ironWrought iron is an iron alloy with a very low carbon...
was produced from iron ore by direct reduction; - Blast furnaceBlast furnaceA blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals, generally iron.In a blast furnace, fuel and ore and flux are continuously supplied through the top of the furnace, while air is blown into the bottom of the chamber, so that the chemical reactions...
s — which made pig ironPig ironPig iron is the intermediate product of smelting iron ore with a high-carbon fuel such as coke, usually with limestone as a flux. Charcoal and anthracite have also been used as fuel...
(or sometimes finished cast ironCast ironCast iron is derived from pig iron, and while it usually refers to gray iron, it also identifies a large group of ferrous alloys which solidify with a eutectic. The color of a fractured surface can be used to identify an alloy. White cast iron is named after its white surface when fractured, due...
goods) from iron ore; - FoundriesFoundryA foundry is a factory that produces metal castings. Metals are cast into shapes by melting them into a liquid, pouring the metal in a mold, and removing the mold material or casting after the metal has solidified as it cools. The most common metals processed are aluminum and cast iron...
— where pig ironPig ironPig iron is the intermediate product of smelting iron ore with a high-carbon fuel such as coke, usually with limestone as a flux. Charcoal and anthracite have also been used as fuel...
was remelted in an air furnace or in a foundry cupola to produce cast iron goods; - Finery forgeFinery forgeIron tapped from the blast furnace is pig iron, and contains significant amounts of carbon and silicon. To produce malleable wrought iron, it needs to undergo a further process. In the early modern period, this was carried out in a finery forge....
s — which fined pig ironPig ironPig iron is the intermediate product of smelting iron ore with a high-carbon fuel such as coke, usually with limestone as a flux. Charcoal and anthracite have also been used as fuel...
to produce bar ironWrought ironthumb|The [[Eiffel tower]] is constructed from [[puddle iron]], a form of wrought ironWrought iron is an iron alloy with a very low carbon...
, using charcoalCharcoalCharcoal is the dark grey residue consisting of carbon, and any remaining ash, obtained by removing water and other volatile constituents from animal and vegetation substances. Charcoal is usually produced by slow pyrolysis, the heating of wood or other substances in the absence of oxygen...
as fuelFuelFuel is any material that stores energy that can later be extracted to perform mechanical work in a controlled manner. Most fuels used by humans undergo combustion, a redox reaction in which a combustible substance releases energy after it ignites and reacts with the oxygen in the air...
in a finery (hearth) and coal or charcoal in a chafery (hearth); - Potting and stampingPotting and stampingPotting and stamping is a modern name for one of the 18th century processes for refining pig iron without the use of charcoal.-Inventors:The process was devised by Charles Wood of Lowmill, Egremont in Cumberland and his brother John Wood of Wednesbury and patented by them...
forges with melting fineries using the first process in which bar ironWrought ironthumb|The [[Eiffel tower]] is constructed from [[puddle iron]], a form of wrought ironWrought iron is an iron alloy with a very low carbon...
was made from pig ironPig ironPig iron is the intermediate product of smelting iron ore with a high-carbon fuel such as coke, usually with limestone as a flux. Charcoal and anthracite have also been used as fuel...
with mineral coalCoalCoal is a combustible black or brownish-black sedimentary rock usually occurring in rock strata in layers or veins called coal beds or coal seams. The harder forms, such as anthracite coal, can be regarded as metamorphic rock because of later exposure to elevated temperature and pressure...
or cokeCoke (fuel)Coke is the solid carbonaceous material derived from destructive distillation of low-ash, low-sulfur bituminous coal. Cokes from coal are grey, hard, and porous. While coke can be formed naturally, the commonly used form is man-made.- History :...
, without the use of charcoalCharcoalCharcoal is the dark grey residue consisting of carbon, and any remaining ash, obtained by removing water and other volatile constituents from animal and vegetation substances. Charcoal is usually produced by slow pyrolysis, the heating of wood or other substances in the absence of oxygen...
