Abstract: A melting and holding furnace includes a main body and a material input mechanism supplying a molten metal to the body which includes a melting chamber; a molten metal receiving chamber; a pumping-out chamber; and a molten metal heating mechanism. The input mechanism includes a molten-metal surface level sensor to detect that the surface height position of the metal in the pumping-out chamber has reached a lower limit that is set to be above the lower surface height position of a lid of the melting chamber, and is set to supply the receiving chamber with the metal and/or the metal block when the sensor detects that the surface height position of the metal in the pumping-out chamber has reached the lower limit so that the surface height position of the metal in the pumping-out chamber is always kept above the lower surface height position of the lid.

Abstract: A method and apparatus for continuous Near Net Shape casting of a liquid metal (10) into a metal strip are described. Liquid metal is transferred in a velocity adjusted manner from a headbox (50) to a chilled substrate (36), via a meniscus gap (69). The headbox (50) has a slot nozzle (68) defined in a bottom portion (66) for the headbox (50) above the chilled substrate (36). The slot nozzle (68) defines a smooth elongated cavity with a slot width (67) and the slot length (65) of the metal strip (34). The generation of some turbulence at the outlet of the apparatus promotes stable Near Net Shape Continuous Casting. The present method and apparatus increase the level of turbulence in the liquid metal of the outlet nozzle upstream of the chilled substrate (36) to minimize premature metal freezing. In a particularly preferred embodiment, the slot nozzle is adjustable.

Abstract: A system and a method comprise an upstream chamber is configured to receive a variable input flow of a wastewater mixture having a maximum input flow rate. A downstream chamber is adjacent to the upstream chamber. An effluent baffle wall separates the downstream chamber from the upstream chamber. An effluent flow port is located in the effluent baffle wall. The effluent flow port comprises a first orifice configured to produce a first modulated flow of the wastewater mixture from the upstream chamber to the downstream chamber, and a second orifice being positioned above the first orifice. The second orifice is configured to produce a second modulated flow having a second flow rate, wherein a combined flow rate including the first and second flow rates is less than the maximum input flow rate.

Abstract: A tundish impact pad, a tundish containing the same, and a method of using and assembly containing the impact pad and tundish are provided. The tundish impact pad features a base having a base surface with a conical impact surface area establishing an apex, a sidewall, and a top wall extending inwardly relative to the sidewall to terminate at an inner edge establishing a mouth opening spaced above and centered relative to the apex. The top wall includes a lip sloping radially inwardly and downwardly towards the conical impact surface.

Abstract: A compressing element, devices for using such a compressing element and methods of use are provided, in which the compressing element has: a upper surface provided with an inlet and an outlet; a lower surface; an at least partially hollow interior provided between the upper surface and the lower surface, the hollow interior being connected to the inlet and the outlet; the hollow interior being provided with: one or more fluid flow constraining surfaces provided by one or more walls of the hollow interior; and one or more fluid flow control elements provided in the hollow interior, the one or more fluid flow control elements being additional to the one or more fluid flow constraining surfaces provided by the one or more walls of the hollow interior. The arrangement of inlet, outlet, fluid flow constraining surfaces and fluid control elements provides for improved cooling of the compressing element, for instance when used to press molten metal processing by-products to extract molten metal.

Abstract: An improved filter is described which is particularly suitable for filtering molten metal. The filter has a porous open celled ceramic foam body with voids separated by struts wherein a portion of the struts are densified with glass.

Abstract: A filter includes a crucible, a filtering container, and a receiving tank. The crucible has a heater for heating a pre-filtered object to comprise a primary material in liquid and at least one other material in solid. The filtering container has a body, a sieve, and a press rod. The body connects with the crucible for receiving the heated pre-filtered object in a channel and provides a guide-out member; the sieve is disposed in said channel; and the press rod movably received in the channel for pressing the primary material of the pre-filtered object to flow through the sieve and to the guide-out member. The receiving tank has an entrance facing the guide-out member of the filtering container to receive the filtered primary material.

Abstract: The present invention relates to a ceramic filter suitable for filtering molten metal, wherein said filter comprises a carbon coating and refractory materials bonded by ceramic binders, and said carbon coating is coated on the refractory materials which are bonded by ceramic binders. Furthermore, the present invention relates to the method for manufacturing said filter. The filter of the present invention has very high mechanical strength and stable quality, the preparation of which is more economic.

