Abstract: A plasma-fired cupola is operated utilizing anthracite or bituminous coal or small size coke to replace foundry coke to melt turnings, borings and chips from machining cast iron and steel, wherein the turnings, borings and chips make up as much as 75% by weight of the metal charge, the remaining portion of the charge being larger scrap; adding alloy oxides to provide the alloy element in the iron produced and providing up to 25% of the carbon required as pulverized coal added via a plasma torch feed nozzle to economically produce a variety of irons in the plasma-fired cupola.

Abstract: A plasma feed nozzle 3 for a furnace 1 which has a tubular mixing chamber 7 open at one end to the furnace, a plasma torch 13 which provides superheated gases axially to the central portion of the mixing chamber 7, shroud gases which enter the end of the mixing chamber opposite the end open to the furnace in such a way as to swirl as it moves axially through the mixing chamber 7 to provide a temperature profile which is substantially hotter in the central portion of the mixing chamber 7 than adjacent the wall portion thereof and a particulate feed nozzle 25 disposed to direct particulate material to the central portion of the mixing chamber.