By Separating Metal In A Molten Mass From Undesired Material, E.g., Slag Patents (Class 266/227)
  • Patent number: 5906790
    Abstract: An incremental rotational system for an aluminium dross processing head includes lever means actuated by the head as it rises to rotate the head by a defined amount, no independent drive system being required.
    Type: Grant
    Filed: July 14, 1997
    Date of Patent: May 25, 1999
    Inventor: Alan Bramley
  • Patent number: 5882580
    Abstract: In a dross press the skim box containing the dross is vibrated to subject the dross to a vibrating motion thereby extracting additional aluminium from the dross.
    Type: Grant
    Filed: July 24, 1998
    Date of Patent: March 16, 1999
    Assignee: J. McIntyre (Machinery) Limited
    Inventor: Michael Pownall
  • Patent number: 5827982
    Abstract: A device for measuring metal purity, comprising a receptacle for holding a sample of molten metal, the receptacle being made, at least internally, from an insulating refractory material and having a bottom wall provided with a hole containing a filter element. The bottom wall is substantially impermeable to air except at the hold. An enclosed collection vessel is positioned below the receptacle for collecting molten metal which passes through the filter element from the receptacle, the collection vessel having an opening permitting extraction of gas from within the vessel to enable a vacuum to be generated within the vessel during use of the device. A leak-tight seal is established between the receptacle for molten metal and the collection vessel to permit vacuum generated in the collection vessel to draw molten metal into the collection vessel from the receptacle through the filter.
    Type: Grant
    Filed: February 25, 1997
    Date of Patent: October 27, 1998
    Assignee: Alcan International Limited
    Inventors: Don Allen Doutre, Gary Hay, Peter Alexander Wales
  • Patent number: 5811056
    Abstract: A cooling system for an aluminum dross press head includes an air inlet means allowing air to be drawn into the press head and a hollow actuating rod connected to the press head which extracts air from the press bead.
    Type: Grant
    Filed: June 27, 1997
    Date of Patent: September 22, 1998
    Inventor: Alan Bramley
  • Patent number: 5788918
    Abstract: A dross press is enclosed within a cabinet which is normally maintained at a negative pressure relative to ambient air pressure. The cabinet is provided with locked doors to prevent egress of explosive gases or pieces of metal. The cabinet is also equipped with safety vents at a high level to prevent destruction of the cabinet by internal explosions. The cabinet also is provided with a fan for extracting fumes therefrom. The fan is connected to a purifier to treat the extracted fumes and air inlet holes in the press head so that the fan may draw air through the head for cooling.
    Type: Grant
    Filed: June 27, 1997
    Date of Patent: August 4, 1998
    Inventor: Alan Bramley
  • Patent number: 5762682
    Abstract: In steel-making, there are conflicting processing requirements at different stages of the process. The method and apparatus of the invention creates different processing conditions at different stages of the process. Molten ferrous material (2) is stirred by bubbling a gas therethrough. A refractory ring (10) is first partially immersed in the molten steel within a substantially slag free portion of the surface of the molten ferrous metal to form a bounded substantially slag-free area. The molten steel is then heated by the introduction of exothermically reacting heating agents such as aluminium and oxygen through an oxygen gas line (7) and an aluminium delivery tube (9), respectively. The refractory ring (10) is then removed from the molten steel when the steel has reached a predetermined temperature and air is then excluded from the volume above the molten steel by placing a hood (16) over the ladle containing the molten steel. Sulphur is then removed from the steel.
    Type: Grant
    Filed: August 21, 1995
    Date of Patent: June 9, 1998
    Assignee: Vacmetal Limited
    Inventor: John Rushe
  • Patent number: 5755889
    Abstract: Apparatus and a method for recovering solder from dross. Dross is poured into a heated chamber (1). The heated dross is then compressed by a piston (21) to force good solder out of the dross into a collecting tray (17).
    Type: Grant
    Filed: November 29, 1995
    Date of Patent: May 26, 1998
    Assignee: Apple House Elecronics Ltd.
    Inventor: Stephen Anthony Johnson
  • Patent number: 5733500
    Abstract: Molten metal (e.g., on its way to a continuous casting machine for forming a bar that will be rolled into a rod to be drawn down to wire) is filtered to remove particulate impurities by passing it through at least one and preferably several ceramic filters. In addition, the molten metal is degassed by injecting a flushing gas into the metal through one or more porous plugs in the bottom of the chamber through which the molten metal flows. A partial vacuum column above each porous plug is used to help pull gas up through and out of the metal.
    Type: Grant
    Filed: March 7, 1996
    Date of Patent: March 31, 1998
    Assignee: Phelps Dodge Industries, Inc.
