Characteristic Of Treated Material Sensed (e.g., Density, Etc.) Patents (Class 75/386)
  • Patent number: 10589251
    Abstract: Biomass (e.g., plant biomass, animal biomass, and municipal waste biomass) is processed to produce useful intermediates and products, such as energy, fuels, foods or materials. For example, systems and methods are described that can be used to treat feedstock materials, such as cellulosic and/or lignocellulosic materials, in a vault in which the equipment is protected from radiation and hazardous gases by equipment enclosures. The equipment enclosures may be purged with gas.
    Type: Grant
    Filed: November 14, 2018
    Date of Patent: March 17, 2020
    Assignee: Xyleco, Inc.
    Inventors: Marshall Medhoff, Thomas Craig Masterman, Robert Paradis
  • Patent number: 10176900
    Abstract: Biomass (e.g., plant biomass, animal biomass, and municipal waste biomass) is processed to produce useful intermediates and products, such as energy, fuels, foods or materials. For example, systems and methods are described that can be used to treat feedstock materials, such as cellulosic and/or lignocellulosic materials, in a vault in which the equipment is protected from radiation and hazardous gases by equipment enclosures. The equipment enclosures may be purged with gas.
    Type: Grant
    Filed: May 25, 2017
    Date of Patent: January 8, 2019
    Assignee: XYLECO, INC.
    Inventors: Marshall Medoff, Thomas Craig Masterman, Robert Paradis
  • Patent number: 8986423
    Abstract: A method of heap leaching including forming a heap lift, installing a horizontal solution collection system between the heap layers including a horizontal tubing with a wireline data collection tool disposed therein, providing a heap leach model for modeling the heap leach operation including a solvent formulation and a irrigation setting, obtaining collected data from the wireline data collection tool while irrigating the heap lift, the collected data including in-situ material parameters of the heap layers and in-situ solution parameters of the solution flowing in the heap layers, modeling the heap leach operation using the collected data based on the heap leach model to generate a result, and adjusting the heap leach operation based on the result.
    Type: Grant
    Filed: December 1, 2010
    Date of Patent: March 24, 2015
    Assignee: Schlumberger Technology Corporation
    Inventors: Kent Lang, Gilles Mathieu, Roland Banas, Robert A. Will
  • Patent number: 8920532
    Abstract: The present invention describes an inoculation process for inoculating a nucleating additive to a cast iron alloy in a pouring distributor by means of using a transferred arc plasma torch, with an anode partially immersed in the cast iron alloy and a cathode located on the surface of said alloy, the anode or the cathode or both comprising graphite, preferably synthetic crystalline graphite, which supplies said nucleating additive to the iron alloy. The invention thus describes an inoculation device useful for carrying out the inoculation process.
    Type: Grant
    Filed: November 25, 2009
    Date of Patent: December 30, 2014
    Assignee: Fundacion Tecnalia Research & Innovation
    Inventors: Luis Cobos Jimenez, Francisco Rodríguez Vázquez, Jose Luis Oncala Avilés, Pedro Carnicer Alfonso
  • Patent number: 8753419
    Abstract: Chrome-containing molten iron and slag are to be obtained in an electric furnace operation using CaF2-free slag. In order to reduce and collect chrome from the slag while simultaneously promoting desulfurization of molten iron, a chrome-containing molten iron produced in an electric furnace and having a Cr content of from 8.0 to 35.0% by mass, and a CaF2-free electric furnace slag formed during the molten iron production, including Cr2O3, SiO2 and CaO as the constituent components and having a basicity CaO/SiO2 of from 0.7 to 1.7, are mechanically stirred with an impeller in a refining vessel. A metal Al-containing substance and CaO are put into the vessel before the end of stirring to thereby control the basicity of the slag after the end of stirring to at least 1.
    Type: Grant
    Filed: December 8, 2010
    Date of Patent: June 17, 2014
    Assignee: Nisshin Steel Co., Ltd.
    Inventors: Takahiro Yoshino, Masakazu Mori
  • Patent number: 8747518
    Abstract: In order to carry out foaming of a slag having a high ratio of chromium oxide having values of often above 20% of a non-corrosive melt in an AOD (Argon Oxygen Decarburization) or MRP (Metallurgical Refining Process) converter or CONARC SSt for stainless steel by adding a foam material, according to the invention a previously defined mixture (5) of a metal oxide, iron carrier, carbon and binding material in the form of pellets or briquettes (4) is introduced into the converter, which reacts in a chemically reducing manner under the slag layer (2) due to the high ambient temperature, wherein gaseous carbon monoxide formed in particular by means of the reduction process of the metal oxide with the carbon within the pellets or briquettes (4) induces the slag foaming with the gas bubbles (7) thereof and wherein the specific density of the pellets or briquettes (4) and the resolve time of the reduction process are selected so that optimal bubble formation in respect of size and duration is achieved.
    Type: Grant
    Filed: January 5, 2011
    Date of Patent: June 10, 2014
    Assignee: SMS Siemag Aktiengesellschaft
    Inventors: Johann Reichel, Lutz Rose
  • Patent number: 8728196
    Abstract: A semi-liquid metal processing and sensing device comprising a crucible that is at least partially encircled by at least one induction coil. The one or more induction coils can be water cooled. The one or more induction coils can be designed to generate a variable power and/or variable frequency magnetic field which can be modulated to control the cooling of a molten metal charge in the crucible from the liquidus temperature to a selected heat content, resistivity and/or viscosity. The magnetic field can be designed to induce toroidal agitation of the metal charge in the crucible. The semi-liquid condition is sensed and can be actively controlled by the induction power supply via real time or non-real time analysis of electrical feedback signals that are obtained from the induction coil.
