1951 CAST IRON / PIG IRON SMELTING DOCUMENTARY " IRON -- PRODUCT OF THE BLAST FURNACE " 18524

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This short film from Academy Films of Hollywood dates to 1951, and shows how iron ore, limestone, and coke are handled and prepared for the blast furnace in the making of pig iron. The blast furnace is used for smelting materials into pig iron aka cast iron, lead or copper and is an age-old practice dating back to the fifth century. This film opens with an outside look at a blast furnace and its cylindrical towers (:40). A diagram follows depicting what happens inside, pointing to where raw materials entered (1:13) and the layering in which it was sent in. Footage of actual raw material entering the furnace is shown in the raw materials yard (2:27). The entire car is seen turned upside down to remove all materials (2:58) and these are then emptied into an underground conveyor belt (3:07). The traveling stacking machine (3:23), reclaiming machine (3:49), and large triangular rake (4:00) are all seen at work. Afterwards materials are moved to another conveyor belt headed for storage hoppers (4:10). The second most important material for the iron blast furnace is called ‘coke’ which is made from coal baked in closed ovens (4:24). At the unloading hopper (4:38) the railcars are unloaded and transported to stock piles (4:56). A crane is seen lifting coal onto another conveyor belt (5:12) to be sent to the coal crushing machinery (5:12). A ‘Larry car’ then sets to work delivering the crushed and screened coal to the coke oven (5:12). The gases which are a by product of this procedure are seen emptying out of the collector pipes (5:55). At the end the coke is pushed out in a stream of molten material which then falls into the hot car (6:12) which will take it to the quenching process in which it is dowsed with water (6:40). It then moves to storage piles near the blast furnace (7:11). Limestone is another important material and it follows a similar process as the iron ore (7:57). On the special scale cars, the installed scale is pointed to (8:07). Afterwards the raw material heads in the skip car to the top of the blast furnace (8:30) in which a worker is seen wearing fireproof clothes as the blast furnace is cast every five to six hours to (8:52). 250 tons of molten iron is dumped into hot metal cars (9:29). A mud gun then seals the cast hole until it must be used again (9:49). The hot metal car heads to one of the open-heart furnaces (10:09) and a small amount is cast into pigs giving the name pig iron (10:23). The film concludes at (10:52).

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