Abstract: In a metal melting furnace, a separation wall 60 is provided between an inclined hearth 30 and a molten metal reservoir 35 to define a molten metal processing portion 65. The separation wall is provided with a connecting passage 61 for the molten metal, between the molten metal reservoir and the molten metal processing portion, at a height level higher than a bottom surface 67 of the molten metal processing portion. The separation wall is also provided on its upper portion with an exhaust gas passage which permits exhaust gas discharged from the molten metal reservoir to pass therethrough. An inspection opening 31 with a door 32 is provided in a furnace wall surface 37W to open into the molten metal processing portion.

Abstract: A strainer for molten metal. The strainer comprises a well and a multiplicity of passages. Each passage comprises a first cavity a second cavity with a smaller equivalent diameter than the first cavity. A neck is between the first cavity and second cavity. An inoculation pellet is received in the well.

Abstract: The present invention relates to a method, whereby the non-ferrous metal content of the slag generated in the production of non-ferrous metals such as copper or nickel in a suspension smelting furnace is reduced by charging metallurgical coke, with a size ranging from 1-25 mm, into the furnace. Baffles can be positioned from the roof of the furnace downwards, by means of which small particles containing copper and nickel are prevented from drifting to the back of the furnace and being tapped with the slag. The baffles force the small particles to settle in the reduction zone of the furnace.

Abstract: The present invention relates to a one-body continuous casting apparatus for fabricating a rod or slab shape of phosphorized copper by means of using a horizontal continuous casting process. Such invention contemplates designing and manufacturing a one-body melting and casting machine using high or low frequency induction heating, wherein a molten metal is deoxidized and refined in the system which comprises installing the multistage graphite filters inside the melting and casting machine, so the procedure of transferring the molten metal from the melting furnace to the casting machine can be eliminated, thereby enabling the horizontal continuous casting apparatus to manufacture a phosphorized copper of high quality.

Abstract: A tundish of improved flow characteristics for molten metal has an outlet in its base. The outlet is spaced longitudinally of the tundish from a pour zone. The pour zone is positioned to receive a stream of molten steel from a ladle. An impact pad is provided on the floor of the tundish in the pour zone, the impact pad comprising a base having an impact surface, an upwardly extending side wall along the periphery of the base, the side wall having an inner surface with an undercut portion to face the incoming steel stream, and the undercut portion having a surface shape to receive and reverse the direction of flow of the incoming stream. A dam is positioned between the impact pad and the outlet. The dam has one or more holes to allow through-passage of a proportion of the steel, and the dam extends upwardly from the tundish floor about 40-60% of the height of the uppermost level of steel in the tundish.

Abstract: Disclosed is a molten metal holding furnace system and a baffle and/or heater for use therein. The baffle/heater includes, among other things, a heat conductive body, at least one heater apertures and at least one passageways from a first side of the baffle body to the second side of the baffle body. Heaters within the heater apertures are isolated within the baffle body from the molten metal.

Abstract: A metallurgical furnace, preferably a metallurgical furnace for the production of copper, is equipped with a forebay. The forebay is in open communication with the settler of the furnace by a passageway that allows for the continuous removal of both slag and metal product, e.g. matte, blister copper, etc. The slag and metal product maintain their phase-separated relationship as they enter the forebay. The forebay is equipped with a weir that divides the forebay into a slag skimming chamber and a riser chamber. The slag skimming chamber has at least one slag overflow notch on at least one sidewall. The notch is located at an elevation on the sidewall such that only slag enters and is removed from the forebay. The notch is above the top surface of the metal product, i.e. it is above the interface between the slag and metal product layers.

Abstract: A chamber for receiving a downward flow of liquid metal includes a generally horizontal base having a generally planar impact surface. A first faceted sidewall having a plurality of facets formed therein, generally extends upwardly from and encompasses the planar surface to define an interior space. The interior space has an upper opening for receiving the downward flow of liquid metal. A second wall extends inwardly and upwardly from the first faceted wall toward the upper opening. A plurality of buttresses are spaced along the first faceted wall. Each of the buttresses extends between the impact surface and the second faceted wall. The buttresses form a plurality of discrete pockets including at least one facet. The pockets are defined by the buttresses, the impact surface, the first faceted wall and the second wall. The buttresses laterally deflect and divide the radial outward flow into a plurality of discrete flow patterns associated with the plurality of pockets.

Abstract: This invention relates to modifying the inside bottom surface of a tundish for continuous casting molten steel to minimize turbulence thereby reducing gas bubble and slag entrainment during continuous casting of steel, especially when initially filling of the tundish. Turbulence mitigation tends to avoid entrapment of oxide inclusions in a cast slab. This invention is for an elongated tundish (10) including a pair of spaced refractory lined side walls (12) disposed in a longitudinal direction, a pair of spaced refractory lined end walls (14) extending in a lateral direction between the side walls, a refractory lined floor (16), a molten metal impact pad (18) and a molten steel outlet (20). A refractory lined weir (26) is positioned between the impact pad and the steel outlet. A refractory ramp (34) is positioned between the weir and the steel outlet. The ramp is mounted to the floor and extends the full width of the floor in the lateral direction contacting each of the side walls.

