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Hot blast allowed the use of anthracite in iron smelting. It also allowed use of lower quality coal because less fuel meant proportionately less sulfur and ash. [11]At the time the process was invented, good coking coal was only available in sufficient quantities in Great Britain and western Germany, [12] so iron furnaces in the US were using charcoal.
The movement away from charcoal in US iron smelting began in 1827, when a puddling furnace in Phoenixville, Pennsylvania started using anthracite coal. Blast furnaces continued to use only charcoal until about 1840, when coke from coal started replacing charcoal as the fuel and reducing agent. [5]
The design of water jacket furnaces differ from the conventional blast furnaces used for smelting iron ore, which use a hot blast. Water jacket furnaces typically used a cold air blast, typically provided by a positive-displacement blower, such as a Roots blower. Preheating of the air blast was used on some water jacket furnaces. [15]
James Beaumont Neilson (22 June 1792 – 18 January 1865) was a Scottish inventor whose hot-blast process greatly increased the efficiency of smelting iron. Life [ edit ]
The tuyeres are used to implement a hot blast, which is used to increase the efficiency of the blast furnace. The hot blast is directed into the furnace through water-cooled copper nozzles called tuyeres near the base. The hot blast temperature can be from 900 to 1,300 °C (1,650 to 2,370 °F) depending on the stove design and condition.
The difficulty of igniting anthracite inhibited its early use, especially in blast furnaces for smelting iron. With the development of the hot blast in 1828, which used waste heat to preheat combustion air, anthracite became a preferred fuel, accounting for 45% of US pig iron production within 15 years. [17]
The ovens for the hot blast were coal-fired, and the blowing engine was driven by a waterwheel tapping the canal at Lock 36. The furnace was blown in on July 3, 1840 and the first four tons of iron produced July 4, 1840. It remained in blast until flooded by a January freshet in 1841, producing 1,080 tons of iron during that period. [6]
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