Abstract: A method for manufacturing a foam material by using a molten slag includes: introducing the molten slag maintained at 1400° C.-1500° C. into a pool for preserving heat, and adding a viscosity modifier and/or a color modifier to the molten slag to adjust a viscosity and/or a color a product manufactured. The molten slag is discharged into a foaming pour while adding a foaming agent to the molten slag, while controlling the foam and mold at 1250° C.-1400° C. The foamed and molded slag is maintained at 800° C.-1000° C. for 20-30 minutes in a non-reducing atmosphere, and then naturally cooled to a room temperature to obtain the foam material. The produced inorganic nonmetal foam material and products thereof have such characteristics as stable color quality, abrasion resistance, pressure resistance, small thermal conductivity, small shrinkage ratio, and excellent sound absorption, adsorption and filtering performances.

Abstract: The present invention relates to formation of a controllable, high velocity, pneumatic stream of particulate solids which can be injected into a furnace containing, for instance, a liquid such as a bath of molten metal.

Abstract: An electric furnace steel contains, by mass %, C: 0.12 to 0.28%, Si: equal to or less than 0.15%, Mn: 0.65 to 0.95%, P: equal to or less than 0.035%, S: equal to or less than 0.035%, Cr: 1.35 to 1.90%, Al: 0.020 to 0.050%, and N: 0.0080 to 0.0230%. A scrap material is selected such that Cu, Ni, and Mo that derive from the scrap material and are thus contained as impurities in the electric furnace steel satisfy Expression 1. The electric furnace steel further contains Fe and unavoidable impurities as a remainder thereof. Accordingly, the electric furnace steel can secure carburizing quality equivalent to or higher than that of Cr—Mo steel, and can have properties equivalent to or higher than that of Cr—Mo steel, without adding Mo. ([Cu]+2×[Ni])0.76×[Mo]?0.

Abstract: A method for producing blister copper directly from copper concentrate is provided, comprising: a) adding copper concentrate, copper matte, slagging material, oxygen enriched air, endothermic material to an upper segment of the reaction furnace; b) adding reducing agent to the lower segment space of the reaction furnace; c) directing the produced hot coke and liquid slag into an electric furnace, and adding copper concentrate into the electric furnace to generate an electric furnace slag and copper matte; d) the copper matte being granulated and finely ground, then re-fed into the reaction furnace.

Abstract: Combined microwave heating and plasma/electric arc heating is utilized in several processes and apparatus which involve co-production of pig iron and high quality syngas, biomass to liquid fuel production, coal to liquid fuel production, co-gasification of biomass and coal, municipal solid waste treatment, waste-to-energy (agriculture waste, ASR and PEF), EAF dust and BOF sludge treatment to recover zinc and iron, hazardous bottom ash vitrification, and bromine, chlorine and sulfur removal/recycling.

Abstract: A process and material for producing foamed slag by which the foaming of a slag with a high chromium oxide content can be achieved. An electric arc furnace is charged with a mixture of metal oxides and carbon and, below the slag at the metal-slag interface, the metal oxide is reduced by carbon and limestone and becomes thermally discordant. The occurring gases cause the slag to foam due to the formation of bubbles.

Abstract: A method for the production of a ?-TiAl base alloy by vacuum arc remelting, which ?-TiAl base alloy solidifies via the ?-phase (?-?-TiAl base alloy), includes the following method steps of forming a basic melting electrode by melting, in at least one vacuum arc remelting step, of a conventional ?-TiAl primary alloy containing a lack of titanium and/or of at least one ?-stabilizing element compared to the ?-?-TiAl base alloy to be produced; allocating an amount of titanium and/or ?-stabilizing element to the basic melting electrode, which amount corresponds to the reduced amount of titanium and/or ?-stabilizing element, in an even distribution across the length and periphery of the basic melting electrode; and adding the allocated amount of titanium and/or ?-stabilizing element to the basic melting electrode so as to form the homogeneous ?-?-TiAl base alloy in a final vacuum arc remelting step.

