Abstract: By appropriately designing a flash tube, spraying of abrasive slurry on the vessel walls and impinging the multiphase jet on bottom of the vessel are minimized. By appropriately designing a flash vessel, once the flash tube has been designed, a slurry pool is provided having a volume that is sufficient to dissipate the flash tube exit jet momentum and the mass of entrained carry-over products exiting from the vapor outlet is minimized.

Abstract: An apparatus for actively transferring a coil of hot metal within a coilbox in hot strip mill. The apparatus is located downstream of the initial coilbox uncoiling station and includes at least one singly pivoting coil cradle. Such a coil cradle has a first support roller with a fixed rotational axis, a swing-frame mounted to pivot about that axis, and a second support roller mounted to the swing-frame, able to pivot about the fixed rotational axis of the first support roller to permit the coil of hot metal to be passed from the coil cradle. In certain embodiments, the apparatus includes a plurality of such singly pivoting coil cradles. The apparatus may also include at least one dually pivoting coil cradle.

Abstract: An apparatus for the removal and replacement of a lid on a metallurgical transport vessel such as a ladle or a torpedo car. The apparatus comprises a frame, means for supporting the frame such that the vessel may be moved into position thereunder, a linkage including at least one lifting member pivotally connected to the frame, and at least one actuator connected to the linkage. The actuator is operable to move the lifting member such that when the vessel is moved to a designated position below the apparatus, the lifting member can be moved by the actuator and linkage from a first position providing clearance above the vessel, through a curved path to an intermediate position where it engages the lid, providing a vertical lifting force and a horizontal hinge releasing force to the lid, and to a second position where the lid is raised to a sufficient height to clear the vessel.

Abstract: Binding systems are described for applying compressive forces on the refractory hearth and/or refractory sidewall of a circular furnace having an outer metal shell which may be segmented. One preferred binding system comprises a tensioning band having one or more segments which extends around the furnace hearth and/or sidewall, with a resilient connection being provided between the opposite ends of the band and, where the band is segmented, resilient connections are also provided between the ends of adjacent segments. Another preferred binding system comprises a plurality of pivoting members provided around the circumference of the furnace. Each pivoting member is acted upon by a force-generating member which applies a controlled amount of force to the pivoting member and causes it to apply a compressive force to the hearth.

Abstract: An apparatus is disclosed for reducing pressure and velocity of a particulate-laden, supersonic vent gas stream from a pressure vessel such as an autoclave. The apparatus includes a diverging duct in which the vent gas expands, and a perforated plate located inside the diverging duct. The perforated plate provides an area reduction that increases back pressure and forces an upstream normal shock in the diverging duct, thereby bringing about a desired reduction in pressure and velocity. The perforated plate is comprised of a material, such as a ceramic, that is resistant to erosion by the abrasive particulate entrained in the high velocity vent gas. The perforated plate has a central portion provided with holes and an imperforate peripheral portion which is resiliently received between connection flanges of the duct.

Abstract: A system for controlling emissions of gas and dust during transfer of a hot feed material from a movable transfer container to a stationary feed bin of a furnace. The system includes an upper duct section which is associated with the movable transfer container, and a lower duct section associated with the feed bin. The lower duct section is attached to a main collection duct with a dust collection fan. The two duct sections are brought into close proximity with one another when the transfer container is brought into position for discharge to the feed bin, so as to form a continuous gas passage throughout the duct sections.

Abstract: A method for removing elemental sulfur from a hot gas stream, such as an autoclave vent gas, while simultaneously cooling the gas stream. The method results in conversion of sulfur in the hot gas stream to the form of solid, non-sticky sulfur allotropes such as rhombic sulfur while avoiding formation of sticky sulfur allotropes such as monoclinic sulfur, thereby avoiding scaling and fouling of plant equipment. According the method, the hot gas stream is contacted with an aqueous medium containing a particulate material inside a quench vessel having a first inlet for the hot gas stream, a second inlet for the aqueous medium, and an outlet for removing a sulfur-containing liquid fraction from the vessel. At least a portion of the sulfur contained in the hot gas stream, along with other condensable materials, becomes incorporated into the aqueous medium and is subsequently drained from the vessel.

