Continuous Refining Patents (Class 266/215)
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Patent number: 9545667Abstract: A casting machine having a furnace body, a first heater, a first surface and pressure means. The furnace body has a melting portion and a holding portion, material being supplied and melted to form the molten metal in the melting portion, the holding portion holding the molten metal which has flowed out from the melting portion. The first heater heats the material supplied to the melting portion to melt it. The first surface is provided on a hearth surface of the melting portion and has concavities and convexities, the material to be heated being laid on the first surface.Type: GrantFiled: March 28, 2014Date of Patent: January 17, 2017Assignee: DENSO CORPORATIONInventors: Kazumasa Yasuda, Yuji Sakakibara, Naoto Uesaka, Atsushi Yamashita
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Patent number: 8883070Abstract: Exemplary embodiments of the invention provide a molten metal containment structure including a refractory molten metal containment vessel having an external surface, and a metal casing for the vessel having an internal surface at least partially surrounding the external surface of the vessel at a distance therefrom forming a spacing between the vessel and the casing. The spacing includes an unobstructed upwardly extending gap that is vented to the exterior of the structure by upper and lower openings in the casing. A layer of insulating material is preferably positioned in the spacing between the internal surface of the casing and the external surface of the vessel, with the layer of insulating material being narrower than the spacing at least at upwardly extending sides of the casing, thereby forming the unobstructed gap. The vessel may be a metal conveying trough, a housing for a metal filter, a container for a metal degasser unit, a crucible, or the like.Type: GrantFiled: December 8, 2010Date of Patent: November 11, 2014Assignee: Novelis Inc.Inventors: Eric W. Reeves, Jason D. Hymas, John Steven Tingey
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Patent number: 8613790Abstract: A lance for injecting a solid material into a vessel, such as a direct smelting vessel for producing molten iron, has a core tube assembly comprising a passageway for solid material. The core tube assembly has an inlet for receiving solid material at a rear end and an outlet for discharging material at a forward end. The core tube assembly comprises an outer tube of a structural material and an inner tube of a wear resistant material that are bonded together. A method of manufacturing the core tube assembly may include spin casting the outer tube of the structural material; spin casting the inner tube of the wear resistant material onto the inner surface of the outer tube; and metallurgically bonding the tubes together.Type: GrantFiled: June 19, 2008Date of Patent: December 24, 2013Assignee: Technological Resources Pty LimitedInventor: Bronislaw Jerzy Minko
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Publication number: 20130319176Abstract: What is proposed is a mixing and kneading machine (1) which is suitable, in particular, for continuously conditioning metals such as aluminium or magnesium for a subsequent die-casting operation. To this end, the mixing and kneading machine (1) has a worm shaft (3) which rotates and at the same time moves in translation in the axial direction in a housing (2). The temperature of both the housing (2) and the worm shaft (3) is controlled by means of a flowing gas in such a manner that the conditioned metal assumes a thixotropic state when it leaves the mixing and kneading machine (1).Type: ApplicationFiled: February 9, 2012Publication date: December 5, 2013Applicant: Buss AGInventors: Rico Trachsel, Martin Werner Trost, Martin Schotzau
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Publication number: 20110140318Abstract: Exemplary embodiments of the invention provide a molten metal containment structure including a refractory molten metal containment vessel having an external surface, and a metal casing for the vessel having an internal surface at least partially surrounding the external surface of the vessel at a distance therefrom forming a spacing between the vessel and the casing. The spacing includes an unobstructed upwardly extending gap that is vented to the exterior of the structure by upper and lower openings in the casing. A layer of insulating material is preferably positioned in the spacing between the internal surface of the casing and the external surface of the vessel, with the layer of insulating material being narrower than the spacing at least at upwardly extending sides of the casing, thereby forming the unobstructed gap. The vessel may be a metal conveying trough, a housing for a metal filter, a container for a metal degasser unit, a crucible, or the like.Type: ApplicationFiled: December 8, 2010Publication date: June 16, 2011Inventors: Eric W. Reeves, Jason D. Hymas, John Steven Tingey
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Patent number: 7618582Abstract: A process for continuous refining of steel via multiple distinct reaction vessels for melting, oxidation, reduction, and refining for delivery of steel continuously to, for example, a tundish of a continuous caster system, and associated apparatus.Type: GrantFiled: May 5, 2006Date of Patent: November 17, 2009Assignees: The Curators of the University of Missouri, The Board of Trustees of the University of IllinoisInventors: Kent D. Peaslee, Jörg J. Peter, David G. C. Robertson, Brian G. Thomas, Lifeng Zhang