Abstract: Method of heating molten metal in a tundish by irradiating a plasma torch on molten metal flowing along an internal surface of a heating compartment, and tundish configured for such method.

Abstract: 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.

Abstract: A tundish of improved flow characteristics for molten metal has an outlet in its base. The outlet is spaced longitudinally of the tundish from a pour zone. The pour zone is positioned to receive a stream of molten steel from a ladle. An impact pad is provided on the floor of the tundish in the pour zone, the impact pad comprising a base having an impact surface, an upwardly extending side wall along the periphery of the base, the side wall having an inner surface with an undercut portion to face the incoming steel stream, and the undercut portion having a surface shape to receive and reverse the direction of flow of the incoming stream. A dam is positioned between the impact pad and the outlet. The dam has one or more holes to allow through-passage of a proportion of the steel, and the dam extends upwardly from the tundish floor about 40-60% of the height of the uppermost level of steel in the tundish.

Abstract: Feed reservoir intended for retaining a molten metal and in particular a steel, which reservoir comprises a refractory bottom, refractory walls, at least one nozzle placed in the refractory bottom in order to feed at least one mold with molten metal, a refractory buffer having a buffer bottom and an approximately vertical partition defining a cavity, the buffer being arranged on the bottom of the reservoir in order, on the one hand, to receive a jet of molten metal coming from a ladle which is moved above said reservoir and, on the other hand, to ensure that said reservoir is separated into two spaces, a first space having at least one nozzle and a second space, the cavity of the buffer, confining the molten metal, which metal then flows out into the first space by spilling over the top of the partition, wherein the buffer, the partition of which defines the second space, is divided into two zones by a barrier, a zone receiving the jet of metal and a zone in which the metal rises, the latter zone being locate

Abstract: A chamber for receiving a downward flow of liquid metal includes a generally horizontal base having a generally planar impact surface. A first faceted sidewall having a plurality of facets formed therein, generally extends upwardly from and encompasses the planar surface to define an interior space. The interior space has an upper opening for receiving the downward flow of liquid metal. A second wall extends inwardly and upwardly from the first faceted wall toward the upper opening. A plurality of buttresses are spaced along the first faceted wall. Each of the buttresses extends between the impact surface and the second faceted wall. The buttresses form a plurality of discrete pockets including at least one facet. The pockets are defined by the buttresses, the impact surface, the first faceted wall and the second wall. The buttresses laterally deflect and divide the radial outward flow into a plurality of discrete flow patterns associated with the plurality of pockets.

Abstract: A continuous melting apparatus for a low melting point metal is disclosed. The apparatus includes a melting furnace main body (5) forming a combustion chamber (6) surrounded by a refractory lining, a crucible (1) formed with a tapping orifice (2) at an appropriate position of a body and housed at the center portion of said combustion chamber, a burner (8) provided on a side wall portion of said melting furnace main body (5) for heating said crucible (1) in said combustion chamber (6) and a receptacle (6, 13) for receiving a melt flowing out through said tapping orifice (2) of said crucible (1). In the continuous melting apparatus, with employing a melting method of burner heating type which is inexpensive, easy to handle and maintenance, with successfully minimizing oxidation loss which was the shortcoming of the burner type. Also, generation of corundum on the furnace wall surface due to reaction of the aluminum melt and the furnace wall can be successfully avoided.

Abstract: A dam surrounding a slag tap on a refractory covered, boiler-tube floor for holding back a protective slag layer. The dam is comprised of a plurality of adjacent refractory blocks mechanically secured to the refractory covered, boiler-tube floor near the slag tap. Each refractory block is shaped to brace an adjacent refractory block against motion toward the slag tap. Additional dams are used when a single dam is not sufficient to cover the entire surface of the floor with slag.

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.

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.

Abstract: A device is located between the outlet zone and the distribution zone of a tundish that is provided with a reheat system, such as a plasma torch, at one side of a heading chamber. The device includes a refractory unit pierced by at least a first conduit having the shape of a truncated cone curved towards the predefined zone of the heating chamber and preferably flared at this zone, so as to ensure that liquid steel flow coming from the outlet zone is guided unidirectionally towards the predefined zone of the heating chamber.

