Abstract: A method for removing elements, including heavy metals, from fly ash and from fly ash resulting from removal of SOx/NOx from flue gas using Na2CO3/NaHCO3/trona, is described. An aqueous suspension of the fly ash and/or a solution of the leachate from the fly ash is treated with dissolved ferrous compounds, such as FeSO4.7H2O and/or FeCl2.4H2O, at a chosen initial acidic pH, and the precipitation of the ferrous ions as the solution basifies sequesters the trace elements.

Abstract: An improved method and apparatus for pretreatment of solid lump feed material for gas and pellet/lump-based direct reduction processes, by initially storing the lump feed in stockpiles for stress release, followed by pre-drying the feed material prior to charging into the reduction furnace and finally increasing the average temperature of the reduction furnace, in order to reduce the amount of reduction at low temperatures, thereby minimizing the formation of fines within the furnace.

Abstract: A process for the improvement of reducibility of iron ore pellets including the steps of preparing a raw material mixture which contains metallic Ni powder, pelletizing the mixture obtained, burning the raw pellets and reducing the burnt pellets under reducing conditions in the presence of CH4.

Abstract: The present invention relates to a method and apparatus for producing reduced iron from ironmaking dust which contains iron oxide which is generated at an ironmaking plant, takes note of the rotary kiln reduction method which does not require pretreatment of the dust, and has as its problem the pursuit of facilities which achieve further improvement of heat efficiency and stable operation. To solve this problem, the present invention is characterized by heating and reducing carbon-containing shaped materials in a single closed space in which an internal heat type rotary kiln and an external heat type rotary kiln are arranged in series and including at least the insides of the two rotary kilns during which making the reduced exhaust gas which is generated at the external heat type rotary kiln burn inside of the internal heat type rotary kiln.

Abstract: The present invention is directed to provide a production method for carbonaceous material-containing metal oxide briquettes, capable of ensuring sufficient strength of briquettes while using a metal oxide material containing a large amount of fine particles, such as steel mill dust. This method comprises a mixing step of mixing a metal oxide material A containing a large amount of fine particles with a carbonaceous material B in a mixer 15, to form a powdery mixture E, a compacting step of compacting the powdery mixture E using a briquette machine 17 to form compacts F, a classifying step of classifying the compacts F into an oversize fraction G and an undersize fraction H, using a sieve 18, and collecting the oversize fraction G as product briquettes, and a compact circulating step of returning a part of the compacts F to the mixer 15 or the briquette machine 17, as a recycle material.

Abstract: A method for producing liquid ferroalloy by direct processing of manganese and chromium bearing iron compounds, by the steps: of mixing carbonaceous reductant, fluxing agent, and a binder with materials such as iron sands, metallic oxides, manganese-iron ore concentrates and/or chromium-iron ore concentrates and silica sands, to form a mixture; forming agglomerates from the mixture; feeding the agglomerates to a melting furnace with other materials; melting the feed materials at a temperature of from 1500 to 1760° C. and forming a slag and hot metal; removing the slag; tapping the hot metal as liquid ferroalloy, and utilizing the off-gases from the melting furnace as combustion fuel to drive a turbine and to generate electricity.

Abstract: A method for producing a substantially metallic iron-containing product from iron oxide. The metallic iron produced according to the invention is non-pyrophoric and may be safely shipped and handled without additional process steps. The method of the invention is simple, economical, and produces high quality metallic product which may be used as a feed for Electric Arc Furnace (EAF), Blast Furnaces and Cupolas among other applications.

Abstract: A method of processing electric arc furnace dust includes the steps of preheating a portion of electric arc furnace dust to a temperature of at least 170 degrees centigrade by convection heating to form a preheated dust. The preheated dust is further heated by microwaves until a zinc in the preheat dust vaporizes to form a metal vapor and a residue. The metal vapor is then condensed.

Abstract: A process for upgrading brown coal is disclosed, including providing at least two converging surfaces defining a nip, wherein at least one of the surfaces is rollable in a direction toward the nip; feeding the brown coal to the nip where, by the rolling action of the rollable surface, the brown coal is subjected to shearing stresses, causing attritioning of the microporous structure of the brown coal and the release of water contained in the micropores; and continuing the shearing attritioning until the brown coal forms into a plastic mass. Processes for the production of char are also disclosed utilizing as feed material pellets formed from the upgraded brown coal produced by the above process, as well as a process for recovering metal from a metal containing material.

Abstract: In the production of reduced iron by agglomerating a mixed powder of an iron material and a reducing agent to form compacts like briquettes or pellets, and reducing the compacts in a high temperature atmosphere, when the temperature of reduced compacts is 900° C. or higher, the oxide content in the reduced compacts is set at 11% or more, and the basicity of the reduced compacts is set at 0.5 or higher.