Abstract: A method of alloying an iron majority compound with an oxide is provided. The method may include: heating the iron majority compound to a molten state; adding an oxide containing manganese to the molten iron majority compound; adding slag forming materials and reducers to the molten iron majority compound; controlling the iron majority compound to achieve a desired temperature environment for a desired period of time; and removing slag from the iron majority compound.

Abstract: In a method for processing and/or reducing solid or molten materials and/or pyrophoric materials, in particular shredder light fractions, the solid or molten materials are charged onto an at least partially inductively heated graphite body, wherein a reducing agent different from the carbon of the graphite is introduced, and the flowing-off reduced and/or degassed melt is collected, wherein the reducing agent is introduced together with the solid or molten charging materials, and, as the reducing agent, natural gas, hydrocarbons, hydrogen, carbon monoxide and/or ammonia are introduced along with water vapor, oxygen, carbon dioxide and/or halogens or hydrogen halides.

Abstract: The invention relates to a method of agglomerating iron oxide-containing residual substances, in particular scale and mill scale, wherein the residual materials and the paper sludge are dried and comminuted and agglomerates are produced by means of hot briquetting from the mixture comprising the residual substances and the paper sludge. In this way, mill scale briquettes of high strength and density can be produced which in steelmaking processes can then be charged into an electric arc furnace for the purpose of recycling the iron contained in the residual substances.

Abstract: The present invention relates to formation of a controllable, high velocity, pneumatic stream of particulate solids which can be injected into a furnace containing, for instance, a liquid such as a bath of molten metal.

Abstract: Process for preparing a foaming slag former for electric furnaces comprising the steps of aggregating solid slag particles into a coarser granular material and carbonating the solid slag particles to form the foaming slag former. The solid slag particles are preferably aggregated before carbonization, so that the carbonates form a solid matrix binding the particles together.

Abstract: The invention relates to a method for producing a steel melt containing up to 30% of Mn, which additionally may comprise up to 5% Si, up to 1.5% C, up to 22% Al, up to 25% Cr, up to 30% Ni, and up to 5% each of Ti, V, NB, Cu, Sn, Zr, Mo, and W, and up to 1% each of N and P, with the remainder being iron and unavoidable steel companion elements.

Abstract: A method for manufacturing molten metal by using a stationary non-tilting electric furnace comprising: forming a raw material layer by charging a particular amount of a carbonaceous material and/or metal oxide agglomerates with carbonaceous material containing a nonvolatile metal element that forms molten metal into the furnace from the raw material charging chute, and having a sloping surface extending downward from the one end of the furnace toward the other end of the; subsequently forming an agglomerate layer on the sloping surface of the raw material layer by charging a particular amount of the metal oxide agglomerates with carbonaceous material into the furnace from the raw material charging chute; and subsequently forming a molten metal layer and a molten slag layer in the furnace by heating the lower end of the agglomerate layer with the heater.

Abstract: A method for reducing oxidic slags and dusts possibly loaded with organics uses an inductively heatable coke bed extending in the axial direction and having a temperature gradient. Reaction gas is sucked off in an axial region of the coke bed between two induction bodies and metal regulus and slag melt are tapped on the lower end. An inductively heatable shaft furnace chargeable with a lumpy coke bed for the reduction of metallic slags is made of an electrically insulating refractory material, has an adjustable temperature gradient includes at least one cooled induction body on the head side, a suction connection in an axial region where the prevailing temperature exceeds the condensation point of the substances to be removed, located below the cooled induction body on the head side, and an opening for tapping metal regulus and slag melt is provided on the lower end of the furnace.

Abstract: A method and apparatus for accessing a furnace melt are provided. Preferably, the method and apparatus provide for the safe and efficient access to the melt. According to one aspect of the invention used in a steel-making process in an electric arc furnace, a furnace aperture burner/lance provides a flame for heating the melt, a lance device for injecting oxygen into the furnace, or both. To access the melt, the furnace aperture burner/lance is disengaged, access is provided to the melt through the furnace aperture, and the furnace aperture burner/lance is reengaged when the access is concluded.