    Inventors: George M. Meseha, Fausto Tavares
  • Patent number: 5683650
    Abstract: A bubble-actuated pump is used for removing dross from the surface of a bath of molten metal. A modification of the pump is employed for delivering molten metal to the dross for diluting it.
    Type: Grant
    Filed: June 12, 1995
    Date of Patent: November 4, 1997
    Inventor: Jorge A. Morando
  • Patent number: 5676731
    Abstract: An apparatus and method for filtering molten metal are disclosed. The apparatus utilizes a continuous filtering medium that is serially indexed into the metal filtering area. The apparatus may be used to filter ferrous and non-ferrous metals, and provides significant cost and time savings. In one embodiment the apparatus allows automatic indexing of a new filter for each shot or pour on high production casting machines. In another embodiment the apparatus is adapted to filter large amounts of metal up to 5,000 pounds or more.
    Type: Grant
    Filed: August 30, 1996
    Date of Patent: October 14, 1997
    Inventor: Jay Hitchings
  • Patent number: 5673902
    Abstract: There is provided a dual stage ceramic foam molten metal filtration system and method. Coarse and fine filters are mounted adjacent to one another in a molten metal flow path. A convection preheat apparatus provides preheat for both filters. A vent structure is included to vent air which may be trapped in a gap which is formed between the two filters.
    Type: Grant
    Filed: February 1, 1996
    Date of Patent: October 7, 1997
    Assignee: Selee Corporation
    Inventors: Leonard S. Aubrey, Clifton L. Oliver, Bruce T. MacPhail
  • Patent number: 5669957
    Abstract: A dross compression apparatus and method utilizes a dross compression head and a skim box or collector having mating ribs. The ribs may be any type of projection or shape of the head and skim box sufficient to form grooves in both sides of the dross which divide or substantially divide the dross. Improved plating of the aluminum metal and separation of the aluminum layers from the aluminum oxide are achieved by using pressures in the range of 50 to 70 pounds per square inch. The ribs by their cutting action through the dross enable the achieving of these pressures with lower rated hydraulic presses. Two specific embodiments are disclosed, one utilizing an elongated substantially hemispheric shaped head and the other utilizing a substantially hemispheric shaped head. In both embodiments, the head and receptacle or skim box are of substantially conforming shapes.
    Type: Grant
    Filed: June 12, 1996
    Date of Patent: September 23, 1997
    Assignee: Altek International, Inc.
    Inventor: David J. Roth
  • Patent number: 5645792
    Abstract: A slag control shape is releasably mounted on a mounting member carried on a cover of a molten metal vessel. A movable member is carried on the cover and moved by an actuator into engagement with and moving the mounting member to move the mounting member to a position releasing the slag control shape for insertion into the molten metal vessel. The actuator is a fluid operated cylinder having an extensible piston rod which is engageable with the movable member to move the movable member into engagement with the mounting member. A valve actuated remotely from the cover supplies pressurized fluid to the cylinder to extend the piston rod. Alignment sensors are mounted on the cover and an actuator support to ensure that the cover is rotatably positioned on the molten metal vessel to align the actuator and movable members.
    Type: Grant
    Filed: January 16, 1996
    Date of Patent: July 8, 1997
    Assignee: AJF, Inc.
    Inventors: Gary L. Forte, David B. Vinson, Thomas Connors
  • Patent number: 5639419
    Abstract: A fabricated bubble operated pump for diluting dross in a steel treating bath.
    Type: Grant
    Filed: September 18, 1995
    Date of Patent: June 17, 1997
    Inventor: Jorge A. Morando
  • Patent number: 5599379
    Abstract: Method and apparatus for recovering free aluminum from a metal bearing dross containing free aluminum metal and oxides of the metal. Hot dross is collected from a hot dross source into a vessel, and the vessel is placed into a sealable storage container. The storage container is insulated to maintain heat generated by the hot dross within the interior of the storage container to maintain the dross at or near its temperature when first placed in the storage container. An inert gas is then introduced into the container to purge the container of all gasses other than the inert gas. The inert gas reduces thermiting of the hot dross and limits the cooling of the hot dross in order to maintain the hot dross at an elevated temperature while the hot dross remains in the storage container. The dross is then removed from the vessel and introduced dross into a dross processing device such as a furnace.
    Type: Grant
    Filed: March 29, 1995
    Date of Patent: February 4, 1997
    Inventors: Han Spoel, William A. Zebedee
  • Patent number: 5567378
    Abstract: A holding furnace apparatus for holding molten metal and a molten metal holding method using the same are provided. The holding furnace includes generally a furnace body defining therein a reservoir chamber in which molten metal is held, an inlet port through which an ingot is supplied, an outlet port through which the molten metal held in the reservoir chamber is drawn outside, and an upper furnace wall defining the reservoir chamber together with the furnace body. The upper furnace wall has an inclined wall surface which is, when the reservoir chamber is filled with the molten metal at a given level, exposed to the molten metal so as to direct impurities contained in the molten metal rising to the surface of the molten metal to the inlet port.
