Originally published at Low-Tech Magazine, September 2013.
Explore
the now-ruined estates of the Irish countryside and you occasionally find a
stone cylinder, as much as several metres high and wide, open at the top and
with a small door at the base. Some
resemble the medieval fortresses that still dot the landscape here -- but no
one built fortresses so tiny, or half-buried in the side of a hill.
In fact,
they are kilns for lime burning, a now-forgotten industry that sustained many
agrarian communities before energy became cheap.
“Lime”
here means neither the citrus fruit nor the tree, but refers to a white powder
derived from limestone. For at least 7,000 years humans created lime in kilns,
as they might have hardened pottery or smelted ore, and used the material for
dozens of purposes now largely replaced by fossil-fuel by-products – perhaps
most commonly to create mortar for construction.
British
and Irish farmers, though, found it most important to neutralise acid soils and
multiply crop production – as much as fourfold, by some contemporary accounts.
For hundreds of years until the mid-20th century, lime supported a vast and
vital network of village industry -- quarries to mine the limestone, carts and
barges to transport it, and specialists to monitor the burning. In the late
1700s, according to one survey, County Cork alone was said to contain an
amazing 23,000 kilns, or one every 80 acres. (1)
Limestone
is mainly coral and shells of long-extinct sea creatures, squeezed over aeons
into a solid mass of calcium carbonate, or CaCO3. When burned at 900
degrees C or more it vents carbon dioxide (CO2), leaving behind the volatile
calcium oxide (CaO) – “quicklime,” “burnt lime” or “unslaked lime.” Then, when
combined with water – hydrated or “slaked” -- the quicklime became calcium
hydroxide or Ca(OH)2, and could be put to many uses. Confusingly, all of these
have been called “lime” at times, but in this article, we will call the
original rock “limestone,” the caustic material from the kiln “quicklime,” and
the hydrated final product “lime” for clarity.
Roman
Concrete
The
earliest use of lime dates to present-day Turkey between 7,000 and 14,000 years
ago, and many ancient civilisations used it to create mortar between stones.
The Romans, however, took lime a step further, mixing it with various other
ingredients to create an early version of cement. In fact, their version has
proven superior to our own in some ways. Our concrete lasts only decades – as
little as a single decade in seawater -- while Romans created concrete that not
only formed in seawater, but have withstood the pounding of waves for 2,000
years.
The
secret, according to two papers released in the summer of 2013, involved mixing
quicklime with volcanic ash to form
mortar. Volcanic ash was plentifully gathered from the volcano at Vesuvius,
according to Pliny the Elder – ironically, the same volcano that would later
kill him. Romans then packed this mortar into wooden forms and lowered them
into seawater, which caused the quicklime to react and form a lime-and-ash mix
of waterproof cement.
The
papers’ authors say such techniques could prove useful even today; not only did
their concretes stand up to time and the elements better than ours, but such
methods are “greener” – generating less carbon emission – than our cement
manufacture. Crushing rocks into Portland cement powder requires enormous
quantities of energy and accounts for seven per cent of all industrial carbon
emissions on the planet. (2) (3) (4) (5) (6)
Romans
brought such technologies with them as they spread across Europe, so lime kilns
appeared in Britain with their invasion and disappeared for several hundred years
after they left. In Ireland, where Romans never set foot, Normans apparently
brought the technology in the 1200s, to build the round towers that still
frequently stand today. (7)
Whitewash,
Limelight and other applications
Lime also
forms the basis of whitewash, used for centuries to protect and brighten
structures, fences, vehicles and even trees, without the alarming and
unpronounceable stew of toxic ingredients in many modern paints. Whitewash is
fundamentally a mix of lime and water, although it could also contain salt,
milk, linseed oil for water-proofing, or hair or cereal husks for strength.
The dried
lime was safe to handle and even for animals to lick, but remained mildly
alkaline enough to disinfect barn and dairy walls. Its brilliant whiteness was
valued in places like Britain and Ireland, where the winters grow very dark –
Irish cottages were traditionally whitewashed in spring and again before
Christmas. In sunnier climates, however, that same colour helped keep buildings
cool.
Lime had
many other uses: Farmers rubbed it on their livestock’s feet as an antiseptic,
or painted it onto fruit trees to prevent fungal diseases. Some mixed a bit of
lime into well-water to disinfect it, or to preserve eggs for months without
spoiling. Tanners used it to remove hair from hides, gardeners to repel slugs
and snails, printers to bleach paper.