Abstract: The invention relates to a process for producing a metal melt containing at least one base metal and at least one further alloy constituent, wherein the production takes place in a melting vessel with slag covering the melt. In accordance with the invention, for increasing the content of the alloy constituent of the melt, an additive is fed to the melt which contains said alloy constituent at a content of ?5-10 percent by weight of the alloy constituent, ?5-10 percent by weight of melting metallurgically harmless volatile matter, ?5 percent by weight of sulfur and possibly fractions of further alloy constituents and/or slag formers. The additive is obtainable by ore leaching and by precipitation in the form of hydroxides and/or carbonates. The invention also relates to such an additive.

Abstract: The present invention relates to a method for treating spent pot liner material (SPL) containing carbon and/or an inorganic material, the method comprising: providing a plasma furnace having first and second electrodes for generating plasma and a crucible having a non-electrically conductive inner surface, heating the SPL material in the crucible in the presence of a flux material and an oxidant by passing an arc between the first and second electrodes via the SPL material to form a molten slag material and convert at least some of the carbon in the SPL material to CO and/or CO2 and/or incorporate at least some of the inorganic material into the molten slag material.

Abstract: A method for producing a foamed slag (1) on a metal bath (2) in a metallurgical furnace (3), in which a mixture (4) containing at least one metal oxide and carbon is introduced into the furnace (3), the metal oxide is reduced by the carbon below the slag (1) that is located there, and the gases produced during the reduction process form bubbles such that the slag is foamed. In order to optimize the formation of foamed slag, the mixture (4) is delivered into the furnace (3) in such a way that a desired height (h) or a desired section of the height (h) of the layer of foamed slag (1) is generated or maintained.

Abstract: A method for producing a ferro-alloy in an electric arc furnace is disclosed. The method comprises the step of charging the furnace with an un-agglomerated carbon-containing polymer such that the polymer functions as a slag foaming agent.

Abstract: A method and apparatus for accessing a furnace melt are provided. Preferably, the method and apparatus provide for the safe and efficient access to the molten metal melt in a furnace. According to one aspect of the invention used in a steel making process in an electric arc furnace, a furnace aperture plug is reciprocated through a furnace aperture, the furnace aperture plug is retracted from the furnace aperture, access is provided to the molten metal melt in the furnace, and the furnace aperture plug is reinserted into the furnace aperture when the access is concluded.

Abstract: A process and material for producing foamed slag by which the foaming of a slag with a high chromium oxide content can be achieved. An electric arc furnace is charged with a mixture of metal oxides and carbon and, below the slag at the metal-slag interface, the metal oxide is reduced by carbon and limestone and becomes thermally discordant. The occurring gases cause the slag to foam due to the formation of bubbles.

Abstract: Disclosed are a method and an installation for producing steel products (1) having an optimum surface quality, especially extremely low carbon contents (UCL steel or IF steel), nitrogen contents, total oxygen contents, high-strength or stainless steel qualities.

Abstract: A method for manufacturing molten iron comprises charging a carbonaceous material, a flux, and solid reduced iron obtained by thermally reducing carbon composite iron oxide agglomerates into an arc melting furnace and melting the solid reduced iron using arc heating in the melting furnace while an inert gas is blown into a molten iron layer from a bottom blowing tuyere on a bottom of the melting furnace, wherein: a carbonaceous material suspending slag layer is formed in an upper portion of a slag layer formed on the molten iron layer when the solid reduced iron is melted into the molten iron; a carbonaceous material coating layer having the carbonaceous material is formed on the carbonaceous material suspending slag layer; and the molten iron and the slag stored in the melting furnace are tapped from a tap hole formed in a lower portion of a furnace wall of the melting furnace.

Abstract: A method for the recovery of refractory debris materials and ladle slags as process slags in the iron metallurgy production in EAFs and the related metering to the furnace for the formation of the process slag comprises the following steps: grinding and screening of the refractory debris materials until powders of controlled granulometry are obtained, storage of the powders in storage sites, injection of the powders into an EAF furnace by means of automatic metering of the various components.

Abstract: A process for tapping a steel furnace with a reduced amount of entrained slag is disclosed. During tapping, particles of a slag foaming agent are added. The foaming agent may include calcium carbide and/or other chemicals. The agent foams the slag to decrease its density during tapping and/or to disrupt initial vortex formation at the tap.

