Abstract: Cast iron having more regular and uniform free graphite particle shape and distribution is more reliably produced by using pre-reduced iron pellets as a major component of the melting stock. Cast iron made in this way may be advantageously used to form ingot molds, brake discs, and other products.

Abstract: Metals are formed from metal oxides in a shaft furnace, by reduction using powdered carbon in pellets, such pellets also including additional powdered carbon for combustion under controlled conditions in the presence of oxygen to achieve the temperature required in the shaft furnace for the reduction reaction and to form molten metal and slag.

Abstract: A first feed comprising particulate material predominantly in the size range 30 mesh to 1/2 in. is fed into an upper portion of an upwardly extending casing, and is a major portion of the particulate material. A second feed, which is a minor portion of the particulate material, comprises at least 50% by weight of fines predominantly in the range 140 mesh to 30 mesh, the remainder being superfines, is also fed into the casing. A gas is fed upwardly along at least a portion of the casing so that the coarse particles, a major portion of the fines and a minor portion of the superfines freely gravitate down the casing in counterflow to the flow of a major portion of the gas and form a packed particulate bed in a container beneath the casing.