Abstract: Process for melting a furnace charge, with post-combustion of the smokes by njecting an oxygenated gas in the furnace atmosphere as a series of jets flowing according to a tangential component in the space between electrodes and cylindrical furnace partition of the furnace, in a direction of injection so as to produce a rotary gas current about the vertical axis of the furnace and preferably in at least two series as two stepped levels to produce gas currents which rotate in opposite directions. Applications to electrical furnaces for the production of steel or ferro-alloys.

Abstract: An apparatus and method are disclosed for processing glass-making materials under oxidizing conditions, and for processing materials, such as hazardous or toxic wastes, or smelting under reducing conditions. As a glass-making apparatus the invention includes a cyclone melt reactor for forming a liquid glass melt and a combustion preheater for receiving the glass-making materials and combusting the fuel and oxidant therein to heat the glass batch materials to a temperature at least equal to the melt temperature of the glass batch material. The combustion preheater has an outlet connected to the glass melt reactor, and at least one inlet is provided into the combustion preheater for introducing oxidizing materials and for creating a well-stirred region within the combustion preheater means.

Abstract: The present invention relates to an overall direct smelting process which provides for separating the carburization function from the heating function to permit separate control of the individual functions. One embodiment of the smelting reactor is divided into a carburization/smelting section and a heating section with a substantial recirculation of the molten product from the heating section back to the carburization/smelting section. The heating section also serves as a slag/metal separation section. Carburization is achieved by injection of solids (fine coal mixed with slagging agents), where desired. Gas generating solids or inert gases are injected into a lift pipe to provide a motive force for circulation of the molten metal. The circulation rate through the system is a function of the injected solid composition, the mass flow rate of the solids injected into the lift pipe and the lift pipe geometry.

Abstract: A smelting reduction process is carried out in a smelting reactor which includes a central internal carburization/combustion plenum or chamber in which hot metal is carburized by the injection of coal fines and heated by post combustion of the coal gases. The chamber has outlets to the first zone of an outer coaxial annular channel where the coal slag is separated off and a carburized hot metal passes into a second zone or smelting channel-chamber that permits introduction of feed material into a molten metal. A majority of the material that passes through the smelting channel-chamber is recycled to the internal carburization/combustion chamber for further processing. The internal carburization/combustion chamber and the smelting channel are completely separate so that the slag and the off gases from the two processes can be kept separate as well. The channel is positioned around the circumference of the internal carburization/combustion chamber where active heating occurs to form a compact reactor.

Abstract: A method for smelting reduction of iron ore, comprises the steps of: introducing iron ore into a preheat and prereduction furnace and preheating and prereducing the iron ore, a prereduction degree being less than 30%; charging the iron ore, carbonaceous material and flux into a smelting reduction furnace; blowing oxygen gas, through decarburization nozzles and post-combustion nozzles placed in a top end of an oxygen lance, into the smelting reduction furnace, the top end of the oxygen lance being located so as to be between a top level and a bottom level of a slag layer; blowing a stirring gas through side tuyeres placed in a side wall and bottom tuyeres placed in a bottom wall of the smelting reduction furnace; and controlling a flow amount of the oxygen gas and the stirring gas so that an oxidation degree of an exhaust gas generated in the smelting reduction furnace ranges 0.4 to 0.9 and still a temperature of the exhaust gas ranges 300.degree. to 1300.degree. C.

Abstract: The device is composed of several separate elements consisting of at least one central tubular element connected, on one side, by means of a first ball-and-socket joint and a first compensator to a first connector supplying preheated air and on the opposite side, by means of a second ball-and-socket joint and a second compensator to a second connector. In order to reduce the length of the device, the second joint is oriented in the opposite direction to the said first joint, its center of curvature being located on the axis of the said second connector on the inside of the latter.

Abstract: A method and apparatus for reducing iron in a steelmaking process including a closed thermal transfer system in which a flow of process ingredients including iron ore is directed in a descending, preferably spiral path defined by a downwardly spiraling pipe with the process ingredients moving in countercurrent flow relation to a continuous flow of reducing gases ascending within the pipe to reduce the process ingredients to a continuously flowing stream of molten iron and slag which moves downwardly in the spiral pipe and into a hearth furnace.

Abstract: A process for producing sponge iron from iron ore is described, which is reduced to sponge iron in a reduction shaft furnace by means of a hot reduction gas. For this purpose reduction gas at a temperature in the range 750.degree. to 900.degree. is introduced into shaft furnace (1) level with bustle plane (5) having been produced in a gasifier (2) then cooled and purified in a cyclone separator (12). Reduction gas is introduced below the bustle plane (5) at a temperature below that of the reduction gas introduced in the bustle plane and is preferably introduced into the shaft furnace (1) between 650.degree. and 750.degree.. Increased carburization of the sponge iron is obtained. Increased carbon separation also results through a volume increase, particularly by increasing the cross-section through the lower part of the shaft furnace.

