Abstract: The invention relates to a method for smelting non-ferrous metal sulfides (13) in a suspension smelting furnace and to a suspension smelting furnace. The suspension smelting furnace comprises at least one injection means (18) for injecting at least one of fluid (19) and pulverous matter (20) into a settler (2) of the suspension smelting furnace from at least one of a first side wall structure (8) and a second side wall structure (9) of the settler (2) so that fluid (19) and/or pulverous matter (20) is injected into the settler (2) above a top surface (16) of a layer of melt (15) in the settler (2).

Abstract: A burner is provided for a pulverous feed material. The burner has a structure that integrates the burner with a reaction vessel, and has an opening that communicates with the interior of the reaction vessel. The burner also has a gas supply channel to supply reaction gas through the opening into the reaction vessel, and a feed supply for delivering pulverous material to the reaction vessel. The burner also has a fluidic control system having at least one port capable of directing a stream of fluid at an angle to the direction of flow of the reaction gas so as to modify the flow of the reaction gas. In addition, components are provided to modify the swirl intensity and turbulence intensity of the reaction gas independently of the exit velocity.

Abstract: A metallizing apparatus which is carbonaceous-based wherein a metallic oxide is converted into a carbon-containing, metallized intermediate that is melted in an induction channel furnace to produce liquid metal from said metallic oxide. In the application of iron ore in the form of fines or concentrate, using low-cost coal will greatly reduce capital and operating costs by virtue of eliminating agglomeration of ore, cokemaking, and blast furnace operation. The liquid iron so produced is efficiently converted into steel in a steelmaking furnace such as a basic oxygen furnace (BOF), especially when it is physically integrated to the induction channel furnace wherein the liquid iron is directly poured into the integrated BOF by the induction channel furnace, producing low-cost steel, little heat loss, and minimum emissions.

Abstract: A conveying system comprising elements for conveying lumpy, particularly hot, conveying stock and a cover for shielding the conveying stock. Disclosed are measures for inerting the conveying stock. A combined system encompasses a reduction plant for reducing oxides in a continuous process and processing unit for producing liquid metal in a discontinuous process. The reduction product is deliverable from the reduction plant to the processing unit. A method for coupling a reduction method used for reducing oxides in a continuous process and a method used for producing liquid metal in a discontinuous process. A reduction product from the reduction method is fed to the liquid metal production method for processing.

Abstract: A process for producing molten iron with a combination of a moving-hearth reducing furnace and an iron bath-type melting furnace includes a step of charging a bedding carbonaceous material having an average particle diameter of 1 to 5 mm on a hearth of the moving-hearth reducing furnace and placing carbonaceous material-containing agglomerates containing a powdery iron oxide source and a powdery carbonaceous reductant on the bedding carbonaceous material; a step of thermally reducing the carbonaceous material-containing agglomerates while moving the hearth in the moving-hearth reducing furnace to generate solid reduced iron and simultaneously thermally carbonizing the bedding carbonaceous material to generate char; a step of continuously charging the solid reduced iron and the char into the iron bath-type melting furnace from thereabove without substantial cooling; and a step of blowing oxygen-containing gas into the iron bath-type melting furnace to melt the solid reduced iron and to thereby generate molt

Abstract: The present invention relates to an apparatus for manufacturing molten irons by injecting fine carbonaceous materials into a melter-gasifier and a method for manufacturing molten irons using the same.

Abstract: A process of continuous metal refinement comprising feeding molten metal to a reaction chamber, introducing gaseous and solid oxidants, adding bulk materials, fully converting the metal and slag into a foamy emulsion, creating, in the reaction chamber, an increased pulsating pressure and a considerable deviation of a system from thermodynamic equilibrium by way of creating a self-organizing system of chemical reaction with gas evolution and taking off the emulsion into a refining sump at the critical speed of egress of two-phase liquid, separating the metal and slag in said refining sump and withdrawing the gas through a high layer of emulsion at a definite rate.

