Abstract: Methods of reducing copper metal content of shredded scrap steel are provided. The method includes continuously separating a first scrap steel fraction from an amount of scrap steel concurrently with separating a second fraction from the amount of scrap steel; continuously separating the second fraction and providing a nonmagnetic fraction and, concurrently, a third scrap steel fraction; grinding the nonmagnetic fraction followed by magnetic separation to provide a fourth scrap steel fraction and, concurrently, an enriched nonmagnetic fraction; continuously combining the first scrap steel fraction, the third scrap steel fraction, and the fourth scrap steel fraction to obtain a combined scrap steel product comprising scrap steel with reduced copper metal content; and introducing the combined scrap steel product to an electric arc furnace. Systems of reducing copper metal content of shredded scrap steel are also provided.

Abstract: Methods of reducing copper metal content of shredded scrap steel are provided. The method includes continuously separating a first scrap steel fraction from an amount of scrap steel concurrently with separating a second fraction from the amount of scrap steel; continuously separating the second fraction and providing a nonmagnetic fraction and, concurrently, a third scrap steel fraction; grinding the nonmagnetic fraction followed by magnetic separation to provide a fourth scrap steel fraction and, concurrently, an enriched nonmagnetic fraction; continuously combining the first scrap steel fraction, the third scrap steel fraction, and the fourth scrap steel fraction to obtain a combined scrap steel product comprising scrap steel with reduced copper metal content; and introducing the combined scrap steel product to an electric arc furnace. Systems of reducing copper metal content of shredded scrap steel are also provided.

Abstract: Methods of reducing copper metal content of shredded scrap steel are provided. The method includes continuously separating a first scrap steel fraction from an amount of scrap steel concurrently with separating a second fraction from the amount of scrap steel; continuously separating the second fraction and providing a nonmagnetic fraction and, concurrently, a third scrap steel fraction; grinding the nonmagnetic fraction followed by magnetic separation to provide a fourth scrap steel fraction and, concurrently, an enriched nonmagnetic fraction; continuously combining the first scrap steel fraction, the third scrap steel fraction, and the fourth scrap steel fraction to obtain a combined scrap steel product comprising scrap steel with reduced copper metal content; and introducing the combined scrap steel product to an electric arc furnace. Systems of reducing copper metal content of shredded scrap steel are also provided.

Abstract: A processed DRI material having an average surface roughness (Ra) of less than 1.5 ?m is disclosed. A method and system for making processed DRI are also disclosed. One embodiment of the method and system may include assembling a rotatable chamber having an internal screen capable of supporting DRI during tumbling, with at least one opening in the chamber to permit fines to exit the chamber during tumbling, and delivering DRI into the chamber to tumble the DRI on the screen to remove fines from the DRI. Another embodiment of the method and system may include assembling a rotatable chamber having a feed end and an exit end, and having a screen therein capable of supporting DRI as the DRI moves through the chamber, and delivering DRI to the chamber and rotating the chamber to tumble the DRI while removing fines.

Abstract: A method of recovering metallic iron from iron-bearing metallurgical waste in steelmaking comprising steps of providing an iron-bearing metallurgical waste containing more than 55% by weight FeO and FeO equivalent and a particle size of at least 80% less than 10 mesh, mixing the iron-bearing metallurgical waste with a carbonaceous material to form a reducible mixture where the carbonaceous material is between 80 and 110% of the stoichiometric amount needed to reduce the iron-bearing waste to metallic iron, and as needed additions to provide a silica content between 0.8 and 8% by weight and a ratio of CaO/SiO2 between 1.4 and 1.8, forming agglomerates of the reducible mixture over a hearth material layer to protect the hearth, heating the agglomerates to a higher temperature above the melting point of iron to form nodules of metallic iron and slag material from the agglomerates by melting.

Abstract: A processed DRI material having an average surface roughness (Ra) of less than 1.5 ?m is disclosed. A method and system for making processed DRI are also disclosed. One embodiment of the method and system may include assembling a rotatable chamber having an internal screen capable of supporting DRI during tumbling, with at least one opening in the chamber to permit fines to exit the chamber during tumbling, and delivering DRI into the chamber to tumble the DRI on the screen to remove fines from the DRI. Another embodiment of the method and system may include assembling a rotatable chamber having a feed end and an exit end, and having a screen therein capable of supporting DRI as the DRI moves through the chamber, and delivering DRI to the chamber and rotating the chamber to tumble the DRI while removing fines.

