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The Bessemer process was the first inexpensive industrial process for the mass production of steel from molten pig iron before the development of the open hearth furnace. The key principle is steelmaking and undesired elements, primarily excess carbon contained in the pig iron by oxidation with air being blown through the molten iron. Oxidation of the excess carbon also raises the temperature of the iron mass and keeps it molten. Virtually all the pig iron carbon is removed by the converter and so carbon must be added at the end of the process to create steel, 0.25% carbon content is a typical value for low carbon steel which is used in construction and other low-stress applications.
The modern process is named after its inventor, the Englishman Henry Bessemer, who took out a patent on the process in 1856. The process was said to be independently discovered in 1851 by the American inventor William Kelly though the claim is controversial.
The process using a basic refractory lining is known as the "basic Bessemer process" or Gilchrist–Thomas process after the English discoverers Percy Gilchrist and Sidney Gilchrist Thomas.
Sir Henry Bessemer described the origin of his invention in his autobiography written in 1890. During the outbreak of the Crimean War, many English industrialists and inventors became interested in military technology. According to Bessemer, his invention was inspired by a conversation with Napoleon III in 1854 pertaining to the steel required for better artillery. Bessemer claimed that it "was the spark which kindled one of the greatest revolutions that the present century had to record, for during my solitary ride in a cab that night from Vincennes to Paris, I made up my mind to try what I could to improve the quality of iron in the manufacture of guns." At the time, steel was used to make only small items like cutlery and tools, but was too expensive for cannons. Starting in January 1855, he began working on a way to produce steel in the massive quantities required for artillery and by October he filed his first patent related to the Bessemer process. He patented the method a year later in 1856. William Kelly was awarded priority patent in 1857.
Bessemer licensed the patent for his process to four , for a total of £27,000, but the licensees failed to produce the quality of steel he had promised—it was "rotten hot and rotten cold", according to his friend, William Clay—and he later bought them back for £32,500. p172. His plan had been to offer the licenses to one company in each of several geographic areas, at a royalty price per ton that included a lower rate on a proportion of their output in order to encourage production, but not so large a proportion that they might decide to reduce their selling prices. By this method he hoped to cause the new process to gain in standing and market share.
He realised that the technical problem was due to impurities in the iron and concluded that the solution lay in knowing when to turn off the flow of air in his process so that the impurities were burned off but just the right amount of carbon remained. However, despite spending tens of thousands of pounds on experiments, he could not find the answer.. Certain grades of steel are sensitive to the 78% nitrogen which was part of the air blast passing through the steel.
The solution was first discovered by English metallurgist Robert Forester Mushet, who had carried out thousands of experiments in the Forest of Dean. His method was to first burn off, as far as possible, all the impurities and carbon, then reintroduce carbon and manganese by adding an exact amount of spiegeleisen, an alloy of iron and manganese with trace amounts of carbon and silicon. This had the effect of improving the quality of the finished product, increasing its malleability—its ability to withstand rolling and forging at high temperatures and making it more suitable for a vast array of uses.. Mushet's patent ultimately lapsed due to Mushet's inability to pay the patent fees and was acquired by Bessemer. Bessemer earned over 5 million dollars in royalties from the patents.
The first company to license the process was the Manchester firm of W & J Galloway, and they did so before Bessemer announced it at Cheltenham in 1856. They are not included in his list of the four to whom he refunded the license fees. However, they subsequently rescinded their license in 1858 in return for the opportunity to invest in a partnership with Bessemer and others. This partnership began to manufacture steel in Sheffield from 1858, initially using imported charcoal pig iron from Sweden. This was the first commercial production.
A 20% share in the Bessemer patent was also purchased for use in Sweden and Norway by Swedish trader and Consul Göran Fredrik Göransson during a visit to London in 1857. During the first half of 1858, Göransson, together with a small group of engineers, experimented with the Bessemer process at Edsken near Hofors, Sweden before he finally succeeded. Later in 1858 he again met with Henry Bessemer in London, managed to convince him of his success with the process, and negotiated the right to sell his steel in England. Production continued in Edsken, but it was far too small for the industrial-scale production needed. In 1862 Göransson built a new factory for his Högbo Iron and Steel Works company on the shore of Lake Storsjön, where the town of Sandviken was founded. The company was renamed Sandviken's Ironworks, continued to grow and eventually became Sandvik in the 1970s.