    Type: Grant
    Filed: May 22, 2012
    Date of Patent: May 20, 2014
    Assignee: Ajax TOCCO Magnethermic Corporation
    Inventor: Alan A. Koch
  • Patent number: 8551209
    Abstract: Methods and apparatuses for improved process control in metal smelting through measurement of off-gas profiles in real time. A tunable laser source is projected across a volume of off-gas and detected to provide a real time profile of gas concentrations. The real time gas concentration profile may be compared with known profiles to identify problems in the smelting process or to identify when the process is complete.
    Type: Grant
    Filed: October 13, 2011
    Date of Patent: October 8, 2013
    Assignee: Unisearch Associates Inc.
    Inventors: Alak Chanda, Gervase I. MacKay
  • Patent number: 8496728
    Abstract: A process for the production and/or treatment of at least one metal in a reactor includes discharging a waste gas stream via a waste gas conduit and after-treating the waste gas stream by supplying a cooling gas and/or a cooling gas mixture. The after-treating includes injecting the cooling gas and/or cooling gas mixture into the waste gas conduit on a side of the waste gas conduit facing the reactor, at a high velocity and substantially tangentially with respect to a main flow direction of the waste gas. A volume of the cooling gas and/or the cooling gas mixture injected into the waste gas conduit is adjusted so as to reduce a mixing temperature below a melting temperature of the molten particles and/or a condensation temperature of the vaporous constituents of the waste gas stream.
    Type: Grant
    Filed: February 12, 2009
    Date of Patent: July 30, 2013
    Assignee: Outotec Oyj
    Inventors: Andreas Orth, Michael Stroeder, Jean-Paul Nepper
  • Publication number: 20120297928
    Abstract: A method of heap leaching including forming a heap lift, installing a horizontal solution collection system between the heap layers including a horizontal tubing with a wireline data collection tool disposed therein, providing a heap leach model for modeling the heap leach operation including a solvent formulation and a irrigation setting, obtaining collected data from the wireline data collection tool while irrigating the heap lift, the collected data including in-situ material parameters of the heap layers and in-situ solution parameters of the solution flowing in the heap layers, modeling the heap leach operation using the collected data based on the heap leach model to generate a result, and adjusting the heap leach operation based on the result.
    Type: Application
    Filed: December 1, 2010
    Publication date: November 29, 2012
    Inventors: Kent Lang, Gilles Mathieu, Roland Banas, Robert A. Will
  • Patent number: 8241390
    Abstract: A semi-liquid metal processing and sensing device comprising a crucible that is at least partially encircled by at least one induction coil. The one or more induction coils can be water cooled. The one or more induction coils can be designed to generate a variable power and/or variable frequency magnetic field which can be modulated to control the cooling of a molten metal charge in the crucible from the liquidus temperature to a selected heat content, resistivity and/or viscosity. The magnetic field can be designed to induce toroidal agitation of the metal charge in the crucible. The semi-liquid condition is sensed and can be actively controlled by the induction power supply via real time or non-real time analysis of electrical feedback signals that are obtained from the induction coil.
    Type: Grant
    Filed: October 10, 2008
    Date of Patent: August 14, 2012
    Assignee: Ajax Tocco Magnethermic Corporation
    Inventor: Alan A. Koch
  • Publication number: 20110236696
    Abstract: A high mechanical strength reinforcement steel comprising, in addition to iron, at most about 0.5% by weight carbon, at most about 0.5% by weight vanadium and/or niobium, and the usual residual elements of scrap steel. A method of reinforcing a dwelling from damage resulting from seismic activity, the method comprising providing, as a component of the dwelling, at least one rebar of a composition comprising, in addition to iron, at most about 0.5% by weight carbon, at most about 0.5% by weight vanadium and/or niobium, at most 1.7% by weight of manganese, at most 0.5% by weight of silicon, and the usual residual elements of scrap steel.
    Type: Application
    Filed: March 25, 2010
    Publication date: September 29, 2011
    Inventors: Winky Lai, Cameron A. Cossette, James F. Petersen
  • Patent number: 8021459
    Abstract: The invention relates to a method and apparatus for controlling a continuous metal removal in conjunction with a zinc preparation process, in which the metal removal is performed in one or more reactors (11a-c), in conjunction with the reactor, the redox potential (16a-c) and the acidity and/or basicity are measured, and based on the measurement results, the process variables (17a-c) of the metal removal are adjusted towards the desired direction. According to the invention, the redox potential measurements (16a-c) are performed from the sludge produced in the reactor in conjunction with the outlet pipe of the reactor outside the reactor, and the measuring instrument (16a-c) is purified at predetermined intervals.
