The Bessemer process was the first inexpensive industrial process for the mass production of steel from molten pig iron before the development of the open hearth furnace. The key principle is removal of impurities from the iron by oxidation with air being blown through the molten iron. The oxidation also raises the temperature of the iron mass and keeps it molten.
Related decarburizing with air processes had been used outside Europe for hundreds of years, but not on an industrial scale. One such process (similar to puddling) was known in the 11th century in East Asia, where the scholar Shen Kuo of that era described its use in the Chinese iron and steel industry. In the 17th century, accounts by European travelers detailed its possible use by the Japanese.
The modern process is named after its inventor, the Englishman Henry Bessemer, who took out a patent on the process in 1856. The process was said to be independently discovered in 1851 by the American inventor William Kelly though the claim is controversial.
The process using a basic refractory lining is known as the "basic Bessemer process" or Gilchrist–Thomas process after the English discoverers Percy Gilchrist and Sidney Gilchrist Thomas.
In the 15th century, the finery process, another process which shares the air-blowing principle with the Bessemer process, was developed in Europe. In 1740, Benjamin Huntsman developed the crucible technique for steel manufacture, at his workshop in the district of Handsworth in Sheffield. This process had an enormous impact on the quantity and quality of steel production, but it was unrelated to the Bessemer-type process employing decarburization.
The Japanese may have made use of a Bessemer-type process, which was observed by European travellers in the 17th century. The adventurer Johan Albrecht de Mandelslo describes the process in a book published in English in 1669. He writes, "They have, among others, particular invention for the melting of iron, without the using of fire, casting it into a tun done about on the inside without about half a foot of earth, where they keep it with continual blowing, take it out by ladles full, to give it what form they please.
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Wrought iron is an iron alloy with a very low carbon content (less than 0.05%) in contrast to that of cast iron (2.1% to 4%). It is a semi-fused mass of iron with fibrous slag inclusions (up to 2% by weight), which give it a wood-like "grain" that is visible when it is etched, rusted, or bent to failure. Wrought iron is tough, malleable, ductile, corrosion resistant, and easily forge welded, but is more difficult to weld electrically.
Steelmaking is the process of producing steel from iron ore and/or scrap. In steelmaking, impurities such as nitrogen, silicon, phosphorus, sulfur and excess carbon (the most important impurity) are removed from the sourced iron, and alloying elements such as manganese, nickel, chromium, carbon and vanadium are added to produce different grades of steel. Steelmaking has existed for millennia, but it was not commercialized on a massive scale until the mid-19th century. An ancient process of steelmaking was the crucible process.
Puddling is the process of converting pig iron to bar (wrought) iron in a coal fired reverberatory furnace. It was developed in England during the 1780s. The molten pig iron was stirred in a reverberatory furnace, in an oxidizing environment to burn the carbon, resulting in wrought iron. It was one of the most important processes for making the first appreciable volumes of valuable and useful bar iron (malleable wrought iron) without the use of charcoal. Eventually, the furnace would be used to make small quantities of specialty steels.
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