    Type: Grant
    Filed: February 10, 1995
    Date of Patent: October 22, 1996
    Assignee: Nippondenso Co., Ltd.
    Inventors: Shunji Mochizuki, Hiromi Takagi, Masahiko Hoshino, Sumi Yoshikawa
  • Patent number: 5556592
    Abstract: An apparatus and method for filtering molten metal are disclosed. The apparatus utilizes a continuous filtering medium that is serially indexed into the metal filtering area. The apparatus may be used to filter ferrous and non-ferrous metals, and provides significant cost and time savings. In one embodiment the apparatus allows automatic indexing of a new filter for each shot or pour on high production casting machines. In another embodiment the apparatus is adapted to filter large amounts of metal up to 5,000 pounds or more.
    Type: Grant
    Filed: August 15, 1994
    Date of Patent: September 17, 1996
    Inventor: Jay Hitchings
  • Patent number: 5527018
    Abstract: In a filter unit (25) and apparatus for desludging salt baths (1), which is flooded at least partially by the salt bath and is in working association with the upper end of a riser tube (23), the bath fluid to be desludged being driven, by means of a compressed air stream, for example, through the riser tube (23) toward the filter unit (9, 25), the filter cloth packet is made of woven wire of a nonferrous metal, preferably an alloy based on aluminum, nickel or titanium, and is surrounded by a filter frame (14), the frame (14) being shaped into a shallow, pyramidal frustum-shaped funnel (18) pointing toward the bottom of the vat, its apical bottom end being provided with a closable opening (19).
    Type: Grant
    Filed: November 21, 1994
    Date of Patent: June 18, 1996
    Assignee: Durferrit GmbH Thermotechnik
    Inventors: George Wahl, Matthias Kremer, Tokuo Sato
  • Patent number: 5511766
    Abstract: A vessel used for transfer of molten metal having a refractory filter wall with filters for removing inclusion from molten metal as it flows through the vessel. The refractory filter wall having passages sized according to a predetermined volume of molten metal that is to be filtered, the desired flow rate of molten metal through the vessel and the limiting characteristics of the filters. In another aspect of the invention, protrusions are provided on refractory walls of the vessel to enhance deposition of non-metallic inclusions on the protrusions by disrupting the boundary layer flow in the molten metal.
    Type: Grant
    Filed: September 28, 1994
    Date of Patent: April 30, 1996
    Assignee: USX Corporation
    Inventor: Achilles Vassilicos
  • Patent number: 5451035
    Abstract: The invention relates to a furnace (1) for melting metal-bearing substances and/or production of liquid metal (4) of the type in which said metal (4) has above it a layer of slag (5) liable to be affected by a "foaming" phenomenon, in which a side wall of said furnace comprises an orifice (17) opening into an adjacent tank (22) capped with a vault (25), said tank (22) being capable of collecting a proportion of said slag (5) by overflowing through said orifice (17) when said foaming phenomenon takes on proportions that risk causing damage to said furnace (1).The invention also relates to a process for the production of liquid metal employing such a furnace.
    Type: Grant
    Filed: May 9, 1994
    Date of Patent: September 19, 1995
    Assignee: Sollac (Societe anonyme)
    Inventor: Raoul Roth
  • Patent number: 5423522
    Abstract: A slag control shape is releasably mounted on a cover for a molten metal vessel. An actuator is connected to a slag control shape release member to retract the release member from a first position engaged with the slag control shape to a second position separated from the slag control shape to allow the slag control shape to freely drop into the molten metal receptacle. The actuating end of the actuator is located at an easily accessible operator position for remote actuation of the release member. In another embodiment, one end of a cable wound in a plurality of turns about a rotatable shaft mounted in a reel is attached to the slag control shape. A spring biasingly engages the shaft to control the rate of rotation of the shaft and thereby the rate of payout of the cable and the rate of descent of the slag control shape into the molten metal vessel.
    Type: Grant
    Filed: February 15, 1994
    Date of Patent: June 13, 1995
    Assignee: AJF, Inc.
    Inventors: Gary L. Forte, James P. McGuire, Wayne Miller
  • Patent number: 5415382
    Abstract: A method and apparatus is provided for temporarily retaining slag and nonmetallic particles in a tundish while molten metal is being transferred through the tundish to other desired vessels. In particular, a meltable dam is placed into an opening between the chambers in a tundish, and the meltable dam retains an accumulation of molten metal in the pour chamber of the tundish with the slag and nonmetallic particles floating on top of that level such that the slag and nonmetallic particles are above the opening between the chambers of the tundish. The dam then completely melts and allows the transfer of molten metal through the opening. The slag and nonmetallic particles are retained in the pour chamber, however, because the molten metal being transferred into the pour chamber maintains the level in that chamber above the opening until almost all of the metal has been transferred into and through the chamber.
