Abstract: A method of operating a channel induction furnace to process a feed material and obtain therefrom at least one of a molten metal product, a vapor phase metal product and a slag product. The method involves the use a variety of feed materials that contribute to the molten metal product and/or the vapor phase metal product and/or the slag product and/or function as a binder for briquetting or pelletizing the feed material.

Abstract: A method of operating a channel induction furnace to process a feed material and obtain therefrom at least one of a molten metal product, a vapor phase metal product and a slag product. The method includes applying a controlled vacuum on the headspace of the channel induction furnace to controlling the amount of ambient air that enters the furnace or adding oxygen into the channel induction furnace. The method also includes controlling the carbon concentration in the molten bath in the channel induction furnace to control the fluidity of the bath.

Abstract: A calcium-sodium polysulfide chemical reagent and methods for producing the reagent. The reagent is a blend of calcium polysulfide and sodium polysulfide that can be prepared using various types, sources and ratios of lime, elemental sulfur and sulfide ion using either virgin or waste materials. The reagent is amenable to inexpensive and high rate production methods at ambient or warmer temperatures. The reagent can be used to precipitate metals from wastewater, stabilize hexavalent chrome in hazardous waste residues, remove mercury from coal fired power plants, and as an electrolyte in large-scale bromide/polysulfide electrical storage batteries.

Abstract: A method of operating a channel induction furnace to process a feed material and obtain therefrom at least one of a molten metal product, a vapor phase metal product and a slag product. A molten metal bath is maintained in the channel induction furnace and the method includes adding a reductant such as carbon or a carbon containing material directly into the molten metal bath independently of the feed material.

Abstract: A method of operating a channel induction furnace to process a feed material and obtain therefrom at least one of a molten metal product, a vapor phase metal product and a slag product. The method involves maintaining a slag layer on the molten bath that has a thickness that is sufficient to support the feed material while minimizing heat transfer through the slag layer and minimizing the resistance of vapor phase components from transferring through the slag layer. The fluidity of the slag layer is controlled by heating the slag layer and adjusting the chemistry of the slag layer.

Abstract: A calcium-sodium polysulfide chemical reagent and methods for producing the reagent. The reagent is a blend of calcium polysulfide and sodium polysulfide that can be prepared using various types, sources and ratios of lime, elemental sulfur and sulfide ion using either virgin or waste materials. The reagent is amenable to inexpensive and high rate production methods at ambient or warmer temperatures.

Abstract: A calcium-sodium polysulfide chemical reagent and methods for producing the reagent. The reagent is a blend of calcium polysulfide and sodium polysulfide that can be prepared using various types, sources and ratios of lime, elemental sulfur and sulfide ion using either virgin or waste materials. The reagent is amenable to inexpensive and high rate production methods at ambient or warmer temperatures.

Abstract: A method of operating a channel induction furnace so as to receive electric arc furnace (EAF) dust, basic oxygen furnace (BOF) sludge/dust and/or other iron and volatile metals containing materials as a feed stream on a batch, continuous or semi-continuous basis together with a iron-containing material feed, and therefrom produce an iron-containing hot metal or pig iron product while recovering iron value from the feed materials and recovering volatile metal components contained in the feed materials.

Abstract: A method of using an induction furnace to process iron ore into an iron product such as pig iron in which iron ore is the main or exclusive source of iron fed into the induction furnace.

Abstract: A process for the stabilization of metal bearing waste is provided that is based upon the discovery that landfills have anaerobic environments. This process includes adjusting the pH of the waste and adding a sulfide containing reducing agent to the waste to achieve a reducing environment. In one embodiment, electric arc furnace dust is stabilized for landfill disposal. Also provided is a method for a determination of landfilled waste leachability. This method is performed under conditions that simulate the chemical characteristics of landfills. In one embodiment, stabilized metal bearing waste is deoxygenated and a simulated leachate is prepared under anaerobic conditions.

Abstract: A method of operating mechanical separation devices at high temperatures to separate various volatile metals, metal halides and metal oxides to produce high purity materials.

Abstract: A method of operating an induction furnace so as to receive electric arc furnace (EAF) dust, basic oxygen furnace (BOF) sludge/dust and/or other iron and volatile metals containing materials as a feed stream on a batch, continuous or semi-continuous basis together with a iron-containing material feed, and therefrom produce an iron-containing hot metal or pig iron product while recovering iron value from the feed materials and recovering volatile metal components contained in the feed materials.

Abstract: A process for separating and recovering a desired metal as metal oxide from raw material is provided. The process includes placing the raw material and a reductant in a container to form a reducing microclimate within the container. A housing having an oxidizing atmosphere is heated to maintain a temperature zone within the housing at a heating temperature sufficient to expose the raw material in the container to a reaction temperature. The container containing the raw material is conveyed through the temperature zone in the housing to expose the raw material and the reductant to the reaction temperature wherein the metal oxide is reduced to a gaseous metal that exits the container. Once outside the container, the gaseous metal is exposed to the oxidizing atmosphere of the temperature zone wherein the desired metal is oxidized to metal oxide and the metal oxide is collected. In preferred embodiments, the raw material is EAF dust and the desired metal is zinc.

Abstract: Methods and apparatus for processing electric arc furnace (“EAF”) dust through a basic oxygen furnace (BOF) to recover iron value from the EAF dust and concentrate zinc from the EAF dust into a material useful as a feed in zinc manufacturing processes. The method results in the reduction of the burden for the regulatory tracking of EAF dust. In addition, the method provides economic savings which result from the reduction of processing fees and the recovery of the value of iron and zinc materials. The apparatus involves the use of existing equipment that is used to recover iron value from other materials generated at steel making facilities, or the installation of new equipment for the purpose of iron reuse.

Abstract: A method of processing electric arc furnace (EAF) dust which involves processing the EAF dust through a basic oxygen furnace (BOF). The method encompasses recovery of iron value from the EAF dust and the concentration of zinc into a material that has more flexible opportunities for its use as a feed to zinc manufacturing processes. The iron and zinc values in the EAF dust can be added to existing iron oxide recovery processes. This allows the EAF dust to be used as a substitute iron feed for BOF's. The method of processing EAF dust and the components thereof results in the reduction of the burden for the regulatory tracking of EAF dust. In addition, the method of processing EAF dust provides economic savings which result from the reduction of processing fees and the recovery of the value of iron and zinc materials.