Abstract: A method and apparatus for the manufacture of metallic filaments is provided. The method and apparatus are used in the continuous manufacture and production of metallic filaments. The apparatus comprises a vertical reactor having a vertical chamber and having three mixing nozzles disposed at the top of the chamber and three vapor lines connecting to the respective three mixing nozzles along the axes of the nozzles, and three gas lines connecting to the respective three mixing nozzles in respective tangential directions. The apparatus also has twelve ring magnets, which are coaxially disposed, and which are mounted on the outside of the vertical ractor. The apparatus also has an outlet duct at the bottom of the chamber. The three vapor lines are supplied through three respective steam-heated heat exchangers from a feed vessel for supplying iron pentacarbonyl vapor to the mixing nozzles. The three gas lines are supplied from a nitrogen receiver tank.

Abstract: Process and apparatus for pyrometallurgically treating finely divided ores, concentrates, residues, slags and like materials. The process utilizes a reactor having two co-axially extending, vertical reaction chambers. The process comprises forming within the upper chamber of the reactor hot fuel-rich reaction gases; passing the hot fuel-rich reaction gases by dump flow into a second vertically extending chamber; introducing into the second chamber the finely divided materials to be treated; and reacting the finely divided materials with the hot fuel-rich reaction gases. The dump flow of hot fuel-rich reaction gases passing into the second chamber is produced by providing a zone of sudden expansion in the flow passage between the first and second chambers.

Abstract: Method and apparatus for producing liquid iron from iron oxide, wherein the iron oxide is substantially converted to sponge iron by passing reducing gas through it in a reduction column and is then melted in a melt vessel which is in open communication with the reduction column by heat generated by reaction of oxygen-containing gas and carbonaceous material which reaction provides said reducing gas. To improve control of the process, the oxygen-containing gas and the carbonaceous material are respectively substantially pure oxygen and coal powder which are delivered separately into the melt vessel, and the liquid iron bath in the melt vessel is stirred so as at least partly to be kept in motion. By separate control of the oxygen and coal supplies, e.g. the level and/or direction of delivery, and by control of stirring, it is possible to control the ratio of CO and CO.sub.2 in the reducing gas and also the heat output in the melt vessel.

Abstract: A fixed bed reactor specially adapted to be used in the gas-solid reaction for the production of sponge iron. The flow of gas is ascendant, entering at the bottom through a gas distributor specially designed to assure a uniform gas flow.

Abstract: A method for producing liquid iron, especially for producing liquid iron directly from iron ore, mainly comprising the steps of saturating an iron bath in a container by blowing particulate carbon into the bath, dropping iron ore onto a central portion of the bath surface to form a cone of iron ore thereon, blowing oxygen onto an uncovered border zone of the bath surface, blowing particulate carbon by means of a carrier gas into the bath between the bottom of the container and the bath surface, and mixing the bath by blowing a neutral gas through a porous member from a substantially central portion of the bottom of the container in upward direction through the bath, whereby the necessary energy for melting the iron ore is produced by afterburning of the CO producing during blowing of oxygen onto the border zone; and an apparatus for carrying out the method.

Abstract: A tuyere for a blast furnace, the main body of the tuyere being in the form of a tube with a central bore and the nose portion of the tuyere having a downwardly-inclined hood-like extension of the upper wall of the tube, whereby gas passing through the nose of the tuyere is deflected downwardly by the said extension, which extension has a gas outlet aperture of greater area than the cross-sectional area of the bore of the tube.

Abstract: An apparatus is provided for regulating the percentage quantities of individual gases present in the combustion air supplied for reaction processes in metallurgy. A molecular sieve absorption material is used on the intake air to absorb the inert constituents to thereby enhance the quantity of oxygen present. The apparatus utilizes several molecular sieve materials in a continuous manner such that one of the devices containing the molecular sieve material is being purged for regeneration while another device is absorbing the inert constituents, while yet another device is cooling, i.e., getting ready for the absorption operation. The countercurrent flow of heated intake air, which air is derived from the metallurgical reaction process, is used in the apparatus for regenerating the molecular sieve material.

Abstract: Static bed type iron oxide reducing apparatus comprises reduction furnaces and cooling chambers respectively associated with the furnaces. Iron oxides are charged into the furnaces and reducing gas is applied to the raw materials to carry out a reducing reaction. After the iron oxides in the furnace have been metallized to a sufficient level, they are transferred to the cooling chamber to be cooled therein.

