Abstract: A continuous nickel matte converter and method for the efficient production of low iron nickel-rich mattes from high-iron nickel-rich mattes, with minimal environmental impact. The present invention processes high-iron, nickel-rich primary furnace mattes to produce low iron, nickel-rich mattes, low value metal-containing slag and sulfur dioxide rich-off gas, with improved cobalt recovery. It eliminates use of the Peirce-Smith converter, with its undesirable environmental, metallurgical and economic features.

Abstract: Continuous steel making is carried out in an elongated approximately horizontal reactor by providing an iron-rich feed more than half of which is an iron-rich material containing a fine iron ore metallized by more than half of its weight to elemental iron by prereduction. The iron-rich feed and a carbonaceous material are smelted and the melt is covered by a slag layer. By submerged injection a carbonaceous material and a tonnage oxygen gas preferably of at least 95% by volume oxygen is introduced and a gas preferably of at least 95% by volume oxygen is introduced into the smelting zone without penetrating the slag layer. Moderate turbulence is introduced in the reactor bath and the iron layer and slag layer flow countercurrently with the iron flowing into a refining zone and the slag flowing from the refining zone into the smelting zone.

Abstract: The invention describes a process for the manufacture of steel with a carbon content of <0.8 wt.-% by reducing iron ore and refining the hot metal. Iron ore and fuel are introduced into the reduction zone of a reactor that contains an iron melt in the reduction zone. This melt is covered by a liquid slag layer from which liquid slag is withdrawn. Further, oxygen-containing gas together with fuel is blown into the iron melt contained in the reduction zone. The iron melt extends into the refining zone of the reactor, the slag layer flows from the refining zone into the reduction zone and in the refining zone liquid steel is withdrawn. Oxygen-containing gas is supplied to the iron melt contained in the refining zone and liquid iron is withdrawn therefrom.

Abstract: A horizontal furnace for converting nonferrous metal sulfide concentrates to a molten matte has a plurality of vertically disposed burners along the longitudinal axis of the furnace roof, the burners spaced from each other, means for introducing oxygen-rich gas to said burners, and means for introducing metal sulfide concentrates and flux into the furnace, with the spaced burners introducing the same into the hot atmosphere of the furnace as a plurality of paraboloidal suspensions whereby substantially uniform heat and mass distribution is effected over a major portion of the horizontal furnace.

Abstract: A process for producing a metal matte from a nonferrous metal-containing sulfide mineral concentrate in a horizontally disposed furnace wherein small sulfide particles are separated from the concentrate, compacted and introduced into the furnace along with the remainder of the concentrate; a melted iron sulfide-rich concentrate is spread onto the slag adjacent the introduction of the sulfide mineral concentrate; and a metallic iron-rich material containing carbon or silicon is spread onto the slag at a location adjacent the introduction of the melted iron sulfide-rich concentrate but spaced from the slag discharge of the furnace, such that a high-grade nonferrous metal matte is produced and the loss of nonferrous metals is averted.

Abstract: A sprinkler burner and method for injecting solid particulate material and a gas into a reactor as a paraboloidal suspension. Means are provided to introduce the gas tangentially into an outer cylindroidal member, comprising a slot-like gas inlet in the cylindroidal member and a spiral shaped conduit communicating with the slot, such that the gas is directed around the periphery and downward between the outer cylindroidal member and an inner tubular member through which the solids are fed. The gas entrains the solids emitting from the inner tubular member and spreads the solids tangentially from the exhaust end of the outer cylindroidal member such that a paraboloidal suspension is formed within a reactor.

Abstract: Method for producing a metal matte from a nonferrous metal containing sulfide concentrate in a reverberatory type furnace by sprinkling a mixture of sulfide concentrates, flux and an oxygen-rich gas as a plurality of paraboloidal suspensions into a hot sulfur dioxide-rich atmosphere above the slag phase of the furnace charge. By introducing the concentrate, flux and oxygen-rich gas in such a manner, oxidation of the sulfide is effected prior to contact with the slag phase and substantially uniform heat and mass distribution are present throughout a major portion of the furnace. Coal is optionally introduced in a homogeneous mixture with the concentrate if nonautogenous operation is desired or slag cleaning is carried out to produce a discardable slag.