Abstract: A method of recovering metallic iron from iron-bearing metallurgical waste in steelmaking comprising steps of providing an iron-bearing metallurgical waste containing more than 55% by weight FeO and FeO equivalent and a particle size of at least 80% less than 10 mesh, mixing the iron-bearing metallurgical waste with a carbonaceous material to form a reducible mixture where the carbonaceous material is between 80 and 110% of the stoichiometric amount needed to reduce the iron-bearing waste to metallic iron, and as needed additions to provide a silica content between 0.8 and 8% by weight and a ratio of CaO/SiO2 between 1.4 and 1.8, forming agglomerates of the reducible mixture over a hearth material layer to protect the hearth, heating the agglomerates to a higher temperature above the melting point of iron to form nodules of metallic iron and slag material from the agglomerates by melting.

Abstract: Apparatus, methods and systems are used to separate fines from objects of a feed mixture being processed (e.g., iron bearing pellets, chips and dust). For example, at least a portion of an endless belt defining a channel is movable up an incline relative to horizontal (e.g., an incline that is at an angle relative to horizontal that is greater than an angle of repose associated with the objects, but less than an angle of repose associated with the fines being removed). Further, obstruction elements may be used on the endless belt to impede the flow of the fines down the incline.

Abstract: A road and repair system and/or method using one or more components including a plurality of magnetite concentrate particles, at least one acidic activator including phosphate anions, and a plurality of reactive aggregate particles including iron.

Abstract: A system and method for cooling and removing metallic iron and other aggregate from a moving hearth is provided. Cooling may be provided by a secondary cooling system and a spray cooling system in a cooling zone. The secondary cooling system may include an arrangement of coolant tubes for absorbing heat. A flow of nitrogen may be provided through the cooling zone. The spray cooling system may provide evaporative cooling. Aggregate removal may be provided by a magnetic removal system, a plow system, and a sweeper system. The magnetic removal system uses a magnetic device and a moving belt to remove iron materials. The plow system uses a plow to separate and remove aggregate from the moving hearth. The sweeper system may use a vacuum device to pull materials from the moving hearth.

Abstract: Apparatus, methods and systems are used to separate fines from objects of a feed mixture being processed (e.g., iron bearing pellets, chips and dust). For example, at least a portion of an endless belt defining a channel is movable up an incline relative to horizontal (e.g., an incline that is at an angle relative to horizontal that is greater than an angle of repose associated with the objects, but less than an angle of repose associated with the fines being removed). Further, obstruction elements may be used on the endless belt to impede the flow of the fines down the incline.

Abstract: A road and repair system and/or method using one or more components including a plurality of magnetite concentrate particles, at least one acidic activator including phosphate anions, and a plurality of reactive aggregate particles including iron.

Abstract: Absorbent magnetic particles are used to remove air pollutants. The adsorbent magnetic particles can adsorb various air pollutants, including nitrogen oxides, sulfur oxides, and mercury, and may be regenerated for reuse.

Abstract: Apparatus, methods and systems are used to separate fines from objects of a feed mixture being processed (e.g., iron bearing pellets, chips and dust). For example, at least a portion of an endless belt defining a channel is movable up an incline relative to horizontal (e.g., an incline that is at an angle relative to horizontal that is greater than an angle of repose associated with the objects, but less than an angle of repose associated with the fines being removed). Further, obstruction elements may be used on the endless belt to impede the flow of the fines down the incline.

Abstract: Apparatus, methods and systems are used to separate fines from objects of a feed mixture being processed (e.g., iron bearing pellets, chips and dust). For example, at least a portion of an endless belt defining a channel is movable up an incline relative to horizontal (e.g., an incline that is at an angle relative to horizontal that is greater than an angle of repose associated with the objects, but less than an angle of repose associated with the fines being removed). Further, obstruction elements may be used on the endless belt to impede the flow of the fines down the incline.