Like making crucible steel the process begins with wrought iron and charcoal. Instead of crucibles, one or more long stone pots are used (typically, in Sheffield, each was 14 feet by 4 feet and 3.5 feet deep). Iron bars and charcoal are packed in alternating layers, with a top layer of charcoal and then refractory matter. Some manufacturers used a mix of powdered charcoal, soot and mineral salts, called cement powder - which gave the process its name. In larger works up to 16 tons of iron was treated in each cycle.
Depending on the thickness of the iron bars the pots were then heated from below for a week or more. Bars were regularly examined and when the correct condition was reached the heat is withdrawn and the pots are left until cool - usually around fourteen days. The iron had 'gained' a little over 1% in mass from the carbon in the charcoal, and had become hetrogenous bars of blister steel.
The bars were then shortened, bound, heated and hammered, pressed or rolled to become shear steel. Or broken up and heated in a reverberatory furnace with a flux to become cast steel.
The process of claim 6 wherein the chloride ion concentration is maintained by the addition of an alkali metal chloride in an amount equal to at most 2 gram-equivalents per liter of chloride.
Whilst remaining within the scope of the process in accordance with the invention, it is thus possible to lixiviate with an excess of the chloride of copper, bismuth, antimony and/or of silver, which may reach 10 and even 20%.
Among the methods capable of providing regenerating agents, it is possible to cite the cementation by means of iron which yields ferrous chloride, or of zinc which yields zinc chloride which may be at least partly pyrohydrolysed into zince oxide or stychloride and hydrochloric acid, and the reduction of lead chloride by means of hydrogen.