Abstract: Flow control apparatus for enhancing inclusion float out in a continuous caster tundish comprising a dam positioned downstream from an impact pad and an energy source positioned between the dam and the exit nozzle of the tundish. The dam receives an incoming flood of molten metal released from the impact pad and redirects the flood of molten metal into multiple sub-flow currents which carry entrained inclusions toward a slag cover on the surface of the molten metal bath to enhance inclusion float out. The energy source provides means to restore kinetic energy to the sub-flow currents and increase the number of passes below the slag cover, thereby further enhancing inclusion float out.

Abstract: Ladle for the filtration of a liquid metal such as aluminum, magnesium, and their alloys over a filter medium of the gravel bed type. The ladle comprises a chamber in which the filter medium rests on a supporting grid, an inlet for supplying liquid metal to the chamber and an outlet for removing liquid metal from the chamber. The ladle includes first and second heaters for heating the liquid metal, the first heater being located outside the filter medium and the second heater being an electrical immersion heater which is located in the inlet or outlet and adjacent the filter medium. The second heater is arranged for immersion in liquid metal flowing through the inlet or the outlet.

Abstract: A method and apparatus are provided for making steel alloys directly in a tundish. Base steel enters the tundish from a ladle. An alloying chamber having a plurality of inlets is positioned above a tundish drain. An alloying material (for example, a wire including one or more alloying ingredients) is fed into the alloying chamber through a feed pipe originating above the liquid level in the tundish. Molten base steel enters the alloying chamber through the inlets and is mixed with the alloying material to make a steel alloy, which exits through the drain. The method and apparatus are especially suitable for making small order quantities of alloy steel of less than one ladle volume.

Abstract: A method and apparatus allow for continuous removal of contaminants from solder. The solder is pumped from a main solder pot to an auxiliary solder pot through a skimmer valve which is heated to keep the solder molten. In the auxiliary pot, the solder is cooled so that dissolved contaminants such as copper precipitate out and are removed from the pot. The purified solder is then returned to the main pot, for example, by a gravity feed.

Abstract: A tundish includes first and second flow control walls which define a flow receiving space. A plurality of outlets are located in the bottom of the tundish and toward the front thereof. Each flow control wall includes a plurality of openings located closer to the back of the tundish than toward the front and located closer to the bottom of the flow control wall than the top thereof.

Abstract: A furnace (1) has a main holding (2) and a charging well (4) into which molten metal from the holding portion is circulated by means of an electromagnetic pump (7). Metal enters the well as a tangential flow and a stationary turbulator (10) is located in the path of the flow so as to upwardly and transversely deflect the flow. Resulting turbulence within the well enhances the rate of assimilation of solids into the melt without resulting in excessive oxidation. The method is suitable for melting aluminium swarf.

Abstract: A tundish has an entry location for receiving a molten alloy, such as steel, and bottom outlet openings for withdrawing the molten alloy. The tundish bottom comprises a sump located downstream of the inlet location and upstream of the outlet openings. Undissolved, molten alloying ingredient, denser than the molten alloy as whole, (e.g. lead or bismuth in the case of molten steel) accumulates in the sump. The sump has a floor and passageways which extend downwardly from the sump floor to a drain in the steel tundish shell underlying the sump. The passageways are permeable to undissolved, molten alloying ingredient but impermeable to the molten alloy. There are expedients for maintaining the passageways at a temperature which prevents undissolved alloying ingredient descending through the passageways from cooling to a temperature at which the undissolved alloying ingredient blocks the passageways against further passage by undissolved, molten alloying ingredient.

Abstract: A tundish baffle having a plurality of fluted openings is provided. The fluted openings interrupt and remove inclusions from molten metal passing through the baffle, using a plurality of obstructive peaks and valleys located at the perimeters of the openings. The fluted openings also include central portions which are not obstructed by the flutes, through which molten metal can flow in a regular fashion.

Abstract: A tundish includes first and second flow control walls which define a flow receiving space. A plurality of outlets are located in the bottom of the tundish and toward the front thereof. Each flow control wall includes a plurality of openings located closer to the back of the tundish than toward the front and located closer to the bottom of the flow control wall than the top thereof.

Abstract: In a metallic vapor condenser for use in recovering, in the form of liquid metal, metallic vapor of a metal having a medium boiling point, the liquid metal of the molten metal is sent from a splash chamber to be circulated through a skimming sump, a cooling sump, and a casting bath to the splash chamber. The liquid metal is always refreshed by circulation in the casting bath to avoid solidification of the metal. A subsidiary chamber may be coupled to the splash chamber to reverve the liquid metal to decrease dust and dross floating on the liquid metal.