Even the
corrosive quicklime, the calcium oxide that came straight from the kiln, had
many uses before it was hydrated. It kept pantries and store-rooms dry – the
1915 household manual “The Best Way” recommended keeping a bowl of it to
reduce humidity, as it sucked moisture from the air. It caught fire easily –
sometimes too easily – and was used to make an early, high-intensity lamp for
the stage – the original limelight. (8)
|
Lime kiln in Porthgain, Wales. Picture: Aelwyn. |
It also
made a rather fearsome weapon, as it could sear the skin and blind the eyes. In
David Hume’s A History of England, he recounts a battle between English
and French ships around 1216, in which the English captain Phillip d’Albiney
ingeniously used quicklime to turn the tide of battle. He saw that the winds
were blowing from his ships to French fleet, and “having gained the wind of the
French, he came down upon them with violence; and throwing in their faces a
great quantity of quick lime, which he purposely carried on board, he so
blinded them, that they were disabled from defending themselves.”
The
compound made a handy terrorist weapon as well; when Irish reformer Charles
Parnell spoke at a political rally in 1891, someone in the crowd threw
quicklime at his face, and “had not [he] shut his eyes in time, he would
undoubtedly have been blinded,” his wife Katherine later wrote.
Quicklime
was also shovelled into graves to decompose bodies more quickly, as Oscar Wilde
saw when he was a prisoner at Reading Gaol (Jail) in Britain:
And all the while the burning lime
Eats flesh and bone away
It eats the brittle bone by night
And the soft flesh by the day
It eats the flesh and bone by turns
But eats the heart away.
Lime in
Agriculture: Sweetening the Soil
Its use
in agriculture, however, eclipsed any other use on these islands, so valuable
was its ability to turn acid bog-lands into croplands. Some 40 per cent of the
arable land in the world is too acidic for many plants to grow – the more
acidic the soil, the more toxic aluminium plants absorb. These days, farmers
often treat such soils with crushed limestone or other energy-intensive
products, and scientists like Chris Gustafson of the University of Missouri are
trying to genetically engineer aluminium-resistant crops. In earlier eras,
however, farmers found that lime temporarily “sweetened” or neutralised the
soil. (9)
This made
lime so valuable that many agrarian communities supported a network of local
industries to create it -- quarries to mine the limestone, wagons to transport
the rocks by road or barges by canal, and specialists to supervise the burning.
By the mid-1600s many families in County Cork, Ireland, for example, paid their
rent by lime-burning on the side, according to a civil survey of the time. (10)
Farmers
treated the soil in quite a straightforward manner: they shovelled quicklime
straight from the kiln onto a horse-drawn cart, drove the cart to the needed
field and drove the horse back and forth across it as though ploughing. Every
several metres the farmer stopped the cart and scooped several shovels of
quicklime in “falls” on the ground -- six to eight barrels to the acre.
Spreading
a highly caustic compound onto cropland might sound inadvisable, but the next
rain both hydrated it into lime and soaked it into the ground. Transporting the
quicklime, however, was dangerous work, as it could spontaneously burst into
flame and burn carts and barns, or simply to eat through wooden containers if
it wasn’t spread quickly. (11) (12)
The
process only sweetened the land for a limited amount of time, according to
contemporary reports – three years in some fields, twelve years in others,
depending on conditions. In any case liming had to be continually re-applied or
it “enriched the father but impoverished the son,” went the saying, so the
kilns were kept in steady business. (13)
Operating
the Kiln
Kilns
themselves needed to be carefully situated: they needed to be as close as
possible to quarries, so that hundreds of tonnes of rock could be carried with
as little effort as possible, by horse or barge. At the same time they had to
lie as close to the lime’s destination as possible – a fortress or church being
built with mortar, or fields that needed sweetening -- so that the quicklime
could also be transported without incident. Moreover, they could not be
situated near populated areas or even campsites, as the burning lime gave off
noxious and potentially lethal gases.
The brick
or stone structures were often built into hillsides to allow people to easily
transport coal and lime to the open top, or mouth, and were often several
metres across and about as high. On the inside they usually tapered down so
that gravity alone fed the fuel down, and at the narrow bottom of the cone, one
wall had an arched opening or “eye.”
The kiln
had to be filled carefully, with precisely measured amounts and materials – if
the lime did not bake at a high enough temperature for long enough, the stone
would not transform into quicklime and the work would be in vain. Lime-burners
filled the bottom of the kiln with the driest wood possible – furze-wood was
often mentioned – and then the men lay alternating layers of fuel and
limestone.
Perhaps
the most common fuel was “colm” – anthracite coal – although charcoal could
also be used, as well as “turf” – dried peat from the
bogs here. Whatever the fuel, it had to be in an opaque layer, insulating the
chunks of limestone from the sides of the kiln and from each other, according
to old lime-burners interviewed decades later for Irish national radio.
