Abstract: A DRI product and method of forming the DRI product. DRI is formed from a reducing process, and thereafter the DRI is subjected to another heat treatment that produces a DRI product. The DRI product formed has a metallic shell around at least a portion of a DRI core. The heat treatment may be delivered through the use of a plasma torch, a gas burner, an oven, or any other like heat source. The heat treatment may heat the DRI for a fraction of a second and quickly cool the DRI in order to melt the surface and form the metallic shell without vaporizing a significant portion of the DRI and without losing a significant amount of the latent energy in the DRI.

Abstract: A method includes the production of a primary ingot, the production of a secondary ingot, and the removal of a flux layer. A CaO—CaF2 flux in a content of 3-20 mass % and obtained by mixing 35-95 mass % of CaF2 with CaO is added to a Ti—Al alloy material including a total of at least 0.1 mass % of oxygen and at least 40 mass % of Al, and the resultant substance is melted by a melting method using a water-cooled copper container in an atmosphere having a pressure of 1.33 Pa or higher and held to produce the primary ingot. The primary ingot is continuously drawn downwards while being melted by a melting method using a bottomless water-cooled copper casting mould in an atmosphere having a pressure of 1.33 Pa or higher to produce the secondary ingot. The flux layer deposited on the surface of the secondary ingot is mechanically removed.

Abstract: A self-stirring induction system includes a vessel that has a plurality of ferromagnetic elements. The system also includes an electromagnetic radiation source that is positioned to deliver electromagnetic radiation to the plurality of ferromagnetic elements. The system further includes a controller in communication with the electromagnetic radiation source. The controller is configured to determine, based at least in part on a desired amount or type of stirring, a pattern in which to heat the plurality of ferromagnetic elements. The controller is also configured to cause the electromagnetic radiation source to target the plurality of ferromagnetic elements with radiation in the determined pattern to induce a convection current in contents of the vessel such that the desired amount or type of stirring occurs.

Abstract: Provided is a technique for increasing the yield of reduced iron, thereby improving productivity when manufacturing reduced iron by heating an agglomerate. This method for manufacturing reduced iron includes: a step in which a mixture is agglomerated, said mixture containing an iron oxide-containing substance, a carbonaceous reducing agent, and a melting point regulator; and a step in which reduced iron is manufactured by heating the obtained agglomerate, reducing and partially melting the iron oxide in the agglomerate, and aggregating the iron component. The particle size of the fine particulate iron generated in the step in which the reduced iron is manufactured is adjusted, and the fine particulate iron is blended into the mixture.

Abstract: A semi-liquid metal processing apparatus and method are presented in which a semi-liquid metal and/or semi-solid metal is introduced into a crucible and his electromagnetically stirred at a first frequency while cooling, and thereafter sidewalls of a metal charge formed of the semi-liquid metal and/or semi-solid metal are partially melted prior to tilting the crucible for removal of the metal charge.

Abstract: According to embodiments of the present invention, an amorphous alloy includes at least Pt, P, Si and B as alloying elements, and has a Pt weight fraction of about 0.925 or greater. In some embodiments, the Pt weight fraction is about 0.950 or greater.

Abstract: A method for the introduction of inorganic solid bodies into hot, liquid melts, whereby inorganic solid bodies are added to a plastic containing hydrocarbon and the mixture obtained is added to the hot, liquid melt.

Abstract: A semi-liquid metal processing and sensing device comprising a crucible that is at least partially encircled by at least one induction coil. The one or more induction coils can be water cooled. The one or more induction coils can be designed to generate a variable power and/or variable frequency magnetic field which can be modulated to control the cooling of a molten metal charge in the crucible from the liquidus temperature to a selected heat content, resistivity and/or viscosity. The magnetic field can be designed to induce toroidal agitation of the metal charge in the crucible. The semi-liquid condition is sensed and can be actively controlled by the induction power supply via real time or non-real time analysis of electrical feedback signals that are obtained from the induction coil.

Abstract: There are provided a method for desulfurizing molten steel, characterized in that a sample taken out from molten steel after the tapping from a converter or during the secondary refining is analyzed rapidly in a high accuracy by a method comprising a high frequency induction heating step wherein the sample is combusted and oxidized under the high frequency induction heating in a pure oxygen atmosphere to convert S in the sample into SO2 and an analyzing step wherein SO2-containing gas produced in the high frequency induction heating step is analyzed through an ultraviolet fluorescence method to quantify S concentration of the sample, whereby S concentration of molten steel after the tapping from the converter can be controlled in a high accuracy to prevent failure of S concentration and also desulfurization time in the secondary refining can be shortened and the amount of the desulfurizer or the like used can be reduced, and a method of manufacturing molten steel by using such a method.

