At 300 Degrees C Or Greater (e.g., Pyrometallurgy, Etc.) Patents (Class 75/414)
  • Patent number: 10745770
    Abstract: The present invention provides a method of simultaneously recycling plastics and detoxifying chromite ore processing residue with residual heat from a steel slag. By heating and gasifying plastics with steel slag, followed by catalytically split-decomposing the plastics with catalysts such as chromite ore processing residue, the plastics are thoroughly converted into a energy gas under water vapor gasification. The surface coking of Chromite Ore Processing Residue is avoided. Meanwhile, the energy gas reduces Cr6+ in Chromite Ore Processing Residue into Cr3+, and the energy gas is cooled, and CO2 and Cl in the energy gas are adsorbed by alkaline substances in Chromite Ore Processing Residue. With this method, chromite ore processing residue is detoxified, and steel slag is cooled, furthermore, energy is saved and a energy gas is obtained.
    Type: Grant
    Filed: July 5, 2018
    Date of Patent: August 18, 2020
    Assignee: QINGDAO TECHNOLOGICAL UNIVERSITY
    Inventors: Dalei Zhang, Shenqian Deng, Jian Li, Ruidong Li, Yuanfeng Qi
  • Patent number: 9951992
    Abstract: The present invention pertains to metallurgical processes and equipment and, more particularly, to a metallurgical furnace capable of operating with a broad range of broad range of raw materials and fuels, including those with high levels of impurities. Accordingly, the metallurgical furnace of the present invention comprises (i) at least an upper tub, (ii) at least a lower tub, (iii) at least a fuel feeder positioned substantially between the at least an upper tub and the at least a lower tub, (iv) at least a row of tuyeres positioned on at least one of at least an upper tub and at least a lower tub, the at least a row of tuyeres fluidly communicating inside the furnace with the outside environment, and (v) at least a burner positioned on at least one of at least an upper tub and at least a lower tub. The use of at least a burner jointly with the at least a row of tuyeres generates a very intense release of heat by virtue of the exothermic reactions which occur by this combination.
    Type: Grant
    Filed: December 22, 2014
    Date of Patent: April 24, 2018
    Assignee: Tecnored Desenvolvimento Tecnologico S.A.
    Inventors: Hermes Joaquim Ferreira Filho, Kleiton Gonçalves Lovati
  • Patent number: 9435005
    Abstract: A method for processing slags containing iron and non-ferrous metals, to produce clean slag free of detrimental substances and non-ferrous metals and suitable for use as a raw material or construction material. Slag is reduced in a reduction furnace with the help of reducing agents so that at least 5% of the iron of the slag is reduced into metal. Some of the non-ferrous metals, such as zinc, lead, arsenic and cadmium, vaporize. The contents of the reduction furnace are continuously mixed to prevent separation of a metallic phase from the slag. The generated slag-metal mixture is tapped off from the reduction furnace, cooled, crushed and ground to a finer size. Finally, a metal fraction is separated from a clean slag.
    Type: Grant
    Filed: April 15, 2013
    Date of Patent: September 6, 2016
    Assignee: Outotec (Finland) Oy
    Inventors: Maija-Leena Metsarinta, Jussi Liipo, Pekka Kurki, Madeleine Scheidema
  • Patent number: 9400138
    Abstract: A melting reduction assembly (1) has a melting gasification zone, including a packed bed (4) formed by solid carbon carriers and ferrous input materials, the zone has a lower section for receiving liquid pig iron (6) or raw steel material and liquid slag (7), a tap (9) for liquid slag and liquid pig iron. A plurality of oxygen nozzles (5) supplies oxygen. The nozzles are in at least two nozzle planes arranged spaced apart from each other and parallel in the vertical direction and horizontally distributed over the circumstances of the shell (10) of the melting reduction assembly (1) and arranged offset to each other in their respective nozzle planes.
