Bloomery Iron Smelting - Experimental Data

Experimental Iron Smelts - 2001 to 2012
EXPERIMENT TEAM DATE TYPE CONSTRUCTION HEIGHT DIAMETER TUYERE AIR ORE TYPE CHARCOAL TIME EXTRACTION BLOOM OBJECTIVES RESULTS
TOTAL STACK INTERIOR TYPE ANGLE from WALL ABOVE DASE TYPE VOLUME Fe WEIGHT WEIGHT average RATE main sequence CONDITION YIELD
cm cm cm degrees cm cm litre/min % kg kg min / charge hr / min kg %
1 Parks Canada 27-Jun-01 boxed bowl stone slabs , clay seal 50 42 35 x 30 steel pipe upwards 3 5 Norse double bag 130 E bog ore 62.7 1.5 8 slug 2:00 disassembled 0.1 cast iron prills n/a primary experiment on forms suggested by LAM restricted by materials and equipment
2 / D1 DARC 26-May-02 boxed bowl stone slabs , clay seal 40 45 x 40 steel pipe slightly up ? Norse double bag 100 E bog ore, forge scale 65.7 6 22 slug 8:00 after cold none partially sintered n/a repeat #1 with shop support development of post smelt measurements
3 / D2 DARC 6-Jun-03 medium shaft cob, refactory lined 90 55 27 to 24 steel pipe flat 5 20 ? vacumn blower NR rock ore 55 - 60 8.1 50 4:30 dissassembled none sintered mass n/a application of learned techniques burn out at about 3/4 of reaction haults
4 / D3 DARC Jun-04 boxed short shaft cobb inside stone slabs 55 50 25 steel pipe 15 down 5 2 Norse / hand crank 125 rock ore 55 - 60 7 19 6 disassembled none vapourized n/a establish standard smelter too wet walls slump for poor tuyere placement
5 Early Iron 1 11-Oct-04 short shaft cobb partially banked 60 46 33 to 30 steel pipe 15 down 3 14 Norse double bag 125 rock ore 55 - 60 8 20 15 5:45 top none pre bloom mass' n/a application of historic methods iron starting to condense in sliced sections
6 / D4 DARC 23-Oct-04 Econo Norse brick inisde stone 68 45 35 steel pipe 20 down 5 23 vacumn blower 550 rock ore 55 - 60 8 22 10 4 top 2 cast iron 25.0% develop easy to build test furnace prototype teaching furnace.
7 Smeltfest 1 25-May-05 Econo Norse brick inside sheet 60 40 25 forged copper 20 down 5 18 vacumn blower 815 rock ore 55 - 60 35 85 8 7 dissassembled 6.5 soft iron 18.6% refine test / teaching furnace use of forged copper tuyere
8 Smeltfest 1 27-Feb-05 Econo Norse brick inside sheet 60 40 25 forged copper 20 down 5 18 vacumn blower 815 rock ore 55 - 60 28 85 7 dissassembled 7.5 not tested 26.8% refine test / teaching furnace dupilcate of above
9 OABA 14-May-05 Econo Norse brick inside sheet 60 40 25 steel pipe 20 down 5 20 various inconsistant taconite 65.0 21.3 67 11 7:30 dissassembled 9.5 workable iron 44.6% introduce method to Ontario Blacksmiths ash / sawdust packing produces much slag
failure of air equipment / multiple systems
10 / D5 DARC demo 11-Jun-05 boxed short shaft cobb inside stone slabs 60 46 25 steel pipe 20 down 5 16 Ubber Bellows * 600 E taconite 65.0 10.9 38 12 5:30 top 3 workable iron 27.5% develop VA demonstration methods switch to blower at 2:30 @ 815 LpM
11 / D6 DARC demo 1-Sep-05 boxed short shaft cobb inside stone slabs 60 46 25 steel pipe 20 down 5 15 Ubber Bellows * 600 E taconite 65.0 10.9 47 9 9 top 2 cast iron 18.3% CANIRON 4 - historic demonstration switch to blower at 6:40 (no volume)
12 Early Iron 2 Oct-05 Flue Tyle reinforced tile 60 40 25 x 25 forged copper 20 down 5 electric blower < 1000 rock ore 55 - 60 15.9 50 + * 7:30 bottom 3.4 * workable iron * NA teaching second 'Rescue' bloom only
