Abstract: A system and a method are provided that take a potentially dangerous waste product and process the product to create a marketable asset. The system and method are configured to create “tb” from “tbgs” by removing the volatility that exists in the “tbgs.” The resultant “tb” may be substantially non-volatile.

Abstract: A method of manufacturing an Fe/Ni-containing material having a low content of sulfur from an Fe/Ni/SO4-containing liquid waste, a ferronickel mass using the Fe/Ni-containing material, and a method of manufacturing the ferronickel mass. The method includes: removing SO4 from an Fe/Ni/SO4-containing liquid waste by adding an SO4 neutralizing agent to the liquid waste so that pH of the liquid waste can be maintained to a pH level of 0.5 to 2.5; precipitating Fe and Ni in the form of hydroxide [(Ni,Fe)(OH)] by adding NaOH to the SO4-free solution; washing the precipitate with water; and manufacturing an Ni/Fe-containing material by filtering and drying the washed Ni/Fe-containing sludge. The method may be useful to suitably apply to the field of recycling of waste acids since an Fe/Ni-containing pellet and a high purity plaster are recovered as the stainless steel material from the waste water at the same time.

Abstract: The invention relates to a method for the agglomeration of iron-oxide-containing residual materials, in particular scale and mill scale, wherein the residual materials and paper sludge are dried and ground and agglomerates are produced, by hot briquetting, from a mixture of the residual materials and paper sludge so processed. In this manner, it is possible to produce mill scale briquettes of high strength and density. These briquettes can then be charged into an electric arc steelmaking furnace for the purpose of recycling the iron contained in the residual materials.

Abstract: Disclosed is a process and apparatus for the treatment of divided metal residues contaminated by one or more organic compounds, including mixing, inside a chamber, of metal residues with at least one calcium/magnesium compound capable of reacting exothermically with water; exothermic reaction of the at least one calcium/magnesium compound with the water that the metal residues contain; rise in temperature of the metal residues subject to an exothermic reaction; dehydration of the metal residues during this exothermic reaction; oxidation of the organic compounds during the mixing, by bringing the metal residues contaminated by one or more organic compounds mixed with the at least one calcium/magnesium compound into contact with a gas stream containing at least partly oxygen; and removal from the chamber of a handleable dehydrated treated product having a residual content of organic compounds of less than 1% by weight of the treated product.

Abstract: A metallurgical process involves providing an ingredient enclosure and placing a plurality of granules of a first material in the ingredient enclosure. The first material contains a first ingredient in a metallurgical process. A metallurgical process furnace having a chamber in which ingredients for the metallurgical process are added is provided and the ingredient enclosure and the first material are added to the chamber. The chamber is heated after the addition of the ingredient enclosure and the first material to the chamber, although it may also be heated prior to such addition. In one form, the granules comprise mill scale and the metallurgical process furnace is a blast furnace.

Abstract: A metallurgical process involves providing an ingredient enclosure and placing a plurality of granules of a first material in the ingredient enclosure. The first material contains a first ingredient in a metallurgical process. A metallurgical process furnace having a chamber in which ingredients for the metallurgical process are added is provided and the ingredient enclosure and the first material are added to the chamber. The chamber is heated after the addition of the ingredient enclosure and the first material to the chamber, although it may also be heated prior to such addition. In one form, the granules comprise mill scale and the metallurgical process furnace is a blast furnace.

Abstract: According to the invention, oil-charged mill-scale is treated such that the oil is encapsulated or bound therein. An escape of oil on use in a shaft oven first occurs when the ignition point is reached, thus guaranteeing combustion. Agglomeration of said mixture is by pelleting. A mixture comprising the following is preferably used for encapsulation and chemical binding of the oil: A zinc salt and a calcium salt of a saturated or unsaturated fatty acid, a hydrophobic inducing agent, an amino alcohol and ammonia. The abstract of the disclosure is submitted herewith as required by 37 C.F.R. §1.72(b). As stated in 37 C.F.R. §1.72(b), “A brief abstract of the technical disclosure in the specification must commence on a separate sheet, preferably following the claims, under the heading “Abstract of the Disclosure.” The purpose of the abstract is to enable the Patent and Trademark Office and the public generally to determine quickly from a cursory inspection the nature and gist of the technical disclosure.