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Publication number: 20090229415Abstract: Aspects of this molten aluminum refining system include a rotor based injection system which provides for the injection and dispersion of both gas and flux for refining molten aluminum.Type: ApplicationFiled: March 11, 2008Publication date: September 17, 2009Inventors: Robert A. Frank, Michael S. Klepacki
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Patent number: 7531126Abstract: The present invention relates to a powder fabricating apparatus. It is an object of the present invention to provide the powder fabricating apparatus, which is capable of obtaining metal powder in a rapid and continuous fashion, various kinds of oxide, or alloy powder. The powder fabricating apparatus for achieving the object of the present invention comprises a barrel wherein an inlet and an outlet are formed at both opposite ends thereof, respectively; a screw which is rotationally mounted in the barrel and by which reactant supplied from the inlet moves toward the outlet; a driving portion for causing a relative rotational motion between the screw and the barrel; reaction control means for controlling reaction conditions of the reactant which moves in the barrel; and a controller for controlling the driving portion and the reaction control means.Type: GrantFiled: July 1, 2003Date of Patent: May 12, 2009Inventor: Jae-Wan Oh
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Publication number: 20080296812Abstract: A degassing apparatus having duplex vacuum vessels for removing impurity gases from molten steel by backflow of molten steel thereby homogenizing molten steel composition. The apparatus includes duplex vacuum vessels of first and second vacuum vessels fixedly arranged at a predetermined interval to a floor which is provided horizontally at a predetermined height from a bottom; first and second ladle carriages arranged to run on first and second rails, respectively, to reciprocate between a treatment position directly under the first and second vacuum vessels and a tapping position where refined molten steel is tapped, each of the first and second ladle carriage loaded with a corresponding one of first and second ladles; and first and second lifting cylinders each for raising and lowering each of the first and second ladles in the treatment position so that a bottom end of each of the first and second vacuum vessels is immersed by molten steel in each of the first and second ladles.Type: ApplicationFiled: December 20, 2006Publication date: December 4, 2008Applicant: Posco Engineering & Construction Co., Ltd.Inventors: Byung-Kyu Jung, Han-Yung Kal, Jin-Ho Son, Young-Sik Shin, Uel-Duk Jin, Kyung-Bae Jin, Jae-Kyu Kim, Chai-Rok Lee
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Patent number: 6096110Abstract: The invention relates to a method for cleaning slag, created in metallurgical processes of non-ferrous metals, in an electric furnace, and particularly the method is related to a semi-continuous cleaning process. According to the novel method, the electric furnace is provided with at least two slag tapping holes, the lower of which is arranged on the same level as the tap hole in a conventional, batchwise operated furnace, and the second tap hole is located higher up, either at the height of the feed inlet or only slightly underneath it.Type: GrantFiled: March 25, 1998Date of Patent: August 1, 2000Assignee: Outokumpu OYJInventor: Tarmo Mantymaki
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Patent number: 5925165Abstract: In a method for processing solid residues from refuse incineration plants the slag is melted and heavy metals from the melt (16) are separated for reutilization. The slag is directly transferred from the refuse incineration plant into a first heating chamber (2) and melted there under oxidizing conditions. The melt (16) produced therefrom is transferred to a second heating chamber (3), in which the heavy metal compounds are reduced to their metallic form. Furthermore, additional finely divided residues, such as fly ash, boiler ash and filter dust, are introduced into the second heating chamber (3) via a hollow graphite electrode (19). The melt (16) is then passed on to a third heating chamber (4), in which the residual readily volatile metals are vaporized and the residual non-volatile metals are sedimented. The essentially heavy-metal-free melt is then cooled to form vitreous granules.Type: GrantFiled: May 22, 1996Date of Patent: July 20, 1999Assignees: Von Roll Umwelttechnik AG, Holderbank Financiere Glarus AGInventors: Karl Heinz Pflugl, Norbert Kiethe, Ernst Hugentobler, Hans Ruegg, Ruedi Frey, Anton Mayer, Theo Rey, Alfred Edlinger
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Patent number: 5398915Abstract: 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.Type: GrantFiled: October 29, 1993Date of Patent: March 21, 1995Assignee: Mitsubishi Materials CorporationInventors: Moto Goto, Nobuo Kikumoto, Osamu Iida, Hiroaki Ikoma, Shigemitsu Fukushima