    Type: Grant
    Filed: December 20, 1993
    Date of Patent: May 16, 1995
    Assignee: Allegheny Ludlum Corporation
    Inventor: James D. Calos
  • Patent number: 5397104
    Abstract: A dross compression apparatus utilizes a substantially hemispheric shaped receptacle in a dross collector and a complementing compression head which is provided with ribs to form grooves in the material formed between the head and the receptacle. The material formed between the head and the receptacle is substantially a shell comprised of an inner layer of aluminum oxide and outer layers of aluminum. The grooves in the shell enable the material to be more easily processed as the shell is readily broken for crushing. The compression head may be applied more than once to the aluminum dross and may be rotated between applications causing multiple grooves and increased decanting of aluminum. The compression head is provided with a water cooling system which more rapidly cools the aluminum dross and reduces the thermite reaction. The cast steel compression head reduces the air flow to the cooling dross thereby reducing the amount of oxygen available, oxidation and the thermite reaction.
    Type: Grant
    Filed: November 22, 1993
    Date of Patent: March 14, 1995
    Assignee: Altek International
    Inventor: David Roth
  • Patent number: 5374299
    Abstract: A process of pyrometallurgically treating a feed material such as a sulphide ore or concentrate is provided. The process includes the steps of:(a) producing a liquid body of feed material;(b) creating a first reaction zone and a second reaction zone which is in contact with the first reaction zone and is in the liquid body;(c) introducing feed material in particulate form and an oxidising gas into the first reaction zone;(d) allowing in-flight oxidation of feed material to take place in the first reaction zone;(e) allowing at least some of the reaction products of the in-flight oxidation to pass into a second reaction zone; and(f) allowing sulphidation or reduction of the reaction products to take place in the second reaction zone.
    Type: Grant
    Filed: November 8, 1993
    Date of Patent: December 20, 1994
    Assignee: Johannesburg Consolidated Investment Company Limited
    Inventors: Johannes J. Bodenstein, Krause L. Ehlers, Kevin P. D. Perry
  • Patent number: 5366209
    Abstract: A filter for molten metal comprises a series of at least two refractory material plates in contact with each other at their periphery and defining between them one or more cavities. Each plate comprises a series of holes through which the molten metal passes and by which the molten metal is filtered. The cavities are at least in part filled with a filter material resistant to the temperature of the molten metal to be filtered and providing additional filtering of the metal. The filter material is based on fibers resistant to the temperature of the molten metal. The filter is used to filter molten metals.
    Type: Grant
    Filed: June 3, 1993
    Date of Patent: November 22, 1994
    Assignee: Daussan & Compagnie
    Inventors: Gerard Daussan, Andre Daussan, Jean-Charles Daussan
  • Patent number: 5336295
    Abstract: Molten metal containing suspended liquid particles is passed preferably generally upwardly through a porous media so constructed and arranged such that the movement of the molten metal therethrough renders the suspended liquid particles gravity separable. The gravity separable liquid particles rise upwardly or settle downwardly so as to be removable from said molten metal for subsequent removal therefrom. An associated apparatus is also provided.
    Type: Grant
    Filed: February 8, 1993
    Date of Patent: August 9, 1994
    Assignee: Aluminum Company of America
    Inventors: David H. DeYoung, Diran Apelian, Rajakkannu Mutharasan
  • Patent number: 5332416
    Abstract: A method and apparatus is provided for temporarily retaining slag and nonmetallic particles in a tundish while molten metal is being transferred through the tundish to other desired vessels. In particular, a meltable dam is placed into an opening between the chambers in a tundish, and the meltable dam retains an accumulation of molten metal in the pour chamber of the tundish with the slag and nonmetallic particles floating on top of that level such that the slag and nonmetallic particles are above the opening between the chambers of the tundish. The dam then completely melts and allows the transfer of molten metal through the opening. The slag and nonmetallic particles are retained in the pour chamber, however, because the molten metal being transferred into the pour chamber maintains the level in that chamber above the opening until almost all of the metal has been transferred into and through the chamber.
    Type: Grant
    Filed: April 23, 1992
    Date of Patent: July 26, 1994
    Assignee: Allegheny Ludlum Corporation
    Inventor: James D. Calos
  • Patent number: 5322546
    Abstract: An apparatus for filtering molten material, such as a molten metal-ceramic particle mixture, includes a porous cloth filter located so that the mixture must pass through the cloth filter, and a mechanical filter shaker that prevents the accumulation of filtered solids on the porous cloth filter. Where a further degree of filtration is required, there is a second filter located so that material leaving the porous cloth filter passes through the second filter after it passes through the porous cloth filter, and a mechanism that prevents an accumulation of filtered solids on the second filter. The second filter is desirably a porous media filter.