Abstract: A method for producing an improved charging stock for use in further metallurgical processes including the steps of providing a source of molten metal of known composition, providing a source of solid particulate material of a known composition which is compatible with the molten metal, combining the molten metal source with the solid particulate material source to produce a combined stream and forming the combined stream into a plurality of uniformly sized metal billets for use in further metallurgical processes.

Abstract: Process for thermal treatment of residual materials containing oil and iron oxide in a multiple-hearth furnace, which has several hearths one above the other, the residual materials containing oil and iron oxide being mixed with a solid reducing agent, introduced continuously into the multiple-hearth furnace, charged on the top hearth and transferred gradually to the lower hearths, the residual materials containing oil and iron oxide being dried in the top hearths, the oil subsequently evaporated and pyrolised and the reducing agent reacting with the iron oxides to form directly reduced iron, the directly reduced iron being discharged with residues of reducing agents in the areas of the bottom hearth of the multiple-hearth furnace.

Abstract: For effectively reprocessing iron-containing residual smelting plant materials (1 to 3), in which iron may be present both in metallic form and in oxidic form, with lowest possible energy expenditure, the residual smelting plant materials (1 to 3) are processed into agglomerates (8,11), the agglomerates (8,11) are charged into an electric arc furnace (10), melted there and reduced, and the resultant melt is refined (FIG. 1).

Abstract: A method for producing the direct reduced iron pellets. The method includes pelletizing, iron oxide-containing material, internal reductant and binder to form green pellets. The binder includes a non-combustible fibrous material. The method also includes firing the green pellets to convert the green pellets into direct reduced iron pellets.

Abstract: A method of making a pneumatically injectable additive for an Electric Arc Furnace, the method comprising screening a waste material comprising oily millscale in water to form uniform particles, and then mixing those particles with carbon and lime; and storing the mixture in air permeable bags in a dry atmosphere until the mixture has chemically cured to form the injectable particles.

Abstract: The technical problem of the invention is to create a process where the second layer is of higher sintering quality and improved waste gas values are achieved. The process according to the invention for the thermal transformation of materials containing organic substances in a two-layer sintering process, charges the second layer (8) containing the organic substances at a maximum layer thickness of 20% of the first layer after ignition of the first layer (1) and thermally treats the second layer when the combustion zone of the first layer ensures the combustion of the organic substances coming from the second layer and entering the combustion zone of the first layer, following the pressure difference, is least 70%. The area above the combustion zone of the first layer still must have a temperature preventing the organic substances coming from the second layer and entering the first layer from condensing.

Abstract: In a method for producing alloyed steels, wherein in a first manufacturing step iron carriers are to a great extent decarburized and dephosphorized by means of oxygen and after removal of the slag resulting therefrom the melt is adjusted to the desired alloy and carbon content in a further manufacturing step after addition of alloy carriers by means of oxygen and inert gas.Especially in order to produce stainless steels in an economical manner while achieving a high level of productivity, in particular while charging major amounts of solids,the first manufacturing step is carried out under supply of electric energy in an electric furnace andthe further manufacturing step is also effected under supply of electric energy, in an electric furnace that is to a great extent free from phosphorus-containing slag.

Abstract: A method is provided for improving the filtration rate of nonhazardous wastewater streams generated at a steel plant. The solids are concentrated in the wastewater stream. No more than about 5% by weight of lime is added to the concentrated wastewater stream which is then dewatered. A friable filter cake is produced by allowing the solids to harden. The lime addition results in a significant increase in the rate at which the stream may be filtered.

Abstract: A method of agglomerating oil-containing steel mill waste includes the step of combining a first steel mill waste component with a second steel mill waste component to form a mixture. The first waste component includes substantially dry non-oily steel mill waste and the second waste component includes oil-containing steel mill waste. The first waste component and the second waste component are agglomerated.