    Type: Grant
    Filed: June 13, 2012
    Date of Patent: July 26, 2016
    Assignee: PRIMETALS TECHNOLOGIES AUSTRIA GMBH
    Inventors: Franz Berner, Jan-Friedemann Plaul, Kurt Wieder, Johann Wurm
  • Patent number: 9359656
    Abstract: A molten bath-based process for direct smelting metalliferous material and producing molten metal in a direct smelting vessel that contains a molten bath that has a metal layer that is at least 900 mm deep. The process includes selecting operating parameters of the process so that feed material (solid material and carrier gas) is injected from above the metal layer into the metal layer via at least one solids injection lance with sufficient momentum to penetrate to a depth of at least 100 mm below a nominal quiescent surface of the metal layer to cause upward movement of molten material and gas from the metal layer.
    Type: Grant
    Filed: February 9, 2012
    Date of Patent: June 7, 2016
    Assignee: Technological Resources Pty. Limited
    Inventor: Rodney James Dry
  • Patent number: 9023128
    Abstract: Methods of forming metal matrix nanocomposites are provided. The methods include the steps of introducing a master metal matrix nanocomposite into a molten metal at a temperature above the melting temperature of the master metal matrix nanocomposite, allowing at least a portion of the master metal matrix nanocomposite to mix with the molten metal and, then, solidifying the molten metal to provide a second metal matrix nanocomposite.
    Type: Grant
    Filed: December 20, 2011
    Date of Patent: May 5, 2015
    Assignee: Wisconsin Alumni Research Foundation
    Inventors: Xiaochun Li, Michael Peter De Cicco, Dake Wang, Hongseok Choi
  • Patent number: 8992662
    Abstract: A method for recovering valuable metals is provided in which the degree of oxidation of molten waste batteries is stabilized and separation between slag and an alloy is ensured. The method includes a roasting step (ST10) in which waste batteries are roasted beforehand at a low temperature of 300° C. or higher but lower than 600° C., an oxidation step (ST20) in which the waste batteries are oxidized by roasting at 1,100-1,200° C., and dry step (S20) in which the waste batteries that were oxidized in the oxidation step are melted, and slag and an alloy of valuable metals are separated from each other and recovered. By conducting the roasting step (ST10), organic carbon, which impairs the stability of the oxidation step (ST20) and which is contained, in plastic components, etc., is removed in advance prior to the oxidation step (ST20), and the efficiency of slag/alloy separation can be improved.
    Type: Grant
    Filed: February 15, 2012
    Date of Patent: March 31, 2015
    Assignee: Sumitomo Metal Mining Co. Ltd.
    Inventors: Kazuhiro Mori, Toshirou Tan, Jun-ichi Takahashi
  • Publication number: 20150047465
    Abstract: Method of combining industrial processes having inherent carbon capture and conversion capabilities offering maximum flexibility, efficiency, and economics while enabling environmentally and sustainably sound practices. Maximum chemical energy is retained throughout feedstock processing. A hybrid thermochemical cycle couples staged reforming with hydrogen production and chlorination. Hydrogen generated is used to upgrade feedstocks including bitumen, shale, coal, and biomass. Residues of upgrading are chlorinated, metals of interest are removed, and the remainder is reacted with ammonia solution and carbon dioxide to form carbonate minerals. The combination provides emissions free production of synthetic crude oil and derivatives, as well as various metals and fertilizers. Sand and carbonate minerals are potentially the only waste streams. Through this novel processing, major carbon dioxide reduction is afforded byminimizing direct oxidation.
    Type: Application
    Filed: August 7, 2013
    Publication date: February 19, 2015
    Inventor: Justin Langley
  • Publication number: 20150040728
    Abstract: Carbothermic reduction of magnesium oxide at approximately 2200 degrees Kelvin yields a high temperature mixture of magnesium vapors and carbon monoxide gas. Previous processes have sought to cool or alter the mixture to cause the yield of pure magnesium, which is then used in subsequent processes for its reducing properties. The present invention takes advantage of the stability and inertness of carbon monoxide at elevated temperatures enabling the magnesium vapor/carbon monoxide gas mixture from the carbothermic process to be used directly for the production of other metals at high temperatures. For example, Chromium oxide or chloride, manganese oxide or chloride, zinc oxide or chloride or sulfide, and several other metal compounds can be reduced by the magnesium vapor/carbon monoxide gas mixture at temperatures high enough to prevent the gas mixture from back-reacting to magnesium oxide and carbon.