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Patent number: 5346528Abstract: The present invention provides a continuous automatic steel making method and a facility which make it possible to make steel continuously and automatically by systematizing all steps of the steel making process. Steel is tapped from an electric furnace while steel making materials are continuously charged into the electric furnace. The tapped molten steel is delivered to a ladle supported by a conveying car. The conveying car is moved to a position associated with a continuous casting machine. The ladle containing the molten steel is moved from the conveying car to a position above a tundish of the continuous casting machine and the conveying car is then returned to the electric furnace. The molten steel is poured from the ladle into the tundish. All of the steps are continuously controlled and coordinated by a master controller.Type: GrantFiled: March 3, 1993Date of Patent: September 13, 1994Assignee: Kyoei Steel Co., Ltd.Inventors: Koichi Takashima, Shoji Nakamura
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Patent number: 5346531Abstract: An apparatus and method are disclosed for receiving molten slag and molten metal or alloy resulting from the smelting of ore from a cupola and for separating the slag from the molten metal or alloy. The slag separator of the present invention includes a refracting lining to protect the separator from the mechanical, chemical and thermal properties of the molten mixture. During the process of separation, the refractory however, suffers from erosion due to the mechanical, chemical and thermal properties of the mixture. A water cooling system is provided including water cooling jackets, provided on the outside of the refractory and surrounding the separation chambers, and water control valves to reduce refractory erosion and greatly increase refractory life. Further, vent holes may be provided in the refractory for venting any water which might leak from the water cooling system. In addition, the separator is provided with two chambers which allow the slag to rise to the top of the metal or alloy.Type: GrantFiled: May 21, 1993Date of Patent: September 13, 1994Assignee: Honda of America Mfg., Inc.Inventor: Frederick T. Streets
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Patent number: 5336296Abstract: The proposed method is characterized in that the liquid bath is constituted by the melt of low carbon steel and molten slag. Oxidation and reducing zones are created through which, along a closed path on the surface of the molten low-carbon steel, is circulated the molten slag, into which are blown powder slag materials which are melted with the heat of a fuel oxygen torch immersed into the melt. The melting is carried out in a melting reservoir shaped as a closed annular chamber (1) provided with partitions (11) hermetically dividing the gas space above the molten slag into oxidation (6) and reducing (7) zones.Type: GrantFiled: May 12, 1993Date of Patent: August 9, 1994Assignee: Scientific Dimensions USA, Inc.Inventor: Vitold M. Lupeiko
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Patent number: 5217527Abstract: There is disclosed a process for continuous copper smelting. At first, a smelting furnace, a separating furnace, a converting furnace, melt launders for connecting the smelting furnace, the separating furnace and the converting furnace in series, a plurality of anode furnaces and blister copper launders for connecting the converting furnace and the anode furnaces are provided. Then, copper concentrate is introduced in the smelting furnace, and melted and oxidized into a mixture of matte and slag. The mixture is received in the separating furnace and the matte is separated from the slag. Subsequently, the matte separated from the slag is oxidized to produce blister copper. Subsequently, the blister copper is caused to flow through the blister copper launders into one of the anode furnaces, and refined into copper of higher quality in the anode furnace. In the refining operation at the anode furnace, the receiving step and the oxidizing step are carried out at least partly in an overlapping fashion.Type: GrantFiled: November 20, 1991Date of Patent: June 8, 1993Assignee: Mitsubishi Materials CorporationInventors: Moto Goto, Nobuo Kikumoto, Osamu Iida
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Patent number: 5064174Abstract: 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.Type: GrantFiled: February 8, 1988Date of Patent: November 12, 1991Assignee: Northern States Power CompanyInventors: John M. Lehto, Raymond L. Smith
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Patent number: 4958809Abstract: A method of controlling the movement of particles entrained in a liquid metal flowing along a confined flow path having a substantially horizontal base characterized by the steps of:(1) disposing a first planar device within the flow path to cause the shedding of vortices downstream of the device so that particles having a predetermined range of terminal velocities are trapped within the vortices and agglomerated into clusters of particles.(2) causing the agglomerated particles to be sedimented either upwardly or downwardly and(3) establishing a flow pattern downstream of the first device in which the local Reynolds number decays to a value sufficiently lower than 10.sup.3 to result in essentially laminar flow of the metal so as to minimize re-entrainment and subsequent break up of the agglomerated particles.Type: GrantFiled: August 2, 1989Date of Patent: September 25, 1990Assignee: Alcan International LimitedInventors: Patrick P. Wai, Steven Rogers