    Type: Grant
    Filed: July 15, 2004
    Date of Patent: September 20, 2011
    Assignee: Outotec Oyj
    Inventors: Aimo Järvinen, Kai Judin, Harri Natunen, Yrjö Oinonen, Panu Talonen
  • Publication number: 20110219914
    Abstract: A reducing dross method of lead-free solder includes the steps of: producing master alloy of reducing dross which comprises Sn and 0.1 to 0.8 wt % P; analyzing the percentage of P in the lead-free solder to be modified, in order to reach 0.008 to 0.015 wt % P in the lead-free solder, adding the master alloy into the lead-free solder with the percentage of P less than 0.008 wt % or no P; then sampling the lead-free solder at regular intervals to determine the percentage and the percentage loss of P, if the percentage of P being less than a given value between 0.008 to 0.015 wt %, adding the master alloy to keep the percentage of P within 0.008 to 0.015 wt %.
    Type: Application
    Filed: June 11, 2009
    Publication date: September 15, 2011
    Inventors: Kun Du, Minghan Chen, Xin Chen, Liesong Cai
  • Publication number: 20110107873
    Abstract: To degas a molten metal, a receptacle containing the molten metal and a layer of slag over the molten metal is positioned in a chamber, and the chamber is evacuated. As the pressure in the chamber reduces, gas is generated at the interface between the molten metal and the slag, which causes the slag to foam. To inhibit overflowing of slag from the receptacle, a gauge outputs a signal indicative of the level of the surface of the slag, and the rate of evacuation of the chamber is reduced to reduce the rate of gas generation.
    Type: Application
    Filed: September 10, 2010
    Publication date: May 12, 2011
    Inventor: SIMON HAROLD BRUCE
  • Publication number: 20100024599
    Abstract: A method for producing molten material, wherein oxygen, reducing agents and iron that has been reduced in a reduction reactor are introduced into a melter gasifier. The reducing agent is gasified with the oxygen and the heat thereby produced melts the reduced iron. Cupola gas from the melter gasifier is used at least as a portion of the reduction gas, and reacted top gas is withdrawn from the reduction reactor. The aim of the invention is to increase energy efficiency and raw material efficiency as well as productivity while at the same time obtaining metallurgically improved properties of the product. For this purpose, at least a portion of the top gas is branched off from the line for the withdrawal of the top gas from the reduction reactor and is returned via at least one return line leading to the melter gasifier and is introduced into the melter gasifier.
    Type: Application
    Filed: October 1, 2007
    Publication date: February 4, 2010
    Inventors: Franz Hauzenberger, Robert Millner, Norbert Rein, Johannes Leopold Schenk, Martin Schmidt, Bogdan Vuletic, Kurt Wieder, Johann Wurm
  • Publication number: 20100005926
    Abstract: Recovering metallic materials, such as copper, from waste materials. The A dynamic sensor measures the rate of change of current generated by metallic materials in the waste materials. Preprocessing and post processing of the waste materials may be completed to further concentrate the amount the metallic materials recovered from the waste.
    Type: Application
    Filed: June 11, 2009
    Publication date: January 14, 2010
    Inventor: Thomas A. Valerio
  • Patent number: 7628308
    Abstract: The rate of decrease of an oxidation suppressing element in a solder bath is measured during a soldering operation. Soldering is then carried out while replenishing the solder bath is then replenished during soldering so as to maintain the surface level of molten solder in the bath with a replenishment solder alloy which supplies the oxidation suppressing element to the solder bath at at least the rate at which the oxidation suppressing element is consumed during soldering. When the oxidation suppressing element is P, the concentration of P in the replenishment solder alloy is preferably 60-100 ppm.
    Type: Grant
    Filed: January 8, 2003
    Date of Patent: December 8, 2009
    Assignees: Senju Metal Industry Co., Ltd., Matushita Electric Industrial Co., Ltd.
    Inventors: Masayuki Ojima, Haruo Suzuki, Hirofumi Nogami, Norihisa Eguchi, Osamu Munekata, Minoru Ueshima
  • Patent number: 7524355
    Abstract: A method is disclosed for producing an energetic metastable nano-composite material. Under pre-selected milling conditions a mixture of powdered components are reactively milled. These components will spontaneously react at a known duration of the pre-selected milling conditions. The milling is stopped at a time at which the components have been compositionally homogenized to produce nanocomposite powder, but prior to said known duration, and thereby before the spontaneous reaction occurs. The milled powder is recovered as a highly reactive nanostructured composite for subsequent use by controllably initiating destabilization thereof.
    Type: Grant
    Filed: November 12, 2004
    Date of Patent: April 28, 2009
    Assignee: New Jersey Institute of Technology
    Inventors: Edward Leonid Dreizin, Mirko Schoenitz
  • Publication number: 20080307926
    Abstract: In a method for determining a dividedness and/or position of a batch material (7) existing essentially in the solid phase in an arc furnace (1) having a furnace vessel (2), acoustic signals (Ne, Ng, Nd) are generated by an arc discharge (6) between an electrode (3a, 3b, 3c) and the batch material (7). The acoustic signals (Ne, Ng, Nd) reflected and/or transmitted through by the batch material (7) are measured by acoustic sensors (5a, 5b, 5c, 5e, 5g, 5h, 5s, 5t), wherein at least one acoustic sensor (5a, 5b, 5c, 5e, 5g, 5h, 5s, 5t) is provided per segment (Sn) of the furnace vessel (2) subdivided into a plurality of segments (Sn), and wherein the dividedness and/or position of the batch material (7) in the arc furnace (1) is determined by evaluating the measured acoustic signals (Ne, Ng, Nd).