; - Puddling furnaces — a later process for the same purpose, again with cokeCoke (fuel)Coke is the solid carbonaceous material derived from destructive distillation of low-ash, low-sulfur bituminous coal. Cokes from coal are grey, hard, and porous. While coke can be formed naturally, the commonly used form is man-made.- History :...
as fuel. It was usually necessary for there to be a preliminary refining process in a coke refinery (also called running out furnace). After puddling, the puddled ball needed shingling (metallurgy)Shingling (metallurgy)Shingling was a stage in the production of bar iron or steel, in the finery and puddling processes. As with many ironmaking terms, this is derived from the French - cinglage....
and then to be drawn out into bar ironWrought ironthumb|The [[Eiffel tower]] is constructed from [[puddle iron]], a form of wrought ironWrought iron is an iron alloy with a very low carbon...
in a rolling mills.
Modern steelmaking
From the 1850s, pig iron might be partly decarburised to produce mild steel using one of the following:- The Bessemer process in a Bessemer converter, improved by the Gilchrist-Thomas process;
- The Siemens-Martin process in an Open hearth furnaceOpen hearth furnaceOpen hearth furnaces are one of a number of kinds of furnace where excess carbon and other impurities are burnt out of the pig iron to produce steel. Since steel is difficult to manufacture due to its high melting point, normal fuels and furnaces were insufficient and the open hearth furnace was...
; - Electric arc furnaceElectric arc furnaceAn electric arc furnace is a furnace that heats charged material by means of an electric arc.Arc furnaces range in size from small units of approximately one ton capacity up to about 400 ton units used for secondary steelmaking...
, introduced in 1907; - Basic oxygen steelmakingBasic oxygen steelmakingBasic oxygen steelmaking , also known as Linz-Donawitz-Verfahren steelmaking or the oxygen converter process is a method of primary steelmaking in which carbon-rich molten pig iron is made into steel. Blowing oxygen through molten pig iron lowers the carbon content of the alloy and changes it into...
, introduced in 1952.
For this period see History of the modern steel industry
History of the modern steel industry
The history of the modern steel industry began in the late 1850s, but since then steel has been basic to the world's industrial economy. This article is intended only to address the business, economic and social dimensions of the industry, since the bulk production of steel began as a result of...
and Steelmaking
Steelmaking
Steelmaking is the second step in producing steel from iron ore. In this stage, impurities such as sulfur, phosphorus, and excess carbon are removed from the raw iron, and alloying elements such as manganese, nickel, chromium and vanadium are added to produce the exact steel required.-Older...
.
Further processing
After bar iron had been produced in a finery forge or in the forge train of a rolling mill, it might undergo further processes in one of the following:- A slitting millSlitting millThe slitting mill was a watermill for slitting bars of iron into rods. The rods then were passed to nailers who made the rods into nails, by giving them a point and head....
- which cut a flat bar into rod iron suitable for making into nailNail (engineering)In woodworking and construction, a nail is a pin-shaped, sharp object of hard metal or alloy used as a fastener. Formerly wrought iron, today's nails are typically made of steel, often dipped or coated to prevent corrosion in harsh conditions or improve adhesion...
s. - A tinplate works - where rolling mills made sheets of iron (later of steelSteelSteel is an alloy that consists mostly of iron and has a carbon content between 0.2% and 2.1% by weight, depending on the grade. Carbon is the most common alloying material for iron, but various other alloying elements are used, such as manganese, chromium, vanadium, and tungsten...
), which were coated with tinTinTin is a chemical element with the symbol Sn and atomic number 50. It is a main group metal in group 14 of the periodic table. Tin shows chemical similarity to both neighboring group 14 elements, germanium and lead and has two possible oxidation states, +2 and the slightly more stable +4...
