Smelting iron ore in the Bloomery furnace

For the last eight days Jake Radcliff from Black Sands Forge has been visiting to conduct a small scale iron smelt using a site built bloomery furnace, local iron ore and local clay for the bricks used in the furnace. In This video we are conducting the smelt in hopes of retrieving an iron bloom that can be refined into usable wrought iron.
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Blacksmithing and related activities can be hazardous. These videos are not a substitute for competent professional instruction. Your safety is your sole responsibility. Always use appropriate safety equipment including eye and ear protection when working in the shop. Follow manufactures safety guidelines for the use of all equipment. In the event something shown in one of these videos seems unsafe, it is up to you to make the appropriate changes to protect yourself.

[@natejohnsonarts]

If you mix a small amount of water into your ore/sand - just until it starts to lightly clump together when compressed between your hands - it will help prevent the ore dust from blowing out of the furnace when you pour it in. I learned this from Wayne Potratz in MN during a smelt.

[@galaxiedance3135]

I watched a video where they showed the traditional way they made Iron Ore in the Country Called Burkina Faso in Africa. Very detailed, making the coal, getting the iron ore from the ground, getting the flux from the ground, making the tubes and bellows, amazing to watch! Rare to find a video that demonstrates something so well. I wonder if I'd be able to do something like this in a very nice neighborhood? I think that I'd have a Karen knocking on the front door saying there's too much smoke :)

[@user-omare]

Can you give me the title of the video you talked about?

[@WatcherintheDark69]

That small piece of bloom iron that was brought to the log first is pretty much what a traditional iron age furnace would yield. Even with modern equipment, that looks like exhausting work. Great video!

[@jakeradcliff3652]

WatcherintheDark69 it was, and I’m at a disadvantage because I’m not used to breathing the thin air. It took a lot out of me.

[@dave_in_florida]

Great Video! Thanks for wearing a microphone, it made the audio so easy to understand even with the blower going.

[@donstephenson9474]

If you add a slag hole and tap the slag you won't get as many impurities in your bloom. If the bloom is not too large the slag hole can then be enlarged to remove the bloom without completely destroying the furnace. The bloom, when removed in this manner can be much further refined right at the stump and won't break apart so badly with more of the slag removed. (and a LOT more hammering) :-)

[@BlackBearForge]

Thanks, thats a good tip

[@jskjsk3986]

Nice to see an Iron Farmer at work. No farmers, no tools!

[@drason69]

Making the iron is incredible...making something from the iron is EPIC! When we did the smelt at the event, Stuart had designed the base of the furnace, to act as our forge, once the tower was toppled, and the bloom collected. Instead of sledge hammers, we used monster wood mallets I made from a maple tree we had cut down a month earlier. Fun project! Thanks for sharing this!

[@BlackBearForge]

I have watched a few of those videos and will plan on watching all of them. I am looking forward to making a finished useful item from the iron.

[@Albiom]

the ore you guys were using was really pure, you can tell that buy how the magnets attracts it

[@garethbaus5471]

That is about the ore being primarily magnetite rather than hematite and isn't actually a good indicator of purity.

[@milonguerobill]

Outstanding, this took a lot less time than I would have thought, really impressive, Thanks to Jake and you for putting up this series, I'm learning a lot.

[@jakeradcliff3652]

Bill Serve there were a few unexpected things that happened. I hope that everyone watching knows that this is just an example of one possible way of accomplishing this project and this is not meant as the definitive how-to method. Thank you and every one that has been commenting on this series. It has been a lot of fun doing it.

[@jjlforge3468]

I’ve been thinking about doing this with my local guild folks this summer... looks very do able.... thanks guys so very much for the effort you have put in to this!

[@BlackBearForge]

I'm glad it helped. I learned a lot

[@jakeradcliff3652]

This is a very doable project for anybody. I would like to see more people attempt it. Do be carful and mind safety. There is real potential to get injured and cause serious property damage. Research and planning is the key!