The trio began setting up a mill in Troy, New York in 1865. The factory contained a number of Holley's innovations that greatly improved productivity over Bessemer's factory in Sheffield, and the owners gave a successful public exhibition in 1867. The Troy factory attracted the attention of the Pennsylvania Railroad, which wanted to use the new process to manufacture steel rail. It funded Holley's second mill as part of its Pennsylvania Steel subsidiary. Between 1866 and 1877, the partners were able to license a total of 11 Bessemer steel mills.
One of the investors they attracted was Andrew Carnegie, who saw great promise in the new steel technology after a visit to Bessemer in 1872, and saw it as a useful adjunct to his existing businesses, the Keystone Bridge Company and the Union Iron Works. Holley built the new steel mill for Carnegie, and continued to improve and refine the process. The new mill, known as the Edgar Thomson Steel Works, opened in 1875, and started the growth of the United States as a major world steel producer.Thomas J. Misa, A Nation of Steel: The Making of Modern America, 1865–1925 (1995): chapter on Holley and Bessemer process online Using the Bessemer process, Carnegie Steel was able to reduce the costs of steel railroad rails from $100 per ton to $50 per ton between 1873 and 1875. The price of steel continued to fall until Carnegie was selling rails for $18 per ton by the 1890s. Prior to the opening of Carnegie's Thomson Works, steel output in the United States totaled around 157,000 tons per year. By 1910, American companies were producing 26 million tons of steel annually.
William Walker Scranton, manager and owner of the Lackawanna Iron & Coal Company in Scranton, Pennsylvania, had also investigated the process in Europe. He built a mill in 1876 using the Bessemer process for steel rails and quadrupled his production. Cheryl A. Kashuba, "William Walker led industry in the city", The Times-Tribune, 11 July 2010, accessed 23 May 2016
Bessemer steel was used in the United States primarily for railroad rails. During the construction of the Brooklyn Bridge, a major dispute arose over whether crucible steel should be used instead of the cheaper Bessemer steel. In 1877, Abram Hewitt wrote a letter urging against the use of Bessemer steel. Bids had been submitted for both crucible steel and Bessemer steel; John A. Roebling's Sons submitted the lowest bid for Bessemer steel, but at Hewitt's direction, the contract was awarded to J. Lloyd Haigh Co.
A Bessemer converter could treat a "heat" (batch of hot metal) of 5 to 30 tons at a time. They were usually operated in pairs: one was blown while the other was filled or tapped.
The Bessemer process revolutionized steel manufacture by decreasing its cost, from £40 per long ton to £6–7 per long ton, along with greatly increasing the scale and speed of production of this vital raw material. The process also decreased the labor requirements for steel-making. Before it was introduced, steel was far too expensive to make bridges or the framework for buildings and thus wrought iron had been used throughout the Industrial Revolution. After the introduction of the Bessemer process, steel and wrought iron became similarly priced, and some users, primarily railroads, turned to steel. Quality problems, such as brittleness caused by nitrogen in the blowing air, prevented Bessemer steel from being used for many structural applications. Chapter 1 online. Open-hearth steel was suitable for structural applications.
Steel greatly improved the productivity of railroads. Steel rails lasted ten times longer than iron rails. Steel rails could carry heavier locomotives, which could pull longer trains. Steel rail cars were longer and were able to increase the freight to car weight from 1:1 to 2:1.
In the U.S., commercial steel production using this method stopped in 1968. It was replaced by processes such as the basic oxygen (Linz–Donawitz) process, which offered better control of final chemistry. The Bessemer process was so fast (10–20 minutes for a heat) that it allowed little time for chemical analysis or adjustment of the alloying elements in the steel. Bessemer converters did not remove phosphorus efficiently from the molten steel; as low-phosphorus ores became more expensive, conversion costs increased. The process permitted only limited amount of scrap steel to be charged, further increasing costs, especially when scrap was inexpensive. Use of electric arc furnace technology competed favourably with the Bessemer process resulting in its obsolescence.
Basic oxygen steelmaking is essentially an improved version of the Bessemer process (decarburization by blowing oxygen as gas into the heat rather than burning the excess carbon away by adding oxygen carrying substances into the heat). The advantages of pure oxygen blast over air blast were known to Henry Bessemer, but 19th-century technology was not advanced enough to allow for the production of the large quantities of pure oxygen necessary to make it economical.
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