UVV. OF MICOH. MAY 7 1908 MANUFACTURE OF IRON IN BUFFALO. A PAPER READ BY INVITATION BEFORE THE BUFFALO HISTORICAL SOCIETY, By JOHN WILKESON, Esq. BUFFALO: PRINTING HOUSE OF WHEELER, MATTHEWIS & WARREN 1864. rI" - E J'.zNIJYT_T~{.Y 23,5 186~. li -c~~ 2 MANUFACTURE OF IRON IN BUFFA O. From time to time other foundries and machine-building shops, for casting stoves and making steam and other machinery, have been added to the n umbe r o f such establis hmenrts, and now we have some twe nty in all, doing in the aggregate a g reat business a nd giving support directly and indirectly to several thousands of people. For more than twenty years our founders and machinists have been a b le t o construct engines of any size required for our lake navigation. In 1838, Mr. Justin built a forge at Black Rock Dam. In 1850, Mr. Charle s Delany built the "Niag ar a For ge," for the fabrication of hea vy masses of wrought iron. This establishment has been very successful. Another forge is now in the cou rse of construction, and it doubtless will lead to the building of other s. We now come to the more important branches of the iron manufacture. The first rolling mill erected here was that known as the ",Buffalo Iron and Nail Works," built in 1846 by Corns; Co., an association of operatives from Pittsburgh. This establishment has been enlarged and improved by M6ssrs. Pratt & Co., into whose hands it has passed, and is now doing an extensive businesss, making iron and nails of the best quality. During the winter of 1859-60, our citizens became very much interested on the subject of the promotion and the extension of manufactures. The depressed condition of our lake commerce and our navigation interests for some years, had convinced all that our city could never maintain its standing with other cities in the basin of the lakes, and hope for a continued increase of population, without providing some certain means of employment Doctor Ure, of England, in speaking of Iron, beautifully says, "Every person knows the manifold uses of this truly precious metal. It is capable of being cast in molds of any form; ot being drawn out in wires of any desired strength or fineness; of being extended into plates or sheets; of being bent in every direction; of being sharpened, hardened, and softened at pleasure." Iron accommodates itself to all our wants, our desires, and even our caprices. It is equally serviceable to the Arts, the Sciences, to Agriculture, and War. The same ore furnishes the sword, the ploughshare, the scythe, the pruning-hook, the needle, the graver, the spring of a watch or of a carriage, the chisel, the chain, the anchor, the compass, the cannon, and the bomb. It is a medicine of much virtue, and the only metal friendly to the human frame. Previous to the year 1826, the manufacture of iron in this city was confined to the ordinary blacksmithing work required by the community. In that year Edward Root erected the first foundry for making plough-irons and other small castings. Mr. Isaac W. Skinner soon after built another for making ploughs and other castings. Messrs. Gibson, Johnson & Ehle built at Black Rock, in 1826, a foundry and machine shop, which in those days was considered a large establishment,in which some large steam engines were constructed. In 1828, itessrs. Beals, Mayhew & Co.,erected in this city at the corner of Ohio and Indiana streets, a foundry and machine shop, in which they built the first steam engines made here. Mr. John Hibbard was their Superintendent; he is still a resident here. Ir = a] ' , ., If. ,!. ". -1", . I 4 during the winter as well as the summer, for its working people. The discovery of numerous inexhaustible deposits of iron ores in Northern Michigan, and their successful use in the blast furnaces of Eastern Ohio, and the opening of canal and railroad communication with the Anthra cite coal fields of Pennsylvania, led some of our citizens who were familiar with iron smelting, to the conclusion that no place in all the lake basin was so favorably situated for the prosecution of that great branch of human industry, as our city. At first sight it appeared to many that the proper place for reducing the ores of Michigan was where they were quar ried, (they are quarried, not mined. ) but the absence of mineral coal there, and the inferior quality of the timber which grows in t his inhospitable region, from which the required charcoal would have to be made, together with the poverty of the soil, almost forbidding agriculture, made it apparent on reflection that the ores would have to seek some more favored region, where cheap labor and supplies were attainable. Several meetings were held, where the subject of manufacturing was discussed, and much light thrown on iron smelting. The result was a determination on the part of several gentlemen to build a furnace. In the meantime, Messrs. Palmer & Wadsworth con cluded to build one, and shortly after, Messrs. Warren and Thompson also decided to build another, and thus the original project fell