Abstract: A fuel supply system for supplying pulverized feedstock to a gasifier includes a feedstock storage apparatus for storing pulverized feedstock. The feedstock storage apparatus operates at a first pressure. The fuel supply system also includes a mechanical conveyance apparatus linking the feedstock storage apparatus to a fuel distribution apparatus. The mechanical conveyance apparatus is operable to continuously convey the pulverized feedstock from the feedstock storage apparatus to the fuel distribution apparatus at a first flow rate. The fuel distribution apparatus operates at a second pressure that is greater than the first pressure. The fuel distribution apparatus includes at least one outlet communicably connected to at least one burner on the gasifier for transferring pulverized feedstock from the fuel distribution apparatus to the at least one burner.

Abstract: Diagnostic methods and systems are used to determine operating condition and performance of a cooling element in a metallurgical reactor during operation of the reactor. A system can include sensing means, processing means and display means. The sensing means is located in or approximate the cooling element for sensing operating conditions of the cooling element. The processing means is in communication with the sensing means for receiving data corresponding to the sensed operating conditions and for processing the data to determine a relative condition indicator of the cooling element. The display means is in communication with the processing means and displays the relative condition indicator to a user of the diagnostic system. The display means can display a first, second or third state representative of the relative health indicator.

Abstract: A composite sparger for use in elevated temperature and corrosive environments. The composite sparger is formed from a substrate tube with a thermally conductive interlayer on its surfaces exposed to the reactor environment. The thermally conductive interlayer is protected with a corrosion resistant layer. The corrosion resistant layer protects the interlayer from the corrosive environment of the reactor vessel and the interlayer material conducts heat away from the corrosion resistant layer to prevent combustion of the corrosion resistant layer. The interlayer material and corrosion resistant material may be selected so as to provide for sufficient thermal conduction to prevent combustion of the corrosion resistant material.

Abstract: A composite sparger for use in elevated temperature and corrosive environments. The composite sparger is formed from a thermally conductive non-combustible metal substrate. The surfaces of the conductive non-combustible metal exposed to the reactor environment are protected with a corrosion resistant layer. The corrosion resistant layer protects the substrate material from the corrosive environment of the reactor vessel and the substrate material conducts heat away from the corrosion resistant layer to prevent combustion of the corrosion resistant layer. The substrate material and corrosion resistant material may be selected so as to provide for sufficient thermal conduction to prevent combustion of the corrosion resistant material.

Abstract: A power generation plant and a method of generating electric energy from recovered heat during an industrial process that uses steam as a means of transferring energy. The method comprises: a) generating a first saturated steam in a first heat exchanger heated by a first source of recovered heat; b) feeding the first saturated steam into a first steam turbine generator, where the first steam turbine generator outputs exhaust steam; c) removing moisture from the exhaust steam with a moisture separator; d) superheating the moisture reduced exhaust steam from step c) in a main heat exchanger with a heat source; and e) feeding the superheated exhaust steam into a second steam turbine generator. The power generation plant comprises a first source of saturated steam, a first steam turbine generator, a moisture separator, a second source of saturated steam, a heat exchanger and a second steam turbine generator.

Abstract: A method and apparatus are disclosed for controlling a temperature within a reactor vessel such as an autoclave operating at elevated temperature and pressure. The apparatus includes a preheating vessel for preheating a feed material such as an aqueous slurry. The preheating vessel forms part of a preheating control system which provides the primary means of temperature control within the reactor vessel, and the reactor temperature is used as the setpoint for the preheating control system. The apparatus also comprises secondary means for heating and cooling the reactor. The feed material temperature is increased or decreased by the preheating control system, based on the reactor temperature. This is sufficient to heat or cool the reactor under most process conditions. Where the preheating control system is at or near its capacity for heating or cooling, the secondary heating or cooling means is activated to bring the reactor temperature within an optimum range.

