Abstract: A conventional electric arc furnace is provided with an outlet in a sidewall of the furnace, the inner and outer ends of which are positioned such that the outer end of the outlet is higher than the inner end of the outlet. The outer end of the outlet communicates directly with a graphite electrode having a hollow interior leading from the sidewall of the electric arc furnace to an electroslag furnace positioned below the electric arc furnace. After an initial charge of ore in the electric arc furnace is brought to the molten state with the slag floating on top of the molten metal, the level of molten metal is maintained above the inner end of the slanted outlet and caused to flow through the slanted outlet and hollow graphite electrode to the electroslag furnace. In the electroslag furnace, the molten metal solidifies on a movable base plate positioned at the bottom of the furnace which is slowly withdrawn out of the bottom of the electroslag furnace, thereby continuously forming the desired steel ingot.

Abstract: A calcium fluoride-containing composition for use in conditioning electric furnace steelmaking slags is prepared from by-product scrubber solutions derived from wet-acid processing of phosphate rock by reacting the scrubber solution with calcium hydroxide.

Abstract: Structurally sound steel ingots are produced by the conventional electroslag process using prereduced iron ore pellets containing as much as 2.8% oxygen pressed into a bar shape as a consumable electrode. A carbon source, such as silicon carbide or titanium carbide, is dispersed in the flux to prevent oxygen transfer from the flux to the ingot thus preventing blowhole porosity caused by the oxygen and allowing production of a structurally sound ingot. Alternatively, ferroalloys can be mixed with the iron ore pellets before pressing. This not only deoxidizes the melt, but also permits the production of specific alloy steel compositions.