through, as it was thought sufficient that these gentlemen should test the feasibility of iron smelting here. In the spring of 1860 the gentlemen named proceeded with the construction of their two blast furnaces, and the next year Messrs. Palmer and Wadsworth put theirs in operation. Its success was so flattering as to convince all that iron smelting in Buffalo would be profitable. In 1862, the two establishments were consolidated in interest, another furnace built, and also a very large and complete rolling mill. These works, termed the Union Irons tVorks, are exceeded in capacity by few similar ones in the United States. Messrs. Pratt & Co. have also erected a very fine blast furnace, which will go into operation the coming spring, Their plans contemplate the erection of a second fiurnace, and those of the tUnion Company a fourth, so that it is probable we will have in operation within a year or two, six blast furnaces of the most formid/ble description. These works will be of capacity sufficient to yield fifty thousand tons of pig iron annually, which will be equal to one-eighteenth of all the pig iron produced in the United States in 1860, or one-eleventh of all produced in the great iron manufacturing state of Penusylvania in that year. It mnay be well to say something of the' prob-' able increase of iron smelting, and kindred branches of the iron trade here, and to state some reasons why it is likely to become a leading branch of our industry. Of course, we cannot hope to make iron, or any other om modity, in competition with other places, un less we can produce it as cheaply as any. In determining the cos t o f products, quality, and cost of transportation to the consumer are ele ments of value. Individuals familiar with the properties of iron have n o hesitation in say ing th at wro ught i ron, ma de from pig iron smelted with Anthracite coal, such as is only to be found in the Wyoming coal-field, and from ores of which that from Lake Superior constitutes the major part, is worth from three to five dollars more per ton, than iron smelt ed by means of bituminous coal. One proof of this is the fact that the iron manufacturers of Pittsburg bring from the east of the Allega nies large quantities of Anthracite pig-iron, to work with the western pig which is made with bituminous coal. As we are situated, at the eastern termina tion of lake navigation, and there being no works west of us (save a few charcoal works) which can produce an equally good quantity of iron at as cheap a rate, or even any quality at less lost, it seems clear that if proper efforts are made to multiply our smelting works, we can supply the western markets. Of our means of cheap transportation to the west and north it is needless to say anything, except perhaps to allude to the direct connection with the state of Minnesota and the territories of Dakotah and Nebraska, which the railroads to be built leading westward from Lake Superior will give us. For a mixture in the furnace with the ore of Michigan we can procure as cheaply as any, the fossiliferous ore of Oneida and Wayne counties, ore from the extensive deposites near Kingston in Canada, and the Blackband ore of McKean county Pennsylvania. As soon as the railroad is completed, from the coal fields of McKean and Elk counties in Pennsylvania we will have cheap bituminous coal for the use in the puddling and boiling furnaces, and in making wrought iron the cost of the requisite bituminous coal for those purposes is an important item. Within eighty miles of us there are exhaustless supplies of the best of bituminous coals, of all the varieties found in the great Allegany coal field. It is not to the credit of our men of means that a railroad has not long since been built leading to this coal field. It argues a want of foresight on their part, most marvellous. This delinquency has already lost to us, millions of wealth, and not less than fifty thousand people, who might have been added to our population. It has also given to another city on the Lakes the place we are entitled to, and which we will yet reclaim. if we act wisely and do not longer neglecIour opportunities. Few cities would have been so neglectful as we have been. They would have raised the money by a tax, if no other means were available, and thus have compelled reluctant capitalists to do their duty. The money we wasted on a Canada road which could only bring to us what we already 5 In consequence of the depreciation of the cu rency and the scarcity of labor, the present cost of iron here, is, I suppose, nearly twice the estimate made, but as it is now selling for quite double its usual price, the business is as profitable as in ordinary times, with readier sales. When we come back to former prices for la bor and materials, as it is altogether probable we will soon after the rebellion is put down, and the rebels put under foot, and the former current of foreign immigration is resumed with renewed force, iron ought to be made here at about the price first named, and