TEAM ONE

Virginia Rock Ore in Flye Tyle

TIME   CHARCOAL   ORE   NOTES
Absolute Elapsed lbs charged total added charged total added  
9:40           pre-heat, firewood
10:38 0:58 22       ungraded
10:44 0:06 4 4      
10:51 0:07 4 8      
10:58 0:07 4 12 0.5 0.5  
11:06 0:08 4 16 0.5 1  
11:13 0:07 4 20 0.5 1.5 approx. 1200 C
11:21 0:08 4 24 0.5 2  
11:29 0:08 4 28 1 3  
11:35 0:06 4 32 1 4  
11:45 0:10 4 36 1 5  
11:53 0:08 4 40 1 6  
12:02 0:09 4 44 1 7 white heat
12:12 0:10 4 48 1.5 8.5  
12:22 0:10 4 52 1.5 10 charcoal floatting in slag
12:30 0:08 4 56 1.5 11.5 cast iron laks from left of tuyere
12:36 0:06 4 60 1.5 13 tuyere at about 20degrees
12:46 0:10 4 64 2 15 made fluttering sound
12:56 0:10 4 68 2 17 tuyere blowing thru slag, poked thru with rod
1:05 0:09 4 72 2 19 increased air flow
1:16 0:11 4 76 2 21 slag forming around rim of tuyere poked thru w/rod, black shinny slag
1:28 0:12 4 80 2 23 released cast iron /slag
1:36 0:08 4 84 2 25 gurgling noise gone
1:44 0:08 4 88 2.5 27.5 slag looking better
1:51 0:07 4 92 2.5 30  
1:56 0:05 4 96 2.5 32.5  
2:03 0:07 4 100 3 35.5  
2:08 0:05 4 104 3.5 39  
2:15 0:07 4 108 4 43 pyrometer: 1580 degrees C, broke up slag
2:21 0:06 4 112 4 47  
2:27 0:06 4 116 4 51  
2:33 0:06 4 120 4 55  
2:40 0:07 4 124 4 59  
2:48 0:08 4 128 1 60 finished 60# ore
2:55 0:07 4 132 0   tapped arch slag looks good using mixed charcoal
3:04 0:09 4 136 0    
3:07 0:03 4 140 0    
3:12 0:05 4 144 0   re-cycling slag
3:17 0:05 4 148 0   re-cycling slag
3:25 0:08 4 152 0   re-cycling slag
3:29 0:04 4 156 0   re-cycling slag
3:35 0:06 4 160 0   re-cycling slag
3:42 0:07 4 164 0    
3:47 0:05 4 168 4 64  
4:00 0:13 4 172 0    
4:09 0:09 4 176 4 68  
4:18 0:09 4 180 0   burn down
            bloom=27 lbs, high in carbon
             
            total charcoal with preheat amount = 202 lbs
             
    BLOOM LBS   27  
      KG   12.27  
      %   39.71  

Last Updated on 23/10/06
By Paul Burden
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Team Two - under Skip Williams

Virginia Rock Ore in Flue Tyle
Time     Event Charcoal (lb)   Ore (lb.)  
absolute elapsed     added total added total
               
10:33     started added 4      
10:45 12     end of 1st 4 lb 4    
10:49 4     4 lb emptied 8    
10:59 10     4 lb emptied 12    
11:11 ? 12 ??     4 lb emptied 16    
11:12 1 ??   added 1st ore 4 lb emptied 20 1lb added  
11:18 6         1st lb emptied 1
11:25 7     4 lb emptied 24    
11:32 7   closed air valve to 2 1/8        
11:37 5     4 lb emptied 28 1 lb emptied 2
11:51 14     4 lb emptied 32 2 lb emptied 4
12:02 11     4 lb emptied 36 2 lb emptied 6
12:22 20   turned air up 1 3/4        
12:26 6     4 lb emptied 40    
12:27 7 ??         3 lb emptied 9
12:30 3   turned air up to 3rd notch        
12:39 9   putting fines on front of charcoal in furnace 4 lb emptied 44 2 lb emply 11
12:47 8     4 lb emptied 48 2 lb emply 13
12:49 10 ??   air reduced a hair        
12:55 6     4 lb emptied 52 3 lb emptied 16
1:07 12     4 lb emptied 56 3 lb emptied 19
1:19 11   slag is bubbling inside tuyere; cast iron leaking out. 4 lb emptied 60 3 lb emptied 22
1:30 11   Poking led to discharge of thick slag, gassy and vesicular. 4 lb emptied 64 4 lb emptied 26
1:35 5   Confusion, frustration, tearing of hair. Resumed smelt at 1:56 4 lb emptied 68 4 lb emptied 26
1:56       added 4 lb 72 added 2 lb 28
2:05 9         4 lb emptied 32
2:12 7     4 lb emptied 72    
2:14 9 ??         4 lb emptied 36
2:18 6     4 lb emptied 76    
2:20 6 ??         4 lb emptied 40
2:27 9     4 lb emptied 80    
2:30 10 ??         4 lb emptied 44
2:38 11     4 lb emptied 84    
2:39 9 ??         4 lb emptied 48
2:50 12     4 lb emptied 88    
2:51 12 ??         4 lb emptied 52
3:00 10     4 lb emptied 92 4 lb emptied 56
3:07 7     4 lb emptied 96    
3:08 8 ??         3 lb emptied 59
3:21 13   added more charcoal to burn down 4 lb emptied 100 4 lb emptied 63
3:35     tapped for good slag, returned this to furnace.        