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Patent number: 4844425Abstract: Apparatus for on-line degassing and filtering aluminum and its alloys, constituted by a thermally insulated container body, provided with a removable lid (2) incorporating heating means (7) for heating the metal to be processed, said container body being internally subdivided, by means of a vertical partitioning wall (11) into two chambers communicating with each other only near the bottom of the container, wherein in one of said two chambers, provided with an inlet for the liquid metal to be processed, injection means (13, 14) are provided, for injecting inert, and/or active gases, which are so located as to perform a degassing in countercurrent relatively to the entering metal stream, while at the bottom of the second chamber at least a substantially horizontal plate, or wall (12) is provided, made of a porous material, such as ceramic, graphite, or the like, which is positioned spaced apart from the bottom of the container, such to allow the metal, coming from the first chamber, to flow upwards, and pass tType: GrantFiled: April 18, 1988Date of Patent: July 4, 1989Assignee: Alumina S.p.A.Inventors: Leonardo Piras, Giuseppe Lazzaro
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Patent number: 4790516Abstract: A reactor for iron making having an upper gas blowing nozzle, a lower gas blowing nozzle, and an iron scrap charging inlet. A vertical shaft is installed directly above the inlet at the top part of the reactor. A mechanism is provided in the lower end of the vertical shaft for controlling charging of the iron scrap to the reactor. A by-pass tube is connected between the top part of the reactor and a gas inlet in the vertical shaft directly above the mechanism for controlling the charging of iron scrap and permits exit of high temperature exhaust gases from the reactor and introduces the exhaust gases to flow through the iron scrap in the vertical shaft to pre-heat the same. Structure is provided in the by-pass tube for introducing oxygen gas or air into the high temperature exhaust gases to react therewith and generate further heat. The structure can comprise a nozzle.Type: GrantFiled: May 21, 1986Date of Patent: December 13, 1988Assignee: Daido Tokushuko Kabushiki KaishaInventors: Saburo Sugiura, Masanobu Ikeda, Noboru Demukai
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Patent number: 4786321Abstract: A method and apparatus for the continuous melting of an iron-containing material in a melting device, the melting device being composed of a vertical shaft having a central axis, a melting furnace disposed below, and communicating with, the shaft, the melting furnace being asymmetrical to the central axis and being formed to have a region which is furthest removed from the central axis, at least one first nozzle opening into the furnace, located in the vicinity of the furnace bottom in the region furthest removed from the central axis, and at least two second nozzles opening into the furnace and located above the furnace bottom.Type: GrantFiled: March 13, 1987Date of Patent: November 22, 1988Assignee: Fried. Krupp Gesellschaft mit beschrankter HaftungInventors: Thomas Hoster, Dieter Neuschutz, Wolf-Dieter Ropke
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Patent number: 4784374Abstract: An aluminum refining vessel has two refining stages positioned side-by-side, with flow of molten aluminum into and out of the vessel being from the same side thereof. The vessel is readily adaptable for the reversal of flow therethrough, and for ease of installation, operation and maintenance.Type: GrantFiled: May 14, 1987Date of Patent: November 15, 1988Assignee: Union Carbide CorporationInventor: John F. Pelton
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Patent number: 4645186Abstract: The present invention relates to a method and apparatus for treating sulphide concentrates of sulphide ores in order to produce raw metal in one and the same process unit (1). According to the invention, the molten matte (5) received from suspension smelting is solidified (7) and, if necessary, crushed (8) and ground (9), whereafter the solid matte (5) is returned into the process unit (1) through the converting shaft (10) located therein. In the converting zone (15) the matte (5) is converted into raw metal (12) by means of a two-phase method. The exhaust gases both from the smelting zone (16) and from the converting zone (15) are discharged through a common uptake shaft (4). Moreover, the slags (6,11) from both zones can be discharged through the same tap hole (17), whereas the matte (5) and the raw metal (11) are advantageously removed from the process unit (1) each through a specific individual tap hole (18,19).Type: GrantFiled: February 7, 1986Date of Patent: February 24, 1987Assignee: Outokumpu OyInventor: Teuvo P. T. Hanniala
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Patent number: 4607825Abstract: The present invention relates to a ladle for the chlorination in co-flow mode of aluminium alloys in a molten state.It is divided by a vertical partition (6) which, with the bottom, leaves a space (7) for the flow of the metal, into a feed compartment (8) and a treatment compartment (9) in which a chlorinated gas distributor rotor (10) is immersed. It is characterized in that the treatment compartment is closed at its base by a horizontal wall (13) which extends at the level of the bottom of the partition and which is apertured at its center by an opening whose axis coincides with the axis of rotation of the rotor.It is used in the removal of magnesium from aluminium alloys and, with ladles of a capacity of close to 1 m.sup.3 and which can therefore be easily maneuvered, it makes it possible to attain treatment capacities of the order of 20 T/hour with suitable levels of efficiency in regard to the removal of magnesium.Type: GrantFiled: July 8, 1985Date of Patent: August 26, 1986Assignee: Aluminum PechineyInventors: Emile Briolle, Jean-Marie Hicter, Adolfo Mateos