which will be for as low a cost as it can be made in large quantities anywhere in the United States, ex cept, perhaps, near Harrisburgh, in Pa., where they produce a rather common quality from the cheap ores of the Iron Hills of Cornwall, and at Johnstown, Pa. It may not be generally known that beside the Specular ores, which are those usually brought from Lake Superior, other varieties abound there, supposed to be valuable for a mixture. In practice it is found best to mix in the fur enance, ores of different chemical compositions, so as to make a better iron than is usually ob tained from one kind. Experts know what this array of figures mean. They mean that where iron can be produced for such prices, a great seat of the iron trade will be fixed. Does it not follow then that our manufactures of iron will go on increasing if we can produce it for the prices named above? The average cost of pig iron in England is about $16 per ton, and in this country about $18, or was, in ordinary times, in my opinion. May we not hope to see before long, instead of our few furnaces now in operation, twenty or thirty more, giving rise to an almost endless variety of kindred manufactures proving a source of wealth, comfort and employment to a great population? The town of Merthyr-Tydvil, in South Wales, with its environs, contains a population of one hundred tho usand souls, sustai ned solely by the manufac uIre of pig and bar iron. The great city of Birminogham is sustained a ltogether by its metallic manufactures. The art of making iron is a noble calling. When in Austria, the writer of this visited the iron works in Styria, in which province the Romans once worked the iron mines and made iron. One large establishment there, was owned and personally managed by the Arch Duke John. He was said to be one o. the most successful managers in that region. At Stoke, in England, there is to be seen a row of fourteen blast furnaces, all owned by the Earl Granville, said to be an experienced iron master. When looking at a pig of iron, one seldom reflects that modern civilizatien is based upon that rough material. Without iron, what would be man's condition? Where would be his boasted progress in the arts and sciences? It may prove new7 and interesting to some, to give a short account of the improvemnents in the art of iron making, coremeuing with the invention of the blast filr possessed ought to have been more wi sely ex pended o n a coal road. Some good iron will be smelted with char c oal i n Michigan, and at a few other po ints w est of us, and probably some will be smelted with Anthracite coal taken as ballast and back loading, by g rain and o re carrying vessels. Before l on g the forests will be consumed a nd then, as it seems unlikely that good smelting coal will ever be fou nd in Indiana, I llinois, Iow a or Missouri, w e probably will supply the bette r qualities of iron to all the regions north of the Ohio and west a s far as t he R ocky Mountains. Eminent geologists have doubts of the ex istence of t rue coal, of the secondary formation, west of t h e Mi ssissippi, and the brown coal found t here is s o sulphury as to be unfitted f or any metallurgic process es. Charcoal is near ly pure carbon. A n thracite coal contains from 80 to 90 per cent. of carbon. Bituminous coal, such as has been found best for smelt ing, contains from 5o5 to 60 per cent. of carbon. Any coal of the latter kind con taining more than f our per cent. o f ashes, or yielding red ashes, is not considered suitable for smelting iron, and a small per centage of sulphur unfits it for that purpose. T he c ost of iron makinve ma t erials in the ol der dis tricts is w ell known, and for the sake of comparison, the following estimates of its cost at this point, are given, based upon prices and wafes paid previous to the outbreak of the rebellion: Anthracite coal was delivered here for $3 75 per ton-$2 75 freight, and $1 for it delivered on board the boat at the pits mouth, with a prospect of a lower price. Freight from Bay de Noquet, based upon the rate of six cents per bushel for wheat from Chicago, (and it has been carried for half that price,) would be on one ton of ore, two dollars. The ores of the M[ichigan Peninsula will hereafter be brought by railroad from the mines to the former port for shipment. The cost of mining or quarrying will be about thirty cents per ton, including the value of the ore in the ground. The cost of railroad transportation to the lake and handling, about one dollar and twenty-five cents per ton. Limestone will cost about fifty cents per ton. When the materials for smelting are selected with proper care, and all inferior qualities rejected, and the iron-maker is as careful of his per centages as the banker is of his, it will require one ton and a half of ore, one ton and a half of coal, and a half a ton of limestone to produ,ice one ton of good pig iron. The item of wages. in large furnaces, was about two dolla-,rs per ton. These items, which would represent the cost of one ton of pig iron, when stated, appear as follows: 1 tons of ore, averaging 66 ^ cent., $ 3 55.. 