. - A plating forge with a tilt hammer, a lighter hammer with a rapid stroke rate, enabling the production of thinner iron, suitable for the manufacture of knivesKnifeA knife is a cutting tool with an exposed cutting edge or blade, hand-held or otherwise, with or without a handle. Knives were used at least two-and-a-half million years ago, as evidenced by the Oldowan tools...
, other cutleryCutleryCutlery refers to any hand implement used in preparing, serving, and especially eating food in the Western world. It is more usually known as silverware or flatware in the United States, where cutlery can have the more specific meaning of knives and other cutting instruments. This is probably the...
, and so on. - A cementation furnace might be used to convert the bar ironWrought ironthumb|The [[Eiffel tower]] is constructed from [[puddle iron]], a form of wrought ironWrought iron is an iron alloy with a very low carbon...
(if it was pure enough) into blister steel by the cementation processCementation processThe cementation process is an obsolete technique for making steel by carburization of iron. Unlike modern steelmaking, it increased the amount of carbon in the iron. It was apparently developed before the 17th century. Derwentcote Steel Furnace, built in 1720, is the earliest surviving example...
, either as an end in itself or as the raw material for crucible steelCrucible steelCrucible steel describes a number of different techniques for making steel in a crucible. Its manufacture is essentially a refining process which is dependent on preexisting furnace products...
.
Manufacture
Most of these processes did not produce finished goods. Further processes were often manual, including- Manufacturing by blacksmiths or more specialist kind of smith.
- It might be used in shipbuildingShipbuildingShipbuilding is the construction of ships and floating vessels. It normally takes place in a specialized facility known as a shipyard. Shipbuilders, also called shipwrights, follow a specialized occupation that traces its roots to before recorded history.Shipbuilding and ship repairs, both...
.
In the context of the iron industry, the term manufacture is best reserved for this final stage.
Great Britain
- CoalbrookdaleCoalbrookdaleCoalbrookdale is a village in the Ironbridge Gorge in Shropshire, England, containing a settlement of great significance in the history of iron ore smelting. This is where iron ore was first smelted by Abraham Darby using easily mined "coking coal". The coal was drawn from drift mines in the sides...
Ironworks - Blaenavon IronworksBlaenavon IronworksBlaenavon Ironworks is an industrial museum in Blaenavon in Wales. The ironworks was of crucial importance in the development of the ability to use cheap, low quality, high sulphur iron ores worldwide...
Heritage Site. BlaenavonBlaenavonBlaenavon is a town and World Heritage Site in south eastern Wales, lying at the source of the Afon Lwyd north of Pontypool, within the historic boundaries of Monmouthshire. The town lies high on a hillside and has a population of 6,349 people...
(Blaenafon) South Wales - Cyfarthfa IronworksCyfarthfa IronworksThe Cyfarthfa Ironworks was a major 18th century and 19th century ironworks located in Cyfarthfa, on the north-western edge of Merthyr Tydfil, in South Wales.-The beginning:...
at Merthyr TydfilMerthyr TydfilMerthyr Tydfil is a town in Wales, with a population of about 30,000. Although once the largest town in Wales, it is now ranked as the 15th largest urban area in Wales. It also gives its name to a county borough, which has a population of around 55,000. It is located in the historic county of...
, GlamorganGlamorganGlamorgan or Glamorganshire is one of the thirteen historic counties and a former administrative county of Wales. It was originally an early medieval kingdom of varying boundaries known as Glywysing until taken over by the Normans as a lordship. Glamorgan is latterly represented by the three...
