Puddling Furnace Working | Types of steel Making | Steel | Engineering Materials | Material Science

Puddling Furnace Working | Types of steel Making | Steel | Engineering Materials | Material Science
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The puddling furnace is a type of furnace that was historically used for the conversion of pig iron into wrought iron. It played a significant role in the Industrial Revolution, especially during the 18th and 19th centuries. Here is a general overview of the working process of a puddling furnace:
Charging: The first step in the puddling furnace process is charging the furnace with pig iron and a certain amount of scrap iron, known as "fettling." The furnace is preheated before charging to ensure a suitable working temperature.
Heating and Puddling: Once the charging is complete, the furnace is heated, usually using coal or coke as fuel. The heat generated melts the pig iron and fettling, forming a molten mass. The furnace is designed to have a shallow hearth, allowing a large surface area for exposure to heat.
Puddling and Stirring: During the heating process, the puddler, a skilled worker, uses long iron bars or rabbles to stir the molten iron mass continuously. This stirring action exposes the molten iron to the oxidizing atmosphere of the furnace, promoting the removal of impurities, particularly carbon and silicon. The worker also introduces additional oxidizing agents like iron oxide (hematite) or iron ore to aid in the removal of impurities.
Decarburization and Slag Formation: As the puddling process continues, the carbon content in the molten iron reduces due to the oxidation reactions occurring at the high temperatures. The silicon and other impurities also oxidize and combine with the added iron oxide or iron ore to form slag. The slag floats on top of the molten iron and helps protect the metal from further oxidation and loss of heat.
Balling: As the impurities are removed and the desired composition is achieved, the puddler forms small masses of wrought iron called "blooms" or "puddle balls" by gathering and rolling the malleable mass of iron using the rabbles. These balls are then removed from the furnace.
Squeezing and Shingling: The puddle balls are taken to a nearby hammering station, where they are repeatedly hammered and squeezed to remove excess slag and further shape the iron into desired forms, such as bars or plates. This process is known as squeezing or shingling.
Further Processing: The resulting wrought iron products are subjected to additional processes, such as rolling, forging, or bending, to achieve the desired shape and strength. The wrought iron can be used for various applications, including construction, machinery, and manufacturing.
It's important to note that the puddling furnace process is an old and labor-intensive method of producing wrought iron. It has been largely replaced by more efficient steelmaking processes, such as the Bessemer process and the open hearth furnace, which allow for the direct production of steel from pig iron.
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