5 32 1S tons of coal, $ 3 75. - -—. —------------------ 5 62 ton limestone, 50c - ----------------------— 5 Wages in furnace,'~ ton.............2 Do We whill add for incidentals........... 1 50, MIaking the pig iron cost.......... 14 6)9 Saying' nothing about interest on the investment, wear and tear and extraordinary repairs. 6 nace. There have been seven Grand Epochs in the history of Iron: 1. The invention of the blast furnace. 2. The use of bituminous coal-coke for smelting. 3. The invention by Cort of the process of puddling and rolling. 4. The adoption of the steam engine for blowing purposes. 5. The application of the heated air blast. 6. The use of anthracite and raw bituminous coal for smelting. 7. The utilization of the waste gases of the furnace for heating the blast. and raising steam to drive the machinery of furnaces. All these improvements, save the two last, originated in England. Cast iron, it is supposed, was unknown to the ancients. They probably made all their iron directly from the ore, in open fires, using charcoal. John Agricola, a German, who wrote fully on metallurgy in the 16th century, and who drew and described everything known in his time on that subject, makes no mention of it. It is asserted that cast iron was known in Holland as early as the 13th century, and it was supposed to have been melted in clay pots. Mushet, to whom I am indebted for many facts, says, "no trace of the blast furnace earlier than in the reign of Queen Elizabeth exists in England." Lord Dudley, of England, in 1619, first successfully used coke for smelting in the blast furnace.Previously charcoal had only been used. His furnaces were small affairs, making from three to seven tons of iron per week,. but were great improvements upon the charcoal furnace then in use, because of the economy of fuel. Dudley's invention met with great opposition from the other iron masters, and was neglected. It was not till 1740 that it was revived with any success-a lapse of 120 years. In 1788, less than eighty years ago, the total iron production of England, Wales and Scotland, was but 65,800 tons of pig iron! Now it is nearly 4,000,000 tons. The earlier furnaces seldom exceed in height fifteen feet, and in width six feet. Now, they often have a height of sixty, with a width of twenty feet, making their forty tons of iron per day instead of three tons per week, which was the produce of Dudley's furnaces. Instead of their former thin streams of cinder, the modern furnace pours out powerful torrents of liquid lava. The next forward step in iron manufacture was the invention by Cort in 1790, of puddling and the rolling processes, by which a great saving of material and labor was effected; the former processes of converting cast into malleable iron were tedious and wasteful. Watts' double acting steam engine for blowing furnaces-by making it possible to erect works near the needful materials without regard to a water power-greatly stimulated the iron manufacture. The application of heated air for the blast, a process invented by Neilson, of Scotland, in 1827, has proved to be of great importance to the iron manufacture. Many ores which could not be smelted with the cold blast now yield the best of iron, and a great saving of fuel is effected, as well as of other materials. Coals, both Bituminous and Anthracite, can be used in the raw state, which with the col d blast was not possible. As anlillustration, suppose that with a cold blast a few degrees more of heat, are wanting-say one degree-to bring an ore to the melting point. Throwing into the furnace an addition al volume of cold air aggravates the evil, by reducing the temperature at the melting point; but if, instead of doing so, you throw in a volume of air heated up to 600 or 800 degrees, you effect your object. The sixth epoch was the use of raw coals, Anthracite and Bituminous, an improvement rendered possible by the invention of the hot blast, and it was a very important one. The utilization of the waste gases of the furnace (chiefly carbonic-oxyde gas), by applying them as a fuel for heating the air for the blast and raising steam for driving the machinery, thus dispensing absolutely with the use of other fuel fbr those purposes, has effected a great economy, and marks the seventh epoch. This is a German improvement, first successfully applied to blast furnaces in this country about the year 1842. Even now it finds little favor in Great Britain. When the writer of this was in England, in 1856, and visited many iron-works there, he did not find one where the gas was saved and used, but saw lying around many evidences of abortive attempts to do so. Step by step the art of smelting iron has advanced, every step reducing the cost of iron and conferring blessings upon the human family, and the inventors have been real benefactors to their race. The art of making iron is'et very far from perfection. Many of its most important processes