Abstract: A method for producing a sponge metal from metal ore or iron ore which comprises reacting said metal ore or iron ore in a reduction zone with a CO— and H2-containing, reducing feed gas source which has been compressed, and after said reaction, withdrawing the remaining feed gas as an export gas from the reduction zone, wherein the CO— and H2-containing feed gas is introduced into the reduction zone form at least to gas sources, whereby upon a breakdown of one of the feed gas sources, at least a portion of the export gas recovered from the reduction zone is compressed, subjected to CO2 elimination recycled to the reduction zone together with the reducing feed gas.

Abstract: Finely divided material, such as flue dust from a steel making furnace, is processed to reclaim constituents. The material in hopper (11) is pelletized. The pellets are dried in a dryer (16) and fed to a first rotary kiln (21) where they are sintered to provide very hard pellets, during which process volatile constituents are driven off and collected. The sintered pellets are screened to remove finely divided material and fed with reductant, such as finely divided washed anthracite (35), to a second rotary kiln (31). Reduction of the pellets causes a second constituent to be driven off and the second constituent is then oxidized in the kiln and collected as finely divided oxide. The original pellets retain their integrity and become essentially sponge iron.

Abstract: A method for separation and recovery of metals and metal oxides from industrial minerals and waste materials containing zinc, lead, cadmium, arsenic, iron, mercury and selenium. The metals and metal oxides in dust form are mixed with a reducing agent and additives, agglomerated, heated above 800.degree. C., and contacted with a flow of inert, reducing or slightly oxidizing gases to volatilize the metals and metal oxides for recovering separate from solid residual product.

Abstract: A process for treating iron-bearing material with a carbonaceous material to form a dry mixture, wherein the amount of carbonaceous material added exceeds the stoichiometric amount required to reduce the metal oxide to elemental metal. In one embodiment, the process also includes blending an organic binder with the dry mixture. The dry mixture is agglomerated to bond the dry mixture and form green compacts. The green compacts are loaded into a heated furnace and heated for about 5-12 minutes at a temperature of between about 2100.degree.-2500.degree. F. to reduce the iron oxide containing compacts to compacts containing elemental iron and an excess amount of carbonaceous material wherein the excess amount of carbonaceous material counteracts re-oxidation of the elemental iron. The reduced compacts are then discharged from the furnace.

Abstract: Apparatus for treating iron ore, comprising an elongate and generally cylindrical inclined kiln mounted for rotation about its longitudinal axis. A drive motor is coupled to the kiln to rotate the latter about that axis. A moving grate is positioned at the upper end of the kiln to feed iron ore pellets into the kiln while the latter is rotating. Port-defining means are provided in the generally cylindrical wall of the kiln to enable gaseous material to be fed into the interior of the kiln at at least one position between the ends thereof. The port-defining means are of such a construction that they are open when they are underneath the iron ore in the kiln. Gaseous oxidizing material feed means are connected to the port-defining means to feed such oxidizing material thereto, whereby oxidizing gaseous material is passed through the iron ore in the kiln when the apparatus is in use so as to raise the temperature of the iron ore, by oxidation thereof, and cause the latter to be indurated.

Abstract: An apparatus for directly reducing pellets of material without melting the material includes the transporting of the pellets through drying and preheating zones on an oxidizing traveling grate and reduction in a ported rotary kiln. There is a kiln having a first end and a second end with the first end being substantially adjacent to the heating and oxidizing component for receipt of the pellets therefrom. The kiln is inclined downwardly and is rotated to advance the pellets through the kiln from the first end to the second end thereof. The kiln includes an induration zone for indurating the pellets. The induration zone is adjacent to the first end and remote from the second end and extends for a substantial portion of the kiln from the first end. The kiln includes a reduction zone extending from the downstream end of the induration zone to the second end. A device is used to inject a reducing agent into the reduction zone of its kiln for making contact with the pellets advancing through the reduction zone.

Abstract: A method and apparatus is disclosed for direct reduction of metal oxides, using a rotary kiln, fed with greenball pellets, the kiln having a feed-end and a discharge end. A first chamber within the kiln, and adjacent to the feed-end, is used for drying, preheating and indurating the greenball pellets. Greenball pellets are fed into the first chamber using a conventional mechanism. The feed-end is sealed to prevent egress of process gas from the kiln into the atmosphere and ingress of the atmosphere into the kiln. A first burner is used for drying, preheating and indurating the greenball pellets within the first chamber. A second chamber within the kiln, adjacent to and connected with the first chamber, having a diameter greater than the first chamber, is used for reducing the pellets, the second chamber being adjacent to the discharge end. A second burner may be used for reducing the pellets within the second chamber. Reduced pellets are discharged from the discharge end.