Abstract: The invention relates to a method and device for producing stainless steel, comprising methods for creating a ferroalloy, such as ferrochromium, and for further processing the alloy in order to produce a desired stainless steel. According to the invention, the melt obtained from the ferro alloy production unit (1) is transferred at least partly to a ferroalloy processing unit (2) arranged in between the ferroalloy production unit (1) and the stainless steel production unit (5); in the said processing unit (2), the composition of the ferroalloy is adjusted to be suitable for the production of stainless steel.

Abstract: There is disclosed an apparatus for smelting copper which includes a smelting furnace, a separating furnace, a converting furnace, and launders connecting these furnaces in series. In the smelting furnace, copper concentrate is melted and oxidized to produce matte and slag. In the separating furnace, the matte is separated from the slag. In the converting furnace, the matte separated from the slag is oxidized to produce blister copper. A plurality of anode furnaces are provided for refining the blister copper produced in the converting furnace into copper of higher quality. A blister copper launder assembly, which has a main launder and a plurality of branch launders branched off from the main launder, is provided to connect the converting furnace and the anode furnaces together. A selecting device may be attached to the launder assembly for selectively bringing the main launder into fluid communication with one of the branch launders.

Abstract: There is disclosed an apparatus for smelting copper which includes a blister copper-producing device. A plurality of anode furnaces are provided for refining the blister copper produced in the blister copper-producing device into copper of higher quality. A blister copper launder assembly, which has a main launder and a plurality of branch launders branched off from the main launder, is provided to connect the converting furnace and the anode furnaces together. A selecting device may be attached to the launder assembly for selectively bringing the main launder into fluid communication with one of the branch launders.

Abstract: A process for continuously smelting iron ore by use of coal to yield molten iron or semi-steel is disclosed. The process comprises the steps of establishing a melt covered by slag; inducing the slag and the molten iron to flow countercurrently to one another, toward opposite ends of the smelter; maintaining iron oxide-reducing conditions in that zone of the smelter towards which the slag flows; maintaining carbon-oxidizing conditions in that zone of the smelter towards which the molten iron flows; continuously or semicontinuously tapping the slag from the reducing zone end of the smelter; continuously or semicontinuously tapping the molten iron from the oxidizing zone end of the smelter; and adding to both zones iron ore, coal, oxygen, and flux at addition rates sufficient to keep the molten iron in the reducing zone substantially saturated with carbon, maintain in the slag being tapped an FeO content of about 5 weight percent or less, and maintain in the molten iron being tapped a carbon content of about 0.

Abstract: This non-blast process for the production of pig iron, cast iron, steel melt and nearly pure iron is carried out in a single furnace based on a tank-type design. Said types of iron melt can be produced in such single furnace individually or simultaneously in different combinations. The furnace interior is divided into immediately adjacent side-by-side chambers, at least one being an ore reduction chamber and at least one being a secondary chamber. Ore introduced into the top of the ore reduction chamber moves downward to the bottom of this chamber and is at first converted into sponge iron, which, absorbing carbon, is then converted into iron-carbon alloy in the form of a flowable layer at temperatures close to its melting point at about 1150 degrees C. while said flowable layer is collected on the bottom. In the melting zone of the secondary chamber such flowable semifinished product is completely melted, producing pig iron.

Abstract: There is disclosed an apparatus for smelting copper which includes a smelting furnace, a separating furnace, a converting furnace, and launders connecting these furnaces in series. In the smelting furnace, copper concentrate is melted and oxidized to produce matte and slag. In the separating furnace, the matte is separated from the slag. In the converting furnace, the matte separated from the slag is oxidized to produce blister copper. A plurality of anode furnaces are provided for refining the blister copper produced in the converting furnace into copper of higher quality. A blister copper launder assembly, which has a main launder and a plurality of branch launders branched off from the main launder, is provided to connect the converting furnace and the anode furnaces together. A selecting device may be attached to the launder assembly for selectively bringing the main launder into fluid communication with one of the branch launders.

Abstract: A method for the preliminary treatment of molten hot metal for steel making comprising passing molten hot metal towards the downstream side in a horizontally disposed trough-like vessel and injecting obliquely downwards a powdered refining agent into the molten hot metal by use of an oxygen-containing gas as a carrier through one or more single-pipe nozzles installed on the side wall of the vessel with the nozzle port being positioned below the surface of the hot metal in the vessel.

