Lecture Notes: The Legacy of Steel Production in Workington

Introduction

• Key phrase: "Where there's muck, there's brass."
• Cumbrians have been producing high-quality rails for over a century.
• Rails produced have been distributed globally, enhancing transportation.

Sir Henry Bessemer and the Steel Age

• Year: 1856
  • Patented a process revolutionizing steel production.
  • Used in Workington since 1872.
• Durability: Bessemer's rails last ten times longer than earlier versions.
• Changes in Method:
  • Few modifications since inception.
  • Early failures led to success with hematite ore from Cumberland Mines.

Steel Production Process

• Converter Specs:
  • Original experiment used 700 weights of iron; modern converter handles 35 tonnes.
  • Steel produced every 40 minutes without outside fuel.
• Production Steps:
  1. Oxidation: Air blown through molten iron removes impurities.
  2. Temperature Stages:
     • Starts at 1300 degrees Celsius, rising to 1600 degrees during production.
     • Monitoring using electronic indicators for safety and efficiency.
  3. Final Pouring Process:
     • Converter tilts to pour molten steel into molds.
     • Additives are introduced during pouring to meet specifications.
• Safety Measures:
  • Pouring is one of the most dangerous tasks; skill of the Bessemer foreman crucial.

Continuous Process of Steelmaking

• Operation:
  • Continuous cycle with two furnaces ensuring 24-hour production.
  • Estimated 25 million metric tons processed over 102 years.
• Monitoring: Each step is monitored for temperature and alloy composition.
• Mold Specifications:
  • Molds, made of cast iron, hold approximately six tons of steel.
  • Thorough cleaning between uses to maintain purity.

Final Stages of Production

• Soaking Pit:
  • Ingot kept hot before processing into rails or sleepers.
• Production Capacity:
  • Remote-controlled operations can reach 5000 tonnes per week.

Transition to Modern Processes

• End of Bessemer Steel Era:
  • Last cast of Bessemer steel produced at Workington.
• Future Plans:
  • Transition to using steel produced via the modern oxygen process at Teesside.
  • Continuation of traditional rail-making methods.
• General Manager’s Statement:
  • Acknowledges the significance of the Bessemer process and looks forward to new opportunities.