are not yet well understood. Those who know the most of the art are free to admit that they have got so far as to understand how much there is yet to learn. There is little doubt that we are far in advance of other nations in a practical knowledge of iron smelting, and quite equal to any in the other metallurgic processes, excepting in that of steel-making. Until 1837, our smelting furnaces were generally of small size, using charcoal and blown with cold blast. The art of smelting at that time was in no wise progressive or flourishing. In that year. Messrs. Baughman, Guiteau & Co., of Mauch Chunk, Pa., demonstrated the possibility of smelting with Anthracite coal. Owing to the want of a proper furnace and machinery, their experiment was not profitable to them; but they succeeded in making good iron, and established satisfactorily the feasibility of smelting with Anthracite coal, thus adding immensely to the wealth of Pennsylvania. Mr. Guiteau will be remembered by our older residents as once our Postmaster. Coke was first used for smelting in our country iu the years 1835, 1836 and 1837, but without much success. The first profitable use of this material was made at a furnace in Maryland. At this time there are not many works using coke. The best quality of pig iron, it is conceded, cannot be made with either coke or raw Bituminous coal. The first furnace in this country which sue imported by us from the former country is goo d, but, as its quality s no t unifor m, it is losing favor. The iron of No rway is e xce llent. The English ma ker s of cast s teel monopolize all the iron made in Swed en from th e celebrated magnetic ore of Dannemora, none of their own iron being good enough for converting into the finer qualities of steel. The iron of Englan d, a as a g en eral fact, may be characterized as of poor quality. The bes t descriptions have to be subjecte d t o sever al refining proces se s, whi ch entails much waste of materials an d loss of labor; facts due to the inferior qualities of the ores and coals from whi ch it is produced. There is bu t litt le iron ore in England except the i mpure carbonates of the coal me asures. Those ores cons tit ute the main reliance of their iron works. Some primitive ores are found in the counti es of Cumberlad nd and Lancashi re. Neither the magnetic or the specular oxydes, so abundant here, are found there. In Wales where they fin d An t hracite coal, and use a portion of primative ores brought from a distance, some tolerable iron is made. While the Germans can avail themselves of charcoal, they will make considerable good iron; but when the forests disappear, their make of the better qualities must fall off. Iron of the average quality of the English is made in the Rhenish provinces with bituminous coal in considerable quantities. Little of it is exported, or probably ever will be, except in the form of hardware and cutlery. Belgium makes considerable coke iron, some of which is exported to Frane, but little to other countries. France produces about a million tons of pig iron, but not much of it of good quality. That country can never supply the better qualities of iron to meet its own wants. The coals of France, which are scattered about in little patches, here and there, are, with rare exceptions, of very inferior quality, and it is only by the exercise of the highest metallurgic skill that a tolerable quality of iron is made in the mineral coal furnaces. Nearly half of the iron of France is made with charcoal. Considerable of that is worked with the pig smelted with bituminius coal, thus improving the whole mass. When the forests of France cease to supply charcoal, then there must be a falling off in the quality of their iron, inferior as it now is, and that day is not distant. Spain possesses a considerable coal field and abundance of ore. Up to this time but little iron is made in that kingdom. It is doubtful if it will for a long time to come be able to supply its own wants; The iron manufacture in all these countries, excepting England, and perhaps Russia, may be considered as stationary. No nations, save those mentioned. in the Old World make any noticeable quantities of iron, and, for the want of the materials, none others will produce any. When we consider the above facts, and reflect that in the progress of the world's civilization the enhanced consumption of iron is rapidly becoming essential to the development, the comfort and the safety of mankind, we en cessfully smelted iron with raw Bituminous boal was built by Wilkeson & Co., of this city, at Poland, Mahoning county, Ohio, in 1845. The use of raw coal in the United States for smelting is confined to a small district lying southerly from Erie and Cleveland, where a coal similar to the Scotch "splint" is found. The same coal is found in MeKean Co., Pennsylvania, and is supposed to be an extension of that seam. Attempts have been made to produce mallable iron without the intervention of the smelti ng fu rnace. Those efforts reach back as far