, south WalesWalesWales is a country that is part of the United Kingdom and the island of Great Britain, bordered by England to its east and the Atlantic Ocean and Irish Sea to its west. It has a population of three million, and a total area of 20,779 km²... - Dowlais IronworksDowlais IronworksThe Dowlais Ironworks was a major ironworks and steelworks located at Dowlais near Merthyr Tydfil, in Wales. Founded in the 18th century, it operated until the end of the 20th, at one time in the 19th century being the largest steel producer in the UK...
also at Merthyr TydfilMerthyr TydfilMerthyr Tydfil is a town in Wales, with a population of about 30,000. Although once the largest town in Wales, it is now ranked as the 15th largest urban area in Wales. It also gives its name to a county borough, which has a population of around 55,000. It is located in the historic county of... - Millwall Ironworks, a shipbuilding firm on the Isle of DogsIsle of DogsThe Isle of Dogs is a former island in the East End of London that is bounded on three sides by one of the largest meanders in the River Thames.-Etymology:...
, on the River ThamesRiver ThamesThe River Thames flows through southern England. It is the longest river entirely in England and the second longest in the United Kingdom. While it is best known because its lower reaches flow through central London, the river flows alongside several other towns and cities, including Oxford,...
, LondonLondonLondon is the capital city of :England and the :United Kingdom, the largest metropolitan area in the United Kingdom, and the largest urban zone in the European Union by most measures. Located on the River Thames, London has been a major settlement for two millennia, its history going back to its...
, EnglandEnglandEngland is a country that is part of the United Kingdom. It shares land borders with Scotland to the north and Wales to the west; the Irish Sea is to the north west, the Celtic Sea to the south west, with the North Sea to the east and the English Channel to the south separating it from continental... - Thames Ironworks and Shipbuilding Co. Ltd, a shipbuilding firm at LeamouthLeamouthLeamouth is the area to the west of the mouth of the River Lea at the River Thames at . The northern part of the area lies within a meander of the Lea; the southern part is bounded in the west by the former East India Docks, on two sides by the Lea and by the River Thames to the south...
on the River ThamesRiver ThamesThe River Thames flows through southern England. It is the longest river entirely in England and the second longest in the United Kingdom. While it is best known because its lower reaches flow through central London, the river flows alongside several other towns and cities, including Oxford,...
, EnglandEnglandEngland is a country that is part of the United Kingdom. It shares land borders with Scotland to the north and Wales to the west; the Irish Sea is to the north west, the Celtic Sea to the south west, with the North Sea to the east and the English Channel to the south separating it from continental...
United States of America
- Bath Iron WorksBath Iron WorksBath Iron Works is a major American shipyard located on the Kennebec River in Bath, Maine, United States. Since its founding in 1884 , BIW has built private, commercial and military vessels, most of which have been ordered by the United States Navy...
in MaineMaineMaine is a state in the New England region of the northeastern United States, bordered by the Atlantic Ocean to the east and south, New Hampshire to the west, and the Canadian provinces of Quebec to the northwest and New Brunswick to the northeast. Maine is both the northernmost and easternmost... - Burden Iron Works in Troy, New YorkTroy, New YorkTroy is a city in the US State of New York and the seat of Rensselaer County. Troy is located on the western edge of Rensselaer County and on the eastern bank of the Hudson River. Troy has close ties to the nearby cities of Albany and Schenectady, forming a region popularly called the Capital...
- Cambria Iron CompanyCambria Iron CompanyCambria Iron Company is a National Historic Landmark located in Johnstown, Pennsylvania. The company was founded in 1852 and made many important contributions to the iron and steel industry...
in Johnstown, PennsylvaniaJohnstown, PennsylvaniaJohnstown is a city in Cambria County, Pennsylvania, United States, west-southwest of Altoona, Pennsylvania and east of Pittsburgh. The population was 20,978 at the 2010 census. It is the principal city of the Johnstown, Pennsylvania, Metropolitan Statistical Area, which includes Cambria County... - Tredegar Iron WorksTredegar Iron WorksThe Tredegar Iron Works was a historic iron foundry in Richmond, Virginia, United States of America, opened in 1837. During the American Civil War, the works served as the primary iron and artillery production facility of the Confederate States of America...
at Richmond, VirginiaRichmond, VirginiaRichmond is the capital of the Commonwealth of Virginia, in the United States. It is an independent city and not part of any county. Richmond is the center of the Richmond Metropolitan Statistical Area and the Greater Richmond area... - Saugus Iron Works in Saugus, MassachusettsSaugus, MassachusettsSaugus is a town in Essex County, Massachusetts, United States, in the Greater Boston area. The population was 26,628 at the 2010 census.-History:Saugus was first settled in 1629. Saugus is an Indian name believed to mean "great" or "extended"...
