Abstract: Methods and systems for producing activated carbon from a particulate coal feedstock that include the introduction of an activation medium such that the water content of the coal feedstock is equal to or greater than that of the feedstock's naturally occurring state. Different methods and system configurations allow the production of activated carbon or other heat-treated carbons while concurrently avoiding adverse reaction conditions.

Abstract: A formed article for making alloying additions to metal melts includes particles of at least one master alloy and a binder material binding the particles of the master alloy in the formed article. The binder material changes form and frees the master alloy particles when the formed article is heated to a predetermined temperature, preferably a temperature greater than 500° F. A method for making an alloy also is provided. The method includes preparing a melt comprising a predetermined quantity of a master alloy wherein the master alloy is added to the melt or the melt starting materials in the form of particles of the master alloy bound into at least one formed article by a binder material that decomposes at a predetermined temperature, preferably a temperature greater than 500° F., and releases the particles of master alloy.

Abstract: Self-reducing agglomerates are provided for use in the production of metal. The agglomerates comprise a mixture of iron oxide containing particles and particles of a reducing agent bonded by use of a pre-gel. The agglomerates are produced by a method and apparatus that provides for mixing and curing thereof. The agglomerates may then be used for reduction thereof for the production of iron.

Abstract: An iron oxide waste agglomerate, preferably a briquette, is provided including 0.03-15 weight percent on a dry basis lignosulfonate binder, 50-99.5 weight percent on a dry basis iron oxide waste, and 0.3-20 weight percent water. The agglomerate can further include 1-40 weight percent on a dry basis carbon source material such as carbon black, coke or coal. The briquette is heated in a furnace where the iron oxide waste is reduced to elemental iron. The binder is effective to prevent the briquettes from crumbling during the reducing opperation. The reduced iron briquette is then dropped into molten steel, thereby recycling iron oxide waste.

Abstract: The present invention is directed to a process of making fired mineral pellets by mixing particulate mineral material with moisture and binder comprising substantially water soluble organic polymer to form a moist pelletizable mix, pelletizing the moist mix by a tumbling process to form green pellets and firing the green pellets, characterized in that the binder comprises alkali metal silicate in a dry weight amount which is either (a) above 0.13% based on moist mix or (b) above 0.08% based on moist mix and at least three times the dry weight of substantially water soluble organic polymer.

Abstract: A method for producing solid metal product is disclosed including the steps of providing carbon and metal bearing compounds in compacts, coating the compacts with treatment materials, encapsulating the compacts with carbonaceous containing materials to form a residual layer, and treating the residual layer before introduction of the compacts into a furnace. The compacts contain carbon containing metal bearing compounds, and are coated with mixtures of carbonaceous materials dispersed within a binder material such as a viscous liquid, molasses, alcohol, or fuel oil. The coated compacts are treated to form a hardened outer residual layer. The outer residual layer provides for a sacrificial outer coating on the compacts that reacts with any oxidizing gaseous components within the furnace, while the carbon containing metal bearing compounds within the compacts are heated and metallized inside the compounds.

Abstract: The object is to provide a powdered metal injection compacting composition adapted to give compacts free from deformation, cracking or blistering without being compromised in compactability or debinder characteristic and without the aid of a special jig.This composition comprises a metal powder and an organic binder comprising (A) a crystalline resin having a melting point of not less than 150.degree. C., (B) an organic compound the weight loss on heating of which begins at a temperature below 150.degree. C. and (C) a composite acrylic resin, the composite acrylic resin mentioned above being a resin obtainable by dispersing a solution comprising the following components (C1).about.(C3) in an aqueous medium containing a dispersant and carrying out a suspension polymerization reaction:(C1) an ethylene-vinyl acetate copolymer or an ethylene-ethyl acrylate copolymer,(C2) a (meth)acrylic ester monomer or a mixture of a (meth)acrylic ester monomer and a styrenic monomer, and(C3) a polymerization initiator.

Abstract: The present invention generally relates to a process of agglomerating particulate material in the presence of water which comprises mixing said particulate material with a binding effective amount of at least one water soluble polymer, and a binder enhancing effective amount of caustic, to produce a mixture, and forming said mixture into agglomerates. The invention also relates to a binder composition useful for the agglomeration of particulate material in the presence of water which comprises a binding effective amount of a water-soluble polymer and a binder enhancing effective amount of caustic.

Abstract: The present invention generally relates to a process of agglomerating particulate material in the presence of water which comprises mixing said particulate matreial with a binding effective amount of at least one water soluble polymer, and a binder enhancing effective amount of caustic, to produce a mixture, and forming said mixture into agglomerates.

Abstract: In an iron ore pelletization process in which particulate ore is mixed with particulate polymeric binder in the presence of moisture and the mixture is pelletised, the particulate binder is a blend of ionic synthetic water soluble polymer, such as a copolymer of acrylamide and sodium acrylate having intrinsic viscosity 2 to 16 dl/g, with a larger amount of a guar gum.

Abstract: Process for producing agglomerates, e.g., by pelletizing a particulate inorganic material for example an ore material, characterized by the addition to the agglomerated material of an organic fibrous material, especially a polyacrylonitrile fiber material, to bind and thereby enhance the properties of the agglomerates and recovery of metal values therefrom.