    Type: Application
    Filed: June 28, 2006
    Publication date: December 18, 2008
    Inventor: Thomas Matschullat
  • Patent number: 7442228
    Abstract: The invention relates to a method for controlling the proportion of aluminum crystals in a mixture of molten aluminum alloy and aluminum crystals. The electrical resistance of the mixture is determined with the aid of a four-point measurement. With the aid of the measured electrical resistance, the proportion of crystals in the mixture can be kept constant within narrow margins. The invention also relates to a device for carrying out the method.
    Type: Grant
    Filed: October 2, 2002
    Date of Patent: October 28, 2008
    Assignee: Aleris Switzerland GmbH c/o K+P Treuhangesellschaft
    Inventor: Paul Alexander De Vries
  • Patent number: 7357826
    Abstract: The present invention is direct to a method/apparatus for verifying a nodularization process in a molten iron disposed within a ladle. The method includes the steps of: transferring the ladle with the molten iron to a nodularization area; adding an amount of magnesium to the molten iron in the ladle for producing the nodularization process in the molten iron; measuring vibration of the ladle containing the molten iron caused by the nodularization process in the molten iron; comparing the measured vibration with a predetermined level of vibration; and determining that the nodularization process occurs if the measured vibration is higher than the predetermined level of vibration.
    Type: Grant
    Filed: November 24, 2004
    Date of Patent: April 15, 2008
    Assignee: Dana Automotive Systems Group, LLC.
    Inventors: David A. Niederhelman, Mark A. Bassett
  • Patent number: 6767382
    Abstract: An apparatus for separating molten aluminium from a mixture of molten aluminium and aluminium dross includes a table for supporting an insulated crucible containing the mixture of molten aluminium and aluminium dross. A rotatable frame supports a plurality of tines which can be lowered into the mixture in the crucible for stirring the mixture. Vibration means are provided enabling simultaneous vibration of the crucible and stirring of the mixture. The tines cuts through the dross in a shearing action gently rolling the dross, mixing and tumbling it and causing the droplets of aluminium to coalesce. The aluminium droplets and particles in the dross coalesce to form larger droplets and gradually sink to the base of the crucible. A screening means is disposed to substantially surround the crucible when it is supported by the table, which includes a door to both allow and prevent access to the crucible.
    Type: Grant
    Filed: July 2, 2003
    Date of Patent: July 27, 2004
    Assignee: Mawar Malaysian Limited
    Inventors: Andreas Stratigos, Brendan O'Neill
  • Patent number: 6699306
    Abstract: This method controls a copper density in a dip solder bath holding a molten solder alloy containing at least copper as an essential composition thereof during a dip soldering step of one of a printed circuit board with a surfaced copper foil and a component part having a copper lead attached thereto. The method includes a step of introducing a replenished solder containing no copper at all or a copper content having a density lower than that of the molten solder in the bath prior to the supply of the replenished solder to the bath so that the copper density in the bath is controlled to a predetermined constant density or lower. The molten solder alloy in the bath contains tin, copper and nickel as the major compositions thereof, and the replenished solder contains nickel and balanced tin, for example. Alternatively, the molten solder alloy in the bath contains tin, copper, and silver as the major components thereof, and the replenished solder contains silver and balanced tin.
    Type: Grant
    Filed: October 23, 2001
    Date of Patent: March 2, 2004
    Assignees: Nihon Superior Sha Co., Ltd., Matsushita Electric Industrial Co., Ltd.
    Inventors: Tetsuro Nishimura, Masuo Koshi, Kenichirou Todoroki
  • Patent number: 6695936
    Abstract: To identify and manufacture metallic glass forming alloys, large inertial forces or “g”-forces are used to sequentially separate crystalline phases (particles) as they sequentially form and grow in a molten alloy during gradual cooling of the alloy below its liquidus temperature. These forces physically remove and isolate the actual crystalline particles from the remaining liquid as they are formed. Under the influence of a large g-force, this is accomplished by rapid and efficient sedimentation and stratification. Further contamination and nascent solid “debris” in the form of oxides, carbides, or other foreign particles can be removed from the molten alloy using the same sedimentation/stratification technique. Finally, a method of efficiently cooling and solidifying the final low melting stratified and decontaminated liquid into a solid glass component is proposed which utilizes convective heat transport by a cooling gas.
    Type: Grant
    Filed: November 14, 2001
    Date of Patent: February 24, 2004
    Assignee: California Institute of Technology
    Inventor: William L. Johnson
  • Patent number: 6666902
    Abstract: The present invention provides a lade refining apparatus capable of suppressing skull deposition in a vacuum/decompression chamber and performing molten steel agitation, slag reforming and degassing efficiently, and a ladle refining method using the apparatus. The apparatus includes a vacuum/decompression chamber directly coupled to a top of a ladle, and is designed to have inert gas blown into the ladle for agitation of molten steel in the ladle. An inner diameter of a shaft of the vacuum/decompression chamber is not larger than an inner diameter of a top end of the ladle, but not smaller than a projected diameter of a bulging portion of a molten steel surface formed by the gas blown into the ladle.