13/ D7 DARC 12-Nov-05 boxed short shaft cobb inside stone slabs 60 42 25 ceramic tube 22.5 down 5 16 vacumn blower 600 E taconite / rock ore 60 E 19.7 80 7 6:15 top 4.3 workable iron 21.8% establish repeatable methods general control and understanding
14 Black Rock 18-Feb-06 Econo Norse brick inside sheet 60 40 25 ceramic tube 22.5 down 5 vacumn blower 800 E taconite 45.5 107 10 7:30 dissassemble 13.5 workable iron 29.7% teaching environment temperature of limited effect
15 Dick Sargent 8-Mar-06 medium shaft cobb on plinth 85 60 30 to 40 ceramic tube 22 down 6 19 vacumn blower 970 hematite 69 45.5 86 7 7:30 bottom 21.8 lacey mid carbon 47.9% use of hematite, modifications to furnace flask shaped with use of hematite
16 Dick Sargent 10-Mar-06 short shaft cobb on plinth 60 40 28 to 40 ceramic tube 22 down 5 14 vacumn blower 970 hematite 69 45.5 68 7 4:00 bottom 20 lacey mid carbon 44.0% repeat above re-use of smelter # 15
17/ D8 DARC 10-Jun-06 half banked short shaft clay cobb 65 45 23 ceramic tube 22.5 down 5 7 vacumn blower 1060 rock ore ? 18 87 9 8:10 top 2.8 cast iron 15.6% use of half banked furnace construction all coverted to cast iron or high iron slag
18 / D9 DARC 2-Sep-06 boxed short shaft cobb inside stone slabs 60 35 E 15 x 19 ceramic tube 20 down E 5 E Ubber Bellows 600 E rock ore 10.5 57 20 6:10 top cast iron ? layout based on LAM - use of Ubber Bellows problems with bellows design and labour
19 Early Iron 3 5-Oct-06 short shaft clay cobb 66 50 20 ceramic tube 22.5 down 5 13 vacumn blower 700 red ochre 8.8 36 15 4:00 dissassemble 0.7 nodules cast iron 8.0% test of ore body assumed low iron content demonstrated
20 Dick Sargent 9-Oct-06 Flue Tyle reinforced tile 60 40 25 x 25 forged copper 20 down E 5 E 15 E electric blower < 1000 E rock ore 55 - 60 45.5 60 9 5 bottom NR workable iron none specifically 1.9 kg reproduction VA anvil from portion.
21 / D10 DARC 4-Nov-06 half banked short shaft clay cobb 60 + 30 75 23 ceramic tube 22.5 down 5 10 vacumn blower 1060 rock ore 55 - 60 23.5 33 6 2:40 top none iron rich slag only none specifically 3rd reuse of furnace - why this result?
22 6-Nov-06 half banked short shaft reuse of above 60 + 30 75 23 ceramic tube 22.5 down 5 10 vacumn blower 1060 rock ore / gauge 55-60 8.8 / 10 49 7 3:20 top 6.8 workable iron 36.2% Reserection' for # 21 self proof of ability
23 Mikaff & Paddon 2-Jun-07 Econo Norse brick inside sheet 60 40 25 ceramic tube 22.5 down 5 15 E vacumn blower 800 hematite 69 22.3 63.5 8 4 dissassemble 12.7 workable mid carbon 57.0% course excellent student results
24 / D11 DARC 9-Jun-07 half banked short shaft clay cobb 60 + 30 75 23 ceramic tube 15 down 5 14 vacumn blower 900 rock ore ? 20 56 9 5 top 0.9 workable iron 4.5% hot swap' doouble smelt 4th use / expected low return from poor ore
25 / D12 DARC 1-Jun-07 half banked short shaft clay cobb 60 + 30 75 23 ceramic tube 15 down ? ? vascumn blower 900 rock ore / hematite ? 23.9 42 9 3:15 top 3.1 workable iron 13.0% hot swap' double smelt 5th use / expected improvement mixed ore
26 Neil Peterson 7-Oct-07 half banked short shaft clay, stone slab front 65 * 55 23 x 27 ceramic tube 22.5 down flush 10 ? vacumn blower 800 * taconite 65 12.3 54 8 4 top 6 workable iron 48.8% use of stone slab above tuyere intial use of low air, increased half way