    Type: Grant
    Filed: November 23, 1992
    Date of Patent: June 21, 1994
    Assignee: Alcan International Limited
    Inventors: Peter Holsgrove, Luc Montgrain, Richard S. Bruski, Gary Hust
  • Patent number: 5303902
    Abstract: A slag control shape is releasably mounted on a cover for a molten metal vessel. An actuator is connected to a slag control shape release member to retract the release member from a first position engaged with the slag control shape to a second position separated from the slag control shape allowing the slag control shape to freely drop into the molten metal receptacle. The actuating end of the actuator is located at an easily accessible operator position for remote actuation of the release member. In one embodiment, the actuator is a flexible cable attached at one end to the release member mounted on the cover and having a second end located remote from the cover at an easily accessible operator position. In another embodiment, one end of a cable wound in a plurality of turns about a rotatable shaft mounted in a reel is attached to the slag control shape.
    Type: Grant
    Filed: February 9, 1993
    Date of Patent: April 19, 1994
    Assignee: AJF, Inc.
    Inventors: Gary L. Forte, James P. McGuire, Wayne Miler
  • Patent number: 5286163
    Abstract: A molten metal pump includes a filter that prevents ingestion of foreign material such as dross from molten metal within which the pump is immersed. The filter is a large structure that is secured to the base of the pump surrounding the pump's inlet. The filter forms a cavity adjacent the pump's inlet. The ratio of the surface area of the filter to the inlet area of the pump is very large due in part to a corrugated end wall included as part of the filter. The filter has a low porosity while maintaining a high flow rate for the pump.
    Type: Grant
    Filed: June 5, 1990
    Date of Patent: February 15, 1994
    Assignee: The Carborundum Company
    Inventors: Lutfi Amra, Ronald E. Gilbert, George S. Mordue
  • Patent number: 5246483
    Abstract: 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 jacket is provided on the outside of the refractory to reduce refractory erosion and greatly increase refractory life. In addition, the separator is provided with two chambers which allow the slag to rise to the top of the metal or alloy. The slag then flows out of the chambers. The use of two chambers greatly increases the purity of the metal or alloy by allowing almost all of the slag to settle out of the metal or alloy.
    Type: Grant
    Filed: June 16, 1992
    Date of Patent: September 21, 1993
    Assignee: Honda of America Manufacturing, Inc.
    Inventor: Frederick T. Streets
  • Patent number: 5207974
    Abstract: Controlling the linear velocity of melt discharge from the discharge outlets of a melt distribution device so as to essentially negate reverse flow from the walls of the mold has been found to produce less oxides and less surface detects in an ingot, particularly an aluminum ingot. This discharge is controlled from the outset of the casting of an ingot because it has been found most defects occur within the initial phase of a cast. A melt distribution device, referred to as a "bag-in-a-bag", is provided which is a pressureless interiorly partitioned receptacle. The partitioning of the receptacle provides an outer bag and a melt-impermeable inner bag in which a pool of melt collects. The pool is deep enough to submerge the discharge end of a spout, to dissipate the kinetic energy of the incoming melt, and to distribute melt from a central zone to discharge zones on either side of the central zone.
    Type: Grant
    Filed: July 29, 1991
    Date of Patent: May 4, 1993
    Assignee: Aluminum Company of America
    Inventor: David I. Yun
  • Patent number: 5203909
    Abstract: The present invention provides a new and improved method and apparatus for tapping molten metal through the tap hole of a metallurgical vessel. The apparatus utilizes a ladle or a BOF furnace or other metallurgical vessel used for the containment of molten metal. At least one extension drive mechanism is attached to the support structure to position the distal end of a lance within the vessel a predetermined distance above the surface of its contents. The lance is connected to an inert gas source such as Argon. Once the lance is properly positioned, the inert gas is directed onto the surface of the molten metal to prevent the slag from entering the tap hole. An alignment drive can also be attached to the support structure to adjust the position of the extension drive relative to the vessel so that the lance may be properly positioned within the vessel above the tap hole.
    Type: Grant
    Filed: October 15, 1991
    Date of Patent: April 20, 1993
    Assignee: LTV Steel Company, Inc.
    Inventors: Robert G. Petrushka, Franklin E. Rote
  • Patent number: 5196051
    Abstract: A ladle for housing and transferring liquid metal includes an outlet for the liquid metal and a ladle bottom. The ladle bottom has a surface adapted to be in contact with the liquid metal and an outlet nozzle formed in the surface adapted to be in fluid communication with the outlet of the ladle. The ladle bottom surface includes means to substantially prevent the entrainment of undesirable matter in liquid metal exiting said ladle.
