Abstract: A stack of copper plates is placed in a melting chamber having a closed roof of refractory material. The stack is placed in a tilted orientation leaning against a side wall of the melting chamber, with lower edges of the copper plates resting on an inclined hearth surface. A door to the melting chamber is closed to block the infiltration of oxygen. A burner is fired into the melting chamber to heat the closed roof of refractory material, and the stack of copper plates is melted under the influence of combustion products from the burner and heat radiated from the closed roof. Molten copper is drained downward from the bottom edge of the inclined hearth surface to avoid immersing the copper plates in a molten bath.

Abstract: A stack of copper plates is placed in a melting chamber having a closed roof of refractory material. The stack is placed in a tilted orientation leaning against a side wall of the melting chamber, with lower edges of the copper plates resting on an inclined hearth surface. A door to the melting chamber is closed to block the infiltration of oxygen. A burner is fired into the melting chamber to heat the closed roof of refractory material, and the stack of copper plates is melted under the influence of combustion products from the burner and heat radiated from the closed roof. Molten copper is drained downward from the bottom edge of the inclined hearth surface to avoid immersing the copper plates in a molten bath.

Abstract: A stack of copper plates is placed in a melting chamber having a closed roof of refractory material. The stack is placed in a tilted orientation leaning against a side wall of the melting chamber, with lower edges of the copper plates resting on an inclined hearth surface. A door to the melting chamber is closed to block the infiltration of oxygen. A burner is fired into the melting chamber to heat the closed roof of refractory material, and the stack of copper plates is melted under the influence of combustion products from the burner and heat radiated from the closed roof. Molten copper is drained downward from the bottom edge of the inclined hearth surface to avoid immersing the copper plates in a molten bath.

Abstract: A stack of copper plates is placed in a melting chamber having a closed roof of refractory material. The stack is placed in a tilted orientation leaning against a side wall of the melting chamber, with lower edges of the copper plates resting on an inclined hearth surface. A door to the melting chamber is closed to block the infiltration of oxygen. A burner is fired into the melting chamber to heat the closed roof of refractory material, and the stack of copper plates is melted under the influence of combustion products from the burner and heat radiated from the closed roof. Molten copper is drained downward from the bottom edge of the inclined hearth surface to avoid immersing the copper plates in a molten bath.

Abstract: A vertical shaft melting furnace is operated in a method that includes firing a plurality of burners to generate combustion products, and directing jets of the combustion products into the shaft in a bottom region of the shaft. The method further includes directing a jet of hot gas into the shaft in an upper region of the shaft in a non-radial direction, whereby the jet of hot gas can induce a swirl to disperse a concentrated channel of combustion products rising from the bottom region to the upper region through a void in unmelted portions of a load of metal pieces in the shaft. The jet of hot gas directed into the upper region of the shaft can include recirculated flue gas, a mixture of air and recirculated flue gas, or combustion products that are generated by a burner. If the jet of hot gas includes combustion products that are generated by a burner, the burner is a secondary burner that preferably is fired into the shaft with a relatively low heat input.

Abstract: A vertical shaft melting furnace is operated in a method that includes firing a plurality of burners to generate combustion products, and directing jets of the combustion products into the shaft in a bottom region of the shaft. The method further includes directing a jet of hot gas into the shaft in an upper region of the shaft in a non-radial direction, whereby the jet of hot gas can induce a swirl to disperse a concentrated channel of combustion products rising from the bottom region to the upper region through a void in unmelted portions of a load of metal pieces in the shaft. The jet of hot gas directed into the upper region of the shaft can include recirculated flue gas, a mixture of air and recirculated flue gas, or combustion products that are generated by a burner. If the jet of hot gas includes combustion products that are generated by a burner, the burner is a secondary burner that preferably is fired into the shaft with a relatively low heat input.

Abstract: A method and system for enhancing the supply of combustion air delivered to a burner of a furnace to increase productivity and thermal efficiency of the burner while minimizing changes to the nominal combustion ratio of the burner are disclosed. Oxygen and fuel are introduced into an air plenum upstream of the burner assembly in controlled quantities to form a nonflammable premix of pressurized gases in the air plenum formed from the air, fuel, and oxygen. The air plenum has an outlet that communicates the nonflammable premix of pressurized gases to the burner for combustion. The nonflammable premix of pressurized gases has a predetermined percentage level of oxygen and a predetermined percentage level of fuel. The predetermined percentage level of fuel is selected so that the percentage level of fuel is less than that required to create a flammable premix in the air plenum.

Abstract: A method of adding gasses to, and removing gasses from a molten metal is disclosed. A molten metal is passed from a metal making furnace and cascaded through a gas or a flame. The flame is generated by a combustion burner and has an inner core of a first gas and an outer core of a second gas which jackets the first gas. As the metal is cascaded through the flame or gas, the first gas is passed into the molten metal. In the alternative, the cascade of molten metal may be passed through the first gas, or the first gas may be mixed with molten metal. The first gas may be used to sparge, react with, degassify, or otherwise dissolve within the molten metal. The device of the invention comprises a vessel for receiving the molten metal, a transfer trough extending from the furnace toward the vessel, and a combustion burner positioned with respect to the transfer trough and the vessel.

Abstract: A gas mixing device for use with a combustion burner assembly is disclosed. The gas mixing device includes an elongate gas expansion nozzle adapted to be positioned within a burner housing, the gas expansion nozzle defining a gas expansion chamber therein extending from a first end to a second end thereof. An inlet port and an outlet port are defined at the respective ends of the gas expansion nozzle. At least one oxidizing gas passageway formed separately of the gas expansion chamber extends from the first end of the second end thereof, and has an oxidizing gas outlet at the second end of the gas expansion nozzle. At least one fuel gas passageway is also formed separately of the gas expansion chamber and extends from the first end to the second end of the gas expansion nozzle, and has a fuel gas outlet at the second end thereof. An elongate gas inlet nozzle is also positioned within the burner housing and is spaced from the first end of the gas expansion nozzle.

Abstract: A method for improving the making of metals such as steel and copper by specially using a gas measurement system to analyze molten metals for gas, particularly H2 content, and to controlling the metal making process based on these values. The preferred gas analyzer comprises a hollow probe and an analyzer wherein the probe is immersed in the molten metal and a carrier gas containing a reducing gas such as CO is cycled through the probe and analyzer. The carrier gas entrains gases in the probe and this gas mixture is electronically compared with a reference value to provide a measurement of the gases in the molten metal and the process is controlled based on the analyzer results.

Abstract: A method is disclosed for improving the continuous casting process for making copper by using a probe and analyzer which measures the gases present in the molten copper and controls the process based on the analyzer results.

Abstract: Continuous casting of discrete solid shapes from a molten material using modified continuous casting machines and processes are disclosed. In a conventional twin belt continuous caster, for example, forming means such as dividers are employed on the upper belt to define a mold cavity in the casting region of the machine. Different size and shape forming means may be used to provide a variety of cast products.