Puddling Furnace

The process of turning pig iron into wrought iron through the puddling furnace involves several
steps and specialized equipment. This method was commonly used in the 19th century for the
conversion of pig iron, which contains a high percentage of carbon, into wrought iron, a more
malleable and purer form of iron.
Here is an overview of the procedure:
Puddling Furnace Setup: The process begins with a puddling furnace, a reverberatory furnace
with a shallow hearth. This furnace has a domed roof to reflect heat downward onto the hearth
where the iron is placed.
Charging the Furnace: Pig iron, along with oxidizing agents and fluxes (substances that aid in
the removal of impurities), is charged into the furnace. The pig iron is heated until it melts.
Puddling Process: A skilled worker, known as a puddler, works the iron. The puddler uses long
iron rods to stir and agitate the molten metal. The agitation exposes the iron to the furnace's
heat and causes impurities, mainly carbon, to burn off, forming slag.
Oxidizing Impurities: The high temperature in the furnace oxidizes impurities such as carbon,
silicon, manganese, and phosphorus. These impurities combine with the added fluxes to form
slag, which floats on the surface of the molten iron.
Monitoring the Process: The puddler continuously works the iron, observing the color, texture,
and behavior of the molten metal to determine when the right level of impurities has been
removed. This process could take several hours.
Balling and Shingling: Once the desired level of purity is achieved, the puddler forms the iron
into balls or lumps. These balls are removed from the furnace and placed under a hammer or a
heavy mechanical press, known as a shingling hammer, to further squeeze out impurities and
consolidate the iron.
Final Product: The resulting wrought iron, with a lower carbon content, is malleable and more
durable than pig iron. It can be further processed into bars, sheets, or other desired forms for
various applications, such as construction, manufacturing, and blacksmithing.
 Cupola Furnace

The cupola furnace is a type of blast furnace used to convert pig iron into cast iron. The process
involves high temperatures and the addition of specific elements to produce a molten metal
suitable for casting various objects. Here's an overview of the procedure:
Preparation and Setup: The cupola furnace, a vertical cylindrical structure, is loaded with a
combination of fuel and iron in alternate layers. The fuel, often coke (a form of processed coal),
is stacked at the bottom, followed by layers of iron and additional layers of coke.
Ignition and Melting: The furnace is ignited at the bottom, and intense heat generated by the
burning fuel melts the iron. As the temperature rises, the iron and coke mix and start to melt
and liquefy.
Addition of Flux and Alloying Elements: Flux materials, such as limestone, are added to the
furnace to assist in the removal of impurities and the formation of slag. Additionally, alloying
elements such as carbon, silicon, and other metals may be added to create the desired cast iron
composition.
Removal of Impurities: The high temperatures in the furnace cause the impurities in the pig iron
to combine with the added flux, forming slag. This slag floats on top of the molten metal and is
periodically removed from the furnace.
Tapping the Furnace: When the desired temperature and consistency of the molten metal are
achieved, the furnace is tapped. The molten cast iron is released through a tap hole at the base of
the furnace into channels or molds for casting.
Casting Process: The molten cast iron is poured into molds to create specific shapes or objects.
The casting process involves allowing the molten metal to cool and solidify in the desired molds
to produce cast iron products like engine blocks, pipes, machinery parts, or decorative items.
Post-Processing: Once the cast iron solidifies, the products are removed from the molds and
may undergo additional processes such as cleaning, finishing, and heat treatment to achieve the
desired final properties.

Done by: Tristan Dixon Class: 4 White