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Patent number: 4589634Abstract: A furnace for smelting nonferrous metals and/or for holding nonferrous metal melts is proposed which has a multiple-chamber trough having at least one filling chamber, at least one smelting chamber and/or one holding chamber and at least one drain chamber, and at least one lid for covering the smelting chamber and/or the holding chamber. The filling chamber communicates with the smelting or holding chamber through a passage and the smelting or holding chamber communicate with the drain chamber through another passage. All passages are located beneath the surface of the metal melt introduced into the furnace. The furnace also has a tapping-off device including a stationary molded piece located at the bottom of the drain chamber where it defines an outflow opening, and a tubular tap plug which is rotatably mounted to the stationary molded piece at one end and extends outwardly from the furnace with its other end.Type: GrantFiled: March 17, 1983Date of Patent: May 20, 1986Inventor: Gerhard Bleickert
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Patent number: 4544141Abstract: A continuous process and apparatus for converting non-ferrous mattes is disclosed. The process comprises feeding continuously or intermittently a liquid matte into a furnace while continuously blowing air, oxygen or oxygen-enriched air into the melt contained in the furnace at a rate in balance with the rate of liquid feed matte and the desired degree of oxidation, introducing flux into the furnace at a rate in balance with the feed matte and air, oxygen or oxygen-enriched air, and removing slag from the top of the melt and a refined product from beneath the melt while continuously blowing air, oxygen or oxygen-enriched air through the melt.Type: GrantFiled: December 21, 1984Date of Patent: October 1, 1985Assignee: Noranda Inc.Inventors: Phillip J. Mackey, J. Barry W. Bailey
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Patent number: 4456231Abstract: An apparatus for continuously refining molten crude lead including a furnace for removal of antimony from the crude lead regardless of whether the crude lead does or does not contain arsenic and/or tin. The furnace is of the reverberatory type having a plurality of transverse walls dividing the interior thereof and thus the lead into a number of distinct but connected compartments with the passageways through the transverse walls being staggered so that molten lead passes along a zigzag or tortuous path through the furnace which is lined with a refractory material. Air is injected into the molten crude lead as it passes from the inlet end of the furnace to the discharge end for progressive softening of the crude lead. The low antimony content slags produced near the lead discharge end of the furnace becomes progressively enriched in antimony as they react with the higher antimony content metal as they pass toward the lead inlet end where they are discharged at a slag overflow device.Type: GrantFiled: December 21, 1982Date of Patent: June 26, 1984Assignee: Paul Bergsoe & Son A/SInventor: Svend Bergsoe
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Patent number: 4385931Abstract: Raw magnesium is charged into a precipitation chamber in a refining furnace beneath the metal surface as a stream directed toward a salt layer beneath the metal. The resultant precipitated sludge is directed along a sloped bottom in the chamber to an adjacent accumulating chamber. Magnesium rises in the precipitation chamber and passes through openings in partition walls between adjacent precipitation chambers. The purest magnesium from an upper metal layer in one chamber is expelled to a lower level in next chamber in the process direction. The refining furnace comprises an accumulating chamber for sludge and plurality of successively arranged precipitation chambers divided from each other by vertical walls. The openings in the partition walls between adjacent precipitation chambers are designed as skewed channels with an inlet at a higher level than an outlet in the following chamber.Type: GrantFiled: October 29, 1981Date of Patent: May 31, 1983Assignee: Norsk Hydro a.s.Inventors: Oddmund Wallevik, Jan B. Ronhaug
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Patent number: 4294433Abstract: A method for processing heavy nonferrous metal raw materials by heating and melting said raw materials in a molten slag with the formation of a heterogeneous melt consisting of a sulfide and an oxide phases. The melt is bubbled oxidized by injecting a gas containing not less than 35% oxygen at an intensity of about 200 to about 2000 m.sup.3 STP/h per square meter of horizontal section of the melt, with the effect that the melt is divided into a top bubbled part and a bottom calm part comprising a slag layer, a matte layer and/or a crude metal layer, each of which is tapped separately. A furnace for putting said method into effect is a shaft terminating in its bottom part by a hearth and having devices for tapping smelting products, whereas the top part is provided with orifices for feeding a charge and removing gaseous smelting products. The furnace has cooled side tuyeres set at a level dividing the shaft into two vertical parts.Type: GrantFiled: July 30, 1980Date of Patent: October 13, 1981Inventors: Andrei V. Vanjukov, Valery V. Mechev, Valentin P. Bystrov, Evgeny I. Ezhov, Mikhail G. Vasiliev, Vladimir Y. Zaitsev, Vladimir A. Romenets, Vladimir V. Ivanov, Sergei Y. Golik, Evgeny S. Grin-Gnatovsky, Alexandr V. Grechko, Ivan V. Savin, Sultanbek M. Kozhakhmetov, Veniamin B. Meierovich, Vladimir D. Nagibin, Nariman A. Ramazanov, Almas B. Umarov, Valentin E. Ziberov, Askar M. Kunaev, Sauk T. Takezhanov, Petr A. Alexandrov, Boris I. Kolesnikov, Dzhonson T. Khagazheev