Abstract: Dusts containing zinc and/or lead in the form of oxides and one or more reducing agents are mixed with each other before or after being introduced into a heat treatment furnace. The mixture is heated to a given temperature range under a substantial vacuum so that the zinc and/or lead in the form of oxides are reduced to zinc and/or lead in the state of pure metals and evaporated in the furnace. The evaporated zinc and/or lead are introduced into a retrieving container also under a substantial vacuum and at a given temperature where the evaporated zinc and/or lead pure metals are condensed and retrieved.

Abstract: A method of producing briquettes for use in steelmaking processes in a melting vessel. Prior to the briquetting step, the residues should have added thereto essentially uniformly distributed carbon carriers, the amount of carbon carriers added corresponding precisely to the amount required for causing an essentially complete reduction of the iron-oxide containing residues. The residues obtained as byproducts in a smelting plant can thus be reused to a high degree by adding them to a steelmaking process. A residue briquette can be supplied to the melting vessel in an amount of up to 30%. This permits the use of residues instead of scrap.

Abstract: A method and system for recovering metal from steel waste products is disclosed. This method and system works on such hazardous and/or toxic wastes as mill scale, flue dust and slag. This method and system operates by mixing the steel waste produce with a flux composition and then melting the mix in a single phase two electrode electric arc furnace. Once the mixture is melted by the heat from the electrodes, the electro-magnetic field induced in the melted mixture serves to enhance the recovery from the steel waste product of useful steel material. Furthermore, this method and system provide a cost effective solution to the hazardous waste disposal problems impacting steel refineries around the world and does so in a manner that removes the toxicity of the waste while producing a variety of useful products, including high grade steel and neutralized fill.

Abstract: The present invention relates to a process for the preparation of a cooling agent containing iron for refining steel in a steel-making converter. The cooling agent is formed from ovoids produced from fatty slurries from rolling mills.The present invention also relates to a cooling agent which contains iron and is obtained by this process.

Abstract: A method of treating steel mill waste containing iron oxides and silica includes reacting the steel mill waste with an alkali aqueous solution in an amount sufficient to raise the pH to at least about 7 to solubilize silica to form soluble silicate compounds and silica gels and thereby produce a chemically reactive mixture. The mixture is reacted with an alkaline silicic compound to produce a solid, stable, non-polluting material.

Abstract: A process of continuous metal refinement comprising feeding molten metal to a reaction chamber, introducing gaseous and solid oxidants, adding bulk materials, fully converting the metal and slag into a foamy emulsion, creating, in the reaction chamber, an increased pulsating pressure and a considerable deviation of a system from thermodynamic equilibrium by way of creating a self-organizing system of chemical reaction with gas evolution and taking off the emulsion into a refining sump at the critical speed of egress of two-phase liquid, separating the metal and slag in said refining sump and withdrawing the gas through a high layer of emulsion at a definite rate.

Abstract: For purification of liquids used for cooling and/or lubrication interspersed with metallic and/or other materials contaminations, especially for separation of rolling scale and of substances containing oil or grease from the industrial process water in open or exposed cooling circulation cycles in the smelting industry, especially in rolling mills, it is proposed to separate the coarse rolling scale by gravity sedimentation from the contaminated process water, to subsequently remove the mid-size and fine rolling scale particles from the process water prepurified in this manner by magnetic separation, to divide by flotation the thus finished clarified or purified process water into fractions containing oil concentrate, water and the finest rolling scale particles carrying little oil, the purified process water is to be used as a cooling agent, the entire rolling scale separated out of the process water is smelted in the form of sinter and the concentrate containing oil is either rejected or subjected to a wast

Abstract: A process for smelting iron-containing source material in a reactor containing a slag bath, includes generating heating and reducing conditions in at least one reducing region of the bath by injection of fuel/reductant and oxygen-containing gas by at least one top submerged lance. The source material is fed to the reactor together with additional reductant and with flux at or adjacent the at least one reducing region so as to be subjected to smelting reduction, using coal as the additional reductant. The rates of injection of oxygen and fuel/reductant are controlled to achieve required and sufficient reducing conditions by providing the injected gas with an oxygen content from about 40% to about 100% sufficient for a degree of combustion of the fuel/reductant of from about 40% to about 50%. The CO and H.sub.