Abstract: The present invention relates to an overall direct smelting process which provides for separating the carburization function from the heating function to permit separate control of the individual functions. One embodiment of the smelting reactor is divided into a carburization/smelting section and a heating section with a substantial recirculation of the molten product from the heating section back to the carburization/smelting section. The heating section also serves as a slag/metal separation section. Carburization is achieved by injection of solids (fine coal mixed with slagging agents), where desired. Gas generating solids or inert gases are injected into a lift pipe to provide a motive force for circulation of the molten metal. The circulation rate through the system is a function of the injected solid composition, the mass flow rate of the solids injected into the lift pipe and the lift pipe geometry.

Abstract: A process and arrangement are provided for the efficient generation of energy from coal, while at the same time providing for a relatively inexpensive step in processing of iron or steel, and the extraction of valuable materials such as oils from coal. An advantage to the process is that relatively low quality coals can be utilized, since the coal is pretreated before any burning operation. Generally, the process involves three interacting stages. In the First Stage, a coal liquefaction/pyrolysis procedure is utilized to drive off volatiles, and form a very low volatile char. The volatiles can be collected and utilized as a valuable oil product, such as for diesel fuel or the like. The char material is preferably pelletized and utilized as a reductant, in a Second Stage of iron reduction and melting.

Abstract: A smelting reduction process is carried out in a smelting reactor which includes a central internal carburization/combustion plenum or chamber in which hot metal is carburized by the injection of coal fines and heated by post combustion of the coal gases. The chamber has outlets to the first zone of an outer coaxial annular channel where the coal slag is separated off and a carburized hot metal passes into a second zone or smelting channel-chamber that permits introduction of feed material into a molten metal. A majority of the material that passes through the smelting channel-chamber is recycled to the internal carburization/combustion chamber for further processing. The internal carburization/combustion chamber and the smelting channel are completely separate so that the slag and the off gases from the two processes can be kept separate as well. The channel is positioned around the circumference of the internal carburization/combustion chamber where active heating occurs to form a compact reactor.

Abstract: A flash smelting furnace includes a reaction shaft defining a reaction chamber therein, a plurality of reaction air blowing pipes passing through the side wall of the reaction shaft for blowing reaction air into the reaction chamber, and at least one concentrate burner attached to the top end of the reaction shaft and comprising a concentrate chute, a tubular auxiliary fuel burner extending vertically through the chute, a tubular oxygen blowing pipe concentrically surrounding the auxiliary fuel burner and a dispersion cone attached to the lower end of the oxygen blowing pipe. The air from the blowing pipes disturbs the jet stream of mixed smelting material and reaction gas in the reaction chamber, thereby achieving a uniform mixture of the material and the reaction air and extending the retention time of the material in the reaction shaft.

Abstract: Lead in separated from a sulfidic concentrate by feeding a finely-divided concentrate, a silicate-high slagging agent, and air or oxygen-enriched air into the upper section of a suspension reaction shaft of a flash-smelting furnace in order to form a suspension and to oxidize the lead to lead oxide, by removing the gases via a riser pipe of the furnace and by discharging melt from a lower furnace of the flash-smelting furnace for further treatment. The slagging agent is fed at such a rate that substantially all of the melt is of the slag type and that all of the melt withdrawn from the lower furnace is directed to a reduction stage in order to reduce the lead silicate and to separate it as raw lead.

Abstract: A method and apparatus for smelting an ore concentrate or the like wherein the concentrate is first melted in an oxidizing atmosphere and the smelt is aftertreated with reducing gases to recover the metal values. The improvement consists in positioning a plurality of rows of lances in a smelting reactor in the direction of molten metal flow, the spacing between the rows of lances being substantially greater than the spacing between individual lances in each row. The reducing gas is blown with a high kinetic energy through each lance to cause an area of toroidal bath movement to occur where the gases from each lance impinge against the moving smelt. The spacing between the rows of lances is sufficiently large so that a relatively quiescent zone exists between the areas of toroidal bath movement between each of the rows. The molten metal and a relatively metal-free slag are withdrawn separately from the furnace enclosure.