    Type: Grant
    Filed: December 14, 2001
    Date of Patent: December 23, 2003
    Assignee: Nippon Steel Corporation
    Inventors: Hideaki Kimura, Atsushi Ishikawa, Hiromi Ishii, Masayuki Arai, Jun Aoki
  • Patent number: 6579339
    Abstract: A system is described for forming a recycled copper product from at least one copper scrap feedstock source containing at least one contaminant. A pre-determined maximum weight percentage of the contaminant in the recycled copper product is initially established. The weight percentage of the contaminant in the copper scrap feedstock source is then determined. A determination is then made as to whether the weight percentage of the contaminant in the copper scrap feedstock source will exceed the established maximum weight percentage of the contaminant in the recycled copper product. If so, another copper scrap feedstock source is then added to the first copper feedstock source so as to cause the combined copper scrap feedstock sources to have an average weight percentage of the contaminant that does not exceed the established maximum weight percentage of the contaminant in the recycled copper product.
    Type: Grant
    Filed: September 10, 2002
    Date of Patent: June 17, 2003
    Assignee: Mueller Industries, Inc.
    Inventors: Tommy Jamison, Paul D. Babin, Glenn Dennis, Allen Popetz
  • Patent number: 6562100
    Abstract: The invention has an object to permit to make the accumulation amount and the temperature of molten metal in the metal material molding machine constant, by performing material supply and melting taking the accumulation amount as reference during the molding operation. The supply apparatus 11 and the agitation means 29 of metal material at the moment of operation starting are controlled to be inactive until the temperature of the melting vessel attains a predetermined value and to start operating when the predetermined temperature is attained, allowing to supply and agitate the metal material. The supply and the agitation of metal material after the predetermined temperature is attained, are performed while gradually supplying and agitating the metal material until metal material of at least 6 times or more of the maximum injection volume is accumulated in melt state.
    Type: Grant
    Filed: August 8, 2001
    Date of Patent: May 13, 2003
    Assignee: Nissei Plastic Industrial Co., Ltd.
    Inventors: Kiyoto Takizawa, Toshiyasu Koda, Yuji Hayashi, Mamoru Miyagawa
  • Patent number: 6517603
    Abstract: A method for reducing metal oxides in a shaft furnace. A charge of metal oxide and a reductant is reacted in the furnace to produce a primary metal of the metal oxide and an additional secondary metal. The temperature of the off gas from the reaction is controlled to prevent condensing of the secondary metal so that it remains in the off gas for separation therefrom.
    Type: Grant
    Filed: March 20, 2001
    Date of Patent: February 11, 2003
    Assignee: Startec Iron LLC
    Inventors: Marcos de Albuquerque Contrucci, Pedro Henrique Carpinetti Costa, Edmar Saul Marcheze
  • Patent number: 6517604
    Abstract: An apparatus and method for measuring the level of a free surface of molten metal in an electromagnetic continuous casting process using an AC electromagnetic field. A detection coil is provided to detect the sum of a magnetic field applied from an induction coil and an induced magnetic field based on eddy current in the molten metal. An arithmetic unit is provided to detect the surface level of the molten metal by removing a variation of the applied magnetic field with a variation in current to the induction coil from an output signal from the detection coil. The surface level of the molten metal can be accurately measured by determining whether a variation in the output of the detection coil results from a variation in the applied magnetic field or a variation in the surface level of the molten metal.
    Type: Grant
    Filed: March 15, 2001
    Date of Patent: February 11, 2003
    Assignees: Pohang Iron & Steel Co., Ltd., Research Institute of Industrial Science & Technology
    Inventors: Goo-Hwa Kim, Ki-Jang Oh, Ho-Young Kim, Dong-Jun Shim
  • Patent number: 6503292
    Abstract: A molten metal treatment furnace (10) with metal treatment and level control includes a heating chamber (12) for containing and heating a supply of molten metal (60), a pump (22) connected to the heating chamber (12), a molten metal treatment chamber (16, 18) located at the outlet of the pump (22), and a dosing chamber (40) located downstream and in fluid communication with the molten metal treatment chamber (16, 18). A trough (44) is connected to the dosing chamber (40) for supplying the molten metal (60) to a downstream process. A molten metal level sensor (66) is located in the dosing chamber (40). The pump (22) is a variable speed pump having a pump inlet (24) connected to the heating chamber (12) and configured to pump the molten metal (60) through the furnace (10) during operation. The molten metal level sensor (66) is connected to the pump (22) for providing a pump speed control signal to the pump (22).
    Type: Grant
    Filed: June 11, 2001
    Date of Patent: January 7, 2003
    Assignee: Alcoa Inc.
    Inventors: Marshall A. Klingensmith, James R. Fields, Michael J. Kinosz
  • Patent number: 6500228
    Abstract: A dosing furnace (10) with metal treatment and level control includes a holding chamber (12) for containing a supply of molten metal (50), a pump (22) connected to the holding chamber (12), a molten metal treatment chamber (16, 18) located at an outlet (26) of the pump (22), and a dosing chamber (40) located downstream and in fluid communication with the molten metal treatment chamber (16, 18). A molten metal level sensor (56) is located in the dosing chamber (40). The pump (22) is a variable speed pump having a pump inlet (24) connected to the holding chamber (12) and configured to pump the molten metal (50) through the dosing furnace (10) during operation. The molten metal level sensor (56) is connected to the pump (22) for providing a pump speed control signal to the pump (22).
    Type: Grant
    Filed: June 11, 2001
    Date of Patent: December 31, 2002
    Assignee: Alcoa Inc.