Abstract: This invention relates to a single-step pyrometallurgical process for the recovery of non-ferrous metals from zinc bearing residues, in particular from by-products of the zinc and lead industry such as goethite and jarosite. A process for the recovery of metals from industrial Zn residues containing Zn, Fe and S is defined, wherein Zn is fumed, Fe is slagged, and S is oxidized to SO2, characterized in that the Zn fuming, the Fe slagging, and the S oxidation are performed in a single step process, by smelting the residues in a furnace comprising at least one submerged plasma torch generating an oxidizing gas mixture, and by feeding a solid reducing agent to the melt. The process achieves the oxidation of S and the slagging of Fe, while simultaneously achieving the reduction and the fuming of metals such as Zn.

Abstract: A Method for the recovery of the secondary metallurgy (LF) slag from a plant for the production of steel, the method comprising a cooling step of the slag, by means of the passage of air and/or other gas, a breakdown step, a step of extracting the powder, wherein the breakdown step is accelerated by means of forced convection of a cooling fluid and/or another reaction, gas and by means of moving the slag mass by overturning and vibrating support gratings. The overturning and vibrating support gratings are provided inside closed metallic boxes which are connected in series and closed with movable containment partitions to form a treatment module. The breakdown, step is accelerated by means of overturning the slag mass from the support grating of one metallic box to the support grating of an adjoining box.

Abstract: A method of operating a channel induction furnace to process a feed material and obtain therefrom at least one of a molten metal product, a vapor phase metal product and a slag product. The method includes avoiding the formation of islands of materials that are fed into the channel induction furnace. The method also involves breaking up islands of materials that are formed within the channel induction furnace. The method further involves adding a heat-conducting metal material into the channel induction furnace together with the feed material.

Abstract: A method of operating a channel induction furnace to process a feed material and obtain therefrom at least one of a molten metal product, a vapor phase metal product and a slag product. The method involves the use a variety of feed materials that contribute to the molten metal product and/or the vapor phase metal product and/or the slag product and/or function as a binder for briquetting or pelletizing the feed material.

Abstract: A method of operating a channel induction furnace to process a feed material and obtain therefrom at least one of a molten metal product, a vapor phase metal product and a slag product. The method includes applying a controlled vacuum on the headspace of the channel induction furnace to controlling the amount of ambient air that enters the furnace or adding oxygen into the channel induction furnace. The method also includes controlling the carbon concentration in the molten bath in the channel induction furnace to control the fluidity of the bath.

Abstract: A method of operating a channel induction furnace to process a feed material and obtain therefrom at least one of a molten metal product, a vapor phase metal product and a slag product. A molten metal bath is maintained in the channel induction furnace and the method includes adding a reductant such as carbon or a carbon containing material directly into the molten metal bath independently of the feed material.

Abstract: A method of operating a channel induction furnace to process a feed material and obtain therefrom at least one of a molten metal product, a vapor phase metal product and a slag product. The method involves maintaining a slag layer on the molten bath that has a thickness that is sufficient to support the feed material while minimizing heat transfer through the slag layer and minimizing the resistance of vapor phase components from transferring through the slag layer. The fluidity of the slag layer is controlled by heating the slag layer and adjusting the chemistry of the slag layer.

Abstract: A method for making a strain aging resistant steel comprises adding boron to the steel, wherein substantially all of the boron in the steel forms boron nitride. A method for making steel comprises adding a nitride-forming element to the steel to lower the free nitrogen content of the steel to a free nitrogen content specification. A high-carbon steel contains boron nitride, wherein the free nitrogen content of the steel is less than 80 ppm. A strain aging resistant steel wherein the carbon content of the steel is between about 0.54 percent and about 0.75 percent.

Abstract: A method and apparatus for accessing a furnace melt are provided. Preferably, the method and apparatus provide for the safe and efficient access to the molten metal melt in a furnace. According to one aspect of the invention used in a steel making process in an electric arc furnace, a furnace aperture plug is reciprocated through a furnace aperture, the furnace aperture plug is retracted from the furnace aperture, access is provided to the molten metal melt in the furnace, and the furnace aperture plug is reinserted into the furnace aperture when the access is concluded.

