Abstract: Disclosed herein, in some aspects, are systems and methods for producing a material comprising iron through self-reduction of iron ore using bio-oil and/or other reducing agents (e.g., bio-based reducing agents), such as biocrude, ethanol, or other bio-based liquids or biologically sourced liquids. The bio-oil and/or other reducing agents can be mixed with the iron ore to form a furnace mixture, which can be heated, such that the components of the bio-oil and/or other reducing agents in the furnace mixture reduce the iron ore to form an iron product (e.g., a material that includes metallic iron). In some cases, the pre-formed furnace mixture allows for the reducing agents to interact with the iron more readily, thereby providing for quicker reaction rates, and thereby quicker reduction of iron ore, as compared to direct reduction iron production.

Abstract: A burner apparatus and process are described. The burner apparatus includes an inlet chamber in communication with a combustion chamber. The combustion chamber has a cylindrical shape defining a longitudinal axis and a radial direction orthogonal to the longitudinal axis. The combustion chamber has an upstream end and a downstream end, and an air inlet is disposed in the inlet chamber. A pilot, a fuel gas inlet, and a refractory material are disposed in the combustion chamber downstream of the air inlet. A mixed gas inlet is positioned downstream of the fuel gas inlet and the pilot in the combustion chamber. The mixed gas inlet includes a manifold having an inlet, a body, and a plurality of nozzles.

Abstract: A composite magnetic body includes soft magnetic metal particles and non-magnetic ceramic particles each having a particle size (D50) smaller than that of the soft magnetic metal particles.

Abstract: The invention relates to a process that involves (1) feeding (a) a first valve metal powder component containing valve metal particles and (b) reducing component into a reactor having a hot zone; and (2) subjecting the first valve metal powder component and the reducing component to non-static conditions sufficient to simultaneously (i) agglomerate the first valve metal powder component particles, and (ii) reduce oxygen content in the valve metal powder component particles, and thereby form a second valve metal powder component containing oxygen-reduced valve metal particles, in which the reducing component is selected from the group consisting of magnesium reducing components, calcium reducing components, aluminum reducing components, lithium reducing components, barium reducing components, strontium, reducing components, and combinations thereof.

Abstract: A method and a device are described for the production of metal powder or alloy powder of a moderate grain sizes less than 10 ?m, comprising or containing at least one of the reactive metals zirconium, titanium, or hafnium, by metallothermic reduction of oxides or halogenides of the cited reactive metals with the aid of a reducing metal, wherein said metal powder or alloy powder is phlegmatized by adding a passivating gas or gas mixture during and/or after the reduction of the oxides or halogenides and/or is phlegmatized by adding a passivating solid before the reduction of the oxides or halogenides, wherein both said reduction and also said phlegmatization are performed in a single gas-tight reaction vessel which can be evacuated.

Abstract: The disclosure relates to metal reduction processes, which comprise adding a mixture comprising at least one metal-containing material, at least one reducing agent, and at least one additive into a reactor, heating the reactor to a selected reduction temperature, moving the mixture through the reactor while stirring the mixture, allowing a reduction period to occur, and obtaining a resulting composition comprising at least one zero-valent metal and a residue. The disclosure also relates to metallurgical processes comprising the metal reduction process, and products made by the metal reduction process. The disclosure further relates to metal reduction apparatuses, as well as metal reduction systems and metallurgical systems comprising the metal reduction apparatuses.

Abstract: [Problem]To provide a method for producing an electrocatalyst having no compositional scatter, wherein nano-level alloy catalyst molecules with an ordered particle size are supported in a highly dispersed state. [Means of Solution] The method includes the steps of preparing a reverse micelle solution by mixing two or more catalyst precursors selected from among metal salts and/or metal complexes, a solvent having hydrophilic groups and a non-aqueous solvent, forming alloy particles in the reverse micelle by adding a non-aqueous solution having a reducing action to the reverse micelle and heating, and supporting the alloy particles on a carrier.