    Inventors: Marshall A. Klingensmith, Andreas Kaleja, Michael J. Kinosz
  • Patent number: 6478847
    Abstract: A system is described for forming a recycled copper product from at least one copper scrap feedstock source containing at least one contaminant. A pre-determined maximum weight percentage of the contaminant in the recycled copper product is initially established. The weight percentage of the contaminant in the copper scrap feedstock source is then determined. A determination is then made as to whether the weight percentage of the contaminant in the copper scrap feedstock source will exceed the established maximum weight percentage of the contaminant in the recycled copper product. If so, another copper scrap feedstock source is then added to the first copper feedstock source so as to cause the combined copper scrap feedstock sources to have an average weight percentage of the contaminant that does not exceed the established maximum weight percentage of the contaminant in the recycled copper product.
    Type: Grant
    Filed: August 31, 2001
    Date of Patent: November 12, 2002
    Assignee: Mueller Industries, Inc.
    Inventors: Tommy Jamison, Paul D. Babin, Glenn Dennis, Allen Popetz
  • Publication number: 20010054329
    Abstract: This invention relates to a method for operation of a moving hearth furnace in conjunction with an electric melter for production of high purity iron product having a range of silicon and manganese, with low sulfur and phosphorus content. The method includes producing high purity iron product and a range of carbon content product from iron oxide and carbon bearing agglomerates, including the steps of providing a furnace for direct reduction of iron oxide and carbon bearing agglomerates, pre-reducing iron and carbon bearing agglomerates in a furnace having a moving hearth surface, producing intermediate carbon-containing metallized iron. An electric melter furnace is utilized for receiving intermediate carbon-containing metallized iron from the pre-reducing step, which is fed directly and continuously into a central interior area of the electric melter, with heating of the carbon-containing metallized iron in the electric melter under elevated temperatures of about 1300° C. to about 1700° C.
    Type: Application
    Filed: June 25, 2001
    Publication date: December 27, 2001
    Inventors: Glenn E. Hoffman, Ronald D. Gray
  • Patent number: 6309442
    Abstract: An apparatus and method for indexing the slag-metal interface level in a metallurgical container uses an insulating refractory brick having a plurality of embedded conductor wires. Distal ends of the conductor wires are exposed at know, fixed distances from the distal end of the stick and flush with the brick face. The proximal ends of the conductor wires protrude a predetermined distance from the proximal end of the brick. The brick is attached to the inner lining of the container at a known distance from the floor of the container. The proximal wire ends are joined by a suitable connector to a signal-transmission cable containing a matching number of individual conductors, which is connected to a multi-channel voltmeter. Output from the multi-channel voltmeter can be input to a multiple-channel PC-based signal interpretation instrument. During operation the voltage output of each sensor circuit is continuously monitored.
    Type: Grant
    Filed: February 25, 2000
    Date of Patent: October 30, 2001
    Inventor: John D. Usher
  • Patent number: 6264716
    Abstract: A process for stirring molten steel in a container. In this process, argon gas is introduced into the container at a flow rate of from about 0.005 to about 0.2 cubic feet of argon per ton of molten steel per minute, the extent to which said container is caused to vibrate is measured, analog signals are produced corresponding to the rate of flow of argon gas into said container, the analog signals are sampled at a rate of at least 800 times per second, the analog signals are converted to digital signals, the digital signals are transformed by subjecting them to fast Fourier transformation, and the transformed digital signals are evaluated.
    Type: Grant
    Filed: March 18, 2000
    Date of Patent: July 24, 2001
    Assignee: Nupro Corporation
    Inventors: Francis L. Kemeny, David I. Walker, Jeremy A. T. Jones
  • Patent number: 6171364
    Abstract: A process of producing molten iron involves: a) introducing iron oxide, flux, oxygen, nitrogen, carbon, and hydrogen to a smelter reactor; b) maintaining conditions to cause (i) the iron oxide to be reduced, (ii) molten iron to be created and stirred in the bottom of the reactor, surmounted by a layer of foaming, FeO-containing slag, and (iii) carbon monoxide gas to rise through the slag; c) causing at least some of the carbon monoxide to react with the oxygen; d) releasing an offgas containing CO, CO2, H2, and H2O; and e) removing at least some of the molten iron and slag from the reactor. Good process stability is achieved by: f) repeatedly measuring, during the process, the conditions of the slag height, the temperature of the molten iron, the levels of CO, CO2, H2, and H2O in the offgas, the carbon level in the molten iron, and the FeO level in the slag, and g) subsequently adjusting one or more process variables (e.g.
    Type: Grant
    Filed: March 21, 1997
    Date of Patent: January 9, 2001
    Assignee: Steel Technology Corporation
    Inventors: Balu Sarma, Kenneth B. Downing
  • Patent number: 6019811
    Abstract: Apparatus and method for controlling metals processing (e.g., ESR) by melting a metal ingot and counting molten metal droplets during melting. An approximate amount of metal in each droplet is determined, and a melt rate is computed therefrom. Impedance of the melting circuit is monitored, such as by calculating by root mean square a voltage and current of the circuit and dividing the calculated current into the calculated voltage. Analysis of the impedance signal is performed to look for a trace characteristic of formation of a molten metal droplet, such as by examining skew rate, curvature, or a higher moment.