Abstract: An apparatus for the removal and replacement of a lid on a metallurgical transport vessel such as a ladle or a torpedo car. The apparatus comprises a frame, means for supporting the frame such that the vessel may be moved into position thereunder, a linkage including at least one lifting member pivotally connected to the frame, and at least one actuator connected to the linkage. The actuator is operable to move the lifting member such that when the vessel is moved to a designated position below the apparatus, the lifting member can be moved by the actuator and linkage from a first position providing clearance above the vessel, through a curved path to an intermediate position where it engages the lid, providing a vertical lifting force and a horizontal hinge releasing force to the lid, and to a second position where the lid is raised to a sufficient height to clear the vessel.

Abstract: Some metallurgical furnaces have a tapblock that is blocked during operation of the furnace. The tapblock may be opened by lancing, drilling, tapping or by other methods to release metal from the furnace. By monitoring acoustic emissions during the opening process, feedback may be provided to improve the opening process and to avoid excessive damage to the tapblock, the cooling elements, a refractory lining of the tapblock or other elements of the metallurgical furnace.

Abstract: An apparatus is disclosed for reducing pressure and velocity of a particulate-laden, supersonic vent gas stream from a pressure vessel such as an autoclave. The apparatus includes a diverging duct in which the vent gas expands, and a perforated plate located inside the diverging duct. The perforated plate provides an area reduction that increases back pressure and forces an upstream normal shock in the diverging duct, thereby bringing about a desired reduction in pressure and velocity. The perforated plate is comprised of a material, such as a ceramic, that is resistant to erosion by the abrasive particulate entrained in the high velocity vent gas. The perforated plate has a central portion provided with holes and an imperforate peripheral portion which is resiliently received between connection flanges of the duct.

Abstract: Some embodiments of the present invention provide systems, methods and apparatus for more accurately determining the thickness of a refractory lining included in an operating metallurgical furnace. Specifically, in some embodiments a transient propagated stress wave is used to determine the condition of a refractory lining, and additionally, provide a systematic way to include the affect that temperature has on the velocity of a compressive wave through a heated refractory material and/or accretions. As identified in aspects of the present invention, and contrary to the common understanding in the art, the velocity of a stress wave, at each frequency and in a refractory material, is not necessarily constant over a temperature range. In accordance with aspects of some specific embodiments of the invention, a scaling factor ? can be calculated for each refractory material to adjust for the presumed velocity of the stress wave through each refractory material.

Abstract: A plant for the continuous manufacture of steel includes a direct reduction furnace for producing direct reduced iron (DRI) and a stationary electric arc furnace for melting the DRI. The electric arc furnace has a plurality of electrodes for melting the DRI. Heat for melting the charge material is preferably provided by open arcs between the electrodes and the metal bath. The slag preferably has low basicity to reduce the rate of refractory erosion, and preferably contains about 8 to 20% by weight MgO, about 7 to 30% by weight FeO and has a basicity of about 1.5 to 2.0. Preferably, the direct reduction furnace is a shaft furnace and is located above the electric arc furnace so that the direct reduced iron can be fed to the electric arc furnace by gravity through inclined conduits.

Abstract: Insulating members are provided for use in nozzles of elevated temperature process vessels employing a structural metal shell (24), an insulating refractory lining (14) and a corrosion-resistant membrane (18) lining between the structural shell and refractory lining. The insulating members comprise pre-formed insulating sleeves and inserts and are made of a thermally insulating material having sufficient thickness and sufficiently low thermal conductivity such that, when the sleeve or insert is heated by the process temperature during operation of the vessel, the thermal energy transmitted through the sleeve or insert to the membrane is insufficient to raise the temperature of the membrane above a target temperature. The most preferred thermally insulating materials are fluoropolymers such as poly(tetrafluoroethylene) flouropolymer resins.

Abstract: Some embodiments of the present invention provide systems, methods and apparatus for more accurately determining the thickness of a refractory lining included in an operating metallurgical furnace. Specifically, in some embodiments a transient propagated stress wave is used to determine the condition of a refractory lining, and additionally, provide a systematic way to include the affect that temperature has on the velocity of a compressive wave through a heated refractory material and/or accretions. As identified in aspects of the present invention, and contrary to the common understanding in the art, the velocity of a stress wave, at each frequency and in a refractory material, is not necessarily constant over a temperature range. In accordance with aspects of some specific embodiments of the invention, a scaling factor ? can be calculated for each refractory material to adjust for the presumed velocity of the stress wave through each refractory material.