Abstract: The process includes melting an initial collector alloy charge to start a converter cycle, introducing feed and injecting oxygen into the alloy pool, allowing ferrous slag to collect, terminating feed introduction and oxygen injection to tap the slag, repeating the feed introduction/oxygen injection/slag tapping sequence a plurality of times, and then tapping the alloy to end the cycle. A delay before non-final slag tappings allows any entrained alloy to settle back into the alloy pool, but the final slag tapping is commenced promptly and alloy is optionally entrained. Slag from the final tapping that may contain entrained alloy can be recycled to the converter, e.g., in a subsequent cycle. The process can also include low- or no-flux converting; refractory protectant addition; slag separation; partial feed pre-oxidation; smelting the slag in a secondary furnace with primary furnace slag; and/or jacketing the converter.

Abstract: Systems, methods, and apparatus for treating a molten metal are provided. A metal treatment system, comprising: a wire feeding subsystem; and a cored wire; wherein the wire feeding subsystem feeds the cored wire into a metal bath at a controlled wire feed rate, and wherein the metal bath comprises a molten metal; wherein the cored wire comprises: a consumable outer sheath having a tubular cross section; and a core fill material coupled to an inner surface of the outer sheath, wherein the core fill material comprises a refining agent for refining the molten metal; and wherein the refining agent reacts with the molten metal, thereby causing an impurity to be removable from the metal bath.

Abstract: A method for recovering thorium and rare earth elements from rare earth waste residues includes the steps of (1) mixing rare earth waste residues with an inorganic acid and heating to obtain a stock solution containing thorium and rare earth elements; (2) extracting thorium and rare earth elements from the stock solution with an organic phase containing an extractant; (3) washing the organic phase obtained after extraction in step (2) with a washing solution to move rare earth elements into the aqueous phase and leave thorium in the organic phase; (4) back-extracting the organic phase containing thorium obtained in step (3) with a back-extraction solution to extract move thorium in the organic phase into the aqueous phase. The extractant contains alkyl phosphonic acid monoalkyl ester and dialkylphosphinic acid.

Abstract: A method for producing direct reduced iron having increased carbon content, comprising: providing a carbon monoxide-rich gas stream; and delivering the carbon-monoxide-rich gas stream to a direct reduction furnace and exposing partially or completely reduced iron oxide to the carbon monoxide-rich gas stream. The carbon monoxide-rich gas stream is delivered to one or more of a transition zone and a cooling zone of the direct reduction furnace. Optionally, providing the carbon monoxide-rich gas stream comprises initially providing one of a reformed gas stream from a reformer and a syngas stream from a syngas source. Optionally, the carbon monoxide-rich gas stream is derived from a carbon monoxide recovery unit that forms the carbon monoxide-rich gas stream and an effluent gas stream. Optionally, the method still further includes providing a hydrocarbon-rich gas stream to one or more of a transition zone and a cooling zone of the direct reduction furnace.

Abstract: A Ti-6A1-4V titanium powder alloy composition having enhanced strength resulting from the addition of one or more of the following elements without requiring an increase in oxygen content: Aluminum Iron Nitrogen Carbon The composition may also be used for Ti-6A1-4V titanium alloy starting bar stock.

Abstract: The invention provides a process of isolating or enriching a heavy metal present in a suspension containing a particulate mineral ore containing a heavy metal, comprising the following steps: incubating a suspension containing (i) a particulate mineral ore containing a heavy metal and (ii) biomass comprising a bacterium capable of binding the heavy metal; separating the biomass having bound heavy metal from the suspension of the previous step; and isolating the heavy metal from the biomass separated in the previous step.

