Plant & Equipment Bilston Works

No. 1 Blast Furnace ‘Elisabeth’

A high top pressure furnace built by Ashmore, Benson, Pease & Co. of Stockton-on-Tees in 1954

Height to large bell 90’ 0”

Overall furnace height 212’ 0”

Dia. of hearth 21’ 0”

Dia. of top (throat) 18’ 9”

Iron Production

Oct. 68 to Sept. 69 306,762 tons

Average weekly 5,899 tons

Average per cast 150 tons

Slag Production

Average month 10,000 tons

Typical Iron Analysis

C 4.38%

P 0.77%

Mn 1.24%

Si 1.06%

S 0.023%

Fe………….Remainder


Pig-Casting Machine
Double Strand type, 200 ft. centres of sprockets
Capacity 40 tons

Swarf Crushing Plant
Three Lindemann type Crushers
Capacity 5-7 tons turnings/hr. each.

Melting Shop

The Melting Shop consists of:-

2 – 1,000 ton Mixers
1 – Scrap Baling Press
1 – Material Handling Plant
7 – Open Hearth Furnaces
1 – Vacuum Degassing Plant
Cooling Water Plant

Mixers

Type
Head Wrightson 2 x 1,000 tonnes nominal capacity.

Yearly Output
285,922 tonnes September 1968 to September 1969

Average Weekly Output
5,840 tonnes September 1968 to September 1969

Operating Temperature
1,300°C average

Fuel
Fired with Blast Furnace gas or oil (C.T.F.50) depending on availaility.

Scrap Baling Press

Type
Lindemann-Sidul Press

Size of Bundle
706 mm x 556 mm x 2.249 mm
Nominal weight -1 ton

Rate
1 bundle every three minutes

Ram Pressure
Final Pressure – 3,500 p.s.i.
Ram diameter – 500 mm

Storage Bunkers
Eight storage bunkers containing: Lime, Ore. Fluorspar.
Ferro-Manganese and Ferro-Silicon.

Siemens-Martin Open Hearth Furnaces

Consists of: —

Seven ‘Basic’ Open Hearth Furnaces

3 x 120 ton capacity

3 x 115 ton capacity

1 x 110 ton capacity


All furnaces are fired with pitch creosote with provision for oxygen enrichment of flame.

The air supply is pre-heated in a chequer type regenerator system, the flame direction being reversed every 20 minutes to maintain a high temperature.

Furnace Construction and Maintenance

Hearth is Magnesite / Rammed Dolomite. Life Five years average.

Walls are Chrome-Magnesite brick. Bottom six courses : Magnesite. Life : Fourteen weeks average

Roofs : Suspended Unfired Chemically Bonded Metal Cased Chrome Magnesite.

120 tonne furnaces installed by Wellman Incandescent Furnace Ltd in 1965.

Processes

37% hot metal charged

63% scrap (charged cold)

Majority of ingots bottom teemed

Furnace Operations (1970)

Tap to tap – eight hours average

Charging time – one hour

Fettling time – one hour

Tons per cast – 115 average

Yearly Output

685,787 tons September 1968 to September 1969


Rolling Mill Equipment

14 Soaking Pits
1 40” Cogging Mill
1 Hot Deseaming machine
1 Hot Shear 12” x 12” (750 ton)
1 32” Roughing Mill
1 32” Finishing Mill
2 Hot Saws 66” diameter
1 Automatic Measuring stop
3 Cooling Beds

Tonnage Rolled

Ingot input to mill: 516,689 tons September, 1968 to Sep-
Tember, 1969. Average tons per week 10,333 tons.

Soaking Pits

Fourteen Stein Atkinson one way oil or gas fired Soaking
Pits arranged in two batteries.

Charged by two Wellman 7½ ton Vertical Ingot Chargers.

Capacity

10.7% ton ingots per pit.

Temperature

Approximately 1,300ºC.

Ingot Tonnage

Approximately 10,000 tons per week.


Plant and Equipment : Wolverhampton and Birchley Works

Wolverhampton

Figures of week ending 31.1.70

9” Mill – – – – 582 tons

14” Mill – – – – 1,527 tons
_________

Total 2,109 tons

Figures for September 1968 to September 1969

9” Mill

Billets charged – – – 32,059 tons

Bars produced – – – 29,501 tons

Yield – – – – 92.02%

14” Mill

Billets charged – – – 87,870 tons

Bars produced – – – 82,350 tons

Yield – – – – 93.7%

Billet Handling

Billet Sizes – 2” to 4” up to 30 ft. long.

Billets received mostly by rail, unloaded by 10 ton E.O.T.
Crane and placed in pens.

Inspection – Each batch or cast of billets is tested in the
Works own laboratory.


Mill Equipment

14” Merchant Bar Mill

Capacity – 80,000 tons a year. Installed in 1963/64.

Seven stands of rolls. Two stands, 3 high 18” roughing
Rolls. Three stands, 3 high 14” intermediate rolls. Two
Stands, 2 high 14” finishing rolls.

Sizes Rolled

Rounds: 1¼” to 2 9/16” diameter

Squares: 1¼” to 1 13/16”

9” Mill

Capacity 30,000 tons a year.
Five stands of rolls: Three, 3 high stands and Two, 2 high
Stands.

Sizes Rolled

Rounds: 13/16” – to 1¼” diameter

Flats: 1¼” to 2” 8/16” to 1” thickness

2¼” to 3” wide x ¼ to 5/8” thickness

Angles: 1¼” x 1½” x 3/16” to 3/8” thickness

This mill also rolls special sections.


Bars are bundled and put into stock for inspection, cold
straightening, reeling or re-shearing prior to despatch.

Warehouse Bays

Includes: Reeling machines for rounds,
Press straighteners.
Two roller angle straighteners
Small sets of shears for accurately cutting short
Lengths.

Ancillary Equipment and Services

Roll Turning

Rolls are designed by works staff.

Six roll turning lathes.

BIRCHLEY WORKS

Figures for week ending 4.4.70

7” Mill – – – – 262 tons

9” Mill – – – – 408 tons

21” Mill – – – – 290 tons
_________

Total – – – – 960 tons

Figures for September 1968 to September 1969

7” Mill

Billets charged – – – 15,225 tons

Bars produced – – – 14,483 tons

Yield – – – – 95.12%