Abstract: The invention is directed to a method of making liquid metal compositions containing a large number of solid particles per unit volume, without external heat removal, which solid particles act as nuclei for grains when the metal is solidified. A method of forming a metal solid includes the step of partially removing a solute of a liquid metallic solution which is at its liquidus temperature to partially solidify a metal solvent component, thereby forming a solid fraction, wherein there is essentially no reduction in temperature of the liquid metallic solution and solid fraction. The method further includes the step of subsequently lowering the temperature of the liquid metallic solution and solid fraction to solidify the remaining liquid metallic solution and thereby form a solid that includes the solid fraction formed during the step of partial solute removal. In an embodiment, the method further includes turbulence from gas evolution which aids in solid particle formation and grain refinement.

Abstract: A carbonaceous-based metallizing method and apparatus wherein a metallic oxide is converted into a carbon-containing, metallized intermediate that is melted in an induction channel furnace to produce liquid metal from said metallic oxide. In the application of iron ore in the form of fines or concentrate, using low-cost coal will greatly reduce capital and operating costs by virtue of eliminating agglomeration of ore, cokemaking, and blast furnace operation. The liquid iron so produced is efficiently converted into steel in a steelmaking furnace such as a basic oxygen furnace (BOF), especially when it is physically integrated to the induction channel furnace wherein the liquid iron is directly poured into the integrated BOF by the induction channel furnace, producing low-cost steel, little heat loss, and minimum emissions.

Abstract: The invention refers to metallurgy, in particular to making low (LH) and specified (SH) hardenability steels in electric arc, induction furnaces or oxygen converters. A metallurgical unit is loaded with metal charge consisting of iron carbon alloy, scrap with a specified content of manganese, silicon, chrome, nickel and copper, providing for the final content of each of them of not more than 0.

Abstract: The invention relates to a method of agglomerating iron oxide-containing residual substances, in particular scale and mill scale, wherein the residual materials and the paper sludge are dried and comminuted and agglomerates are produced by means of hot briquetting from the mixture comprising the residual substances and the paper sludge. In this way, mill scale briquettes of high strength and density can be produced which in steelmaking processes can then be charged into an electric arc furnace for the purpose of recycling the iron contained in the residual substances.

Abstract: Provided is a manufacturing method of ferromolybdenum from molybdenite concentrate, and more particularly, a manufacturing method of ferromolybdenum with copper content of 0.5% or less from molybdenite with high copper content without carrying out a separate copper removing process by putting molybdenite, aluminum metal and iron metal, in a heating furnace and reacting them at high temperature to manufacture the ferro molybdenum at the lower portion thereof, forming a slag using aluminum sulfide and iron sulfide as the main components at the upper portion thereof, and putting most of the copper (80 to 95%) existing in the molybdenite in a slag layer. The exemplary embodiment can shorten a process as compared to a metallothermic reduction (Thermit) method of the related art and reduce the consumption of a reducing agent, i.e., aluminum.

Abstract: A semi-liquid metal processing and sensing device comprising a crucible that is at least partially encircled by at least one induction coil. The one or more induction coils can be water cooled. The one or more induction coils can be designed to generate a variable power and/or variable frequency magnetic field which can be modulated to control the cooling of a molten metal charge in the crucible from the liquidus temperature to a selected heat content, resistivity and/or viscosity. The magnetic field can be designed to induce toroidal agitation of the metal charge in the crucible. The semi-liquid condition is sensed and can be actively controlled by the induction power supply via real time or non-real time analysis of electrical feedback signals that are obtained from the induction coil.

Abstract: A carbonaceous-based metallizing method and apparatus wherein a metallic oxide is converted into a carbon-containing, metallized intermediate that is melted in an induction channel furnace to produce liquid metal from said metallic oxide. In the application of iron ore in the form of fines or concentrate, using low-cost coal will greatly reduce capital and operating costs by virtue of eliminating agglomeration of ore, cokemaking, and blast furnace operation. The liquid iron so produced is efficiently converted into steel in a steelmaking furnace such as a basic oxygen furnace (BOF), especially when it is physically integrated to the induction channel furnace wherein the liquid iron is directly poured into the integrated BOF by the induction channel furnace, producing low-cost steel, little heat loss, and minimum emissions.

Abstract: Provided is a manufacturing method of ferromolybdenum from molybdenite concentrate, and more particularly, a manufacturing method of ferromolybdenum with copper content of 0.5% or less from molybdenite with high copper content without carrying out a separate copper removing process by putting molybdenite, aluminum metal and iron metal, in a heating furnace and reacting them at high temperature to manufacture the ferro molybdenum at the lower portion thereof, forming a slag using aluminum sulfide and iron sulfide as the main components at the upper portion thereof, and putting most of the copper (80 to 95%) existing in the molybdenite in a slag layer. The exemplary embodiment can shorten a process as compared to a metallothermic reduction (Thermit) method of the related art and reduce the consumption of a reducing agent, i.e., aluminum.