Last Updated on 26/10/06
By Elizabeth Hamilton - modfied D. Markewitz
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EARLY IRON 3 - Zymurgy

Virginia Rock Ore in Flue Tyle
Team supervised by Mike McCarthy
TIME     EVENT ORE   CHARCOAL
ABSOLUTE RELATIVE ELAPSED   AMOUNT TOTAL TOTAL
        (as lb) (as lb) (4 lb each)
             
9:30     start preheat      
10:20 0:00   fill with graded charcoal      
10:25 0:05 5 start fuel charges     4
10:30 0:10 5       8
10:36 O: 16 6       12
10:42 0:22 6       16
10:46 0:26 4   1 1 20
10:53 0:33 7   1 2 24
11:00 0:40 7   1 3 28
11:07 0:47 7   1.5 4.5 32
11:17 0:57 10 first ore hits tuyere? 1.5 6 36
11:24 1:04 7   1.5 7.5 40
11:32 1:12 8   2 9.5 44
11:39 1:19 7   2 11.5 48
11:47 1:27 8   2 13.5 52
11:56 (E) 1:36 9   2 15.5 56
12:02 (E) 1:42 6   2 17.5 60
12:10 1:50 8   2 19.5 64
12:18 1:58 8   2.5 22 68
12:26 2:06 8   2.5 24.5 72
12:33 2:13 7   3 27.5 76
12:42 2:22 9   3 30.5 80
12:49 2:29 7   4 34.5 84
12:59 2:39 10   4 38.5 88
13:09 2:49 10 increased air blast 4 42.5 92
13:16 2:54 7 "brockworst" 4 46.5 96
13:22 3:02 6   4 50.5 100
13:31 3:11 9   4 54.5 104
13:38 3:18 7   4 58.5 108
13:45 3:25 7   4 62.5 112
13:54 3:34 9   4 66.5 116
14:02 3:42 8   4 70.5 120
14:09 3:49 7 last ore charge 4 74.5 124
             
      TOTALS LBS 74.5 124
        KG 33.86 56.36
             
      BLOOM PRODUCED   ??  

Last Updated on 26/10/06
By Darrell Markewitz
Email: [email protected]
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Early Iron 3 -Overview

Peter's Valley Craft Center - Layton, New Jersy
October 7 - 9, 2006

Dick Sargent was the host and organizer for the third annual Early Iron Symposium. The setting was the wonderful Peter's Valley Craft Centre, tucked into the very top north west corner of rural New Jersy. A bit of a challenge to find, but well worth the effort. The weather was perfect, bright and sunny and not to warm. Alhough there were a few less particpants than eariler years, those who attended certainly felt this event was one of the best.

Early Iron 3 overlapped the annual 'Pig Iron Fest' providing a chance for both public demonstration and late Saturday night of roast Pork and beers.

As with past Early Iron events, Lee Sauder, Skip Williams, Mike McCarthy and Darrell Markewitz served as primary demonstrators and team leaders. Participants were broken up into three person teams. Each team then prepared ore and charcoal, and then constructed a Flue Tyle type test smelter. Sunday they finished and fired these smelters, and in most cases spent the evening consolodating the resulting blooms. Each team had a sucessful smelt, creating large blooms with variations in carbon content.

The individual teams have contributed their field notes from their smelts. These are included here for comparision. The results were quite consistant, showing that the hard work and enthusiam of the teams certainly paid off.

Team One

(Sauder)

Team Two

(Williams)

'Boar Iron'

(Markewitz)

'Zumurgy'

(McCarthy)

 

Three additional smelts were undertaken by the team leaders. On Saturday, Lee Sauder and Mike McCarthy demonstrated the Flue Tyle furnace to the participants and the general public. Darrell Markewtiz also did a demonstration smelt, but this was a test of both a smaller clay furnace design and use of some usual bog ore material. On Monday, after most of the participants had gone, Darrell and Dick Sargent re-fired Saturday's Flue Tyle to test out a variation on method suggested by Mike.

Details on these two smelts can be found on the Wareham Forge Iron Smelting documentation:

'Loki' Norse Short Shaft

Flue Tyle - test large ore charges
Text and Images © 2006 - 2007 Darrell Markewitz - the Wareham Forge
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