    Type: Grant
    Filed: July 19, 1991
    Date of Patent: March 23, 1993
    Assignee: Premier Refractories and Chemicals Inc.
    Inventors: Lawrence J. Heaslip, James D. Dorricott
  • Patent number: 5176742
    Abstract: An apparatus for filtering a molten solder bath comprises, a housing having an entrance end and an exit end enclosing a channel means extending from the entrance end to a filter means adjacent the exit end. The channel means being configured for receiving molten solder at the entrance end and directing the solder to the filter means in a turbulent flow. The filter means being configured to filter particles from the flow and direct the filtered flow to the exit end. A cooling means is positioned on the housing for cooling solder flowing through the channel means without reacting with the solder. A method for filtering a molten solder bath comprises, directing solder from the bath in a turbulent flow and cooling the flow to form a precipitate of an impurity in the molten solder. The cooled flow is filtered to remove particles and form a high-purity solder, and the high-purity solder is returned to the bath. Preferably, the molten solder is protected by an inert atmosphere that does not react with the solder.
    Type: Grant
    Filed: September 30, 1991
    Date of Patent: January 5, 1993
    Assignee: General Electric Company
    Inventors: Robert J. Zabala, Bruce A. Knudsen, Mark G. Benz, Lee E. Rumaner
  • Patent number: 5174746
    Abstract: A method for operation of a flash smelting furnace comprising a reaction shaft, a settler connected at one end thereof to the lower portion of the reaction shaft and having a slag discharge port and a matte discharge port disposed on the side thereof, an uptake connected to the other end of the settler and at least one concentrate burner disposed to at least one of the top of the reaction shaft and the ceiling of the settler, in which the concentrate burner comprises at least a concentrate shoot, an oxygen blowing tube inserted in the concentrate shoot and an auxiliary fuel burner inserted into the oxygen blowing tube. In this method, the lower end of the oxygen blowing tube is protruded downward to lower than the lower end of the concentrate shoot and an amount of oxygen at least greater than that required for the auxiliary fuel is blown as an industrial oxygen by way of the oxygen blowing tube into the furnace. Oxygen efficiency can be improved remarkably while the rate of dust occurrence can be reduced.
    Type: Grant
    Filed: April 6, 1992
    Date of Patent: December 29, 1992
    Assignee: Sumitomo Metal Mining Company Limited
    Inventors: Nobumasa Kemori, Akihiko Akada, Yasuhiro Kondou
  • Patent number: 5171358
    Abstract: An apparatus for producing solidified metals of high cleanliness removes floating matter such as oxides from the surface of molten metals prior to melt atomization. The apparatus includes a water-cooled melt vessel having a dam extending from a sidewall of the vessel at an acute angle to the sidewall. The dam extends above a preselected metal surface level of the interior of the vessel to form a floating matter trap region within the apex of the acute angle. There is a passageway through the dam sufficiently remote from the trap region that floating matter in the trap region is not in communication with the passageway. The passageway may be entirely below the metal surface level or extend from below the metal surface level to above the metal surface level, but sufficiently far away that floating matter can be forced away from the passageway, as by the herding action of a plasma torch.
    Type: Grant
    Filed: November 5, 1991
    Date of Patent: December 15, 1992
    Assignee: General Electric Company
    Inventor: David P. Mourer
  • Patent number: 5169591
    Abstract: An impact pad for eliminating surface turbulence in a continuous caster tundish, the impact pad having a base for receiving an incoming ladle stream, and one or more sidewalls extending in an upward direction along the periphery of the base. Each upward extending sidewall includes an inner surface having an undercut portion facing the incoming ladle stream. And, each undercut portion extends along the length of the inner surface, and comprises a shaped surface for receiving and reversing the direction of a fluid flow generated by the incoming ladle stream.
    Type: Grant
    Filed: February 7, 1992
    Date of Patent: December 8, 1992
    Assignee: Bethlehem Steel Corporation
    Inventors: Manfred Schmidt, Scott B. Newman
  • Patent number: 5169128
    Abstract: An apparatus for filtering a molten solder bath comprises, a housing having an entrance end and an exit end enclosing a chanel means extending from the entrance end to a filter means adjacent the exit end. The channel means being configured for receiving molten solder at the entrance end and directing the solder to the filter means in a turbulent flow. The filter means being configured to filter particles from the flow and direct the filtered flow to the exit end. A cooling means is positioned on the housing for cooling solder flowing through the channel means without reacting with the solder. A method for filtering a molten solder bath comprises, directing solder from the bath in a turbulent flow and cooling the flow to form a precipitate of an impurity in the molten solder. The cooled flow is filtered to remove particles and form a high-purity solder, and the high-purity solder is returned to the bath. Preferably, the molten solder is protected by an inert atmosphere that does not react with the solder.