Abstract: A process for producing a semi-solidified slurry of an iron alloy including the steps of pouring a melt of an iron alloy into a semi-solidified slurry producing vessel 30 and cooling the melt therein to obtain a semi-solidified slurry having a crystallized solid phase and a residual liquid phase, wherein a hypereutectoid or hypoeutectic cast iron composition containing 0.8-4.3 wt. % C is used as a material, a melt of the composition is poured into the semi-solidified slurry producing vessel in a predetermined amount at a time, a temperature of the melt when poured into the semi-solidified slurry producing vessel is controlled to be not lower than a crystallization initiation temperature of the composition and not greater than a temperature that is 50° C. higher than the crystallization initiation temperature, and a cooling rate of the melt poured into the semi-solidified slurry producing vessel is controlled not to exceed 20° C. per minute.

Abstract: A process of producing magnetite with a high purity of greater than 90% magnetite, more typically greater than 98% magnetite, by reducing powdered hematite into magnetite under maximum temperatures of about 700 to 1300° C. against a counter-current of or concurrent with methane or natural gas in a heating device. The amount of methane used to reduce the hematite may be about 0.18 and 1.8 standard cubic feet of methane per pound of hematite. A product of high purity methane produced from the process is also provided, where the magnetite is below 1 ?M in diameter and has a magnetic saturation greater than 90.0 emu/g. Corresponding apparatus using an improved feeder system for powdered hematite is provided.

Abstract: A method for introducing dust into a molten bath of a pyrometallurgical installation is described. According to the method, a carrier gas containing dust particles is guided through a heating zone of an electrode less plasma torch, the gas being converted to a plasma by inductive heating prior to being blown into a region of the installation which receives the molten bath.

Abstract: There is described a method for producing ultrahigh-purity Fe-base, Ni-base, and Co-base alloying materials to achieve impurity levels of (C+O+N+S+P)<100 ppm, and Ca<10 ppm, in the form of a large ingot, using a refining flux while forcibly cooling the crucible. A refining flux selected from the group consisting of metal elements of the Groups IA, IIA, and IIIA of the Periodic Table, oxides thereof, halides thereof, and mixtures thereof, is added to the molten metal during primary melting and the molten metal is held in contact with the refining flux for at least 5 minutes before tapping. Thereafter, the molten metal is caused to undergo solidification inside a mold, thereby producing a primary ingot.

Abstract: There is provided a melting furnace with an agitator. The melting furnace with an agitator includes a melting furnace that contains melt, and an agitator that agitates the melt by an electromagnetic force. The agitator includes a first electrode that is provided at an arbitrary position of the melting furnace so as to come in contact with the melt contained in the melting furnace, a second electrode that is provided near a bottom wall of the melting furnace so as to come in contact with the melt, a first magnetic field device that is provided outside the melting furnace so as to face the bottom wall of the melting furnace and makes a north pole face the bottom wall, and a second magnetic field device that is provided outside the melting furnace so as to face the bottom wall of the melting furnace and makes a south pole face the bottom wall. The first and second magnetic field devices are disposed with a gap in a certain direction.

Abstract: A method for making a strain aging resistant steel comprises adding boron to the steel, wherein substantially all of the boron in the steel forms boron nitride. A method for making steel comprises adding a nitride-forming element to the steel to lower the free nitrogen content of the steel to a free nitrogen content specification. A high-carbon steel contains boron nitride, wherein the free nitrogen content of the steel is less than 80 ppm. A strain aging resistant steel wherein the carbon content of the steel is between about 0.54 percent and about 0.75 percent.

Abstract: The invention provides a Martensite wear-resistant cast steel with film Austenite for enhancement of toughness comprises 0.25˜0.34 wt % C, 1.40˜2.05 wt % Si, 0.90˜1.20 wt % Mn, 1.80˜2.50 wt % Cr, 0.0005˜0.005 wt % B, 0.01˜0.06 wt % Ti, 0.015˜0.08 wt % Rare Earth, 0.015˜0.06 wt % Al, less than 0.035 wt % S, less than 0.035 wt % P, and the balance of iron. The method of producing the cast steel includes smelting and heat-treatment, after smelting as normal operation, adding Ferro-Rare Earth and Ferro-Boron in the ladle in sequence, then high temperature normalizing, water quenching and low temperature tempering. TEM structure of the cast steel is martensite lath with film austenite between martensite laths. Cast steel of the invention exhibits high hardenability and toughness, and low cost without precious Molybdenum and Nickel, applied to a range of wear-resistant castings, especially to heavy-section castings, i.e. heavy-section tooth.