Abstract: A method and apparatus for testing characteristics of a furnace melt are provided. Preferably, the method and apparatus provide for the safe and efficient testing of metal temperature and composition of molten metal during the melt cycle of the metal. According to one aspect of the invention used in a steel making process in an electric arc furnace, a furnace probe is reciprocated through a furnace probe plug aperture, the furnace probe is retracted from the furnace probe plug aperture, a furnace probe is inserted through the furnace probe plug aperture, the furnace probe is retracted from the aperture, and the furnace probe aperture plug is inserted into the furnace probe plug aperture.

Abstract: The invention provides a Martensite wear-resistant cast steel with film Austenite for enhancement of toughness comprises 0.25˜0.34 wt % C, 1.40˜2.05 wt % Si, 0.90˜1.20 wt % Mn, 1.80˜2.50 wt % Cr, 0.0005˜0.005 wt % B, 0.01˜0.06 wt % Ti, 0.015˜0.08 wt % Rare Earth, 0.015˜0.06 wt % Al, less than 0.035 wt % S, less than 0.035 wt % P, and the balance of iron. The method of producing the cast steel includes smelting and heat-treatment, after smelting as normal operation, adding Ferro-Rare Earth and Ferro-Boron in the ladle in sequence, then high temperature normalizing, water quenching and low temperature tempering. TEM structure of the cast steel is martensite lath with film austenite between martensite laths. Cast steel of the invention exhibits high hardenability and toughness, and low cost without precious Molybdenum and Nickel, applied to a range of wear-resistant castings, especially to heavy-section castings, i.e. heavy-section tooth.

Abstract: To produce metallic iron from iron ore, a composition comprising a mass of material formed from a mixture of iron ore particles and particles of a reductant that is either a biomass material in particulate form or a plastic resinous material in particulate form is used. The reductant can also be a mixture of biomass material and resin in any proportions. The mass of material comprises at least one body having a shape adapted for smelting such as pellets, briquettes, pieces or lumps. The pellets have sufficient cohesion to maintain the shape into which they have been formed.

Abstract: A pyrometallurgic process for the treatment of post-steelwork residues, comprises the following phases: preparing a furnace (1) of the electric type, suitable for the introduction of the residues; preparing the residues, for example in a hopper with the possibility of mixing with additives and reaction elements; introducing the residues, together with suitable additives and chemical reagents, into the furnace (1); introducing directly into the slag, by means of lances (4), additives, flushing and reaction elements to correct the composition of the slag (7); reacting the residues with the slag (7) to obtain: a) separation of the liquid metallic phases which are added to the metal bath (6) to form a sellable liquid metal; b) separation of the metallic volatile elements in vapour phase which, when transferred to the free zone of the furnace (1) recombine with the oxygen for the formation of oxides and consequently of powder.

Abstract: A method and an apparatus for advantageously introducing a flame, a high velocity oxidizing gas, and a high velocity particulate flow into a furnace for metal melting, refining and processing, for example, steel making in an electric arc furnace. The steel making process of an electric arc furnace is made more efficient by shortening the time of the scrap melting phase, introducing a more effective high velocity oxidizing gas stream into the process sooner to decarburize the melted metal and introducing a more effective particulate injection to reduce FeO, form or foam slag and/or recarburize. Improved efficiency is obtained by mounting a fixed burner/lance and carbon injector lower and closer to the hot face of the furnace refractory at an effective injection angle.

Abstract: The direct reduced iron (DRI) which for at least 80 wt-% has a grain size of not more than 3 mm is melted in an electric arc furnace. The furnace contains a bath of liquid iron. During the operation of the furnace a foamy slag layer is formed on the bath and the DRI falls by gravity through at least one movable lance into the foamy slag layer on the iron bath. Preferably, the distance of the aperture of the lance to the iron bath is kept practically constant.

