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The Catalan forge... "Farga Catalana"


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The ore was readied by roasting and crushing in two different sizes: one finely crushed and the other larger.

A total of 22 Kg (48.5 lbs.) of hematite and siderite.

 

 

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We placed a dividing plate in the furnace. In the front section we charged the large ore bits along with charcoal.

 

 

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miquel.

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We continued to add layers of charcoal and ore. Large size ore in the front section and fine ore in the back.

 

 

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miquel.

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We tried to remove the slag but had no luck.

 

 

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We were a bit disappointed in not being able to drain the slag.

 

 

 

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miquel.

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On the other cooking side, the charcoal is being burned away and we can start to feel something solid inside.

 

 

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miquel.

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A video looking inside the furnace.

 

<iframe src="https://skydrive.live.com/embed?cid=6E5339E98BC4CEC9&resid=6E5339E98BC4CEC9%211232&authkey=AHZ-cVhacAKwgDA" width="320" height="256" frameborder="0" scrolling="no"></iframe>

 

 

 

 

A video of the Masser ( bloom) extraction.

 

 

<iframe src="https://skydrive.live.com/embed?cid=6E5339E98BC4CEC9&resid=6E5339E98BC4CEC9%211233&authkey=AHYFbQkDKsITn68" width="320" height="256" frameborder="0" scrolling="no"></iframe>

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Miquel,

That is quite a project and very clearly presented...I enjoy reading the posts most, when the outcome is uncertain and there is an element of risk to the project. Did you discover why the slag did not drain?

 

Were all those people really that interested in iron or was it the food...looks like a good time. Thanks for taking the time to post it.

Jan

 

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Seeing the paella makes me hungry. You shouldn't do that to me.

Thank you for sharing all this wealth of information, Miquel.

I am curious as to how much charcoal you used in relationship to the ore and what was the final weight of the bloom and how you compare that to the yield of other furnaces that you have run before.

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Hola Miquel. I am English but live in Spain ( Yecla, Murcia ) - your Catalan forge is amazing.

 

Maybe you can sell me some of the steel ? ;):)

 

Greetings Sid. If you are in a position to travel to Barcelona we could even share one of our metallurgical ventures. You can contact me by PM.

 

 

 

miquel.

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Thank you for the comments. There are a few more questions that I need to answer and mistakes we made that will need to be explained. I would like to address those with some pictures too and I will need some time to posts those but I will hold no secrets other than the recipe for the paella. ;)

 

 

 

miquel.

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SO AWESOME!!!!!!

 

Great stuff Miquel. Thanks so much for sharing.

 

I did a half ass try with the Catalan furnace when I started smelting. I sure want to do it again.

I just found a place not far from my work, that crushes fire brick for the Al. The guy told me I could likely buy as many as I wanted for the price of the Al.
Like 100$ a pallet. I think I will go make that deal today. That would sure help get me going on it.

 

Mark

 

I love your top cover/chimney, over the smelter.
Do you plan to do any initial compaction, straight from the furnace next time? To remove a lot of that stuck on slag.
Was it a pain, to clean the slag out from the bottom of the smelter, after the smelt?
I would love to see the numbers in comparison as well. :)

Edited by Mark Green
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I am glad you liked it.

Mark. It will be interesting to compare notes if you go ahead and give the Catalan Forge ("Farga") another go. I am not using refractory bricks, I am using the cheapest regular bricks lined up with refractory mortar.

That works just fine. In the old Catalan Forges,("Farga") they built the furnace against a corner of the building thus taking advantage of the walls to pile up the charcoal. We did not have that kind of set-up so we improvised the metal plates.

This is a picture of the best rebuilt or restored Catalan Forge that I have seen. It is located in Andorra and called “Farga Rosell.”

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For the next smelts we plan to consolidate the bloom but for this one we were interested in keeping it in the original form. More later…

miquel.

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