[@waskasoometalworks3329]

This was awesome! You should definitely run this project again, there's something to be said about taking a step farther back in history to better appreciate the steps forward society has taken. I've partook on this experiment a few times and its so relaxing and rewarding in its own way

[@Theelderdragon01]

You guys are giving me ideas.

[@ha-y-in6938]

I lack bear forge made my hold downs, still have them and still working great, thanks guys

[@ricksmith9086]

Thank you for sharing your smelt project. I liked the presentation. I have smelted about six times over the past couple years and always looking for ideas to improve my operation. It is a trial and error process so far. I have used several types of material and some have produced nice glass pieces, which I will use in another project, but my current smelting material is mineralized wood (almost petrified) with a very high iron content. It has produced the best results. Anyway this is a great video.

[@gardeninginnorway478]

This is a very interesting project to follow! Thanks.

[@workwithnature]

only half way in this and the video before are real great, looking forward to watching you guys forge the bloom in a bit.

[@kenziestieward07]

A

[@frankgaletzka8477]

Hello John I stumbelt over your Video Smelting iron what a great thing I like to see it All the best wishes Yours Frank

[@chrisspalding1971]

Very cool video!! Can't wait for the next part.

[@gustavpedersen9134]

Turn the blower off while pouring in the ore and then turn it back on when charcoal is added, adding a switch to the blower makes it easier.

[@bvictory5698]

There is a switch on the side of the blower xD I have one of them

[@emandejnozka1369]

Hi ! I have used an old Electrolux vacuum cleaner backwards as my air source. My cupola was two thirty gallon barrels with the twyer chamber made from a 55 gallon barrel.

[@timbair6608]

no joke. hair dryer. works perfect

[@user-omare]

Did you succeed in dissolving the iron?

[@waskasoometalworks3329]

bloom iron has got to be the most interesting thing to forge! its squishy, with slight rebound

[@charlesmay8251]

thanks Jake!

[@jakeradcliff3652]

Charles May thank you for watching!

[@MfJfb]

thats a beautiful bloom you've got !

[@Rottinrock]

it looks real nice

[@Pseud0rand0m]

Very neat! I'd love to try this

[@bentoombs]

This is totally cool. I'm going to have to try this. Thanks for the inspiration

[@GorVala]

Awsome video! Thank you. Well made and very easy to watch. No silly generic music.. great watch

[@G19amc]

That was freaking awesome.. the neighbors wud just love me..

[@tengu190]

Reminds me of the time back in high school I smelted with Lee Sauder in the early 2000s.

[@motome8]

Wow.. so cool. Thanks Jake!

[@jakeradcliff3652]

Kaitlin McCall the real thanks goes to John for hosting this project!

[@Uncle_Bucks_Forge]

Very cool video. Enjoyed it. Looking forward to more on on this process.

[@jeffreypikul6402]

I keep finding your videos searching for so much info. Great work as always

[@klkkylekin5948]

Very cool thanks for sharing

[@williamjacobs4274]

Very interesting. I enjoyed this video. It really shows what can be done. Thank you. Keep up the good work.

[@111raybartlett]

Very cool series!

[@davephillips7550]

Who the hell would give some good old work a thumbs down.? I live in Western PA and we have oodles of mid 19th iron furaces and would love to try this sometime. Great job 😎

[@BlackBearForge]

I picture someone sitting around searching for blacksmithing videos that look just like forged in fire.

[@davephillips7550]

Black Bear Forge believe me. I'm into 18th century recreation. Am currently building a hand hewn Appalachian cabin. People think I'm nuts but will post a KZbin when I'm done. Thanks for the comment back. Take care

[@davephillips7550]

Thanks John. I have built a picture of pic's but most people don't understand the entire work from the foundation to the end. Take care and keep forging. 😎. PS. Can I email you of my progress?

[@ljk8059]

Using that magnet to pick up the black sand is vacuuming for men ;-)

[@joshstamps6718]

Using that fan, genius

[@kevinkult]

So very cool. Well done guys!

