In this excerpt from the book "The Age of Alchemy: How Early Innovators Shaped Modern Chemistry" (Profile Books, 2026), author Kit Chapman, a science journalist and honorary researcher at Falmouth University in the U.K., reveals the extraordinary story of Wootz steel and the experiments that finally showed how it was created using furnaces powered by monsoons.
If the world was going to modernise, it had to come up with a better material. Steel was the obvious answer, but how did you get rid of just the right amount of carbon in pig iron? The answer was found by an inventor called Henry Bessemer, who was hired by the British government to try to make cheap steel for use in guns. Bessemer's great innovation was to suggest that, once you've got your molten-hot pig iron, you blow air — a lot of air, between 85,000 and 550,000 litres per minute — up from beneath it.
Bessemer became one of the leading figures of the "Second Industrial Revolution" at the tail end of the nineteenth century. He was knighted by Queen Victoria; his steelworks in Sheffield led to it becoming synonymous with steel; and in the US, eight towns were named after him. Without Bessemer, the world would never have known steel's true potential, and our skylines wouldn't be dominated by modern structures that rely on them, such as skyscrapers, railroad tracks and suspension bridges.
A Damascus blade forged from Wootz steel. (Image credit: HDesert via Getty Images)
As early as 500 BCE, steel began to originate from the Indian subcontinent that was far greater in quality than any other. The blades were forged with intricate, elaborate patterns and banding, like the marbling of the finest cut of steak. These were harder than any other blades, cut sharper and cost more.
"It's not a material that your everyday blacksmith would necessarily want," Juleff says. "High-carbon steel is an awful lot harder to work. It's not for arrowheads or kitchen knives. It became used by specialist swordsmiths." Then, around 1100 CE, the mysterious, intricately patterned blades simply vanished. Subsequent versions emerged (the most famous is Damascus steel), but Wootz steel had disappeared completely. It left a gaping hole in the history of chemistry.
"We discovered that the furnaces were all placed at the top of hills," Juleff explains. "Hundreds of them, of a type we'd never seen before; we only knew they were furnaces because there was slag everywhere. For some reason, the early Sri Lankans had their villages at the bottom of a hill, and then dragged all their iron to the top to smelt it." Initially, the strange furnaces were a puzzle. Typically, a furnace is tall and erect, like a chimney; this creates a natural draught that feeds oxygen to the fire, drawing air in and pushing out the exhaust gases. The Sri Lankan furnaces were totally different. They were flat, half a metre high and 2 metres long, with hundreds of holes bored into the front and back. They looked like oversized harmonicas.
Ancient people forged Wootz steel near Sri Lanka's central highlands at the tops of hills to utilize the monsoon winds. (Image credit: Jakub Specjalski via Getty Images)"A monsoon wind blows up to 90km an hour [56 mph]," says Juleff. "When you're at the top of a hill, you get an aerodynamic effect, where all the wind's rushing up and cresting. You're battered by it. Everyone told me you couldn't run a furnace just using the wind, because it's not strong or reliable enough. So, I decided to experiment. I built one." Juleff's furnace was identical to the Sri Lankan ruins she had found. She fed it using charcoal and iron sourced locally from surface deposits — exactly as would have been available to the villagers who built them.
But then Juleff's mood changed. "It was like a Transformers toy, everything rearranged in my mind. I had a eureka moment! It wasn't wrong at all; it was how it was designed to work. The wind was blowing up the hill — it wasn't blowing into the tubes at all, it was blowing over the top of the furnace. It's like an aeroplane wing: by blowing over the furnace, you're creating this incredible pocket of low pressure." The Sri Lankan furnace wasn't a harmonica, with air puffed through it; instead, it was played like a flute.
Related storiesThis is the Bernoulli effect, the same principle that sticks a race car to the road, or keeps water moving through your plumbing. The change in pressure and the smooth, ordered air flow was creating a furnace beyond anything western science had considered possible. The team continued putting in ore and charcoal throughout the day, then allowed things to cool. The next day, they returned to see what they had produced. At the top was a knotted lump of pure iron — a bloom, as expected. "But then below that, stuck to the bottom of our slag, was another layer of metal," Juleff says. "High-carbon steel. The wind did it. We couldn't stop the wind doing it. We had created a furnace that could make the best steel anywhere in the world."
"The metal-makers weren't moving," Juleff says. "They were here, sat in the interior of Sri Lanka, season after season, running these incredible furnaces." Why did Wootz steel vanish? In the twelfth century CE, Sri Lanka was invaded by the Pandya dynasty of southern India. It triggered a societal collapse, as Sri Lankans were forced to pay tribute to their conquerors. The most likely explanation is that, during the chaos of the invasion and its messy aftermath, the traders and middlemen who brought the Wootz steel to the coast, and the ships that transported it around the world, had stopped coming.
Excerpted from "The Age of Alchemy: How Early Innovators Shaped Modern Chemistry," Profile Books, 2026.
Profile Books The Age of Alchemy: How Early Innovators Shaped Modern Chemistry"Age of Alchemy" is a fascinating and funny dive into chemistry long before chemistry existed. It captures the ingenuity of humans across cultures and time, revealing how ultimately the work of these early innovators would eventually meld into modern science.
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