Sleeping
by the Kiln
Once the
kiln was filled, the wood – at the bottom of the kiln, by that little door –
was set on fire, and that, in turn, lit the fuel through the rest of the
structure. Once the kiln was lit there was no going back; the lime-burners had
to maintain a watch over the kiln for the next three or four days, sleeping
nearby. Burning was often done in winter, when there were fewer farm chores to
be done, so it must have been tempting for men sleeping out in the cold to move
closer to the warm glow of the kiln.
According to lime expert Colin Richards,
however, sleeping by the kiln was extremely dangerous, between the poison gases
and the open pit. There were cases of itinerants sleeping near the mouth for
warmth, he said, rolling into it as they slept and being roasted alive.
Certainly
the men did exhausting work for days at a stretch, making them “thirsty as a
lime-burner” as the saying went. A single kiln could hold a hundred tonnes of
material, which had to be shovelled in by hand, yet delicately measured and
arranged inside. Of course there was less to shovel out – the coal had
burned away, and the limestone had lost some of its mass – but that material
was much more difficult to handle.
“Drawing
out the lime underneath was the dirtiest part of it,” said one anonymous
lime-burner who worked in Ireland in the 1930s and 40s and was interviewed for
a radio documentary in 1981. “It was there that you got the dust, and you got
too much of it and you began bleeding from the nostrils.”
Magic and
Ritual
With
their furnace-like heat, poison vapours, alchemical transformations, hazardous
products and vital importance to agrarian survival, it was perhaps inevitable
that farmers associated kilns with all kinds of magic and ritual. According to
Irish elders interviewed in the 1930s, young people often performed Halloween
rituals around lime-kilns to find out who they would marry.
In one
instance, fairies were said to have killed off a farmer’s livestock after he
inadvertently built a kiln in their way. Other peoples were said to have
summoned evil spirits there; a reverend in Carnmoney, rumoured to have sold his
soul to the Devil, was said to have courteously invited him to a kiln so the
Devil would feel at home. (15)(16)(17) The lime burners themselves had a
simpler ritual, one they said was practiced among “all the lime burners of
old.”
“You took
a bottle with you that morning … of holy water,” one said, and before the kiln
was fired up “you just sprinkled it on top the stones, and made the Sign of the
Cross, for you were burning – what they used to say was -- you were burning the
bones of the Earth.”
Notes:
(1)
Topographical Directory of County Down, by Samuel Lewis, 1837.
(2)
“Microscopy of historic mortars — a review,” by J. Elsen, Cement and Concrete
Research, July 2005
(3)
“Chemistry and Technology of Lime and Limestone,” J. Elsen, Cement and Concrete
Research, December 2005
(4)
“Material and elastic properties of Al-tobermorite in ancient Roman seawater
concrete,” by Marie D. Jackson, Juhyuk Moon, Emanuele Gotti, Rae Taylor,
Abdul-Hamid Emwas, Cagla Meral, Peter Guttmann, Pierre Levitz, Hans-Rudolf
Wenk, and Paulo J. M. Monteiro, Journal of the American Ceramic Society.
(5)
“Unlocking the secrets of Al-tobermorite in Roman seawater concrete,” by Marie
D. Jackson, Sejung Rosie Chae, Sean R. Mulcahy, Cagla Meral, Rae Taylor,
Penghui Li, Abdul-Hamid Emwas, Juhyuk Moon, Seyoon Yoon, Gabriele Vola,
Hans-Rudolf Wenk, and Paulo J. M. Monteiro, American Mineralogist.
(6)
“Roman Seawater Concrete Holds the Secret to Cutting Carbon Emissions,”
Berkeley, http://newscenter.lbl.gov/news-releases/2013/06/04/roman-concrete/
(7)
“Pre-industrial Lime Kilns,” English Heritage, May 2011
(8) The
Best Way - A Book Of Household Hints & Recipes, 1915
(9)
“Famine Fighter,” Illumination magazine, Spring / Summer 2013
(10)
The Ancient and Present State of the County and City of Cork, by C. Smith, 1815
edition.
(11)
“Burning the Bones of the Earth,” a documentary by Radio Telefis Eireann, 1981
(12)
Edwardian Farm, BBC Television
(13)
Essay on the Use of Lime as a Manure, by M. Puvis, 1836.
(14)
“Pre-industrial Lime Kilns,” English Heritage, May 2011.
(15)
Maureen Cunney, Currower, Attymass, Ballina, County Mayo, as part of the
1937-38 schools initiative.
(16)
Researches in the South of Ireland, by Thomas Crofton Croker, p. 82
(17)
Irish Witchcraft and Demonology, by St. John D. Seymour, [1913]