Abstract: A low-temperature process of producing high-purity iron powder by feeding hematite and a reducing agent into a rotary reactor under pressure to form a mechanical fluid bed. The fluid bed is rotated at a particular speed within a rotary reactor. The fluid bed is simultaneously heated to a reaction temperature, and the pressure is then reduced within the rotary reactor to a pressure in a range of 0.01 bars to 2.0 bars, as a result reducing the reaction temperature to a temperature in a range of 600° C. to 850° C. Maintaining the pressure and the rotation results in the formation of a high-purity iron oxide without the requirement for post-grinding process steps because sintering is prevented by using a combination of pressure reduction and a rotary set at an optimum rotation speed, resulting in useful additives produced by a more environmentally-friendly process.

Abstract: The invention relates to a process for the production of metal alloy powders, in particular the invention relates to a process for producing titanium metal alloys from titanium dioxide and aluminium. Optionally the process can also include the use of one or more other oxides (metal or non-metal). The result is at least a Ti—Al alloy powder. If another metal oxide is used the result is a Ti-ternary alloy powder. If SiO2 is used the result is a Ti—Al—Si alloy.

Abstract: The present invention relates to a process for producing sponge iron with in-situ carbon removal. The process for producing the sponge iron includes the steps of preparing a sandwich of at least two layers wherein the at least two layers includes a first layer (10) of iron oxide source which content is carbon free or comprises of only self-contaminant carbon or carbonaceous and second layer (12) is a mixture of iron oxide source and carbon source and subjecting the sandwich of at least two layers to a pyrolysis process in a non-oxidative environment at temperature between 950° C. to 1900° C. for a period between 10 minutes to 36 hours. The carbon source in the second layer (12) is equal to or more than stoichiometric weight of carbon according to a predominant reaction. The non-oxidative pyrolysis occurs in a reactor. The sandwich of two layers is placed in a moving carrier (16) such as tray to accommodate the sandwich of two layers in the reactor.

Abstract: The present invention provides a method and facility for preventing crumbling and powderization of green pellets when producing high strength green pellets using a powder feedstock and using the pellets in a rotary hearth reducing furnace and for efficiently reducing the same. It comprises kneading by a kneader 5 a feedstock of a powder of a fine particle size (20 to 80 wt % having size of not more than 10 ?m) including a metal oxide and carbon-bearing powder fed from a feed storage tank 1 and producing green pellets by a pan type pelletizer 7. The green pellets are screened by a pellet screen 9, then dried by a pellet dryer 11 and reduced by firing in a rotary hearth reducing furnace 13. At that time, the green pellets are continuously conveyed to prevent crumbling.

Abstract: It is to propose a method of producing super-micro powders of pure metal-alloy in which cheap materials can be used and the production is efficient. In the production method of pure metal super-micro powder by heating a starting material containing a metal chloride and reducing the resulting vapor of the metal chloride with hydrogen gas, an elementary metal constituting the metal chloride is added to the starting material containing the metal chloride and a metal chloride having a large valence among metal chlorides having two or more valence is used as the metal chloride. Also, in the production method of alloy super-micro powder, a metal chloride is used as one to (number of all alloying components—1) alloying components in the starting material and an elemental metal is used as the other alloying component.

Abstract: The present invention relates to the tantalum powder and the process for preparing the same, and also relates to the electrolytic capacitor anode made of the tantalum powder. More particularly, the present invention relates to the tantalum powder having a BET surface area not more than 0.530 m2/g, Fisher mean particle size not less than 3.00 ?m. The present invention relates to the process for preparing the tantalum powder, wherein the tantalum powder is prepared through reducing tantalum compound with a reducing agent, wherein the tantalum powder as seed is added during reduction, and said tantalum powder as seed is the tantalum powder that has been milled.

Abstract: The present invention is generally directed towards a method for producing a solid metallic composition by reacting a gaseous metal halide with a reducing agent are described. In one embodiment, the method includes reacting a gaseous metal halide with a reducing agent in a manner effective to form a nonsolid reaction product, wherein the metal halide has the formula MXi, in which M is a metal selected from a transition metal of the periodic table, aluminum, silicon, boron, and combinations thereof, X is a halogen, i is greater than 0, and the reducing agent is a gaseous reducing agent selected from hydrogen and a compound that releases hydrogen, and combinations thereof; and solidifying the reaction product, thereby forming a metallic composition comprising M that is substantially free from halides. The invention may be used to produce high-purity metallic compositions, particularly titanium particles and alloys thereof for use in powder metallurgy applications.

