Abstract: A process for preparing solid slag granules from a molten slag composition comprises: (a) providing the molten slag composition; (b) converting the molten slag composition into the solid slag granules in a dispersion apparatus; and (c) sorting the solid slag granules by shape in a separator to produce a plurality of fractions having different sphericities. Granular slag products comprise one or more fractions of solid slag granules produced by the process, and include proppants, roofing granules, catalyst supports, which may be porous or non-porous, and coated or uncoated.

Abstract: A highly flexible sealing arrangement designed to seal high-temperature furnace ports, particularly the electrode port of an electric furnace. The seal comprises an annular support member fixed to a flexible sealing member and employs the use of a garter spring to uniformly apply the desired amount of seal compression. The arrangement and flexibility of the sealing member allows the seal to adapt itself to the wide range of operating and upset conditions that typically exist for a furnace electrode seal. Frictional wear on the seal may be greatly reduced as the design inherently allows for a much lower amount of seal compression to be applied, furthermore, the seal is able to move axially which can significantly reduce wear caused by electrode regulation.

Abstract: A process and reactor for arsenic fixation in which a first gas stream comprises oxygen and an iron-containing particulate material. The oxygen and particulate material may be fed to reactor through respective first and second inlets. A second gas stream containing one or more volatile arsenic compounds is fed through a third inlet and mixed with the first gas stream and the particulate material to produce a combined gas stream containing the volatile arsenic compounds and the particulate material. The arsenic compounds are reacted with iron in the particulate material as the combined gas stream flows through the reactor to produce solid iron arsenates which are then recovered. The portion of the reactor including the first, second and third inlets is vertically oriented, and the reactor may include a venturi arrangement having a throat at which the second inlet is located.

Abstract: A system, method and controller for managing and controlling a micro-grid network. The system includes a plurality of energy resources including at least one dispatchable energy resource and at least one intermittent energy resource, wherein the at least one of the energy resources is an energy storage element and at least one of the intermittent energy resources is responsive to environmental conditions to generate power, a controller configured to record operational constraints of the energy resources, obtain an environmental condition prediction and generate a component control signal based on the environmental condition prediction and the operational constraints corresponding to the energy resources. The controller is further configured to receive a network disturbance signal and generate a dynamic control signal based on such disturbances.

Abstract: A furnace is provided suitable for metallurgical processes, comprising at least one section comprised of refractory bricks with an outer shell plate adjacent to the refractory bricks, including exterior bricks whose external faces adjacent the shell plate define gaseous media cooling channels extending along the exterior of the refractory bricks between them and the shell plate. The furnace further comprises cooling plates within the cooling channels and joints between the successive courses of bricks. Advantageously, the conductivity of the cooling plates is at least 5 times the conductivity of the refractory lining into which it is inserted. Suitable materials include copper and copper-based alloys, brasses, bronzes, cast irons, aluminum alloys, silver, high-temperature steels, refractory metals and their alloys, graphite, silicon carbide, and aluminum nitride.

Abstract: A pond for cooling and/or recovering salt from a hot aqueous solution of a salt such as potassium chloride produced by solution mining. The pond comprises a plurality of channels arranged side-by-side, each of the channels being defined by a plurality of sides. An inlet is provided in a side of a channel for receiving the aqueous solution, and an outlet is provided in a side of another one of the channels for discharging the aqueous solution. The pond has at least one dike separating the channels from one another. A gap is formed in each dike to permit the aqueous solution to flow between the channels, the gap having a length which is about 10 to about 40 percent of the length of the sides of the channels. Salt is crystallized and the solution is cooled as it passes through the channels of the pond.

Abstract: A method for recovering metal values from a molten slag composition includes atomizing the slag with an oxygen-containing gas in a gas atomization apparatus, to produce solid slag granules. Oxygen in the atomizing gas converts metals to magnetic metal compounds, thereby magnetizing the metal-containing slag granules. These metal-containing slag granules are then magnetically separated. Larger amounts of metals may be removed by passing the molten slag through a pre-settling pan with an adjustable base, and/or discontinuing atomization where the metal content of the slag exceeds a predetermined amount. Solid slag granules produced by atomization may be charged to a recovery unit for recovery of one or more metal by-products. An apparatus for recovering metal values from molten slag includes a gas atomization apparatus, a flow control device for controlling the flow of atomizing gas, a control system, and one or more sensors to detect metal values in the slag.

Abstract: An aluminum reduction cell having a shell structure with a pair of longitudinally extending sidewalls, a pair of transversely extending endwalls, a bottom wall, and an open top having an upper edge. The aluminum reduction cell also has a transverse support structure with transverse bottom beams located under the shell structure and extending transversely between the sidewalls, each of the transverse bottom beams having a pair of opposed ends. The aluminium reduction cell also has compliant binding elements fixed to the transverse support structure, each extending vertically along an outer surface of one of the sidewalls for applying an inwardly directed force said sidewall. The compliant binding elements are in the form of cantilever springs. Each spring has a metal member with a lower end which is secured to the transverse support structure, and a compliant, upper free end which is movable inwardly and outwardly in response to expansion and contraction of the shell structure.

Abstract: A feed charging device comprises a holding vessel having an interior chamber for holding a reserve of a solid particulate feed material in a fluidized state, wherein the feed material is held in said fluidized state in a lower zone of the interior chamber. The feed material is supplied to the interior chamber through at least one outlet opening, and is discharged from the interior chamber through at least one outlet opening. The at least one outlet opening is in flow communication with the lower zone of the interior chamber. A gas supply means supplies a fluidizing gas to the lower zone of the interior chamber, and an outlet conduit in flow communication with the at least one outlet opening receives said feed material discharged from the interior chamber.