27 / D13 DARC 27-Oct-07 half banked short shaft stone with clay seal 70 45 35 x 25 ceramic tube 26 down flush 18 vacumn blower 430 hematite 69 12 34 21 4:50 bottom 1 poorly sintered 8.3% all stone slab - low air 1.8 kg unsintered + 2.3 kg gromps = 4.1 kg
28 Martin Group 25-Nov-07 short shaft clay cobb 72 50 25 ceramic tube 22.5 down 5 10 vacumn blower 770 taconite 65.0 18.2 60 4 top 5.5 workable iron 30.2% course excellent student results
29 Williams & Keen 13-Mar-08 medium shaft clay cobb 105 60 30 tapered plate & hole 6 set back ? electric blower rock ore 55 - 60 23 45 12 4:30 bottom 5.5 soft, crescent 23.9% test of plate & blow hole better yield than expected
30 Williams & Keen 16-Mar-08 medium shaft repeat above 105 60 30 tapered plate & hole 6 set back ? electric blower DD 1 54 30.2 60 13 5:30 bottom 1.7 high carbon 5.6% test of plate & blow hole expected lower yield from method
31 Williams & Keen 17-Mar-08 medium shaft repeat above 105 58 30 tapered plate & hole 22 do2wn 13.5 set back ? electric blower rock ore 55 - 60 59.5 68 12 6:00 bottom 7.7 soft iron column 12.9% test of plate & blow hole moving hole position
32 / D14 DARC 13-Apr-08 Econo Norse brick inside can 70 45 20 ceramic tube 20 down 5 15 electric blower 450 - 365 DD1 54 18 34 14 - 17 5:30 bottom 2 workable iron 11.1% test of furnace good function of smaller transportable unit
33 Arne Espelund 30-Apr-08 modified medium shaft clay cobb 55 (of 110) 30 25 steel pipe 20 down flush ? danish vacumn 1000 Goulage bog 56 15 13 11 for 2 kg 2:30 bottom none iron rich slag Espelund theoretical slag produciton only
34 Arne Espelund 2-May-08 modified medium shaft clay cobb 70 (of 110) 50 25 steel pipe 20 down flush 10 danish vacumn 1000 iron rich slag 38 7.75 12 11 for 2 kg 2:30 bottom none Espelund theoretical poor results - question method?
35 4-May-08 medium shaft clay cobb 110 85 25 steel pipe 23 down flush 10 danish vacumn 1000 Danish / Swedish mix 15.2 20 9 for 2 kg 3:50 bottom 1.8 lacy in slag block 11.8% demonstration of developed methods less than good result, ore quality?
36 / D15 DARC 14-Jun-08 half banked short shaft clay cobb 65 47 23 - 26 ceramic tube 23.5 down 3.5 11 E electric blower 660 - 780 DD1 54 20 30 10 3:20 bottom 1.9 partially consolidated 9.5% ore test in proven furnace 3 x consolidation cycles
37 Ken Cook 27-Sep-08 short shaft clay cobb on plinth 65 + 20 45 25 ceramic tube 22.5 down 5 20 electric blower 800 rock ore 34.5 64 10 4:20 top 9.5 workable iron 27.5% Quad State demo excellent demonstration results
38 / D16 DARC 12-Oct-08 banked short shaft clay cobb 65 37 22 plate & hole / ceramic tube tube 10 D ? 20 electric blower 740 - 625 poor rock & taconite 23 46 13 4:50 bottom 4.9 colder on extraction 21.3% working systems test / plate and blow hole problems with slag too high, shift to insert
39 / D17 DARC 8-Nov-08 banked short shaft clay cobb 65 + 20 42 26 - 24 plate & hole 25 down 2.5 set back 20 electric blower 400 - 1000 poor rock & hematite 23 48 12 4:50 top 3.25 lumpy texture 14.1% working systems test expected lower yield from method