as its invention, an d are a s active now as ever before. It seems like going back to first principles, when we reflect that the item of labor in the smelting furnace is a small one, and that there is l ittl e w aste o f m aterial in it. We may well d oubt ifsuccess will at tend any such efforts. Th at nation which can produce t he mo st, the best, and, all things considered, the cheapest iron, i s d estined, other circumstances being equal, to lead in arms, in commerce, and in t he arts. The invention of iron-clad ships-ofwar, the incr eased size and power of artillery and projectiles, th e us e of iron s hips, and the extens ion of railwavs all over the world, has given to iron a power greater than ever, and cr e ated uses and demand s for it which ean only be supplied by c ountrie s having the means of producing it in g rea t quanttities and at low p rices. The elements of power have changed. T he world need no longer dread the destruction of civilization by irruptions of barbarians. A modern Attila, with h is ru de ho s ts, w ould only march to certain destruction. Nations without abundance of i ron are in the condi tion of a m an wh o w ould pr opos e to defend himself if his antagonist would supply him with the weapons. As was r emark ed before, it d oes not fo llow that th e cheap est iron is tha t which is sold for the least money. The best foreign iron known is th e Russi an, which comes t o u s in shee t s and bars. Possibly some qualities of the Norwegi an i ron are superior, but no sheet iron made elsewhere is comparable to theirs. The Government of Perme is the chief seat of the iron manufacture of Russia. Vast deposits of magnetic and other primitive ores of iron abound there. They are situated like our ores in Michigan (which they resemble) in hills, high above the water-courses, and are easily quarried. Wood for charcoal abounds. This iron finds its way to the markets of the world, down the river Kama and up the Volga. It is started in boats on the spring floods, and is first taken to Novgorod, where much of it is sold at the great annual fair held in that city. That portion of it which comes to our markets is taken by canals and water-courses to St. Petersburgh. It takes nearly two summer seasons to complete this voyage to the port of shipment. If this iron was not of the very best quality, it could not pay the enormous charges of transit it is subjected to, and leave any profit to its producers. Considerable iron is made in Sweden and Norway by means of charcoal. Much of that 7 8 United States for the year past, is estimated to have been 1,000,000 tons. In 1840 the amount made was, in round numbers, 286,000 tons.This shows an increase in twenty-four years of about 250 per cent. During all that period of time there has been a still greater ratio of increase in our importations of iron, our productions not keeping pace with the demand. Our population has increased from seventeen millions in 1840, to thirty-one millions in 1860less than 100 per cent. This shows that the increased demand for iron, the great lever of material improvement, outstrips the increase of our population. Thus it would seem that there is little likelihood, for a long time to come, of any overproduction of iron in our country. That sheerest of humbugs, Free Trade, when adopted by nations whose legitimate manufactures are not firmly fixed, dies under our load of debt, and with it Slavery and the bullion theory are shuffled aside. With stable and sufficient duties, our iron masters can go on securely and extend their operations, and when they succeed in supplying the home demand, they will have become so firmly established that they can enter into competition for foreign markets with every assuirance of success. counter one of the most striking problems of the age. Europe has already exhausted its capacity for the production of Iron, but its future needs have as yet hardly begun to be demonstrated. It follows, therefore, that the United States is destined from its inexhaustible iron resresources to become the source of supply of the world. This fact, once established, will confer upon us an importance and an influence among the nations which can hardly be appreciated-certainly not overrated. Our enormous debt incurred in waging war to save the life of the nation whose existence was threatened by the atrocious traitors of the South, will impose upon us for many years the necessity of collecting heavy revenues on imports, which will have all the beneficial effects upon home industry of a protective tariff without its instability. Thus, out of this great mountain of evil, we will have this little grain of good. Our iron manufacturers will be protected from ruinous foreign competition, which under the advalorem system imposed the least duty when prices were the lowest abroad, often having the almost instantaneous effect of closing our works (saving those making iron for the least cost,) and putting a stop to all new enterprises. The production of pig, or crude iron, in the