Abstract: Methods and apparatus for condensing vapour phase compounds or elements, typically metals such as magnesium, obtained by reduction processes.

Abstract: Superalloy component castings, such as turbine blades and vanes, are fabricated or repaired by an electroslag or electrogas welding process that at least partially replicates the crystal structure of the original cast substrate in a cast-in-place substrate extension. The process re-melts the base substrate surface and grows it with new molten filler material. As the base substrate and the filler material solidify, the newly formed “re-cast” component has a directionally solidified uniaxial substrate extension portion that at least in part replicates the crystalline structure of the base substrate. The “re-cast” component can be fabricated with a unified single crystal structure, including the extension portion. In other applications, a substrate extension can replicate a directionally solidified uniaxial crystal structure of an original base substrate casting.

Abstract: A method of suppressing a distribution of PGM into a Cu2O slag in an oxidation smelting of a method of recovering PGM, is provided, including: carrying out reduction smelting to a treatment target member containing PGM, Cu and/or Cu2O, and flux, to thereby generate a molten slag and a Cu alloy containing PGM; and oxidizing and melting the Cu alloy containing the PGM, to thereby generate a Cu2O slag containing PGM and the Cu alloy, with more concentrated PGM concentration than the Cu alloy containing the PGM, wherein when carrying out the oxidation smelting, acidic oxide or basic oxide is added.

Abstract: The invention relates to a method and to an arrangement for refining copper concentrate (1). The arrangement comprises a suspension smelting furnace (2) comprising a reaction shaft (5), and a settler (6). The reaction shaft (5) is provided with a concentrate burner (8) for feeding copper concentrate (1) such as copper sulfide concentrate and/or copper matte and additionally at least reaction gas (9) into the reaction shaft (5) to obtain a blister layer (11) containing blister and a first slag layer (12) containing slag on top of the blister layer (11) in the settler (6), and a slag cleaning furnace (3). The arrangement comprises feeding means (16, 18, 23) for feeding blister from the blister layer (11) in the settler (6) and for feeding slag from the first slag layer (12) in the settler (6) into the slag cleaning furnace (3).

Abstract: Copper is produced by a looping oxidizing process wherein oxidation of copper sulfide concentrate to molten blister copper by conversion with copper oxides (and optionally oxygen from air) in a one step, molten bath operation to produce molten blister copper, iron oxide slag, and rich SO2 off gas. The blister copper is treated in an anode furnace to reduce the iron content and oxidize residual sulfur, and prepare it for either electrolysis or reoxidation.

Abstract: One aspect provides for the separating of two or more joined materials by heating with microwaves, thereby producing differential thermal expansion of the materials. The pieces to be treated are exposed to microwave energy, producing differing rates of heating, and therefore expansion, of the differing materials making up the treated pieces of material. The differential thermal expansion of the differing materials will cause sufficient strain to separate the differing materials. Separation can be enhanced in some cases by following microwave heating with rapid cooling of the treated material.

Abstract: A method of using scrap rubber and other scrap materials, such as tires or parts or pieces of tires, to manufacture or melt steel and other metals in a furnace is disclosed. The scrap rubber may be used as a carbon source for the manufacture of steel and other metals, and may be used as an energy source to melt the scrap metal used to make the steel and other metals. The net benefit of this method includes reducing the amount of scrap rubber, such as tires, to be sent to a waste disposal facility or landfill, thereby improving the environment. In addition, by increasing the use of scrap rubber as a source of energy for steel or metal production, less energy is required from other sources.

Abstract: Metallic titanium is continuously produced in an electric-arc furnace under a vacuum by the metallothermic reduction of titanium tetrachloride by a reducing agent such as magnesium. The nanoparticles of titanium obtained from the reduction are simultaneously melted in a bath of molten titanium formed by the heat of an electric arc between a consumable titanium electrode and the molten titanium. A voltage applied across the electrode and the molten titanium is adjusted so that molten titanium is maintained in a cooled crystallizer during the entire process. The molten titanium solidifies on the top of a dummy bar that is drawn down as additional titanium is produced. Upon completion of each iterative reduction reaction, the vaporized reducing agent chloride is pumped out of the electric-arc furnace into a condenser using a vacuum pump. Then, additional reducing agent and titanium tetrachloride are added into the furnace, and the process is repeated.