Abstract: A continuous autogenous multi-stage process for converting non-ferrous metal sulfides, in an oscillating, elongated, gently sloped, sealed, tiltable, rounded cross-section furnace, discharging crude metal or low-iron matte at one end, and silicate slag and sulfur dioxide-rich gas at the other end. The concentrates, fluxes, commercial oxygen, sulfur dioxide, a carbonaceous reducing agent and optionally other materials are introduced into the furnace in stages to provide a molten bath of slag and matte flowing countercurrently. Slag scavenging is accomplished by deconverting to produce low grade, cleansing matte in situ in the slag layer, followed by settling. At least a substantial proportion of the commercial oxygen is continuously blown in through injectors extending through the refractory lining of the vessel and communicating with its interior below the bath surface, where necessary with a protective fluid, desirably surrounding the oxygen.

Abstract: A continuous autogenous multi-stage process for converting non-ferrous metal sulfides, in an oscillating, elongated, gently sloped, sealed, tiltable, rounded cross-section furnace, discharging crude metal or low-iron matte at one end, and silicate slag and sulfur dioxide-rich gas at the other end. The concentrates, fluxes, commercial oxygen, sulfur dioxide, a carbonaceous reducing agent and optionally other materials are introduced into the furnace in stages to provide a molten bath of slag and matte flowing countercurrently. Slag scavenging is accomplished by deconverting to produce low grade, cleansing matte in situ in the slag layer, followed by settling. At least a substantial proportion of the commercial oxygen is continuously blown in through injectors extending through the refractory lining of the vessel and communicating with its interior below the bath surface, where necessary with a protective fluid, desirably surrounding the oxygen.

Abstract: A continuous autogenous multi-stage process for converting non-ferrous metal sulfides, in an oscillating, elongated, gently sloped, sealed, tiltable, rounded cross-section furnace, discharging crude metal or low-iron matte at one end, and silicate slag and sulfur dioxide-rich gas at the other end. The concentrates, fluxes, commercial oxygen, sulfur dioxide, a carbonaceous reducing agent and optionally other materials are introduced into the furnace in stages to provide a molten bath of slag and matte flowing countercurrently. Slag scavenging is accomplished by deconverting to produce low grade, cleansing matte in situ in the slag layer, followed by settling. At least a substantial proportion of the commercial oxygen is continuously blown in through injectors extending through the refractory lining of the vessel and communicating with its interior below the bath surface, where necessary with a protective fluid, desirably surrounding the oxygen.

Abstract: A continuous autogenous multi-stage process for converting non-ferrous metal sulfides, in an oscillating, elongated, gently sloped, sealed, tiltable, rounded cross-section furnace, discharging crude metal or low-iron matte at one end, and silicate slag and sulfur dioxide-rich gas at the other end. The concentrates, fluxes, commercial oxygen, sulfur dioxide, a carbonaceous reducing agent and optionally other materials are introduced into the furnace in stages to provide a molten bath of slag and matte flowing countercurrently. Slag scavenging is accomplished by deconverting to produce low grade, cleansing matte in situ in the slag layer, followed by settling. At least a substantial proportion of the commercial oxygen is continuously blown in through injectors extending through the refractory lining of the vessel and communicating with its interior below the bath surface, where necessary with a protective fluid, desirably surrounding the oxygen.

Abstract: A continuous autogenous multi-stage process for converting non-ferrous metal sulfides, in an oscillating, elongated, gently sloped, sealed, tiltable, rounded cross-section furnace, discharging crude metal or low-iron matte at one end, and silicate slag and sulfur dioxide-rich gas at the other end. The concentrates, fluxes, commercial oxygen, sulfur dioxide, a carbonaceous reducing agent and optionally other materials are introduced into the furnace in stages to provide a molten bath of slag and matte flowing countercurrently. Slag scavenging is accomplished by deconverting to produce low grade, cleansing matte in situ in the slag layer, followed by settling. At least a substantial proportion of the commercial oxygen is continuously blown in through injectors extending through the refractory lining of the vessel and communicating with its interior below the bath surface, where necessary with a protective fluid, desirably surrounding the oxygen.