40 / D18 DARC 30-May-09 short shaft clay 62 45 20 ceramic tube 23 down 3 17 electric blower 640 DD2 64 18 31 16 4:30 top 4.9 very dense 27.2% furnace design viability of working space
41 / D19 DARC 11-Oct-09 short shaft clay block & fire brick 62 48 20 ceramic tube 22 down 3 14 electric blower 900 E DD + hematite mix 61 20.7 43 12 4:45 top 5.6 very dense 27.1% placement of slack tub / Frankenbellows interpret as stubb / failed mechanical design
42 / D20 DARC 7-Nov-09 short shaft clay / sand 55 40 22 ceramic tube 22.5 down 5 15 smelt bellows 700 E DD2 64 18 31 16 3:30 top - broken 2.9 dense 16.1% human powered air expected lower yield / different placement
43 / D21 DARC 12-Jun-10 short shaft clay / sand 68 48 23 to 28 steel pipe 22.5 down 5 19 smelt bellows 700 E DD1 & hematite mix 55 20 ? unknown ? top 1.6 lumpy 8.0% all historic method expected lower yield / working layout
44 / D22 DARC 21-Aug-10 short shaft clay / sand 63 45 22 to 24 steel pipe 19 down 4.5 18 smelt bellows 700 E DD2 64 20 35.5 14 4:30 top - broken 2.8 lumpy fragments 14.0% demonstration on site proof of historic method
45 / D23 DARC 6-Nov-10 Econo- Norse fire brick 76 55 28 ceramic tube 23 down 4 21 electric blower ? hematite 67 24 42 9 3:00 dismantle 8.5 higher carbon 35.4% team experience needs more practice
46 Smeltfest 18-Mar-11 flask with shaft clay cobb 110 + 85 65 clay mulitple slight down 10 at floor passive ?? rock ore 66.5 91 195 14 10:00 bottom none proof of concept only too much focus on fine detail / modify method
47 Brown Students 21-Apr-11 short shaft on plinth clay cobb 64 48 24 to 25 ceramic / pipe 22.5 down 4.5 16 electric blower 850 rock / DD1 / hematite ? 29 45 12 5:45 bottom 2.2 20% E teaching proves viablity of progam
D24 DARC 11-Jun-11 Econo-Norse fire brick 65 45 25 ceramic tube 22.5 down 5 20 electric blower 900 rock ore 24 48 11 4:20 dismantle 2.65 spongey 11.0% team experience too much detail on construction
D25 DARC 28-Jul-11 Econo-Norse fire brick 65 45 25 ceramic tube 22.5 down 5 20 electric blower 900 DD1 54 26 47 12 5:00 dismantle 5 workable iron 19.2% public demonstration good team performance
48 / D26 Burnham, Peterson 9-Oct-11 short shaft / slag pit clay cobb 55 43 25 ceramic tube 22.5 down 5 13 electric blower 800 rock ore 48 65 10 5:45 attempt bottom none proof of concept questionable ore means no iron
49 Peterson 5-Nov-11 short shaft / slag pit reuse above 55 43 25 ceramic tube 22.5 down 5 10 electric blower 900 taconite 65.4 19.2 48.5 11 4:00 top 6.4 workable iron 33.3% proof of concept repeat with good ore proves system
50 5-May-12 short shaft clay / sand 77 40 25 to30 forged copper 22.5 down 5 15 electric blower 800 rock ore 42.9 55 16 6:20 top - botom 12.27 a bit lumpy 28.6% production furnace build solid durable design as expected
51 / D28 DARC 26-May-12 banked short shaft clay 60 48 28 - 26 ceramic tube 22 down 5 10 electric blower 800 DD1 48 31.8 49 12 5:30 top 5.8 after 2 x compression 18.2% resume Icelandic series re-familurization
52 Celtic College 11-Aug-12 short shaft on plinth clay cobb 64 45 32-25 ceramic tube 22.5 down 5.5 15 electric blower 800 DD 1 + scale 31.8 50 11 4:00 top 7.1 dense 22.3% public demonstration excellent demonstration & teaching

Last Updated on January 2013
By Darrell Markewitz
Email: smelt@warehamforge.ca
Text © 1998 - today, Darrell Markewitz