[@meyer3846]

I think its a really cool idea that all the material was locally sourced. I'd be interested to see what he comes up with in Hawaii when he does his smelt. Ive been thinking about getting either one of those bouncy house blowers or a regular forge blower to make a forced air ribbon burner forge. Smelting is defiantly on my bucket list.

[@BlackBearForge]

This was a lot of fun. For a ribbon burner, I think you can get by with a much smaller blower, also a quieter blower than this thing.

[@jakeradcliff3652]

The ore is going to be very similar. I’ve collected most everything I’ll need for a smelt in Hawaii, so that will be happening soon.

[@andrewlast1535]

That’s a dandy of a bloom. Probably the best I have watched. And strangely, I have watched a lot. I suppose the magnetite really helps too? Most of the others I have watched were with bog iron.

[@jaredlariscey713]

Nice job guys!

[@J800613]

This is great stuff as usual. Absolutely fascinating. Good job!

[@tomharrell1954]

Great job

[@andytree001]

I have the same blower on my forge. You can control the air flow with a cheap rheostat,I got mine on ebay for pocket change. Makes the noise level a lot more civilised too

[@BlackBearForge]

Good tip, especially if it reduces the noise.

[@jakeradcliff3652]

I will look into that. Thanks for the tip.

[@wallacedavis8922]

Thanks to both of you very interesting can't wait to see the billet another great video

[@BlackBearForge]

Hopefully thew forging of the billet will be completed today

[@jackdawg4579]

Very cool!

[@krustysurfer]

Great video

[@TheDistur]

Amazing work. Well done.

[@johnmitchell3254]

Thanks to both of you for the videos. Hope there is at least one more showing the refinement and end product. Too many questions for this forum or my typing speed. Much more research ahead. Again thank you. ....

[@BlackBearForge]

I will be wrapping that video up today

[@WinDancerX]

Wow- and maybe some iron for a project! This was a ton of work [Thanks Jake!!] and very interesting and dirty as all get out :) Thanks for doing this excellent video for us. Dave- WinDancerKnives

[@gregsmith3289]

Very interesting stuff.

[@alansloas777]

Very Interesting

[@paulorchard7960]

Great stuff John, first time I have seen this and interesting! Not something my neighbors, who are very relaxed and supportive of my workshop noises and other small issues, would be that keen about! We are experiencing sever fire restrictions at this time because of drought but even when it lifts I will stay on the side of caution and not antagonize anyone!

[@mxcollin95]

Very cool! 👍

[@bc65925]

Probably the best show I have seen can be viewed here on the Tube. It's a Nova special called "Secrets of the Viking Sword Documentary." I bet you have seen it.

[@BlackBearForge]

Yes I have. Of course they are making crucible steel for the sword as opposed to wrought iron, That is why that sword was superior to the swords made from blister steel.

[@DavoShed]

Really interesting stuff. Well to me any way. My Wife says put your head phones on 😀

[@motome8]

David Pollard LOL ditto..

[@clydecox2108]

Mine too

[@henrygardiner7740]

Fantastic!!

[@bearshield7138]

wonderful

[@adampablodayc]

Sweet.

[@tuhaisegerald6556]

Wooo here in Uganda we have started making that prosses

[@porit1023]

This is great content! Thank you for making it

[@katnip6289]

Marvelous!

[@shifty3453]

Ohh man the billet is the bit I'm looking forward to.

[@BlackBearForge]

Hopefully I will have that video completed today

[@workwithnature]

Quick question for the two of you. Would it make sense to keep the blower going till the last moment and also rush to the soft consolidating bit. Am just thinking that the hotter the bloom the easier it will forge weld together. Or am I totally of there.

[@BlackBearForge]

I think we came as close that as reasonably possible. The large section of bloom consolidated very nicely. All of the other stuff simply had to much slag or was in such small pieces it didn't lend itself to refining on the spot.

[@workwithnature]

Ah I see. Looking forward to the hammer axe video.

[@pnwprospecting]

Why no port at the bottom for slag? Great video! Thanks!

[@yoostburg]

What is the proper name for the rolling magnet tool? I could really use one!