Abstract: Converting process with slag separation and recycle to the converter. The process includes introducing converter feed into the pot holding a molten alloy pool, oxygen injection into the pool, tapping the slag, and tapping the PGM-enriched alloy. The collector alloy contains no less than 0.5 wt % PGM, 40 wt % iron, and 0.5 wt % nickel, and no more than 3 wt % sulfur and 3 wt % copper, and the recovered slag is separated into recycle and non-recycle portions. The recycle slag portion preferably contains more PGM than the non-recycle portion. The process can also include low- or no-flux converting; using a refractory protectant in the converter; magnetic separation of slag; partial pre-oxidation of the converter feed; smelting catalyst material in a primary furnace to produce the collector alloy; and/or smelting the converter slag in a secondary furnace with slag from the primary furnace.

Abstract: Methods of preparing Zr based metallic using Zr sponge refined by a refining process are described. An exemplary method includes heating Zr sponge in a processing chamber with an electron-beam-heating apparatus or an arc-melting apparatus under a desired pressure condition to release volatile contaminants from the Zr sponge, introducing a purge gas into the processing chamber and permitting the purge gas to intermingle with at least some of the released volatile contaminants, evacuating the processing chamber to extract at least some of the purge gas and released volatile contaminants, repeating the heating of the Zr sponge, the introducing of the purge gas, and the evacuating of the processing chamber release and evacuate additional volatile contaminants from the Zr sponge to provide a processed Zr sponge with enhanced purity, and melting the processed Zr sponge with multiple other alloy constituents to provide a Zr-based metallic alloy.

Abstract: A method for recovering tin and/or tin alloy from a substrate comprising providing a substrate having tin and/or tin alloy thereon; contacting the tin and/or tin alloy with a stripping solution comprising an inorganic acid and a persulfate compound; recovering tin salt and/or tin alloy salt precipitated from the stripping solution; and recovering tin and/or tin alloy from the tin salt and/or tin alloy salt, respectively.

Abstract: The present invention provides a method for recovery, extraction and separation of rare earth elements from rare earth containing materials such as ore and tailings. In accordance with preferred embodiments, the method of the present invention includes grinding rare earth-containing ores to form ore powder and leaching the powered ore with at least one mineral acid. Further, the method of the present invention includes forming a leach solution of metal ions, forming an aqueous-metal concentrate, and precipitating the aqueous-metal concentrate to selectively remove the metal ions from the leach solution. Further, the method of present invention includes the steps of obtaining a precipitate of the rare earth elements, mixing the precipitate with ammonium salt and subjected the mixture to an electrowinning process.

Abstract: A process for recovery of metal comprising copper and/or a precious metal from a metal containing material, including the steps of: leaching the metal containing material with an alkaline lixiviant and an amino acid or derivative thereof in order to produce a metal containing leachate; and extracting the metal from the leachate.

Abstract: A method is provided which can separate rhenium from a solution containing rhenium by a simple procedure in a shorter time. A method of selectively recovering rhenium from a solution containing rhenium and one or more different metals is also provided. A method of recovering rhenium is used. The method involves (A) adding an electron donor (aliphatic secondary alcohol or aliphatic secondary thioalcohol) and a ketone compound to a solution containing perrhenate ions, (B) irradiating the solution after the addition step with ultraviolet light to precipitate a reduced species of the perrhenate ions contained in the solution, and (C) separating the reduced species of perrhenate ions from the solution, the reduced species being precipitated during the ultraviolet light irradiation.

Abstract: The present invention relates to an Ni-based superalloy for hot forging, containing, in terms of % by mass, C: more than 0.001% and less than 0.100%, Cr: 11% or more and less than 19%, Co: more than 5% and less than 25%, Fe: 0.1% or more and less than 4.0%, Mo: more than 2.0% and less than 5.0%, W: more than 1.0% and less than 5.0%, Nb: 0.3% or more and less than 4.0%, Al: more than 3.0% and less than 5.0%, Ti: more than 1.0% and less than 3.0%, and Ta: 0.01% or more and less than 2.0%, with the balance being unavoidable impurities and Ni, in which the component composition satisfies the following two relationships: 3.5?([Ti]+[Nb]+[Ta])/[Al]×10<6.5 and 9.5?[Al]+[Ti]+[Nb]+[Ta]<13.0.