    Type: Grant
    Filed: May 8, 1992
    Date of Patent: December 8, 1992
    Assignee: General Electric Company
    Inventors: Robert J. Zabala, Bruce A. Knudsen, Mark G. Benz, Lee E. Rumaner
  • Patent number: 5164146
    Abstract: Foundry furnace particularly for light non-ferrous metal, such as zinc or aluminum, including a longitudinal chamber (4, 8, 11, 12) made of a heat-resistant material, including close to one end an inlet for scrap (18) and/or bars (5), a slag outlet (5,6), an outlet flow passage (13) including a dispensing opening (14) at the other end, and heating elements for melting the metal, including direct radiating resistance elements (3, 3') in the cover of the chamber (4, 12) and vertically free moving dip-elements (9) extending downwardly from the cover of the chamber (8) for flowing on and into the melt metal in the chamber (8). According to the invention the height of the outlet flow passage is around 1/3-2/3 of the height of the chamber (8, 12), and the active part (7) of the dip-elements in the vertical direction at most equals the distance of the bottom (16) of the outlet flow passage (13) from the bottom (17) of the chamber.
    Type: Grant
    Filed: November 6, 1990
    Date of Patent: November 17, 1992
    Assignee: AB Jafs Export Oy Holimesy
    Inventors: Daniel Jafs, Jakob S. Jafs
  • Patent number: 5145806
    Abstract: A porous filter for metal hot melt comprises ceramic aggregate particles bound by an inorganic binder. The aggregate particles contain not less than 50 wt % of particles with a shape factor in the range of 100 to 130 and the binder has needle-shaped crystals deposited on the surface thereof. By employing this filter, debris catching ability and initial impregnation of metal hot melt are highly improved.
    Type: Grant
    Filed: March 7, 1991
    Date of Patent: September 8, 1992
    Assignees: NGK Insulators, Ltd., NGK Adrec Co., Ltd.
    Inventors: Hiroshi Shirakawa, Osamu Yamakawa
  • Patent number: 5126047
    Abstract: A molten metal filter includes a refractory plate having an opening therethrough. A refractory filter element is attached to the refractory plate and projects therefrom, the exterior surfaces of the filter element generally defining a rectangular prism. The filter element is hollow so as to define an interior cavity. The filter element includes an opening in that portion of the filter element that is attached to the refractory plate, the opening surrounding the opening in the refractory plate such that fluid communication is established between the cavity and the opening in the refractory plate. In the preferred embodiment, a plurality of filter elements are provided, which filter elements are connected to the refractory plate such that adjacent sides of the filter elements are oriented vertically and are disposed generally parallel to each other.
    Type: Grant
    Filed: May 7, 1990
    Date of Patent: June 30, 1992
    Assignee: The Carborundum Company
    Inventors: Harvey Martin, George S. Mordue
  • Patent number: 5114472
    Abstract: A filter system for removing solid impurities from molten metal is described comprising a housing containing vertically disposed rigid coarse filter facing the incoming flow of molten metal and capable of removing solids having a particle size of at least 10 microns and a rigid fine filter mounted vertically behind the coarse filter and capable of removing solids having a particle size as small as 1 micron. The apparatus further includes a heater for maintaining the temperature of the molten metal and a sparger mounted adjacent the front face of one filter to provide an intermittent gas flow over the face of the filter to dislodge solids on the filter as filter cake. In a preferred embodiment, the rigid filters are nested cylinders, and the molten metal is directed to the center of the smaller coarse filter cylinder from which it then flows through the coarse filter outward to and through the fine filter cylinder and then from the fine filter out of the filter housing.
    Type: Grant
    Filed: December 13, 1990
    Date of Patent: May 19, 1992
    Assignee: Aluminum Company of America
    Inventors: C. Edward Eckert, Thomas R. Hornack, George E. Lyness, John A. Kaems, Clarence J. Cox, Ronald E. Miller, Diran Apelian, Rajakkannu Mutharasan
  • Patent number: 5110096
    Abstract: A preformed expendable lining of high density, erosion resistant, castable refractory material is provided for a metallurgical vessel, such as a tundish. The lining is integrally formed in one piece and has a floor, walls, and at least one integrally formed flow control device. The flow control device may comprise a pair of upright baffles with apertures (some of them angled to the horizontal) for the passage of molten metal; or may comprise dams and weirs. The lining is particularly useful for the pour area of a T-shaped tundish, or a similar area for a conventional trough shaped tundish.