[@TheNoodlyAppendage]

2 suggestions. The bloomery needs to be more cone shaped to reflect heat better. Second the tuyere needs to be forced air and use much less air than in the video. If your charcoal to ore ratio is correct, there will be a point where you need almost no air as the point is to use the Oxygen bound to the iron. If you can get the temperature up to about 3000 degrees F it will flash over and self sustain.

[@Rottinrock]

did you make the hand rail in the back ground [ leaning against the shed ] ?

[@BlackBearForge]

No a friend of mine made that years ago. It was on his shop building and when he relocated he took it down but couldn't take it with him, so he gave it to us, we will eventually install it

[@timriggs5192]

May have been hot on your end but i thought this was really cool

[@scottwallingwindyacresiron2654]

That was so intriguing. I wonder if a 10-12 inch concrete drainage pipe would work?? They are about 4 feet long. I don’t think I have those resources available in corn patch Iowa. Guessing I’m going to have to tell them he wife Colorado is our next vacation destination. It could be a surprise trip!! Thank you both for another fantastic video! Btw awesome view love the woods.

[@BlackBearForge]

Concrete does not like high heat. It tends to blow off big chunks when it gets hot.

[@neilyeag]

Very interesting

[@cgmcpherson33]

Man that was sweet

[@pnwprospecting]

How many pounds of charcoal do you think you used

[@mathiasrapp8904]

realy great job! saludos desde canarias

[@WildmanPB]

I use a simular blower on my ribbon burner,don't add a reostat to it you will burn it up,also they are not meant to free Flo into open air as this will cause motor burn out,they are intended to run against pressure. I have a gate valve between the blower and the forge to control the amount of air to the burner and keep back pressure on the fan.

[@jakeradcliff3652]

WildmanPB that makes sense thank you. I’ll look at doing that modification to the blower.

[@andytree001]

You might be right, have you managed to burn one out that way? I only ask because I have been ruining mine through a statt on a daily basis for more that 2 years without any problems. Before I used it, I did ask an electrical engineer who works for Siemens, he looked at the plate on the "no name" PRC blower motor and declared it good to go, he said something about it making a difference how the motor was wound but I probably stopped listening after the good to go part, can you shed any light on that? I get the blowers on ebay for about 20 pounds (UK) and the rheostat costs even less but if it ever burns out I ill let you know.

[@dannydrake7348]

I found some very old chucks of metal in my field with a metal detector, land been in family since 1877 and no know structures in that area, metal is rough and varied in thickness and size, looks like some pictures I’ve seen of billets but not sure, would love to have them tested to see how old they were, would welcome any help and could share pictures if needed, enjoyed your post

[@jonsey3645]

What ratio of black sand to ingot did you achieve? Also how much charcoal was consumed? VERY interesting, thanks.

[@stevesyncox9893]

Cool

[@tonyelk1126]

what can you do with to the extra slag?

[@meredrums1]

Usefll information.

[@mikep.coplin6800]

You should try to use a router speed controler on that blower, to adjust the blower speed down.

[@djjoel1]

Is there a way to build a bloomery furnace that can be re-used? I want to make tons of iron this year with magnetite. Should I use another method or is this the only way to go for magnetite?

[@BlackBearForge]

I am sure there are, but I don't have any details on making one

[@johntompkins147]

Does elevation have any variance on this process? Did elevation play any part in the amount of blume that was created? Never seen this before, Thanks for demonstration.

[@BlackBearForge]

I think it might be a factor, but I really can't say for sure.

[@jakeradcliff3652]

That’s kind of why I went with the largest blower I could find. I thought that because of the thinner air at Beulah’s elevation, the furnace may have been starved of oxygen. Turned out that the bigger blower ended up hurting us by kicking a lot of ore out of the furnace.

[@mattharvey8712]

Bravo..........it's all feed and air flow..........what if u feed oxygen in the stinger.........cheers

[@h2o270]

Awesome! Have you seen the DVD Ore to Axe? Great video

[@BlackBearForge]

No, but I think I will have to get a copy.