Spain
- Altos Hornos de VizcayaAltos Hornos de VizcayaAltos Hornos de Vizcaya was a ironworks business that began in 1902 in Bilbao with the merger of three iron and steel businesses: Altos Hornos de Bilbao, La Vizcaya, and La Iberia...
in BilbaoBilbaoBilbao ) is a Spanish municipality, capital of the province of Biscay, in the autonomous community of the Basque Country. With a population of 353,187 , it is the largest city of its autonomous community and the tenth largest in Spain... - ArcelorArcelorArcelor S.A. was the world's largest steel producer in terms of turnover and the second largest in terms of steel output, with a turnover of €30.2 billion and shipments of 45 million metric tons of steel in 2004...
facilities in AvilésAvilésAvilés is a city in Asturias, Spain. Avilés is with Oviedo and Gijón, one of the main towns in the Principality of Asturias.The town occupies the flattest land in the municipality, in a land that belonged to the sea, surrounded by small promontories, all of them having an altitude of less than...
and GijónGijónGijón , officially Gijón / Xixón, is a coastal industrial city and a municipality in the autonomous community of Asturias in Spain. Early mediaeval texts mention it as "Gigia". It was an important regional Roman city, although the area has been settled since earliest history...
, formerly Ensidesa.
Historical
- KindibaKindibaKindiba is an ancient iron extraction site located in Tougo Department, Yatenga Province, Burkina Faso. The site consists of mines and three clay built furnaces. -World Heritage Status:...
, in Burkina FasoBurkina FasoBurkina Faso – also known by its short-form name Burkina – is a landlocked country in west Africa. It is surrounded by six countries: Mali to the north, Niger to the east, Benin to the southeast, Togo and Ghana to the south, and Côte d'Ivoire to the southwest.Its size is with an estimated...
. Ancient iron extraction site consisting of mines and three clay built furnaces. - Darkhill IronworksDarkhill IronworksDarkhill Ironworks, and the neighbouring Titanic Steelworks, are internationally important industrial remains associated with the development of the iron and steel industries. Both are scheduled monuments. They are located on the edge of a small hamlet called Gorsty Knoll, just to the west of...
, in the Forest of DeanForest of DeanThe Forest of Dean is a geographical, historical and cultural region in the western part of the county of Gloucestershire, England. The forest is a roughly triangular plateau bounded by the River Wye to the west and north, the River Severn to the south, and the City of Gloucester to the east.The...
, EnglandEnglandEngland is a country that is part of the United Kingdom. It shares land borders with Scotland to the north and Wales to the west; the Irish Sea is to the north west, the Celtic Sea to the south west, with the North Sea to the east and the English Channel to the south separating it from continental...
. Experimental ironworks established in 1818 and designated an 'Industrial Archaeological Site of International Importance' - Falling Creek IronworksFalling Creek IronworksFalling Creek Ironworks was the first iron production facility in North America. It was established by the Virginia Company of London in Henrico Cittie on Falling Creek near its confluence with the James River. It was short-lived due to an attack by Native Americans in 1622.The long-lost site was...
- Royal St. John of Ipanema Iron FoundryRoyal St. John of Ipanema Iron FoundryRoyal St. John de Ipanema Iron Foundry as known Ipanema Iron Foundry or Factory, Fazenda Ipanema was the first ironworks in Brazil. It is located in Sorocaba region, near city of Iperó, state of São Paulo.- Background :...
Brazil