Abstract: The invention concerns an iron powder for fortifying foodstuff. The powder consists of a reduced iron powder having irregularly shaped particles, wherein the iron powder has a ratio AD:PD less than 0.3, wherein AD is the apparent density in g/cm3, and PD is the particle density in g/cm3. The specific surface area of the powder particles is above 300 m2/kg as measured by the BET method and the average particle size is between 5-45 ?m.

Abstract: Grinding media, including shaped media such as spheres or rods ranging in size from about 0.5 micron to 100 mm in diameter, are formed from a multi-carbide material consisting essentially of two or more carbide-forming elements and carbon, with or without carbide-forming elements in their free elemental state. The media have extremely high mass density, extreme hardness, and extreme mechanical toughness.

Abstract: A method for manufacturing sponge iron includes heating iron oxide together with a solid reducing agent to reduce the iron oxide into sponge iron, wherein the iron oxide includes a mixture of powdered hematite and powdered iron ore or a mixture of powdered hematite and powdered mill scale, the powdered hematite has a specific surface area of 2.0 m2/g or more, and the content of the powdered hematite is 5-45% by mass with respect to the total quantity of iron oxide.

Abstract: Disclosed is a method of forming a W—Cu composite powder having a Cu particle surrounded by tungsten by mixing and pulverizing tungsten oxide powder and copper oxide powder using turbular mixing or ball milling, reducing the Cu powder firstly at 200˜400° C. under a hydrogen atmosphere or a reducing gas environment including hydrogen, generating W nuclei on the reduced Cu powder at 500˜700° C., and growing the generated W nuclei at 750˜1080° C. as well as a use of the same for the use of powder injection molding.

Abstract: The invention relates to a process for the production of metallic and metal-ceramic composite components by powder injection molding of a system comprising a metal composite powder, a binder and optionally a ceramic component, where the metal composite powder used is mixed with a protecting liquid in an inert atmosphere before the mixing with the binder. The invention furthermore relates to molybdenum/copper and tungsten/copper composite powders which have a primary metal particle size of predominantly <2 ?m, an oxygen content of <0.8% by weight and optionally a ceramic component, to the use of these composite powders for the production of composite components by powder injection molding, and to a process for the preparation of composite powders in which oxides of molybdenum or tungsten and of copper are mixed, dry-ground and reduced using hydrogen at a temperature of from 800 to 1050° C., and a ceramic component is optionally admixed with the resultant metal composite powder.

Abstract: A magnetic powder of an Sm—Fe—N alloy, which has a mean particle diameter of 0.5 to 10 &mgr;m, and either an average acicularity of 75% or above or an average sphericity of 78% or above. The powder exhibits an extremely high residual magnetization and an extremely high coercive force, since particles characterized by the above acicularity or sphericity have particle diameters approximately equal to that of the single domain particle and nearly spherical particle shapes. The powder can be produced by preparing an Sm—Fe oxide by firing a coprecipitate corresponding to the oxide, mixing the obtained oxide with metallic calcium and subjecting the mixture to reduction/diffusion and nitriding successively.

Abstract: The cost-effective titanium powder is manufactured by (a) magnesium-thermic reduction of titanium chlorides characterized by the formation of a hollow block of the reaction mass having an open cavity in the center of the block, (b) thermal-vacuum separation of the hollow block from excessive Mg and MgCl2 at 850-950° C. and residual pressure of 10−2-10−3 mm Hg, (c) cooling of obtained titanium hollow block in a H2-contained atmosphere at an excessive hydrogen pressure, (d) crushing the hydrogenated titanium block, (e) grinding the crushed titanium pieces into the powder combined with a hydro-metallurgical treatment of obtained titanium powder in a diluted aqueous solution of at least one chloride selected from magnesium chloride, sodium chloride, potassium chloride, or titanium chloride, and (f) drying and, optionally dehydrating the titanium powder ground to a predetermined particle size.

Abstract: A method for manufacturing sponge iron includes heating iron oxide together with a solid reducing agent to reduce the iron oxide into sponge iron, wherein the iron oxide includes a mixture of powdered hematite and powdered iron ore or a mixture of powdered hematite and powdered mill scale, the powdered hematite has a specific surface area of 2.0 m2/g or more, and the content of the powdered hematite is 5-45% by mass with respect to the total quantity of iron oxide.