[@jakeradcliff3652]

I’ve seen excerpts and that along with a couple other things is what got me interested in doing this.

[@h2o270]

I really want to do one

[@johnroot8215]

Fantastic! What are you going to make from the bloom? Thanks for the demo.

[@BlackBearForge]

I am hoping there is enough to make a small axe

[@johndilsaver8409]

I really enjoyed this. I'm wondering what project(s) you might have in mind for the wrought iron you produce. I have a small amount of wrought iron -- roughly 100 year old fence material -- that from bending/breaking and spark testing is wrought iron. Curious to see what hints and tips you might have for working with wrought iron in general. Also, I appreciate your cautions about mineral rights, one should get their ore legally, but for most of us a more basic challenge is just where to begin looking.

[@BlackBearForge]

I have a few ideas, but I am still not sure how much actual wrought iron will come out of this. Probably the top of my list would be a small Viking style axe, that will also require turning some of the wrought iron into steel.

[@keithandjeanbrazil4316]

I'm glad you made this video. Very educational. Where did you obtain the black sand?

[@BlackBearForge]

Stream beds mostly. Jake had contacts with mineral claims that he could harvest sand from.

[@andyhowey7351]

Could you use a bloomery furnace for scrap iron/steel, shavings, filings, etc. How about to recycle scale?

[@BlackBearForge]

I have no idea

[@bryanrobinson1980]

Adding a reostat controlled receptacle adapter would be a suggestion, especially if folks use it for a forge blower.

[@BlackBearForge]

I suspect Jake will be adding one for the next smelt

[@oromoctoecv6411]

why couldnt you use a mesh screen over the top to keep so much stuff from flying out? you could just move it to pour stuff in

[@johnparkerthegimpygardener]

Very interesting ! Would you address the cast iron part ?

[@BlackBearForge]

There wasn't any cast iron produced. The product achieved is bloomery iron that will be refined into wrought iron.

[@nikoniko3037]

didn't the air need to be stronger?

[@johnwaw6363]

How much charcoal would you say you ran through?

[@BlackBearForge]

We used three 55 gallon barrels full

[@pennyraven1222]

OK I'm about as dumb as a pail of that sand. You're making wrought iron I see mentioned. Can wrought iron be used to make a blade?? Will it hold an edge. Thinking axe or knife. Loved the video. Missed the making of the smelter. As always keep them coming.

[@shadowcastre]

Wow..! Very cool..! What type of clay/refractory was the furnace made from? I'm looking forward to the next segment. Thanks for the video...

[@beanyboom18]

They sourced the clay locally, if I recall correctly from the previous video.

[@BlackBearForge]

The clay was locally sourced from a quarry about 5 miles from here. Since this is a one time use furnace, just about any clay will work.

[@terrychaney1249]

very interesting. I live near Iron City, the extreme Southwest corner of GA. there is supposed to be some iron ore in this area. Do you know what the ore here would look like? I think I heard John say you did this process in GA before, but I presume it was in North GA.

[@drason69]

Take a good strong magnet, and a bucket, and go prospecting. From what I learned from a friend who has done this several times, he recommends 'roasting and crushing the ore' prior to smelting. It drives off moisture and breaks down the bits to smelt easier.

[@jakeradcliff3652]

We were at Trent Tye’s forge in south west Georgia when I did the smelt out there. We were collecting ore by running a magnet along side the dirt roads. I heard that iron ore can also be found at the peanut processing plants. There is this pebble like sand that is separated from the peanuts that is mostly magnetic. You could check there.

[@clydecox2108]

So how much black sand did you start out with? In pounds?

[@BlackBearForge]

I don't recall exact;y, but about half a 5 gallon bucket full

[@clydecox2108]

I have access to the black sand, and I want to make a sword for my son. Learning a lot from your videos, thank you

[@trollmcclure1884]

shouldnt the oxidizing fire burn it? I think I need more of the theory

[@BlackBearForge]

The fire shouldn't be oxidizing. The goal is to have a good oxygen to fuel ratio so that all of the oxygen consumed