Abstract: A method and apparatus for the continuous recovery of tin of low iron content from an iron rich concentrate wherein the concentrate is smelted in suspension in an atmosphere ranging from neutral to weakly reducing to produce a smelt containing tin and iron silicates, the smelt is reduced with a gaseous reduction agent under conditions of high velocity jet treatment, the reduction being at a suitable reaction temperature and with a reduction potential of reducing gas so as to substantially prevent the reduction of the iron silicate to metallic iron.

Abstract: Apparatus for reducing particulate iron oxide and producing molten iron in which coal and oxygen are injected into a molten iron bath to melt the iron, gasify the coal and produce a hot off-gas which is then used as the reductant in a counterflow shaft furnace to reduce iron oxide pellets and/or natural ore in a continuous manner. The hot reduced iron product from the shaft furnace is discharged directly into the molten iron bath from which the molten iron product is discharged.

Abstract: The invention is concerned with novel apparatus and process for converting crude carbon such as coal, carbonaceous wastes and the like into valuable chemical products and/or energy. A mass of solid crude carbonaceous fuel is fed into a high temperature liquid which acts as a solvent for carbon at a temperature sufficient to carbonize the mass and by which the carbon is separated from impurities. Volatile fractions are removed from the mass which acts as a distillation column. Air, or another oxygen source, is introduced into the reactor wherein it reacts with the carbon dissolved in the liquid therein, which may preferably be iron to form a hot fuel gas. The hot fuel gas is then used to produce useful energy, generally via a stepwise procedure.

Abstract: A suspension smelting furnace is disclosed for the suspension smelting of finely-grained oxide or sulfide ores and concentrates, and provided with a horizontal lower furnace to which have been connected the lower ends of at least one vertical suspension reaction zone and rising flow zone, with devices at the upper end of the suspension reaction zone for the production of a suspension of finely-grained oxide and sulfide ores or concentrates with air and oxygen, and for feeding this suspension downwards in the reaction zone at the lower end of which there are optionally means for the sulfidization or reduction of the suspension, and in the lower furnace under the suspension reaction zone there is the main smelt reaction zone in which the bulk of the suspension dissolves vertically in the smelt accumulated in the lower furnace main reaction zone, and in the rising-flow zone there are devices for removing the remaining suspension at its upper end.

Abstract: The blast furnace in the present invention comprises a V-shaped or an inclined hearth, tuyeres disposed along said hearth, a tap hole for discharging matte and/or slag, said tap hole being disposed at the lowest part of the hearth, and dampers having V-shaped or inclined fore end, each of said dampers being disposed to agree with said tuyeres. The present blast furnace, when employed for smelting by feeding briquetted Zn bearing materials as the material thereto and blowing preheated air therein through the tuyeres disposed along the hearth, displays an improved smelting efficiency in separating and recovering volatile valuable metals and non-volatile valuable metals.

Abstract: A suspension smelting furnace system for suspension smelting of finely-divided sulfidic and/or oxidic ores or concentrates is disclosed. The furnace system has a horizontal lower furnace to which the lower ends of at least one vertical suspension reaction shaft and one rising-flow shaft are connected, with devices at the upper end of the suspension reaction shaft for producing a suspension of the finely-divided raw material with an oxygen containing gas and for directing the suspension downwards in the reaction shaft perpendicular to the surface of melt accumulated in the lower furnace in order to discharge most of the suspension into the melt. The rising-flow shaft includes means for removing the residual suspension, and there are means for removing slag, metal and matte from the lower furnace.

Abstract: Starting materials continuously charged into a cyclone reactor are continuously discharged in molten state into a flow-through buffer hearth chamber from which the gases are withdrawn, the molten materials flowing continuously as received at one end of a relatively short flow area along the bottom of the chamber toward the opposite end of the chamber from which the molten materials are continuously discharged downwardly into the top of an upright axis centrifugal separator in which the materials are centrifugally separated into a metallic phase and a slag phase and respectively discharged through exits at the lower end of the separator and offset from the axis of the separator and radially spaced from each other.