Abstract: A method is disclosed for recovering precious metals from source materials containing precious metals which involves leaching the source material in aqueous reducing liquor to provide a treated solid residue and processing the treated residue to recover precious metals.

Abstract: A process for the production of a valve metal oxide powder, in particular an Nb2O5 or Ta2O5 powder by continuous reaction of a fluoride-containing valve metal compound with a base in the presence of water and calcination of the resultant product, wherein the reaction is performed in just one reaction vessel and at a temperature of at least 45° C. Valve metal oxide powders obtainable in said manner which exhibit a spherical morphology, a D50 value of 10 to 80 ?m and an elevated BET surface area.

Abstract: A process and apparatus for producing titanium metal is described herein. The process comprises generating an RF thermal plasma discharge using a plasma torch provided with an RF coil; reducing titanium tetrachloride to a titanium metal by supplying titanium tetrachloride and magnesium into the RF thermal plasma discharge; and collecting or depositing the titanium metal at a temperature not lower than the boiling point of magnesium chloride and not higher than the boiling point of the titanium metal.

Abstract: A process for recovering non-ferrous metals, in particular copper, nickel and cobalt, from metallurgical residues containing these non-ferrous metals at an oxidation state of greater than or equal to zero, in an alternating current type plasma arc electric furnace comprising a plurality of electrodes, containing a liquid copper heel covered by a fluid slag comprising at least one fusion-reduction phase, comprising charging of metallurgical residues comprising the non-ferrous metals onto the heel contained in the plasma arc electric furnace, fusion of the metallurgical residues in the fluid slag or at the slag-metal bath interface, reduction of at least the non-ferrous metals to oxidation state zero, and intense stirring of the copper heel by injection of inert gas, preferably nitrogen and/or argon, so as to avoid crust formation and to accelerate the reduction reaction and to cause the copper-miscible non-ferrous metals to pass into the copper heel.

Abstract: In the process of recovering platinum group metals from platinum group metal- and base metal-containing materials, the present invention uses reductants and a sulfur-deficient matte to aide the separation of the furnace matte from the furnace slag and therefore improve recovery of platinum group metals.

Abstract: Provided is a high-purity copper or high-purity copper alloy sputtering target of which the purity is 6N or higher and in which the content of the respective components of P, S, O and C is 1 ppm or less, wherein the number of nonmetal inclusions having a particle size of 0.5 ?m or more and 20 ?m or less is 30,000 inclusions/g or less. As a result of using high-purity copper or high-purity copper alloy from which harmful inclusions of P, S, C and O system have been reduced as the raw material and controlling the existence form of nonmetal inclusions, the present invention addresses a reduction in the percent defect of wirings of semiconductor device formed by sputtering a high-purity copper target so as to ensure favorable repeatability.

Abstract: In a method for reducing metal-oxidic slags or glasses and/or degassing mineral melts, solid particles and/or melts are charged onto an at least partially inductively heated bed or column containing lumpy coke, and the reduced and/or degassed melt running off is collected. The device for reducing metal-oxidic slags or glasses and/or degassing mineral melts, which includes a charging opening (1) for solid or molten material and a tap opening (12) for the treated melt, is characterized by a tubular or channel-shaped housing (3) for the reception of lumpy coke (6), and a heating means surrounding the housing and including at least one induction coil (7, 8, 9).