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Patent number: 4213599Abstract: In a apparatus for the production of aluminium a molten alumina slag, containing combined carbon is circulated through one or more alternately arranged relatively low temperature zones where carbon is added to increase the combined carbon content of the slag by reaction with the alumina slag and high temperature zones where aluminium metal is released by reaction of aluminium carbide and alumina in the slag with consequent depletion of the combined carbon content. Alumina is supplied to the slag at one or more locations. The energy to drive the reactions is preferably supplied by resistance heating of the slag particularly in transit from a low temperature zone to a high temperature zone although usually additional energy is supplied to the slag in the return from a high temperature zone to the next low temperature zone.In most instances the aluminium-liberating reaction is carried out in an upwardly inclined passage and the gas evolved is employed to achieve the circulatory movement of the slag.Type: GrantFiled: May 26, 1978Date of Patent: July 22, 1980Assignee: Alcan Research and Development LimitedInventors: Ernest W. Dewing, Jean-Paul R. Huni, Raman R. Sood, Frederick W. Southam
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Patent number: 4208041Abstract: A metallurgical apparatus; air is continuously blown into a mixture of agglomerates of lead concentrates and carbonaceous fuel in a shaft furnace. The resulting slag is delivered from the shaft furnace into a settling tank to which the slag continuously flows while the slag is continuously delivered from the settling tank into a fuming furnace, so that the slag flows in cascade from the shaft furnace to the settling tank and from the settling tank to the fuming furnace, thereby providing a continuous flow of the treated slag from the shaft furnace through the settling tank into the fuming furnace; the slag, in addition, is continuously withdrawn from the shaft furnace.Type: GrantFiled: August 29, 1977Date of Patent: June 17, 1980Inventors: Jordan T. Jordanov, Georgi I. Abrashev, Velyu D. Jekov, Georgi T. Georgiev, Georgi A. Haralampiev, Janco H. Janev, Velcho A. Prodanov
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Patent number: 4200265Abstract: A furnace for the melting and refining of raw copper and/or blister copper comprises a shaft furnace having a lock-chamber feeder for the material at the top of the shaft furnace and an opening into a hearth furnace in which the copper is refined. The shaft furnace and the hearth furnace are constructed unitarily with one another with the shaft furnace surmounting the hearth furnace in such manner that, when the apparatus has been charged, a pile of copper is formed which is supported on the bottom of the hearth furnace and slopes toward a portion of the length of the hearth furnace.Type: GrantFiled: July 27, 1978Date of Patent: April 29, 1980Assignee: Norddeutsche AffinerieInventors: Gerhard Berndt, Gerhard Kapell, Anton Schummer, Jens U. Hansen
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Patent number: 4159104Abstract: The disclosure teaches an improvement in the degassing and filtration of molten metal, especially aluminum, using an apparatus which employs a pair of sequentially placed, removable filter-type plates and at least one fluxing gas inlet positioned therebetween. The first of said filter-type plates is characterized by a plurality of holes which provide a preferential path through which the fluxing gas flows upwardly through the first of said filter plates in countercurrent contact with the melt. Said plate serves to break up said fluxing gas into a fine dispersion to assure its intimate and extensive contact with the melt. Dissolved gases and non-metallic inclusions are thereby abstracted and removed from the melt.Type: GrantFiled: April 26, 1978Date of Patent: June 26, 1979Assignee: Swiss Aluminium Ltd.Inventors: Jonathan A. Dantzig, Derek E. Tyler
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Patent number: 4093194Abstract: Magnesium metal is made by injecting sodium metal beneath the surface of a magma of MgCl.sub.2 and withdrawing molten magnesium metal from the magma surface.Type: GrantFiled: December 28, 1976Date of Patent: June 6, 1978Assignee: E. I. Du Pont de Nemours and CompanyInventors: Norval D. Clare, Charles H. Lemke
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Patent number: 4087080Abstract: A metal melt is filtered by causing the melt to flow successively into a filter chamber, downwards through the filter chamber, into a riser chamber, upwards through the riser chamber, and out of the riser chamber, and simultaneously introducing a counter-current flow of gas into the filter chamber, while the filter chamber contains a loose bed of granulate, whereas in the riser chamber there is no granulate nor is gas introduced therein.Type: GrantFiled: February 5, 1976Date of Patent: May 2, 1978Assignee: Swiss Aluminium Ltd.Inventors: Alfred Steinegger, Robert Moser
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Patent number: 4085923Abstract: 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.Type: GrantFiled: September 29, 1975Date of Patent: April 25, 1978Assignee: Q-S Oxygen Processes, Inc.Inventors: Paul E. Queneau, Reinhardt Schuhmann, Jr.