Abstract: A method is disclosed for controlling retention time in a reactor, such as an autoclave, having a plurality of compartments separated by dividers with underflow openings. A retention time of the reaction mixture is calculated and compared with an optimal retention time, and the volumes of the reaction mixture in the compartments are adjusted while maintaining the flow rate of the reaction mixture, so as to change the retention time to a value which is closer to the optimal retention time. The reactor may include a level sensor in the last compartment for generating volume data; a control valve for controlling the liquid level in the last compartment; and a controller which receives volume data from the level sensor and controls operation of the control valve.

Abstract: Various systems and method for acoustic monitoring of smelting furnaces and similar devices are disclosed. Acoustic sensors (and optionally other sensors) are mounted to the furnace. Acoustic emission events generated in the furnace are analyzed to identify conditions that exceed one or more thresholds. The location of acoustic emissions may be identified and reported. Output signals may be generated in response to acoustic emissions. The location of acoustic emissions may be used to identify the location of potential failures in the furnace.

Abstract: A burner is provided for a pulverous feed material. The burner has a structure that integrates the burner with a reaction vessel, and has an opening that communicates with the interior of the reaction vessel. The burner also has a gas supply channel to supply reaction gas through the opening into the reaction vessel, and a feed supply for delivering pulverous material to the reaction vessel. The burner also has a fluidic control system having at least one port capable of directing a stream of fluid at an angle to the direction of flow of the reaction gas so as to modify the flow of the reaction gas. In addition, components are provided to modify the swirl intensity and turbulence intensity of the reaction gas independently of the exit velocity.

Abstract: A highly flexible sealing arrangement designed to seal high-temperature furnace ports, particularly the electrode port of an electric furnace. The seal comprises an annular support member fixed to a flexible sealing member and employs the use of a garter spring to uniformly apply the desired amount of seal compression. The arrangement and flexibility of the sealing member allows the seal to adapt itself to the wide range of operating and upset conditions that typically exist for a furnace electrode seal. Frictional wear on the seal may be greatly reduced as the design inherently allows for a much lower amount of seal compression to be applied, furthermore, the seal is able to move axially which can significantly reduce wear caused by electrode regulation.

Abstract: Various systems and methods for monitoring the level of a feed material layer in a metallurgical furnace are described. At least one non-contact sensor is used to sense a distance between the feed layer and a reference position. A process controller linked to the sensor provides a control signal based upon the sensed distance. The control signal may be used to control various factors in the operation of the metallurgical furnace.

Abstract: Various systems and methods for monitoring the level of a feed material layer in a metallurgical furnace are described. At least one non-contact sensor is used to sense a distance between the feed layer and a reference position. A process controller linked to the sensor provides a control signal based upon the sensed distance. The control signal may be used to control various factors in the operation of the metallurgical furnace.

Abstract: A chill mold is used to cool molten material to form a casting. A support holds the chill mold so that a bottom of the chill mold is elevated. A baffle is arranged to divert a generally horizontal flow of cooling air upwardly to impinge the bottom of the chill mold. A plurality of chill molds may be aligned generally in a row, and at least one fan may be arranged at an end of the row to direct the flow of cooling air underneath the chill molds. The size and the vertical position of the baffles may be varied along the row, so as to generally equalize convective cooling rates among the chill molds in the row.

Abstract: A furnace is provided suitable for metallurgical processes, comprising at least one section comprised of refractory bricks with an outer shell plate adjacent to the refractory bricks, including exterior bricks whose external faces adjacent the shell plate define gaseous media cooling channels extending along the exterior of the refractory bricks between them and the shell plate. The furnace further comprises cooling plates within the cooling channels and joints between the successive courses of bricks. Advantageously, the conductivity of the cooling plates is at least 5 times the conductivity of the refractory lining into which it is inserted. Suitable materials include copper and copper-based alloys, brasses, bronzes, cast irons, aluminum alloys, silver, high-temperature steels, refractory metals and their alloys, graphite, silicon carbide, and aluminum nitride.

Abstract: A method and apparatus for controlling a temperature within a reactor vessel such as an autoclave operating at elevated temperature and pressure. The apparatus includes a preheating vessel for preheating a feed material such as an aqueous slurry. The preheating vessel forms part of a preheating control system providing the primary means of temperature control within the reactor vessel. The apparatus also comprises secondary means for heating and cooling the reactor. Feed material temperature is increased or decreased by the preheating control system, based on the reactor temperature. Where the preheating control system is at or near its capacity for heating or cooling, the secondary heating or cooling means is activated to bring the reactor temperature within an optimum range.

Abstract: A process for direct reduction of iron oxide in a shaft furnace. The process includes feeding iron oxide to the furnace, passing the iron oxide successively downwardly through a pre-reduction zone, a transition zone, a metallization zone, and a cooling zone while passing rich fuel gas produced by external partial combustion with a sub-stoichiometric volume of air upwardly through the pre-reduction zone in counter-current flow so as to partially reduce the iron oxide, and passing reducing gas downwardly through the metallization zone in co-current flow so as to substantially complete the reduction of the iron oxide to metallic iron. The reducing gas is first pre-heated in a gas heater and then subjected to partial combustion with oxygen to further increase its temperature. The process includes removing a metallized iron product from the cooling zone.

Abstract: A burner for a flash smelting furnace. The burner has an adjustable nozzle to control the velocity of the combustion gas supply to the reaction shaft. The nozzle is defined by the burner injector and a surrounding structure that extends from the burner wind box through an opening in the burner block that integrates the burner with the furnace. The nozzle is adjusted by control means that is exterior of the wind box.