Abstract: A direct smelting process and a fixed, i.e. non-rotatable, metallurgical vessel for producing metal from a metalliferous feed material is disclosed. The process is a molten bath-based process which includes injecting solid feed materials with a carrier gas into the molten bath via one or more downwardly extending lance/tuyere (11) and causing gas flow from the molten bath at:a flow rate of at least 0.30 Nm3/s/m2 at the interface between the metal layer (15) and the slag layer (16) of the molten bath (under quiescent conditions).

Abstract: A novel process for refining high or low impurity blister copper containing S, As, Sb, Pb, Ni, Bi, Se, and/or Te to anode quality by means of a solution containing sulphates and alkali oxides is provided. More specifically, the process comprises the steps of (1) injecting air/O2 gas mixtures in the presence of an alkali source, over a period of time sufficient to complete the sulphur removal stage, with the innovation of removing the SO2 in situ, thereby forming an effective amount of a molten alkali sulphate on top of the copper bath, the temperature in the bath being maintained between 1100-1300° C.; (2) adding and/or injecting molten or solid alkali sulphates together with basic oxides or carbonates into the copper bath to promote the in situ scrubbing of As and Sb into a solution containing sulphates, while the dissolved oxygen in copper increases from 0.1 to 0.

Abstract: An improved method and apparatus for metal melting, refining and processing, particularly adapted to steel making in an electric arc furnace. The method provides auxiliary thermal energy to the steel making process, particulate injection for the formation of slag and foamy slag, and oxygen injection for the decarburization of the melt, for the formation of foamy slag and for post combustion burning of carbon monoxide. The burner includes two injection barrels for providing finely pulverized particles and for providing either a supersonic or a subsonic primary flow of an oxidizing gas. The barrels are positioned side by side in a nozzle at the entrance of a flame shaping chamber of a fluid cooled combustion chamber. The nozzle also contains a plurality of fuel orifices for the providing pressurized fuel to the combustion chamber and a plurality of oxidizing gas orifices for providing a secondary flow of an oxidizing gas around the periphery of the nozzle.

Abstract: A process for treating zinc mine tailings wherein a series of wave tables and cone separators are utilized to remove various components from the zinc mine tailings, such as carbon, zinc, lead, copper and precious metals. The recovered carbon is then transferred to a cogeneration plant where it is utilized as fuel.

Abstract: In a process for splashing and/or teeming liquid metal, in particular steel, through a discharge in the wall or in the bottom of a metallurgical vessel, the discharge is electromagnetically coupled to the electromagnetic field of at least one fluid-cooled, in particular air-cooled, inductor. The inductor and the discharge are at least partially disposed in the wall or in the bottom of the metallurgical vessel. For teeming, the electromagnetic field of the inductor, or of the inductors, is coupled directly to the discharge and also the liquid metal. For this purpose, the frequency of the electromagnetic field or the electromagnetic fields, if appropriate, is adjusted correspondingly.

Abstract: A solid charge of metal or alloy is placing in a crucible melting chamber defined by a monolithic refractory tubular sleeve disposed on a water cooled metallic base, an energizing induction coil disposed about the sleeve to inductively heat the solid charge to a molten state in the melting chamber including forming a skull of solidified metal or alloy on inner surfaces of the sleeve and base to confine the molten charge, and removing the molten charge from the melting chamber, leaving the skull in place on the inner surfaces of the sleeve and base. The crucible can be reused in melting another solid charge of metal or alloy after the molten charge is removed.