    Type: Grant
    Filed: August 13, 1997
    Date of Patent: February 1, 2000
    Assignee: Sandia Corporation
    Inventors: Eric Schlienger, Joanna M. Robertson, David Melgaard, Gregory J. Shelmidine, James A. Van Den Avyle
  • Patent number: 6004504
    Abstract: A method and apparatus for improved control of continuous electric arc furnace steelmaking in which a charge velocity detector measures charge velocity of metallic charge introduced to the furnace. A charge mass detector measures a charge mass of metallic charge introduced to the furnace. A computer determines a feed rate based on the charge velocity and the charge mass. An automatic bath level probe detects a steel bath. The computer determines a steel bath level and optimal positions to insert a temperature probe and an oxygen lance, and further predicts new bath levels from one tapping time to the next tapping time. The temperature probe is inserted to an optimal measurement position based on the steel bath level and measures a steel bath temperature. The oxygen lance is positioned and maintained at an optimal oxygen injection position and injects oxygen into the bath.
    Type: Grant
    Filed: March 12, 1998
    Date of Patent: December 21, 1999
    Assignee: Techint Compagnia Tecnica Internazionale
    Inventor: John A. Vallomy
  • Patent number: 5948137
    Abstract: An on-line system for measuring the composition of scrap metal, including a loader with a load sensor having a motion compensator linked to a bulk material analyzer such as a prompt gamma-ray neutron activation analyzer. The grade of scrap used to prepare batches for a melt is controlled to provide a batch having desired properties and composition.
    Type: Grant
    Filed: July 23, 1998
    Date of Patent: September 7, 1999
    Assignee: The David J. Joseph Company
    Inventor: Daniel A. Pflaum
  • Patent number: 5908488
    Abstract: The magnesium melting furnace (1) has a plurality of chambers. The material to be melted is fed into a melting chamber (2) through a charging chute (20), one end of which terminates under the surface of the melting bath. The melt is slowly transferred into a holding chamber (4) through a passage (3) situated in the lower third of a dividing wall (11) above a layer of impurities settling at the bottom (14) of the melting chamber (2). The melt slowly flows through the holding chamber (4), with impurities rising to the surface or settling on the bottom (15). The purified melt flows through a second passage (5) situated in the lower third of a second dividing wall (12) into a metering chamber (6). The melt can be removed from the metering chamber (6) through a transfer pipe (28) using a metering pump (27). The magnesium melting furnace (1) makes it possible to simultaneously melt, purify and remove the magnesium in metered quantities.
    Type: Grant
    Filed: July 2, 1996
    Date of Patent: June 1, 1999
    Assignees: Schmitz + Apelt LOI Industrieofenanlagen GmbH, Rauch Fertigungstechnik Ges. m.h.H.
    Inventors: Dominik Schroder, Erich Rauch
  • Patent number: 5885322
    Abstract: A process of smelting iron that comprises the steps of:a) introducing a source of iron oxide, oxygen, nitrogen, and a source of carbonaceous fuel to a smelting reactor, at least some of said oxygen being continuously introduced through an overhead lance;b) maintaining conditions in said reactor to cause (i) at least some of the iron oxide to be chemically reduced, (ii) a bath of molten iron to be created and stirred in the bottom of the reactor, surmounted by a layer of slag, and (iii) carbon monoxide gas to rise through the slag;c) causing at least some of said carbon monoxide to react in the reactor with the incoming oxygen, thereby generating heat for reactions taking place in the reactor; andd) releasing from the reactor an offgas effluent,is run in a way that keeps iron losses in the offgas relatively low. After start-up of the process is complete, steps (a) and (b) are controlled so as to:e) keep the temperature of the molten iron at or below about 1550.degree. C.
    Type: Grant
    Filed: March 21, 1997
    Date of Patent: March 23, 1999
    Assignee: Steel Technology Corporation
    Inventors: Balu Sarma, Kenneth B. Downing
  • Patent number: 5884685
    Abstract: A rapid analysis device for analyzing nonmetallic inclusions in steel by a cold crucible method is combined with a mathematical model, and the quality of cast steel is predicted online by simulating the behavior. of the nonmetallic inclusions by calculation. Further, continuous casting process variables are controlled to minimize the amount of nonmetallic inclusions in the cast steel.
    Type: Grant
    Filed: November 26, 1996
    Date of Patent: March 23, 1999
    Assignee: Nippon Steel Corporation
    Inventors: Kazushige Umezawa, Takehiko Toh, Makoto Tanaka, Eiichi Takeuchi, Takeo Inomoto
  • Patent number: 5669956
    Abstract: Apparatus and method for determining when the depth of molten (18) poured into a vessel (12) has reached a selected level. A conduit (22) connected to a source of pressurized gas and having an orifice (43) at its distal end (38) restricts the flow of gas out of the conduit which is positioned at a selected level in the vessel. A drop in pressure in the conduit (22) resulting from escape of compressed gas when the distal end (38) is melted by the rising molten metal is detected and signalled to a visible, audible indicator or directly to an electronic controller to discontinue pouring of metal (18) into the vessel (12).
    Type: Grant
    Filed: May 22, 1996
    Date of Patent: September 23, 1997
    Assignee: Midwest Instrument Co., Inc.