Abstract: Particulate ore is pelletized by forming an intimate mixture with particulate binder in the presence of moisture, forming green pellets by agitation of the mixture and then firing these to produce ore pellets and the particulate binder comprises particles of a water soluble, partly cross-linked, polymer formed from water soluble, ionic, ethylenically unsaturated monomer or monomer blend, wherein the extent of cross-linking is insufficient to render the particles predominantly water insoluble but is sufficient to increase the dry strength of the ore pellets.

Abstract: A binder composition for use in making metal parts via a metal powder injection molding process containing the following components: (a) a first polymer with a relatively low solubility parameter such as polyethylene and polypropylene; (b) a second polymer with a relatively high solubility parameter such as polystyrene and poly(methyl methacrylate); and (c) a block copolymer containing blocks of the first and second, or other structurally similar, constituting monomeric units. Examples of the block copolymers include ethylene/styrene copolymer, propylene/styrene copolymer, and isoprene/styrene copolymer, etc. The binder composition is dispersed in an appropriate dispersant, such as an oil or wax, then blended with a metal powder to form a metal powder injection composition. The metal powder injection composition forms a green compact with a predetermined shape and dimension using an injection molding machine. Finally the green compact is sintered to form the final product.

Abstract: The invention concerns an agent for treating metal melts in the form of a cored wire comprising a metallic sheath of steel or iron and a filling which contains a compound that splits off gas at the temperature of the metal melt and is based on an organic polymer in amounts of 0.2 to 20 g per meter cored wire. The invention also concerns the use of the agent for homogenizing, refining and homogeneously cooling as well as alloying metal melts.

Abstract: Process for producing agglomerates, e.g., by pelletizing a particulate inorganic material, for example, an ore material, characterized by the addition to the agglomerated material of an organic fibrous material, especially a polyacrylonitrile fiber material, to bind and thereby enhance the properties of the agglomerates and recovery of metal values therefrom.

Abstract: A binder for pelletizing particulate mineral material. The binder including about 30-99.5% modified native starch, and about 0.2-80% of water-dispersible polymer material selected from the group consisting of water-dispersible natural gums, water-dispersible pectins, water-dispersible starch derivatives, water-dispersible cellulose derivatives, water-dispersible vinyl polymers, water-dispersible acrylic polymers and mixtures thereof. Alternate embodiments include from about 0.5-50% lignosulfonates and/or about 0.2-40% soda ash. Mineral ore concentrate is also disclosed as are mineral ore and iron ore pellets. In addition, methods of binding particulate mineral material and of making mineral ore pellets are also disclosed.

Abstract: A binder for pelletizing particulate mineral material. The binder including about 50-99.5% modified native starch, and about 0.5-50% of water-dispersible polymer material selected from the group consisting of water-dispersible nature gums, water-dispersible pectins, water-dispersible starch derivatives, water-dispersible cellulose derivatives, water-dispersible vinyl polymers, water-dispersible acrylic polymers and mixtures thereof. An iron ore concentrate is also disclosed as are mineral ore and iron ore pellets. In addition, methods of binding particulate mineral material and of making mineral ore pellets are also disclosed.

Abstract: Minor amounts of water insoluble elastomeric polymers are combined with oil which is applied in an aqueous spray as an agglomeration aid.

Abstract: A binder composition and method for its use to bind metal ores in a pelletizing process is disclosed. The composition includes the use of superabsorbent cross-linked polymers alone or in combination with at least one of the materials chosen from linear water-soluble vinyl addition polymers and polysaccharides.

Abstract: Steel mill by-product material briquettes or pellets and processes for making the same that results in a briquetted or cold agglomeration pelleted material made from by-product material and a binder comprising gypsum-free cement and sucrose residue for the briquettes or a binder comprising gypsum-free cement and, if required, a sucrose residue for the pellets. These briquettes or pellets are made using a cold roll briquetting process or a cold agglomeration pelletizing process at ambient temperature and can be fed directly into a blast furnace thereby recycling by-product materials while completely by-passing the environmentally adverse and costly sintering process or landfill disposal process.

Abstract: A binder for pelletizing particulate mineral material. The binder including about 50-99.5% modified native starch, and about 0.5-50% of water-dispersible polymer material selected from the group consisting of water-dispersible nature gums, water-dispersible pectins, water-dispersible starch derivatives, water-dispersible cellulose derivatives, water-dispersible vinyl polymers, water-dispersible acrylic polymers and mixtures thereof. An iron ore concentrate is also disclosed as are mineral ore and iron ore pellets. In addition, methods of binding particulate mineral material and of making mineral ore pellets are also disclosed.

Abstract: A binder for agglomerating an ore in the presence of water, contains 10% to 90% of a water-soluble sodium carboxymethylhydroxyethylcellulose and 10% to 90% of sodium carbonate. A process comprises mixing a binder composition containing cellulose and sodium carbonate, water, and the ore, agglomerating the mixture into wet balls, drying the wet balls, and heating the resultant dry balls at a temperature of at least about 1204.degree. C. A preferred ore is taconite.

Abstract: A binder useful for agglomerating a concentrated ore material in the presence of water comprising (a) a water-soluble polymer selected from the group consisting of alkali metal salts of carboxymethyl celluylose or carboxymethyl hydroxyethyl cellulose and (b) sodium tripolyphosphate, a process for agglomerating the concentrated ore material using this binder, and the agglomerated product of this process, are disclosed.