Abstract: Converting process with partial pre-oxidation of PGM collector alloy. The process includes partially pre-oxidizing a raw alloy, introducing an initial charge of the partially pre-oxidized alloy into a converter pot, melting the initial charge, introducing converter feed to the pool, oxygen injection into the pool, tapping the slag, and tapping the PGM-enriched alloy. The collector alloy contains no less than 0.5 wt % PGM, 40 wt % iron, and 0.5 wt % nickel, and no more than 3 wt % sulfur and 3 wt % copper. The process can also include low- or no-flux converting; using a refractory protectant in the converter; magnetic separation of slag; recycling part of the slag to the converter; smelting catalyst material in a primary furnace to produce the collector alloy; and/or smelting the converter slag in a secondary furnace with slag from the primary furnace.

Abstract: The present invention relates to a method for pneumatically blowing a powdery substitute reducing agent in a dense flow process, by means of a transport gas, into a gasification reactor, or via a tuyere into a blast furnace. The substitute reducing agent is gasified in a gasification reaction. The transport gas comprises a fuel gas, the constituents of which or the oxidation constituents of which are at least partly involved in the gasification reaction.

Abstract: An apparatus and method for filtering molten metal, such as aluminum or an aluminum alloy includes at least one ceramic foam filter or any other type of filtration media such as porous tube or alumina balls disposed in a receptacle for the molten metal. A vibrator vibrates at least one of the filter, the receptacle or the metal and may be used to induce priming, filtering and/or drainage of the filter. The vibrator may be retrofitted to an existing filter system and may be adjustable in frequency and amplitude. The vibration may be continuous over a given period or produced in a single shock.

Abstract: A hardfacing material includes a metal matrix material and particles of crushed polycrystalline diamond material embedded within the metal matrix material. An earth-boring tool includes a body comprising particles of fragmented polycrystalline diamond material embedded within a metal matrix material. The particles of fragmented polycrystalline diamond material include a plurality of inter-bonded diamond grains. A method includes forming an earth-boring tool including a metal matrix material and particles of crushed polycrystalline diamond material.

Abstract: The invention relates to a hydrometallurgical process which makes it possible to selectively recover at least one “heavy” rare earth metal, i.e. a rare earth metal with an atomic number at least equal to 62, that is in an acidic aqueous phase resulting from the treatment of spent or scrapped permanent magnets. It also relates to a hydrometallurgical process which makes it possible to selectively recover, on the one hand, at least one heavy rare earth metal present in an acidic aqueous phase resulting from the treatment of spent or scrapped permanent magnets and, on the other hand, at least one “light” rare earth metal, i.e. a rare earth metal with an atomic number at most equal to 61, that is also in this acidic aqueous phase.

Abstract: A process for manufacturing an iron-based alloy comprising forming targeted fine oxide and/or carbide dispersoids in a melt, and sequentially precipitating transition-metal nitrides on the dispersoids for heterogeneous nucleation of equiaxed grains. An iron-based cast alloy having a highly equiaxed fine grain structure.

Abstract: A method for recovery of platinum group metals from a spent catalyst is described. The method includes crushing the spent catalyst to obtain a catalyst particulate material including particles having a predetermined grain size. The method includes subjecting the catalyst particulate material to a chlorinating treatment in the reaction zone at a predetermined temperature for a predetermined time period by putting the catalyst particulate material in contact with the chlorine containing gas. The method also includes applying an electromagnetic field to the chlorine-containing gas in the reaction zone to provide ionization of chlorine; thereby to cause a chemical reaction between platinum group metals and chlorine ions and provide a volatile platinum group metal-containing chloride product in the reaction zone. Following this, the volatile platinum group metal-containing chloride product is cooled to convert the product into solid phase platinum group metal-containing materials.