Abstract: High density compacts are made by providing a compactable particulate combination of Class 1 metals selected from at least one of Ag, Cu and Al, with material selected from at least one of CdO, SnO, SnO.sub.2, C, Co, Ni, Fe, Cr, Cr.sub.3 C.sub.2, Cr.sub.7 C.sub.3, W, WC, W.sub.2 C, WB, Mo, Mo.sub.2 C, MoB, Mo.sub.2 B, TiC, TiN, TiB.sub.2, Si, SiC, Si.sub.3 N.sub.4, usually by mixing powders of each, step (1); uniaxially pressing the powders to a density of from 60% to 95%, to provide a compact, step (2); hot densifying the compact at a pressure between 352 kg/cm.sup.2 (5,000 psi) and 3,172 kg/cm.sup.2 (45,000 psi) and at a temperature from 50.degree. C. to 100.degree. C. below the melting point or decomposition point of the lower melting component of the compact, to provide densification of the compact to over 97% of theoretical density; step (3); and cooling the compact, step (4).

Abstract: An electrical vacuum interrupter comprising a pair of separable contacts enclosed within a vacuum enclosure whose walls have joints formed of a polymeric material which can maintain sufficient vacuum, mechanical, thermal, and electrical properties to permit proper operation. Major part of the vacuum enclosure, in addition to the joint, may be formed of a polymeric material. A method of assembly is provided that avoids need for high temperatures and includes use of electrical discharge between the contacts for cleaning the interior of the vacuum enclosure.

Abstract: A method for processing metallurgical waste characterized by collecting metallurgical waste containing oxides of such metals as lead and zinc which when reduced form volatile and non-volatile metals; compacting a mixture of metallurgical waste, carbonaceous material and silica into pellets; heating the pellet at a temperature sufficient to reduce the oxides to vapors of elemental metals; and condensing the vapors to liquid or solid status of the elemental metal.

Abstract: An arc-heated plasma lance characterized by an elongated tubular housing containing arc heater ports for producing a plasmic jet at one end of the housing and service ports for providing electric power, gas, and coolant fluid to the arc heater ports, and the service means extending into the housing from the other end.

Abstract: This invention relates to an electric arc heater process and apparatus for the essentially complete decomposition of hazardous materials including polychlorinated biphenyls. Finely divided liquid or gaseous hazardous material is injected into a primary gas stream which has been superheated in an electric arc heater. The mixture is directed into a primary reactor for complete decomposition with dwell times in the reactor being in the order of 0.05 to 0.15 seconds. The decomposition products are neutralized with the gases being released to atmosphere and any remaining particulates being collected for ultimate disposal. Large solid hazardous material is first shredded then heated in a roaster or rotary kiln to vaporize the primary gas stream. A soaking reactor is provided where increased dwell times are required for the decomposition of thermally stable compounds which may be formed in the primary reactor. When these compounds are absent the soaking reactor can be by-passed.

Abstract: An apparatus and process for the reduction in a plasma stream of a feed material including a comminuted metal oxide, a slag former and a reductant utilizing an enclosed horizontal reactor having a reduction chamber and a filter chamber therein separated by an either common partition having a plurality of holes therethrough or a refractory lined passageway. Coke filter media in the filter chamber act to filter out entrained molten metal contained in the plasma stream with the partition or passageway preventing entry of the coke from the filter chamber into the metal bath contained in the reduction chamber thereby limiting the amount of carbon entering the metal produced. Unreduced metal oxide is provided in the slag layer of the metal bath to maintain the stoichiometric ratio between the metal and reductant in the reduction chamber.

Abstract: A high power non-transferred electric arc heater utilizing interelectrode segments which create a stepped arc chamber intermediate two hollow, substantially cylindrical, axially spaced electrodes. Gas to be heated is admitted upstream of the arc chamber and between adjacent segments. Gas is used to form a cold boundary layer about the expanding core of arc-heater gas. Additional secondary gas inlets adjacent the electrode provide fluid dynamic means for arc positioning on the electrode segments. Gas pressures of less than or in the range of about 1 atmosphere to about 50 atmospheres are used with power levels of about 10 MW being possible. The stepped arc chamber facilitates arc transfer to the downstream electrodes and allows a larger diameter for the arc heated gas while the boundary layer of gas maintaining comparable spacing along the length of the arc-heated gas and the surface of the arc chamber reducing the rate of heat transfer from the arc heated gas to the segments of the arc heater.

Abstract: A melting furnace or cupola utilizing electric arc heaters to provide an arc-heated air stream to melt loose metal chips as well as larger pieces of metal scrap. In one embodiment, the arc-heated gas stream and metal chips are directed into a melting segment with the melted chips and gas stream passing therefrom into the furnace through a tuyere. In another embodiment an electric arc heater serves as a tuyere for the furnace with the metal chips being fed into the arc-heated stream at the outlet of the arc heater. The chips and arc-heated air stream immediately enter the furnace wherein melting of the metal chips occurs. With either embodiment, recycling of the gases in the furnace and metal chip preheat can be provided.