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: The invention is a method and apparatus for iron-making/steel-making using a modified rotary hearth furnace, that is a finisher-hearth-melter (FHM) furnace. In the method the refractory surface of the hearth is coated with carbonaceous hearth conditioners and refractory compounds, where onto said hearth is charged with pre-reduced metallized iron. The pre-reduced metallized iron is leveled, then heated until molten, and then reacted with the carbon and reducing gas burner gases until any residual iron oxide is converted to iron having a low sulfur content. Nascent slag separates from the molted iron forming carburized iron nuggets. The nuggets are cooled, and then the iron nuggets and the hearth conditioners, including the refractory compounds, are discharged onto a screen, which separate the iron nuggets from the hearth conditioner.

Abstract: For the evaporation of given components from initial multiple-substance mixtures and systems at subatmospheric pressure, individual portions (P1, P2, P3, P4, P5) of the multiple-substance mixture and systems are placed in ring crucibles (17) stacked at several levels. Vapors of the lower-boiling component are drawn off through a vapor exhaust opening in each crucible, while the top ring crucible (17) is closed except for its vapor exhaust opening.

Abstract: The invention concerns a method for the manufacturing of steel in an electric arc furnace, comprising melting of charged steel raw material, substantially iron carrier, characterised in that at least 5 weight-%, preferably at least 10 weight-%, of charged iron carrier consist of granulated pig iron, here denominated GPI.

Abstract: A method capable of suppressing damages to furnace wall refractories in a melting furnace and making the working life of them longer and a technique capable of obtaining a molten iron with homogenized composition while keeping a high productivity upon arc heating a pre-reducing iron in a melting furnace to obtain a molten iron, the method comprising supplying a pre-reducing iron to a stationary non-tilting type melting furnace and melting the iron by an arc heating mainly composed of radiation heating, the melting being performed while keeping a refractory wearing index RF represented by the following equation at 400 MWV/m2 or less.

Abstract: Apparatus for a metal reduction and melting process, in which a metal and carbon-containing burden is heated in an induction furnace including a heating vessel in which the burden can float in at least one heap on a liquid metal bath in the vessel, is characterized in that the apparatus includes at least one induction heater or inductor located at the bottom center line of the vessel, with the longitudinal access oriented perpendicular to the access of the vessel.

Abstract: A method of producing a molten steel, including the steps of putting, in an electric furnace, an iron material and a carbon material, to melt the iron material and the carbon material and produce a high-carbon molten iron whose carbon content is not lower than 1%, storing, in a reservoir furnace whose capacity is larger than a capacity of the electric furnace, an amount of the high-carbon molten iron that corresponds to a plurality of charges of the electric furnace, and using a portion of the high-carbon molten iron stored in the reservoir furnace, to produce the molten steel in a steel producing furnace.

Abstract: An energy efficient, coal-based method and apparatus that are environmentally friendly which produce under pressure metallized/carbon product and molten metal directly from abundant coal or other carbonaceous material, and low cost fines (or ore concentrate) wherein the metal is devoid of gangue material and possesses the inherent advantage of retaining the heat for subsequent processing. This method and apparatus which are modular and highly integrated significantly reduce capital and operating costs; they also provide the capability selective placement of the reductant for the delivery of high levels of thermal energy input which leads to ease of desulflurization and high productivity. The technology herein disclosed is entirely closed and is applicable to various ores including ferrous and non-ferrous.

Abstract: There is disclosed a process for reducing oxidic slags or combustion residues above a metal bath. The metal bath is formed of an iron alloy containing metals nobler than iron and whose redox potential is adjusted such FeO is reduced to Fe not at all or only partially.

Abstract: An apparatus and a method for melting solid metals, including iron, are provided. The apparatus includes a vertical shaft furnace through which the metal is fed. The shaft furnace is mounted on a horizontal induction furnace containing a molten pool of metal. Metal solids are charged at the top of the vertical shaft furnace down onto a refractory pedestal in the molten metal pool or suspended magnetically in the vertical shaft above gas burners. The metal is melted by contact with the molten metal pool. The combination of oxygen fuel burner preheating and induction melting creates an extremely efficient melting unit that can process metal at a much lower cost than conventional systems while preventing the oxidation problems incurred by apparatuses which melt metal using combustion only.

Abstract: A metal reduction and melting process which involves the heating of a burden comprising a metal containing component and a carbon containing component in a channel type induction furnace in order to reduce such metal containing component, in which at least part of the gaseous products of the process is utilized for preheating the burden; and apparatus for carrying out such preheating.