Abstract: A method and apparatus is disclosed for reducing metal ore to sponge metal in a vertical shaft, moving bed, gaseous reduction reactor by controlling the amount of gas intermixing between the reduction and cooling zones of the reactor to result in increased productivity and improved carburization of sponge iron. In accordance with a preferred embodiment, process efficiency is maximized while capital cost is minimized through the use of an optimally designed reactor with a pre-determined equivalent height to equivalent diameter ratio.

Abstract: A cupola for the melting of metal is provided with an auxiliary gas generator which supplies through the forehearth hot carbon monoxide rich gas to the bottom of the cupola as a source of heat. The heat of the gases maintains the cupola hearth and forehearth hot. Ordinary coal, or coke breeze or any other carbonaceous fuel may be burned in the generator. Additionally, the cupola may be allowed to go to zero output without cooling off.

Abstract: A method and apparatus for producing molten iron in which pulverized coal is gasified with oxygen in an iron melting chamber, iron pellets on an upstanding hearth in the melting chamber are exposed to the gasification heat and melted. Molten iron trickles down from the hearth to a surrounding liquid bath. Off-gases from the chamber are utilized for direct reduction of iron oxide pellets to produce hot reduced iron pellets which are melted in the chamber.

Abstract: Iron, for example is directly recovered from relatively fine-grained (having a grain particle size range of less than 250 microns), iron-bearing ore whereby carbon-containing materials and oxygen-containing materials are fed through a molten metal bath and converted into a CO/H.sub.2 -rich reduction gas which is sequentially passed upwardly at gas speeds of at least 1.5 m/sec. through downwardly moving ore particles within a reduction apparatus comprised of a sequence of interconnected cyclones so that ore particles in each cyclone are in a state of suspension and in intimate contact with the reduction gas and each other whereby extensive reduction of the ore particles occurs at each cyclone so that after a last cyclone the so-reduced ore particles are directly fed into a smelting means, from which liquid iron is recovered.

Abstract: Improved cooling of sponge iron in the cooling reactor of a multi-stage gaseous reduction system for particulate iron ore is achieved by using a hollow foraminous closure plug at the bottom of the reactor. The plug is pivotally mounted for movement from a reactor-closing to a reactor-discharge position and has a cooling gas inlet nipple which, when the plug is in its reactor-closing position, registers with the discharge end of a cooling gas supply conduit to cause cooling gas to flow into the plug and through the wall thereof to cool the adjacent portion of the sponge iron bed within the reactor. The plug can also be used to distribute hot gas to an ore bed in a reduction reactor.

Abstract: A method and apparatus for the direct reduction of iron in which a fossil fuel is gasified to produce a hot gas which is tempered with a carbon dioxide lean gas. The mixture is reacted with carbon to upgrade it in reducing potential and is desulfurized by reaction with lime in a first shaft furnace to form a hot reducing gas. The hot reducing gas is utilized as the reductant in a counterflow shaft reduction furnace and the spent reducing gas is recycled as tempering gas for the gas from the hot gasifier. The apparatus includes a gasifier, counterflow shaft gas reactor, a shaft type direct reduction furnace and associated equipment.

Abstract: Disclosed is a method and apparatus for producing synthetic gas by using a blast furnace as a gasifier. The furnace is charged in a conventional manner with particles of solid carbonaceous material such as normal, low grade or undersized coke together with slag-producing material, such as limestone, silica and/or basic oxygen furnace and/or open hearth furnace slag. Fluent fuel such as pulverized coal mixed with oxygen-containing gas and with lime if desired is injected into pre-ignition chambers near the hearth line of the furnace. The fluent fuel is ignited and partially gasified in the pre-ignition chambers, creating a hot reducing gas that enters the furnace raceway and passes upwardly into and through the body of charge material in the furnace stack. At the resulting high temperatures ash from the fluent fuel liguifies within the system to provide a liquid slag. Under a controlled high temperature reducing atmosphere, the liquid lime removes essentially all sulfur from the product gas.

Abstract: A mixing chamber for mixing hot blast exiting from a hot blast stove with cold blast from a supply thereof to provide a uniform blast mixture adapted to be introduced into a blast furnace. The chamber comprises an open ended tubular member defining openings at opposite ends thereof, one of these openings being an entry into the tubular member and the other being an exit therefrom. The entry is adapted to have introduced therethrough hot blast exiting from a hot blast stove while the exit is adapted to communicate with the blast furnace. The tubular member is provided with a pair of diametrically opposed passageways therethrough, each of which is oriented tangentially with respect to the inner surface of the tubular member.