    Type: Grant
    Filed: February 15, 1991
    Date of Patent: May 5, 1992
    Assignee: Foseco International Limited
    Inventor: Donald R. Zacharias
  • Patent number: 5104540
    Abstract: A molten metal filter is disclosed having a carbon or carbon-thermite coating that reduces thermal shock to the filter, and protects the filter from corrosion from the metal or components and impurities in the metal, and prevents metal from freezing in the filter. A molten metal assembly suitable for casting molten metal is disclosed which comprises a filter for molten metal and means for molten metal flow passage leading through the filter. The means have surfaces defining a molten metal path. The filter has a coating of carbon or carbon in intimate contact with a thermite material on the surface of the filter. A process is disclosed for filtering molten metal which comprises passing molten metal through the above described coated filter.
    Type: Grant
    Filed: June 22, 1990
    Date of Patent: April 14, 1992
    Assignee: Corning Incorporated
    Inventors: J. Paul Day, Timothy V. Johnson, Ronald D. Quinn
  • Patent number: 5093289
    Abstract: A ceramic material made of a skeleton reaction-bonded silicon powder is distinguished by an open-cell pore structure produced by using a matrix of an appropriately shaped polyurethane foam structure. For the preparation, a foam matrix is coated with a suspension of silicon powder, synthetic resin and solvent and is subjected to a heat treatment, during which the foam matrix is expelled and the silicon is stabilized. The thermally and chemically stable product can be used, for example, as a filter medium for metal melts, as a catalyst carrier, or as a boundary medium between the flame zone and unignited combustible mixtures in burners.
    Type: Grant
    Filed: February 14, 1989
    Date of Patent: March 3, 1992
    Assignee: Heliotronic Forschungs- und Entwicklungsgesellschaft fur Solarzellen-Grundstoffe mbH
    Inventors: Volker Braetsch, Josef Dietl, Gerald Nitzl, Klaus Liethschmidt
  • Patent number: 5083754
    Abstract: Apparatus for retaining slag in a tundish or a ladle or similar vessel containing molten metal such as used in the steel industry. A refractory nozzle member and a refractory retainer member are secured to the bottom of the vessel around the molten metal discharge orifice. A refractory plug member of a density between that of the molten metal and the slag is positioned laterally within the retainer member but free to move vertically during discharge of the molten metal from the vessel.
    Type: Grant
    Filed: June 20, 1991
    Date of Patent: January 28, 1992
    Assignee: Bethlehem Steel Corporation
    Inventor: Thomas J. Russo
  • Patent number: 5084094
    Abstract: The present invention relates to a method for cleaning a liquid metal bath, in particular a zinc or zinc-aluminum bath intended for the continuous production of a steel strip coated by immersion in a coating zone (5a), according to which method the metal coating bath (2) is cycled continuously between the coating zone (5a) and a cleaning zone (5b), the rise of solid intermetallic compounds contained in the said bath to the surface is brought about in the cleaning zone (5b), the rise of the said compounds in accelerated and the cleaned bath (2), the iron content of which is close to or below the solubility limit, is led back to the zone (5a).The invention also relates to an apparatus for carrying out the method.
    Type: Grant
    Filed: November 21, 1990
    Date of Patent: January 28, 1992
    Assignee: Sollac
    Inventors: Bernard Francois, Robert Haaser, Pierre Commun, Jean-Paul Hennechart
  • Patent number: 5078572
    Abstract: A molten metal pump includes a filter that prevents ingestion of foreign material such as dross from molten metal within which the pump is immersed. The filter is a large structure that is secured to the base of the pump surrounding the pump's inlet. The filter forms a cavity adjacent the pump's inlet. The filter has a low porosity while maintaining a high flow rate for the pump. The filter is a semi-toroidal structure that is attachable to a pump base having an upper inlet. The filter surrounds the pump's inlet. The filter includes a central opening through which access can be had to the pump's impeller for purposes of inspection, repair, or replacement without disturbing the attachment between the filter and base.
    Type: Grant
    Filed: January 19, 1990
    Date of Patent: January 7, 1992
    Assignee: The Carborundum Company
    Inventors: Lutfi Amra, Ronald E. Gilbert, George S. Mordue
  • Patent number: RE35685
    Abstract: An impact pad for eliminating surface turbulence in a continuous caster tundish, the impact pad having a base for receiving an incoming ladle stream, and one or more sidewalls extending in an upward direction along the periphery of the base. Each upward extending sidewall includes an inner surface having an undercut portion facing the incoming ladle stream. And, each undercut portion extends along the length of the inner surface, and comprises a shaped surface for receiving and reversing the direction of a fluid flow generated by the incoming ladle stream.
    Type: Grant
    Filed: December 1, 1994
    Date of Patent: December 9, 1997
    Assignee: Bethlehem Steel Corporation
    Inventors: Manfred Schmidt, Scott B. Newman