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Patent number: 4073481Abstract: Apparatus for the continuous sulphur drossing of lead to reduce its copper content including a plurality of reaction vessels arranged in series, each reaction vessel having a curved bottom and a stirrer for creating a vortex of the contents. Bullion and sulphur are fed into the series through a vortex at controlled rates and through the series at controlled temperatures and a controlled total reaction time, optimally between 8 and 15 minutes. The bullion, dross and unreacted sulphur, if any, are overflowed from vessel to vessel and into an unagitated vessel for separation of the dross and bullion. The bullion feed device splits the undrossed bullion into a metered stream and an unmetered stream, the unmetered stream being utilized to carry away the separated dross for further processing.Type: GrantFiled: July 14, 1976Date of Patent: February 14, 1978Assignees: The Broken Hill Associated Smelters Proprietary Limited, Monash UniversityInventors: Frank Lawson, Denby H. Ward, Robert G. Kelly
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Patent number: 4054275Abstract: A method and apparatus for producing modified grey iron, and particularly nodular cast iron, is disclosed. The apparatus comprises refractory elements including an inclined flow course for continuous reception of molten grey iron, a V-shaped inclined receptacle interposed in said course into which a predetermined supply of modifying agent, such as magnesium, is injected to react with said iron, and means for controlling the egress of iron from the receptacle in order to sequentially stage the build-up and dissipation of a pool of iron in said receptacle facilitating chemical reactions and thorough mixing for attaining and improving the homogeneity of the modified iron elements. The product and composition uniquely is characterized by about 3.5 carbon, by weight, 2.5% silicon, 0.2-0.9Mn sulfur no greater than 0.015%, the remainder being essentially iron; the composition is devoid of carbide and dross or slag and has a graphite nodule count of at least 400 per square millimeter in a 1/2inch section.Type: GrantFiled: February 2, 1976Date of Patent: October 18, 1977Assignee: Ford Motor CompanyInventors: Gerald S. Cole, Bela V. Kovacs, Robert A. Sensoli, Herschel B. Smartt
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Patent number: 4052043Abstract: The continuous refining of molten metal is carried out in a refining apparatus having communicating first and second refining stage spaces. Refining gas, such as oxygen, is blown into the molten metal in the presence of a slag layer on the molten metal. The molten metal and the slag are conveyed as two separate non-intermingled streams through the refining stage spaces, as distinguished from a slag-metal emulsion. The slag in the second refining stage space is caused continuously to flow back into the first refining stage space to form a slag layer on the molten metal in the first refining stage space. Refining gas is blown into the molten metal in the first refining stage space below the slag layer, and the molten metal is conveyed from the first refining stage space to the second refining stage space while preventing the flow of slag from the first refining stage space to the second refining stage space.Type: GrantFiled: June 30, 1976Date of Patent: October 4, 1977Assignee: Stahlwerke Peine-Salzgitter AGInventors: Paul Rheinlander, Gustav Mahn, Klaus Schulz, deceased, Ingrid Ruhland, legal representative, Klaus Berner
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Patent number: 4042228Abstract: Apparatus for debismuthising lead containing one or more alkaline earth metals or alloys thereof, including a separation vessel having independently temperature-controlled upper liquation and lower separation zones, devices for adding a reagent selected from the group consisting of antimony, arsenic and alloys containing antimony and/or arsenic to the input lead to form a crust/bullion mixture and continuously and directly introducing the crust/bullion mixture into the lower separation zone of the vessel at a point below the upper liquation zone, the crust particles being separated from the bullion in the lower separation zone and moving upwardly in the vessel, the entrained lead being separated from the crust particles in the upper liquation zone and moving downwardly in the vessel, the enriched crusts being removed from the upper surface of the material in the vessel, and the debismuthised product lead being withdrawn from near the lower end of the lower separation zone.Type: GrantFiled: August 18, 1976Date of Patent: August 16, 1977Assignee: The Broken Hill Associated Smelters Proprietary LimitedInventors: Denby Harcourt Ward, James Dixon Iley