Abstract: The disclosure is made for the use of a hearth for receiving metals to be melted and exposing the molten metals to the furnace atmosphere with the upper surface of the molten metal free to float impurities such as oxides, carbides, or other undesirable materials on the upper surface of the molten metal or alloy. Gas jets blow an inert gas in one direction over the upper surface of the molten metal, generally parallel to the upper surface of the molten alloy. Thus, the gas jets remove impurities from the upper surface of the molten alloy by blowing or skimming the impurities off the top of the pool toward the walls of the hearth. The preferred position of the gas jets is in the notch of the hearth over which the molten alloy flows from the main body of the hearth into a withdrawal crucible.

Abstract: An impact pad for use in a tundish vessel utilizes outer and inner guides which partially surround the region of impact except in the direction of the one or more tundish drains. Much of the molten iron or steel entering the tundish is directed toward a drain by the inner guide or guides. The inner and outer guides define a channel such that molten iron or steel which splashes or otherwise flows over the inner guides can also be directed toward the one or more tundish drains.

Abstract: An improved impact pad includes a plurality of channels which direct the flow of molten iron or steel toward the tundish drains, and ramps which elevate the flow in the directions of the drains. The ramps cause the molten iron or steel to follow a trajactory path after leaving the impact pad, first rising and then falling toward the drains. The trajectory path increases the residence time of the molten iron or steel in the tundish, allowing more time for impurities to float to the top of the vessel. The trajectory path also helps propel the impurities partially toward the top of the tundish vessel.

Abstract: Nozzles positioned in the bottom portion of tundish barriers, such as baffles, improve the flow of molten metal in the tundish.

Abstract: Disclosed is a tundish apparatus for holding and filtering molten metal, such as steel, prior to the molten metal being continuously cast. An enclosure around the discharge orifice of the tundish accommodates a ceramic filter medium. The enclosure has a removable cover plate to allow continuous discharge of the molten metal in the event the filter medium becomes clogged and to allow access to the tundish nozzle.

Abstract: Molten steel in tundishes can be contacted with high surface area ceramic shapes which remove the alumina and other impurities contained in steel. Certain ceramic shapes, in particular tundish baffles, having a large surface area which acts as alumina traps for molten steel contained in tundishes are also disclosed.

Abstract: A melting and holding furnace comprising a preheating and melting chamber defining a preheating tower section in an upper position and a melting section in a lower position, a holding chamber communicating with the melting chamber, and a well communicating with the holding chamber. A melting burner is provided for jetting out flames obliquely downwardly into the melting section.

Abstract: The invention relates to a means of purifying molten metal, particularly steel, by the removal of impurities/inclusions during continuous casting.The molten metal (3) is passed in a tundish (1) through a vertical array of baffles (8) that are spaced apart transversely across the tundish to provide restricted flow channels (12). The baffles (8) may be flat boards or tiles (9a, 9b) and are preferably used in contact with a weir (7) and dam (10), upstream and downstream respectively of the baffles.The speed and direction of flow of the molten metal can thereby be controlled and directed to give more effective dwell time in contact with a surface covering layer (11) of flux.

Abstract: A tundish consisting essentially of a rigid metallic outer casing having walls and a bottom at least one permanent layer of heat insulating material adjacent said casing, and a unitary, integrally formed expendable inner lining made of a hydrocarbon-free refractory composition and having at least one liquid metal flow control device integrally formed therewith, the lining being chemically compatible with the molten metal to be placed in the tundish. The invention also comprises the unitary integrally formed expendable lining and the method to form the same.

Abstract: A tundish system for teeming an entire heat from a furnace into a mold. The tundish includes a plurality of chambers; one chamber including a nozzle. The chambers are arranged to interrupt the flow of the heat from one chamber to another thereby causing better separation between the metal and the slag. The tundish is mounted on a movable frame supporting a plurality of molds. A trough is disposed between the tundish and the molds. During the pour, the tundish remains stationary as the trough and the molds are moved underneath in succession.

Abstract: 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.

Abstract: An article of refractory holloware for use in a runner assembly for casting molten metals e.g. ferrous metals, has at least one inner surface adapted to increase the internal surface contact area of the article. The surface is so arranged as to effect at least two abrupt changes of direction of flow of molten metal flowing through the article. Use of the article minimizes the level of non-metallic inclusions in ingots and castings.

Abstract: A melting and holding furnace comprising a melting chamber, a well, and a holding chamber disposed between the melting chamber and the well. The holding chamber includes a plurality of submerged banks projecting from its bottom and extending transversely of a line linking the melting chamber and the well.