Abstract: A transfer pipe of dried concentrate for transferring dried concentrate, having a double pipe structure, comprising an inner pipe 2 through which the dried concentrate is transferred by compressed air, an outer pipe 3 arranged around the outer periphery of the inner pipe 2, and a joint flange 5 forming an annular space 4 sealed between the inner pipe 2 and the outer pipe 3, arranged at both ends of the inner pipe 2 and the outer pipe 3, and integrally fixing the inner pipe 2 and the outer pipe 3; wherein the inner pipe 2 is positioned inside the outer pipe 3 and is formed of a metal pipe 2a forming the annular space 4, a ceramic sleeve 2c forming an innermost layer of the metal pipe, and a filler 2b for fixing the ceramic sleeve 2c provided between the metal pipe 2a and the ceramic sleeve 2c.

Abstract: Metallic titanium is continuously produced in an electric-arc furnace under a vacuum by the metallothermic reduction of titanium tetrachloride by a reducing agent such as magnesium. The nanoparticles of titanium obtained from the reduction are simultaneously melted in a bath of molten titanium formed by the heat of an electric arc between a consumable titanium electrode and the molten titanium. A voltage applied across the electrode and the molten titanium is adjusted so that molten titanium is maintained in a cooled crystallizer during the entire process. The molten titanium solidifies on the top of a dummy bar that is drawn down as additional titanium is produced. Upon completion of each iterative reduction reaction, the vaporized reducing agent chloride is pumped out of the electric-arc furnace into a condenser using a vacuum pump. Then, additional reducing agent and titanium tetrachloride are added into the furnace, and the process is repeated.

Abstract: A smelting furnace having a vessel (102) for receiving material to be smelted. An inner surface (109) of the furnace is concave and reflective, at least an upper part thereof. A conductive electrode (120) of the furnace is continuously formed in the furnace by casting.

Abstract: A method for recovering platinum group elements comprises charging into a closed electric furnace and melting, together with flux components and a reducing agent, a platinum group element-containing substance to be processed and a copper source material containing copper oxide, sinking molten metal of primarily metallic copper below a molten slag layer of primarily oxides, and enriching the platinum group elements in the molten metal sunk below, and is characterized in that molten slag whose copper content has decreased to 3.0 wt % or less is discharged from the electric furnace and that the copper source material charged into the electric furnace is a granular copper source material of a grain diameter of not less than 0.1 mm and not greater than 10 mm.

Abstract: A graphite electrode for an electrothermic reduction furnace is formed from anode grade coke and graphitized at a graphitization temperature below 2700° C. The resulting electrode is particularly suited for carbothermal reduction of alumina. It has an iron content of about 0.05% by weight, a specific electrical resistivity of above 5 ?Ohm·m, and a thermal conductivity of less than 150 W/m·K. The graphite electrode is manufactured by first mixing calcined anode coke with a coal-tar pitch binder, and a green electrode is formed from the mixture at a temperature close to the softening point of the pitch binder. The green electrode is then baked to carbonize the pitch binder to solid coke. The resultant carbonized electrode, after further optional processing is then graphitized at a temperature below 2700° C. for a time sufficient to cause the carbon atoms in the carbonized electrode to organize into the crystalline structure of graphite.

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 avoiding the formation of islands of materials that are fed into the channel induction furnace. The method also involves breaking up islands of materials that are formed within the channel induction furnace. The method further involves adding a heat-conducting metal material into the channel induction furnace together with 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 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: Metallic titanium is continuously produced in an electric-arc furnace under a vacuum by the metallothermic reduction of titanium tetrachloride by a reducing agent such as magnesium. The nanoparticles of titanium obtained from the reduction are simultaneously melted in a bath of molten titanium formed by the heat of an electric arc between a consumable titanium electrode and the molten titanium. A voltage applied across the electrode and the molten titanium is adjusted so that molten titanium is maintained in a cooled crystallizer during the entire process. The molten titanium solidifies on the top of a dummy bar that is drawn down as additional titanium is produced. Upon completion of each iterative reduction reaction, the vaporized reducing agent chloride is pumped out of the electric-arc furnace into a condenser using a vacuum pump. Then, additional reducing agent and titanium tetrachloride are added into the furnace, and the process is repeated.