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Patent number: 4031309Abstract: An electric furnace has an inlet opening for introduction of starting materials in the upper region thereof. A pre-melting vessel is arranged above the furnace and has a discharge opening above and in communication with the inlet opening of the furnace. The bottom portion of the furnace is formed with a depression in which the starting material forms a body after its introduction through the inlet opening and is heat-treated so as to obtain slag and steel. The furnace is provided at its sides with a pair of mounting members each having a cam surface of part-circular configuration having a center on an axis which extends substantially horizontally and is located at the inlet opening of the furnace. A plurality of rollers engages the cam surfaces, the rollers being mounted on a support for rotation about their axes.Type: GrantFiled: October 22, 1975Date of Patent: June 21, 1977Assignee: Klockner-Werke AGInventors: Manfred Chitil, Gotthard Hubatsch
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Patent number: 4025059Abstract: An apparatus for the continuous production of steel comprising a generally vertical shaft melting zone having a floor, a generally horizontally running refining zone in fluid communication with a lower region of said vertical shaft, the floor of said refining zone disposed at an inclination with respect to the floor of said shaft, said horizontally running refining zone being in fluid communication with an oxidation zone comprising a well disposed below the level of the floor of said horizontally running refining zone.Type: GrantFiled: April 8, 1975Date of Patent: May 24, 1977Assignee: Fried. Krupp Huttenwerke AGInventors: Eberhard Steinmetz, Jurgen Kuhn
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Patent number: 4021026Abstract: An externally heated cast iron vessel, intended for containing a reactive molten metal, such as aluminum, is made resistant to attack by the molten metal, thereby increasing its useful service life and minimizing contamination of the melt, by lining the inside of the cast iron shell with a plurality of inert self-supporting, refractory plates, of for example, graphite, in such manner that the plates are free to move along their joints as well as relative to the shell upon thermal expansion, and permitting the molten metal to penetrate behind the lining through the joints and crevices therein opened by thermal expansion, thereby producing a refractory layer, in situ in the space between said lining and the inside surface of said cast iron shell, comprising a solid (FeAl.sub.3) reaction product of iron and said molten metal.Type: GrantFiled: June 4, 1976Date of Patent: May 3, 1977Assignee: Union Carbide CorporationInventor: Andrew Geza Szekely
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Patent number: 4001013Abstract: A method of operating a reverberatory furnace for copper smelting, wherein an oxygen fuel burner is provided in addition to the main fuel oil burners, and the oxygen content and flow rate of the oxygen-fuel gas mixture is so adjusted that the latent heat due to CO and H.sub.2 produced through the combustion in the combustion gas can be utilized at its maximum for increasing the smelting speed and SO.sub.2 content.Type: GrantFiled: September 29, 1975Date of Patent: January 4, 1977Assignee: Onahama Seiren Kabushiki KaishaInventors: Motoo Goto, Minoru Fujiwara, Makoto Ishikawa
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Patent number: 3980283Abstract: An apparatus for performing a continuous metallurgical refining process in which metal and slag contact one another comprising a counter-current channel in which nozzles are passed through longitudinal side walls of the channel in the region of the predetermined boundary surface between metal and slag, the discharge directions of the nozzles being disposed parallel to or at an inclination to the predetermined boundary surface.Type: GrantFiled: April 26, 1974Date of Patent: September 14, 1976Assignee: Gesellschaft zur Forderung der Eisenhuttentechnik mbHInventors: Eberhard Steinmetz, Jurgen Kuhn
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Patent number: 3971549Abstract: Metal in the molten state is transferred from one treating stage or zone to a succeeding stage or zone by gravity flow, the flow from one zone to the next being controlled by gas pressure, thus eliminating the need for valves, gates or similar moving parts. The process is particularly adapted to the treating of ferrous metal, more particularly to the making of steel. By providing sufficient zones in the series a continuous process can be run, starting with feed from a blast furnace, and conducting the material through alloying stages and a degassing stage and into a continuous casting zone.Type: GrantFiled: March 5, 1975Date of Patent: July 27, 1976Inventor: Alan L. Habig