Abstract: The present invention provides a metallic powder which exhibits superior sintering properties in a production of multilayer ceramic capacitors, and exhibits superior dispersion characteristics in forming of conductive pastes, thereby preventing delamination. Metallic powder produced by bringing a metallic chloride gas into contact with a reducing gas in a reducing temperature range is subjected to a surface treatment by a nonionic surfactant in a wet or dry process to obtain final metallic powder.

Abstract: A process for producing metallic powders a chlorination step for continuously producing chloride gas of metal by reacting metal with chlorine gas, and a reduction step for continuously reducing the metallic chloride gas by reacting the metallic chloride gas produced in the chlorination step with reducing gas. Regulating the feed rate of the chlorine gas can control the feed rate of the metallic chloride gas, whereby the particle diameters of produced metal powders can be stably controlled. Thus, the invention can make the particle diameters stable and arbitrarily control the diameters in the range of 0.1 to 1.0 &mgr;m.

Abstract: The low temperature reduction of a metal oxide using mechanochemical processing techniques. The reduction reactions are induced mechanically by milling the reactants. In one embodiment of the invention, titanium oxide TiO.sub.2 is milled with CaH.sub.2 to produce TiH.sub.2. Low temperature heat treating, in the range of 400.degree. C. to 700.degree. C., can be used to remove the hydrogen in the titanium hydride.

Abstract: The manufacture of powdered feed materials for hard fine grained metal body production includes the reduction of metal oxides into powdered metal and the subsequent carburization into metal carbide. Processes currently used are very cost intensive, mainly because of very long reaction times at high temperatures. According to applicant's economical process, the above reactions occur in the range of seconds and in a high-temperature cyclone as the reaction chamber. The apparatus is rather simple to construct. The stock to undergo reaction is continuously introduced into the chamber as a solid powdered phase with reaction gas and/or carrier gas, and passes through the chamber on predetermined paths for reaction, without leaving the solid state thereby.

Abstract: A mechanochemical process for producing fine WC/Co composite powder which is so small in WC grain size and in mean free path, and contains such a uniform distribution of WC and Co that its hard metal is superior in strength, compressive strength, TRS and wear resistance and considerably free of impurities. The method comprises the steps of drying an ammonium metatungstate--Co(NO.sub.3).sub.2 solution in a spray dry manner to give initial powder of porous spheroids or in a common manner to give a cake of initial powder, removing the salts and humidity from the initial powder by a thermal treatment, mixing and milling the desalted initial powder with carbon black, and subjecting the mixed powder to reduction/carburization in a reactor.

Abstract: A method of producing iron powder comprises the step of providing a supply of iron oxide powder of a size less than 1000 microns which is then heated in a reducing agent atmosphere to a temperature between 1000.degree. F. and 2100.degree. F., thus resulting in the iron oxide powder being reduced to iron powder, cooling the iron powder in an inert gas atmosphere to a temperature below 150.degree. F. and milling to a median particle size diameter of less than or equal to 20 microns.

Abstract: A method for manufacturing hydrogen storage alloy particles comprises steps of obtaining a melt of the hydrogen storage alloy and pulverizing the hydrogen storage alloy by water atomizing process, whereby the melt is pulverized by contacting or colliding with high-speed jetting thereto to be dispersed in the form of solidified fine particles. By employing an aqueous solution of hypophosphorous acid or an alkali aqueous solution in place of water during the water atomizing process, or by etching the oxide films once formed on the surface of the hydrogen storage alloy particles with an aqueous solution of a strong acid, the thickness of the oxide film can be made thinner, and thus a high discharge capacity of a battery configured with a negative electrode comprising the alloy particles can be realized.

Abstract: A process for extracting precious metal from volcanic ore includes the steps of crushing the ore, heating the ore in a hydrogen atmosphere to soften oxide mineral encapsulating the precious metal, cooling the ore, grinding the ore, and processing the ore to extract precious metal.

Abstract: A method for the manufacture of finely divided particles of palladium, palladium oxide or mixtures thereof comprising the sequential steps:A. Forming an unsaturated solution of thermally decomposable palladium-containing compound in a thermally volatilizable solvent;B. Forming an aerosol consisting essentially of finely divided droplets of the solution from step A. dispersed in an inert carrier gas;C. Heating the aerosol to an operating temperature above the decomposition temperature of the palladium-containing compound, but below the melting point of palladium metal by which finely divided particles of palladium, palladium oxide or mixtures thereof are formed and densified; andD. Separating the particles of palladium, palladium oxide or mixtures thereof from the carrier gas, reaction by-products and solvent volatilization products.