Abstract: Residual metallurgical materials which contain zinc and lead are reprocessed by a thermal treatment in a circulating fluidized bed. The required heat is generated in that solid carbon is combusted in the fluidized bed reactor of the circulating fluidized bed. A solid carbon content of 5 to 30% is maintained in the lower part of the fluidized bed. Oxygen-containing gases are supplied to the upper part of the fluidized bed reactor, and CO.sub.2 is formed only in such an amount that zinc metal will not be reoxidized. Substantially all solids are removed from the discharged suspension in a recycle cyclone and are recycled. The gas is cooled to a temperature at which zinc metal is oxidized to ZnO. The dustlike compounds of zinc and lead are separated from the gas.

Abstract: Steel mill waste containing iron, iron oxides and polluting compounds are treated with a strong alkali to raise the Ph to 14 to allow more alkali to solubilize silica. The mixture of materials and silica gels is then reacted with alkaline silicic compounds and allowed to cure and form hard sedimentary rock-like materials, solidified into a non-polluting solid which can be recycled in a steel-making furnace to produce iron and non-polluting slag.

Abstract: A process for the recovery of at least a major proportion of the useful metallic iron values in small sized ferrous slags and drosses in which the slags and drosses are subjected to at least one grinding step in a wet grinding mill. Depending on the size of the slag and dross particles, either a peripheral end discharge rod mill or an axial discharge ball mill is used. In a preferred configuration, two wet grinding stages are used, comprising a peripheral end discharge rod mill followed by a ball mill. Products with different metallic iron contents are recovered by interposing screens with suitably sized openings between and after the grinding mills. This process makes it possible to recover at least about 80% of the metallic iron in the feed material.

Abstract: A process for the agglomeration of flue gas desulfurization dust is disclosed comprising the steps of introducing flue gas desulfurization dust as feed material into a conventional, high-intensity mixing device and admixing with water to form spheroidal agglomerates ranging in size from a Tyler number of about 40 mesh to about 1/2 inches in size. The agglomerates are either dried to ambient temperature, or by dusting them with a portion of the dry feed material, and recovered. The process can effectively agglomerate any calcium- and sulfur-containing flue gas desulfurization dust by adjusting the amount of water added and providing for the proper amount of mixing energy and duration. The mixing device can be selected from any one of a group of conventional, high-intensity mixers consisting of, but not limited to, a pin mixer, paddle mixer, plow mixer, pan pelletizer and disc pelletizer.

Abstract: A process for de-oiling mill sludge employs the steps of admixing mill sludge with water and surface active agent to form a mill sludge slurry which is subjected to high shear agitation to form an oily water emulsion. Then at least 40 weight percent of the solids present in the mill sludge treated is separated from the oily water emulsion.

Abstract: A process for de-oiling mill scale which comprises(a) collecting mill scale and analyzing for oil content; and then(b) slurrying the portion of mill scale containing more than 0.5 weight percent oil in water to achieve an aqueous mill scale slurry having at least 25 weight percent solids content; and then(c) high shear agitating the aqueous mill scale slurry to form a reduced oil mill scale suspension in an oily water emulsion; and then(d) phase separating the reduced oil mill scale from the oily water emulsion forming a reduced oil mill scale and an oily water emulsion; and then(e) fresh water rinsing the reduced oil mill scale to form an oil-free mill scale and a waste wash water; and then(f) recycling the waste wash water to form at least a portion of the aqueous mill scale slurry of step b; and then(g) repeating steps (a) through (f) until the oil-free mill scale contains less than 0.

Abstract: A particular scrubbing agent/detergent formulation useful in removing contaminated oils and oily components from mill scale generated in a steel mill as disclosed. The formulation is based around medium aliphatic and heavy aromatic naphthas, linear and/or branched alkyl phenols, alkoxylated alkyl phenols, pentaethylene hexamine partial fatty acid amides, and alkyl and/or aromatic acid imidazolines. Optionally, fatty alcohol sulfonates can be used to protect the de-oiled mill scale surfaces from reabsorption of contaminating oily components.