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 for preparing a redox flow battery electrolyte is provided. In some embodiments, the method includes the processing of raw materials containing sources of chromium ions and/or iron ions. The method further comprises the removal of impurities such as metal ions from those raw materials. In some embodiments, a reductant may be used to remove metal impurities from an aqueous electrolyte containing chromium ions and/or nickel ions. In some embodiments, the reductant is an amalgam. In some embodiments, the reductant is a zinc amalgam. Also provided is a method for removing ionic impurities from an aqueous acid solution. Further provided a redox flow battery comprising at least one electrolyte prepared from the above-identified methods.

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 method of smelting copper includes: a generating step of generating blister and calcium ferrite slag from copper matte by charging the copper matte into a smelting furnace and oxidizing the copper matte; and a refining step of refining another blister from the calcium ferrite slag in an electrical furnace under a temperature condition of 1250 degrees C. to 1350 degrees C. and under a reductive atmosphere condition of oxygen partial pressure logPO2??9.3.

Abstract: Method and plant for pre-heating, transforming and melting a metal charge comprising metal scrap, in an electric arc furnace associated with a tunnel to transport, pre-heat and discharge the scrap. The furnace comprises a hearth and a roof through which the electrodes pass. The method provides that the furnace is weighed at least periodically in order to detect the quantity of discharged scrap present inside the furnace itself, that the temperature of the liquid bath inside the furnace is detected at least periodically and that at least the discharge delivery of the scrap inside the furnace is detected by weighing and is regulated in order to maintain the temperature of the liquid bath around a pre-determined value.

Abstract: Metallic titanium is continuously produced in an electric-arc furnace under a vacuum by the metallothermic reduction of titanium tetrachloride by a reducing agent such as magnesium. The nanoparticles of titanium obtained from the reduction are simultaneously melted in a bath of molten titanium formed by the heat of an electric arc between a consumable titanium electrode and the molten titanium. A voltage applied across the electrode and the molten titanium is adjusted so that molten titanium is maintained in a cooled crystallizer during the entire process. The molten titanium solidifies on the top of a dummy bar that is drawn down as additional titanium is produced. Upon completion of each iterative reduction reaction, the vaporized reducing agent chloride is pumped out of the electric-arc furnace into a condenser using a vacuum pump. Then, additional reducing agent and titanium tetrachloride are added into the furnace, and the process is repeated.

Abstract: Methods of enhancing the segregation roast through the use of microwave radiation and chloride ions are disclosed. The processes provide means of recovering metals trapped in ores and slags by reaction of these materials with carbon, chloride and water using microwave radiation as the primary energy source. The metals may be present in starting materials such as metallic sulfides, slags, metallic oxides such as laterites, magnetites, iron oxides, silicates and carbonates. The metals are reduced and can be recovered by separation from the gangue. Water, carbon and chloride can be recycled to the reaction to reduce costs.

Abstract: Graphite electrodes for the production of aluminum by carbothermic reduction of alumina are either submerged in the molten bath in the low temperature compartment or they are horizontally arranged in the side walls of the high temperature compartment. The electrodes are manufactured by using a mixture of coke particles covering the complete particle size range between 25 ?m to 3 mm and by using an intensive mixer to effectively wet all coke particles with pitch. The electrodes have a flexural strength of at least 20 N/mm2. By using a complete range (continuum) of particle sizes in conjunction with an intensive mixer, the geometric packing of the particles is significantly improved, hence the material density is increased and thus a higher mechanical strength as well as improved electrical conductivity in comparison to conventional graphite electrodes is achieved.

Abstract: A method to enhance the extraction of an element from an ore includes subjecting the ore, or element bearing material to electromagnetic radiation to induce pyrolysis of the material. The residue of the pyrolysis may then be processed in a conventional manner to extract the element. The radiation used in the invention has a wavelength longer than microwave radiation, and is preferably 100 mm or longer. Preferably, radio waves are used as the radiation to effect pyrolysis.