Abstract: This invention relates to an electric-arc fired blast furnace system for the reduction of iron-bearing material utilizing electric-arc heated air containing a reducing gas or carbon-containing fuel allowing for a decrease in the amount of coke normally used in the reduction process. The excess reducing gases exiting the furnace are utilized as a source of power via a system consisting of turbines, compressors and a heat exchanger to drive the electrical generators which are used to provide electricity to the arc heaters. This arrangement forms an essentially closed loop furnace system for metal reduction. Injection of finely-divided coal into the arc-heated air to provide reductants is also employed.

Abstract: A DC electric arc furnace utilizing a magnetic field stabilized electric arc. A DC magnetic field is employed to cause rotation and angular deflection of the electric arc about the surface of the melt. In one embodiment the DC magnetic field is induced by a field coil. In an alternate embodiment a specially shaped electrical insulating member can be positioned in the melt so that the flow of arc current through the melt creates a magnetic field which is used to cause arc rotation. In a further embodiment a plurality of coil sets are located about the periphery of the furnace are used in conjunction with current reversing and current sequencing means to create a rotating DC magnetic field which is used to rotate the arc. A ceramic electric insulator can also be supplied in the chamber of the furnace to prevent arc fixation in the region wherein the DC magnetic field is substantially parallel to the flow of arc current.

Abstract: A blast furnace for reducing iron ore characterized by a vertical tubular refractory shell forming an upper reduction zone and a lower hearth which shell is adapted to contain a charge of iron ore and ore reductance, at least one arc heater mounted on the shell and extending therethrough for injecting an arc heated mixture of gas containing carbon monoxide into the reduction zone.

Abstract: A process for converting silicon intermediates to high purity silicon by an arc heater characterized by the steps of preliminarily reacting gaseous silicon intermediate, such as a silicon halide, with a metal reductant, such as sodium, to form preliminary reaction products including small solid silicon particles and droplets of salt of the metal reductant, at temperatures below the boiling point of the metal reductant, subsequently heating the reaction products to temperatures above said boiling point in an arc heater chamber to convert the reaction products to droplets of silicon to merge and form larger silicon droplets, and thereafter separating the mixture of silicon droplets and salt vapor.

Abstract: Apparatus for melting metal chips comprising a preheating chamber, a prereducing chamber, and a melting chamber, the latter comprising a metallurgical vessel having a refractory wall with arc heater means mounted on the wall and extending therethrough which arc heater means provides an electric plasma arc which extends through an opening in the refractory wall, and the arc heater means comprising a downstream cylindrical electrode extending through the refractory wall for improved heating efficiency.

Abstract: A method for melting machine chips characterized by a preheating zone, a prereducer zone, and a melting zone the latter of which is heated by an arc heater through which a reducing inert gas is introduced into the communicating zones, whereby metal chips entering the preheating zone move through the subsequent zones in counterflow to the reducing gas flow.

Abstract: A liquid silicon casting control mechanism characterized by means for producing liquid elemental silicon and comprising a collecting vessel having a tap hole therein for periodically removing liquid silicon in a controlled manner, and comprising a tubular constricted opening.

Abstract: A method and apparatus for melting metal chips characterized by a preheating zone, a pre-reducer zone, and a melting zone in conjunction with an arc heater through which a reducing or inert gas atmosphere is introduced into the communicating zones, whereby metal chips entering the preheating zone move through the preheating, pre-reducing and melting zones in counterflow to the reducing or inert gas movement.

Abstract: An arc heater method and system for producing a high energy heat source characterized by a housing forming a mixing compartment, a plurality of arc heaters radially mounted on the housing and communicating with the mixing compartment, a reactor communicating with the downstream end of the mixing compartment with a reduced opening therebetween, inlet means at the downstream end of the compartment for introducing an oxidizable metal compound into the reactor, and means within the mixing compartment for flowing superheated gases from the arc heaters at the upstream end of the compartment and into the reactor.

Abstract: An arc heater system for producing high purity silicon characterized by the use of an arc heater into which a silicon halide is injected together with a liquid metal reductant, such as an alkali metal, which are reacted together by projecting them into a reaction chamber to cause the formation of liquid silicon, and the walls containing the system being provided with cooling jacket means for preliminarily heating the reactants.

Abstract: An arc heater method and system for producing a high energy source characterized by a housing forming a mixing compartment, a plurality of arc heaters radially mounted on the housing and communicating with the mixing compartment, a reactor communicating with the downstream end of the mixing compartment with a reduced opening therebetween, inlet means at the downstream end of the compartment for introducing an oxidizable metal compound into the reactor, and means within the mixing compartment for flowing superheated gases from the arc heaters at the upstream end of the compartment and into the reactor.

Abstract: A process for producing high purity silicon characterized by the employment of an electric arc heater into which a silicon halide is injected together with a metal reductant such as an alkali metal or an alkaline-earth metal which are reacted together by projecting them tangentially into a reaction chamber to cause the formation of liquid silicon and a gaseous metal halide salt which are separated in a suitable manner such as centrifugally or by condensation.