Abstract: A method of melting and refining metals by high-temperature impinging combustion products generated by a single or multiple oxy-fuel or fuel/oxygen/air combustors that direct a flame towards a predetermined area of scrap to be melted. Once a portion of charged scrap contacted by the flame or flames is melted, an injection of solid carbonaceous fuel is initiated, preferably through a combustion tunnel of at least one of the combustors. High velocity oxygen is directed, simultaneously with carbonaceous material, through at least one dedicated nozzle toward injected solid carbonaceous fuel to mix with this fuel and to generate CO, which is capable of forming foamy slag. Optionally, a supersonic stream of multiple streams of additional oxygen is directed toward the iron--carbon melt to initiate rapid melt refining.

Abstract: A burner/injector for providing a localized impingement flame or multiple flames for scrap heating and melting through use of a fluid fuel and at least one oxygen rich oxidizing gas. The burner/injector includes a liquid-cooled combustor for generating an impinging flame directed toward a scrap pile and a structure for injecting a controllable amount of a solid material and a controllable flow of high velocity oxidizing gas. The burner/injector may be arranged as a simple liquid-cooled combustor permanently mounted through the furnace wall or roof, and may be equipped with single or multiple channels for injection of solid material and high velocity oxidizing gas. The burner/injector can also be arranged as a water-cooled burner/injector lance accompanied with a water-cooled oxygen injecting lance, both movable through the slag door opening toward the furnace interior.

Abstract: A burner/injector for providing a localized impingement flame or multiple flames for scrap heating and melting through use of a fluid fuel and at least one oxygen rich oxidizing gas. The burner/injector includes a liquid-cooled combustor for generating an impinging flame directed toward a scrap pile and a structure for injecting a controllable amount of a solid carbonaceous fuel and a controllable flow of high velocity oxidizing gas into space that has been previously occupied by the impinging flame. The burner/injector may be equipped to inject a solid slag forming materials and/or slag deoxidizing materials and/or to inject an additional oxidizing gas for burning a small portion of preheated scrap, post-combustion of CO and iron-carbon melt refining. The burner/injector may be arranged as a simple liquid-cooled combustor permanently mounted through the furnace wall or roof, and may be equipped with single or multiple channels for injection of solid material and high velocity oxidizing gas.

Abstract: A burner/injector for providing a localized impingement flame or multiple flames for scrap heating and melting through use of a fluid fuel and at least one oxygen rich oxidizing gas. The burner/injector includes a liquid-cooled combustor for generating an impinging flame directed toward a scrap pile and a structure for injecting a controllable amount of a solid carbonaceous fuel and a controllable flow of high velocity oxidizing gas into space that has been previously occupied by the impinging flame. The burner/injector may be equipped to inject a solid slag forming materials and/or slag deoxidizing materials, and/or to inject an additional oxidizing gas for burning a small portion of preheated scrap, post-combustion of CO and iron-carbon melt refining. The burner/injector may be arranged as a simple liquid-cooled combustor permanently mounted through the furnace wall or roof, and may be equipped with single or multiple channels for injection of solid material and high velocity oxidizing gas.

Abstract: A burner/injector for providing a localized impingement flame or multiple flames for scrap heating and melting through use of a fluid fuel and at least one oxygen rich oxidizing gas. The burner/injector includes a liquid-cooled combustor for generating an impinging flame directed toward a scrap pile and a structure for injecting a controllable amount of a solid carbonaceous fuel and a controllable flow of high velocity oxidizing gas into space that has been previously occupied by the impinging flame. The burner/injector may be equipped to inject a solid slag forming materials and/or slag deoxidizing materials, and/or to inject an additional oxidizing gas for burning a small portion of preheated scrap, post-combustion of CO and iron-carbon melt refining. The burner/injector may be arranged as a simple liquid-cooled combustor permanently mounted through the furnace wall or roof, and may be equipped with single or multiple channels for injection of solid material and high velocity oxidizing gas.

Abstract: A burner/injector for providing a localized impingement flame or multiple flames for scrap heating and melting through use of a fluid fuel and at least one oxygen rich oxidizing gas. The burner/injector includes a liquid-cooled combustor for generating an impinging flame directed toward a scrap pile and a structure for injecting a controllable amount of a solid carbonaceous fuel and a controllable flow of high velocity oxidizing gas into space that has been previously occupied by the impinging flame. The burner/injector may be equipped to inject a solid slag forming materials and/or slag deoxidizing materials, and/or to inject an additional oxidizing gas for burning a small portion of preheated scrap, post-combustion of CO and iron-carbon melt refining. The burner/injector may be arranged as a simple liquid-cooled combustor permanently mounted through the furnace wall or roof, and may be equipped with single or multiple channels for injection of solid material and high velocity oxidizing gas.

Abstract: A method of applying a hot composite on top of the refractory lining of steel making and processing vessels is disclosed. The composite may be applied to the refractory wall in more than one layer, including a dense intermediate layer for adhesion, and a less dense layer on top that is designed to be consumed as a slag-forming component during steel making and refining. The composite is applied by discharging a carrier gas containing a mixture of small particles, including particles of silica, particles of at least one high-temperature oxide based material and particles of solid carbonaceous fuel, through a carrier gas discharge nozzle. Additional substances may be added to the mixture to enhance the slag-forming process. A controllable flow of oxidizing gas is charged at high and preferably supersonic speed through an essentially crescent-shaped nozzle partially surrounding the carrier gas discharge nozzle.

Abstract: A steelmaking process is disclosed utilizes solid ferrous metallic material as a substantial part of the metallic charge and uses heat released by combustion of two different types of carbonaceous materials and steel scrap that have been strategically charged inside of at least a partially refractory lined steelmaking vessel. One of the carbonaceous materials contains a high content of volatile hydrocarbons and is primarily responsible for early preheating and partial melting of the solid ferrous material. The second carbonaceous material contains a low content of volatile hydrocarbons and is primarily responsible for providing a reducing capability to the slag, for carburizing the melt and for providing additional heat generated by combustion which is used to enhance heating and melting of solid ferrous materials.