Abstract: A system and a method for electroslag smelting, involving a furnace having a wall, an internal atmosphere, and an external atmosphere; a trough for accommodating an ore being smelted into a molten metal and a slag, the trough being disposed within the furnace; and a carbon electrode having a proximal end and a distal end, the electrode distal end being disposed in the trough, the electrode being submersible in the molten metal, and the electrode being separated from the slag by a ceramic barrier.

Abstract: A method of manufacturing titanium or titanium alloy semi-finished or ready-to-use products is disclosed. The method includes forming shaped bodies of titanium oxide particles and positioning the shaped bodies in an electrolytic cell which includes: an anode, a cathode, and a molten electrolyte. The shaped bodies are positioned to form at least a part of the cathode. The electrolyte includes cations of a metal that is capable of chemically reducing titanium oxide. The method further includes reducing the titanium oxide to titanium in a solid state in the electrolytic cell so that the shaped bodies become shaped bodies of titanium sponge. Finally, the method includes processing the shaped bodies of titanium sponge to reduce the volume or at least one of the dimensions of the bodies thereby to form the semi-finished or ready-to-use products.

Abstract: A process for treating a metal sulphide concentrate which includes the steps of: a) roasting the concentrate to reduce the sulphide content of the concentrate, to a negligible value and b) melting the concentrate, under reducing conditions, in an electrically stabilized open-arc furnace, in particular a DC arc furnace.

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. RF=P×E/L2 (wherein RF represents the refractory wearing index (MWV/m2); P represents an arc power for one phase (MW); E represents an arc voltage (V); and L represents the shortest distance between the electrode side surface of a tip within an arc heating furnace and a furnace wall inner surface (m).

Abstract: A process for forming metal nanocrystals involves complexing a metal ion and an organic ligand in a solvent and introducing a reducing agent to reduce a plurality of metal ions to form the metal nanocrystals associated with the organic ligand. The nanocrystals are optionally doped or alloyed with other metals.

Abstract: A method for producing molten metal by the reduction and melting of raw materials in a submerged arc type electric furnace includes at least one electrode, where substantial amounts of slag are generated so that the electric furnace contains a bath of molten metal covered with a thick layer of molten slag having a mass per unit area of at least 1000 kg/m2. The thick layer of molten slag is made to foam locally around the at least one electrode so as to create around the electrode a local layer of foaming slag in which the density of the slag is at least 50 per cent lower than in the rest of the electric furnace.

Abstract: A method of manufacturing a nanocrystallite from a M-containing salt forms a nanocrystallite. The nanocrystallite can be a member of a population of nanocrystallites having a narrow size distribution and can include one or more semiconductor materials. Semiconducting nanocrystallites can photoluminesce and can have high emission quantum efficiencies.

Abstract: Method for the production of primary aluminium from alumina comprising the step of converting alumina into aluminium sulfide (Al2S3) and subsequently the separation of aluminium from aluminium sulfide wherein the conversion of alumina into aluminium sulfide is performed by reacting alumina with CS2 containing gas at a temperature Tal whereby the alumina is mainly &ggr;-alumina.

Abstract: A metal alloy, such as steel, is manufactured in an electric arc furnace system equipped with at least one sensor, at least one a controller including a logic program and a variable valve in fluid communication with the furnace and a material source. The nature and quality of the slag formed over a molten metal during manufacture of steel is dynamically controlled by continuously adjusting the addition of one or more material to the arc furnace through the variable valve.

Abstract: A method for the direct preparation of metal from metal containing ore by applying microwaves, alone or in combination with other heating means, to extract metal from masses made by forming a powder of ore and an optional reducing agent. The method minimizes the expenditure of energy used to refine the metal, the level of contamination introduced into the metal, and the production of environmental pollutants.

Abstract: A process for producing a foaming slag above a stainless steel melted in an electric furnace, in which: a powder containing at least one metal oxide and carbon in its composition is introduced into the slag, at least one oxide present in the powder is reduced by its reaction with the carbon to form in the slag bubbles composed of the metal of the metal oxide and of carbon monoxide, the bubbles present in the slag giving rise to a slag in the form of a stable foam.