Abstract: Doped tungsten powder, or sintered tungsten bodies formed therefrom, having a fine dispersion of oxide particles of at least one metal from the group zirconium, hafnium, lanthanum, yttrium, and rare earth's are formed by the method of this invention. A mixture of a salt solution comprised of a soluble salt of the metal, and a tungsten blue oxide powder is formed. A hydroxide precipitating solution is admixed with the mixture to form a hydroxide precipitate of the metal on the tungsten blue oxide powder. The tungsten blue oxide powder and hydroxide precipitate are heated in a reducing atmosphere to form the tungsten powder having the dispersion of oxide particles. The doped tungsten powder can be consolidated and sintered to form tungsten bodies having a fine dispersion of the metal oxide.

Abstract: This invention discloses a process for preparing rare earth containing hard alloy, comprising preparing metal carbide powder containing rare earth metals or cobalt powder containing rare earth metals by using wet coprecipitating method; according to the composition of alloy, at least one kind of the metal carbide powder containing rare earth metal and cobalt powder containing rare metals being mixed homogeneously with other raw materials, shaping and finally sintering under high temperature. The process of the invention is simple technologically. The properties of the products produced by the process of the invention are good, stable and repeatable.

Abstract: A hydrogen battery alloy is prepared which is substantially free of inclusions of chromium by preparing a first precursor alloy or master alloy containing vanadium, nickel, and chromium using relatively equal amounts of vanadium and nickel and then adding from 5% to 12% by weight of chromium. The alloy materials are introduced into an aluminothermic reaction as vanadium pentoxide, nickel powder and chromium powder with the aluminum metal being in slight excess of its stoichiometric amount. The first precursor alloy described further alloyed with preselected amounts of nickel, zirconium, titanium, cobalt, manganese, aluminum, and chromium to form an alloy suitable for use as an electrode material in rechargeable electrochemical hydrogen storage cells.

Abstract: A method of making extrafine pure elemental metal powder from a highly malleable pure elemental metal powder. The pure elemental metal powder is oxidized, ground to a desired average particle size, reduced in a reducing atmosphere to a pure elemental metal powder, and then sieved to obtain the desired fraction of extrafine pure elemental metal powder.

Abstract: A process for producing salt free titanium powder by reacting zinc and a titanium halide in the presence of a reducing agent to form a solid zinc titanium product. Titanium halide vapor is introduced into a liquid alloy of zinc and the reducing agent at a temperature between 650.degree.-907.degree. C. The titanium halide is introduced beyond the titanium solubility limit in zinc to precipitate a zinc titanium intermetallic compound and also produce a liquid halide salt. The intermetallic compound forms and accumulates at an interface between the salt and liquid alloy. The compound is periodically removed from the interface, crushed into a powder, and the zinc is evaporatively separated from the titanium to produce pure titanium powder. The process preferably occurs above the peritectic decomposition temperature of Zn.sub.3 Ti, and most preferably above the peritectic decomposition temperature of Zn.sub.2 Ti, to maximize the titanium content of the resulting product.

Abstract: A method is disclosed for producing an agglomerated molybdenum plasma spray powder with a controlled level of oxygen which comprises forming a relatively uniform mixture of agglomerated powders containing molybdenum dioxide and one or more ammonium-containing compounds of molybdenum wherein the mixture has an oxygen content of greater than about 25% by weight and reducing the mixture in a moving bed furnace at a temperature of from about 700.degree. C. to about 1000.degree. C. for a sufficient time to remove a portion of the oxygen therefrom and form reduced molybdenum powder agglomerates having an oxygen content of no greater than about 25% by weight. The reduction takes place in the direction from the outside surface of the agglometates to the inside surface.

Abstract: Particles for the production of permanent magents are obtained by producing an article having Ca and a rare earth oxide including at least Nd oxide. The article is heated to effect Ca rare earth oxide reduction. Thereafter, particles of -60 mesh or finer are formed from this article. Leaching of Ca from the particles is achieved by contacting the particles with an organic acid having at least 3 carbon atoms, preferably propionic or butanoic acid.