Title Smelting: Three-Day Direct Method

  • Shimane
Topic(s):
Historic Sites/Castle Ruins
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App, QR code, etc.
Text Length:
≤250 Words
FY Prepared:
2023
Associated Tourism Board:
tetsu no michi bunkaken suishin kyogikai

製錬: 三日直接法


三日直接製錬は奥出雲地方でしか行われていなかった。長年の試行錯誤の末、鉄工職人たちは4日法を改良し、3日で済む製法を開発した。


直接法では、マサと呼ばれる優れた砂鉄とアコメ砂鉄が併用された。マサは酸性の岩石から採れるため不純物が少ないが、溶ける温度ははるかに高い。溶けた銑鉄が炉の外ににじみ出る間接法とは異なり、直接法の製品は、ケラと呼ばれる多孔質の大きな鉄鋼塊が炉内に残る。操業が終わると、炉は解体され、ケラは粉々に砕かれ、さまざまな等級の金属に選別される。これが、刀鍛冶が珍重する玉鋼を製造できる唯一の方法だった。


鉄穴炉製鉄所(島根県奥出雲町)の記録には、1901年に直接法を適用したことが記されている。13.5トンの砂鉄(マサとアコメ)と約14トンの木炭を使い、2.1トンの銑鉄と2トンのケラを生産した。つまり、砂鉄の30パーセントが使用可能な製品に変換されたことになる。

Smelting: Three-Day Direct Method


The three-day direct method of smelting was only practiced in the Okuizumo region. Through years of trial and error, ironworkers were able to improve on the four-day method and develop a process that required only three days.


The direct smelting method used a superior iron sand called masa in combination with akome iron sand. Masa iron sand, which comes from acidic rock, has fewer impurities but melts at a much higher temperature. Unlike the indirect method, which produced molten pig iron that oozed out from the furnace, the main product of the direct method remained inside the furnace as a large, porous lump of iron and steel called a kera. At the end of an operation, the furnace would be dismantled and the kera smashed apart and sorted by grade. This was the only method capable of producing tamahagane steel, which is vital to the production of Japanese swords.


Records from the Kanna Ironworks (Okuizumo, Shimane Prefecture) show the materials consumed during a single instance of the three-day method in 1901: 13.5 metric tons of iron sand (masa and akome) and roughly 14 metric tons of charcoal were used to produce 2.1 metric tons of pig iron and a kera weighing 2 metric tons, meaning that about 30 percent of the iron sand was converted to usable metal.

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