    Inventors: James A. Behring, William Falk
  • Patent number: 5669955
    Abstract: A process for producing pig iron from iron ores involves the iron ores traveling from the top downwards through a reduction unit via a succession of oblique trays which are staggered in a cascade-like manner. A hot reduction gas containing carbon monoxide and hydrogen flows from the bottom of the reduction unit upwards. A reduction product is drawn off at the bottom end of the reduction unit and is fed to a unit for further treatment thereof. A reduction gas is generated in a gas generator by partial oxidation of carbon carriers or by cracking of natural gas or petroleum. Iron ores having at least a high proportion of dust-like and/or fine granular iron ores are sorted into fractions according to grain size and introduced into the reduction unit in such a way that the course fraction of the iron ore is introduced into the top section of the system and the fine fraction of the iron ore is introduced into the middle zone or into the middle and bottom zones of the system.
    Type: Grant
    Filed: July 17, 1995
    Date of Patent: September 23, 1997
    Inventors: Bogdan Vuletic, Bojan Vuletic, Vladan Vuletic
  • Patent number: 5567222
    Abstract: A method of controlling slag coating in a steel converter in which slag is left in the converter after tapping, and a slag solidifying agent is added to the slag to form a coated slag which is used to coat the bottom and/or side wall surface of the converter. The method is performed bya) examining the composition of the slag at the tapping time;b) determining, based on the examined slag and through an equilibrium calculation using thermodynamic data, the amount of solidifying agent per unit weight of the slag necessary for maintaining the liquid volume fraction of the coated slag to a value not greater than about 40% at the planned tapping temperature of the next charge of steel;c) determining the amount of charge of the solidifying agent based on the calculated required amount of the solidifying agent and the amount of the slag remaining in the converter; andd) adding the calculated charge of the solidifying agent to the slag after tapping, to form a coated slag.
    Type: Grant
    Filed: March 21, 1995
    Date of Patent: October 22, 1996
    Assignee: Kawasaki Steel Corporation
    Inventors: Katsunori Takahashi, Eizo Maeda, Hajime Suzuki, Sumio Yamada, Taichi Nakazawa, Yasuo Imaiida
  • Patent number: 5500033
    Abstract: A method of heating a melt containing an oxidizable substance in which a fuel is burned with an oxidant by projecting fuel oxidant jets over the melt. The fuel and the oxidant jets have a fuel jet momentum and an oxidant jet momentum, respectively. The oxidant jet produces a top oxidation layer on the top surface of the melt and such top oxidation layer has a thickness. The oxidant jet momentum is adjusted to be below a threshold momentum at which the top oxidation layer is forces aside by the oxidant jet to expose fresh melt that potentially can be oxidized and can increase the thickness of the top oxidation layer. The fuel-jet momentum is adjusted so that it is greater than the oxidant jet momentum to draw the oxidant jet towards the fuel jet and thereby forms a desired combustible mixture in a mixing layer.
    Type: Grant
    Filed: February 27, 1995
    Date of Patent: March 19, 1996
    Assignee: The BOC Group, Inc.
    Inventor: Loo T. Yap
  • Patent number: 5417738
    Abstract: A method for recovering useful metal included in slag generated from steel-making process in a convertor. The method comprises the steps of atomizing the slag in water, screening the atomized slag so as to be classified by sizes, dropping the classified slag of similar sizes into a flow of blowing air to sort it into a high-weight group and a low-weight group, and transferring the high-weight group into a furnace to recovering useful metal therefrom. The useful metal can be recovered at a low cost. In addition, since the inventive method does not accompany with the pulverization, polluting factor such as noise and dust is eliminated and thus, the working conditions become more comfortable. Moreover, the inventive method is advantageous in a view of reuse because the low-weight slag is used as useful materials such as short balls, grits, fluxes and aggregates.
    Type: Grant
    Filed: December 22, 1993
    Date of Patent: May 23, 1995
    Assignee: Ok-Soo Oh
    Inventors: Ok-Soo Oh, Won-Dae Cho, Eun-Soo Oh
  • Patent number: 5405121
    Abstract: The purpose of this invention is to present an apparatus consisting of a graphite rod, a vibration signal sensor, a signal processing unit, a data processing unit, and a data display unit to indicate the oxygen content of a copper melt. As such graphite rod is immersed into the molten metal it vibrates and the level of vibration is statistically correlated to the level of dissolved oxygen in the copper melt.
    Type: Grant
    Filed: April 29, 1994
    Date of Patent: April 11, 1995
    Assignee: Centro de Investigation y de Estudios Avanzados del IPN
    Inventors: Manuel Mendez-Nonell, Juan Mendez-Nonell, Joel Chaparro-Gonzalez, Gregorio Vargas-Gutierrez
  • Patent number: 5330555
    Abstract: The invention relates to a process and apparatus for manufacturing low-gas and pore-free aluminum casting alloys by vacuum degasification and densification of the melt. Contact between the aluminum melt and the atmospheric humidity of the alloying process, from refining to continuous casting of the cast bars, is kept extremely short, so that effective vacuum degasification, and a high cooling rate, can prevent the formation of gas pores. After the metal melt is alloyed in a smelting furnace, the melt is fed through a system of gutters directly to at least one vacuum furnace. Refining components are added in the vacuum furnace and heating is conducted to provide the pouring temperature required for continuous casting.
    Type: Grant
    Filed: April 13, 1993
    Date of Patent: July 19, 1994
    Assignee: VAW Aluminium AG
    Inventor: Heinz Lorenz