Abstract: Method and apparatus for feeding an oxidant such as air and/or a fuel rich gas within the confines of a substantially air tight enclosure employed in the heat treatment of volatile containing materials which are deposited on the floor of a rotary hearth mounted within the enclosure. A larger number of air and/or fuel rich gas inlet ports are provided in the roof of the enclosure at the outer periphery thereof than at the central or intermediate areas of the enclosure to thus provide a more oxidizing atmosphere at the outer peripheral area of the enclosure than at the central and intermediate areas of the enclosure. The oxidant is admitted into the furnace enclosure through concentrically arranged rows of inlet openings formed in the roof of the enclosure.

Abstract: In the blowing of smelting shaft furnaces tuyeres are used which are not water-cooled and which comprise three concentric conduits leading directly into the furnace, the central conduit receiving the hot blast, the intermediate conduit receiving an oxidizing gas which is not preheated and the outer conduit receiving a fluid or emulsion containing hydrocarbons.

Abstract: Iron ore pellets on a grid in a treatment chamber are hardened by contact with a heat treated, low calorific gas. The gas is generated in the gasification chamber of a slag bath generator. The generator receives a gasification agent and solid fuel that preferably further includes sulfur-binding materials, such as dolomite for generating a stream of low calorific gas. Inclined water-cooled pipes at the upper end of the slag bath generator extract liquid slag from the gas stream. The slag drips from the pipes into the slag bath generator. A mixing chamber receives the gas at a temperature of about 1450.degree. C passed beyond the inclined water-cooled pipes together with an air supply for heat treating the gas to a temperature of about 1100.degree. C. The heat treated gas is then passed into the treatment chamber for hardening the iron ore pellets contained therein.

Abstract: The stack gas from a shaft furnace in which iron ore is directly reduced is cooled and filtered and then subjected to steam so as to convert its carbon monoxide into carbon dioxide and water. The carbon dioxide and water are then scrubbed out of this stack gas so as to leave virtually pure hydrogen which is heated to a temperature between 400.degree. and 600.degree. C and added to the output of an oxygen reactor that transforms coal and oxygen into a synthetic gas having a carbon-monoxide/hydrogen volume ratio of at least 1.5:1. The addition of this hydrogen to the output of the reactor lowers the volume ratio to 1:1 at most so that this mixture can be reintroduced into the shaft furnace at a temperature of around 1000.degree. C as a reducing gas.

Abstract: Blast furnace tuyere comprising three separate injection chambers, a first axial chamber for injecting hot blast, a second narrow annular chamber concentric therewith for injecting fuel oil and a third annular chamber concentric with the other two for injecting oxygen mixed with cold air. This tuyere dispenses with a water cooling circuit.

Abstract: Apparatus for direct reduction of iron ore containing sulfur comprises a shaft type reduction furnace with means for withdrawing two separate streams of spent reducing gas. One stream, being substantially free of sulfur is recycled through a catalytic reformer to produce fresh reducing gas. The other stream containing sulfur, is connected to process equipment such as a burner where sulfur is not of consequence.

Abstract: A gravity feed shaft furnace for direct reduction of iron ores having substantially cylindrical reducing and cooling zones, an inwardly tapering discharge zone of ellipsoidal cross section, an elongated substantially cylindrical member disposed axially within the furnace extending upwardly through the discharge and cooling zones to terminate in the reducing zone, a conical top secured to the elongated member and configured to cause uniform downward solids flow, and means for introducing hot reducing gas and cooling gas into the elongated member. Means are provided for distributing the hot reducing gas into the center of the reducing zone, for distributing the cooling gas into the center of the cooling zone, and for causing part of the cooling gas to cool the hot reducing gas distribution means.

Abstract: A hermetic expansion joint for use between conduits lined with refractory material and a tuyere stock for blast furnaces utilizing a plurality of such expansion joints. The expansion joints include a bellows coaxial with and connected to the exterior of the conduits to be coupled and, located within the bellows, a shielding tube and a protective layer of compressible refractory material. The compressible refractory layer is positioned within the shielding tube and bridges the joint between the conduits.

Abstract: The invention relates to means for establishing an equalized pressure across the insulating sheath of a hot isostatic press system. Tubes are positioned in the outer, insulation portion of the sheath to provide a substantially resistance free passage between a source of high pressure gas input to the system and the upper portions of the sheath. The invention also tends to reduce convection currents in the furnace chamber.

Abstract: A magnetic field is generated whose flux lines extend normal to a planar supporting surface which is located in an enclosed annular space. Carbonyls of metallic material are fed into the enclosed space so that they travel lengthwise of the flux lines and normal to the plane of the supporting surface. The space is then heated to a decomposition temperature at which the carbonyls undergo thermal decomposition and liberate metal atoms which agglomerate under the influence of the flux lines on the supporting surface and form on the latter metal fibers which project from the supporting surface in a direction normal thereto, i.e., opposite to the direction of travel of the carbonyls themselves.