Abstract: A method and an apparatus for advantageously introducing a flame, a high velocity oxidizing gas, and a high velocity particulate flow into a furnace for metal melting, refining and processing, for example, steel making in an electric arc furnace. The steel making process of an electric arc furnace is made more efficient by shortening the time of the scrap melting phase, introducing a more effective high velocity oxidizing gas stream into the process sooner to decarburize the melted metal and introducing a more effective particulate injection to reduce FeO, form or foam slag and/or recarburize. Improved efficiency is obtained by mounting a fixed burner/lance and carbon injector lower and closer to the hot face of the furnace refractory at an effective injection angle.

Abstract: A method of alnico alloy melting includes melting a charge, oxidizing refining of the melted charge, with the melting including introducing the charge into a flux that is heated try electrical current, maintaining a temperature of the flux in a range of 1500-1800° C., and carrying out the oxidizing refining until an aluminum content reaches 0.05-1.0%.

Abstract: The invention relates to a method for feeding solids into metal or steel melts whereby granular solids required during the analysis adjustment are fed in a predetermined quantity into the turbulent regions of the metal melt in a dense flow process by means of a pneumatic conveying device in order to achieve a high output while avoiding expensive and complex measures associated with lances and capital-intensive investments for injection devices and lance-moving devices.

Abstract: A component adjustor is added to an incineration residue containing salts to adjust a component ratio determined by the equation (Ca+Mg)/(Si+Al) in the range of 0.7 to 2.0. The incineration residue having the adjusted component ratio is charged to a melting furnace maintained in a reducing atmosphere to form a melt. The melt is separated into a molten slag layer, a molten salt layer, and a molten metal layer. The molten slag is fractionated and discharged from the melting furnace. The discharged molten slag is rapidly cooled. The temperature of the vapor phase in the melting furnace is maintained at 700 to 1000° C. A non-oxidizing gas is blown into the vapor phase in the melting furnace to increase the amounts of exhaust gases exhausted from the melting furnace.

Abstract: An improved method and apparatus for metal melting, refining and processing, particularly adapted to steel making in an electric arc furnace. The method provides auxiliary thermal energy to the steel making process, particulate injection for the formation of slag and foamy slag, and oxygen injection for the decarburization of the melt, for the formation of foamy slag and for post combustion burning of carbon monoxide. The burner includes two injection barrels for providing finely pulverized particles and for providing either a supersonic or a subsonic primary flow of an oxidizing gas. The barrels are positioned side by side in a nozzle at the entrance of a flame shaping chamber of a fluid cooled combustion chamber. The nozzle also contains a plurality of fuel orifices for the providing pressurized fuel to the combustion chamber and a plurality of oxidizing gas orifices for providing a secondary flow of an oxidizing gas around the periphery of the nozzle.

Abstract: An improved method and apparatus for EAF steelmaking wherein the method provides additional thermal energy to the steel making process, carbon injection for the formation of foamy slag, and oxygen injection for the decarburization of the melt, the formation of foamy slag and post combustion burning of carbon monoxide. The apparatus comprises a unique burner configuration which has a central conduit for alternatively supplying fluid hydrocarbon fuel or particulate carbon with a carrier gas which are discharged through a exit opening. The fuel or carbon is mixed with a high speed, preferably supersonic, stream of oxidizing gas. The high speed stream of oxidizing gas is provided by an annular supersonic nozzle which causes the oxidizing gas to surround the fuel or the particulates with an annular flow. The annular nozzle design can be adjusted to direct the flows of particulates and oxidizing gases in the areas and shapes desired for efficient management of the steelmaking process.

Abstract: Rare earth alloy compositions, such as the neodymium iron boron (NdFeB) alloy are made by a Reduction-Melting process. The Reduction-Melting process comprises preparing a primary electrode containing at least one compound or metal to be reduced to form a refined metal or metal alloy ingot; placing the electrode in an electroslag refining furnace; passing a current through the electrode into a molten flux or slag to melt the electrode; reducing the metal or compound in the slag while forming an oxide by-product; collecting melted metal or metal alloy droplets falling through the slag; forming an ingot of the metal or metal alloy from the melted droplets; and collecting the solid oxide byproducts in the slag.