    Type: Application
    Filed: August 29, 2014
    Publication date: February 12, 2015
    Inventor: John Joseph Barsa
  • Patent number: 8951331
    Abstract: Provided is a method for stabilizing the degree of oxidation of molten battery waste, and definitively separating slag and alloy. The method is provided with a pre-oxidation step (ST20) for roasting and oxidizing battery waste; and a drying step (S20) for melting the battery waste oxidized in the pre-oxidation step, and separating and recovering the slag and the valuable metal alloy. By providing the pre-oxidation step (ST20) for oxidizing the battery waste by roasting in advance of the drying step (S20), it is possible to stably obtain the optimal degree of oxidization in a melting step (ST21), and to improve the slag-alloy separation efficiency.
    Type: Grant
    Filed: February 15, 2012
    Date of Patent: February 10, 2015
    Assignee: Sumitomo Metal Mining Co. Ltd
    Inventors: Jun-ichi Takahashi, Kazuhiro Mori, Toshirou Tan
  • Patent number: 8936664
    Abstract: One embodiment provides a method of melting, comprising: providing a mixture of alloy elements that are at least partially crystalline; and heating the mixture in a container to a temperature above a melting temperature of the alloy elements to form an alloy, wherein the container comprises silica, and wherein the mixture comprising Zr and is free of Ti and Be.
    Type: Grant
    Filed: August 5, 2011
    Date of Patent: January 20, 2015
    Assignee: Crucible Intellectual Property, LLC
    Inventor: Theodore Andrew Waniuk
  • Patent number: 8926727
    Abstract: Methods for condensing metal vapors comprising directing a mixture of metal vapor and carrier gas into at least one inlet conduit are provided. Some methods comprise directing the mixture of metal vapor and carrier gas into a holding tank for liquid metal and subsequently into at least one outlet conduit operatively connected to the tank; cooling the at least one outlet conduit to cause some of the metal vapor inside the conduit to condense to solid metal; subsequent to condensing solid metal, stopping the cooling of at least one of the outlet conduits and commencing heating of the same outlet conduits to cause the solid metal to melt to form liquid metal; collecting the liquid metal in the tank; and preventing the remaining metal vapor and carrier gas from exiting the same outlet conduits during at least a portion of the heating of the same outlet conduits.
    Type: Grant
    Filed: October 4, 2013
    Date of Patent: January 6, 2015
    Assignee: Infinium, Inc.
    Inventors: Adam Clayton Powell, IV, Soobhankar Pati, Jason Douglas, Stephen Joseph Derezinski, Luciano Spiridigliozzi, Michael Buchman, Thomas Eagar
  • Patent number: 8920536
    Abstract: An ore containing crystal water (bond water) is heated to dehydrate the crystal water in the form of water vapor, thereby rendering the ore porous to generate a porous ore. Next, the porous ore is forced into contact with a dry-distilled gas (organic gas) obtained by dry-distillation of an organic substance such as wood and the like or an organic liquid such as tar and the like. An organic compound such as tar and the like contained in the dry-distilled gas or organic liquid adheres to the surface of the porous ore. Next, the porous ore adhered with an organic compound is heated at 500° C. or higher, to generate an ore in which a part of an oxide of an element such as iron and the like contained is reduced by carbon in the organic compound.
    Type: Grant
    Filed: September 6, 2007
    Date of Patent: December 30, 2014
    Assignees: Bio Coke Lab. Ltd.
    Inventors: Tomohiro Akiyama, Yuichi Hata, Sou Hosokai, Xinghe Zhang, Purwanto Hadi, Junichiro Hayashi, Yoshiaki Kashiwaya, Hiroshi Uesugi
  • Publication number: 20140318319
    Abstract: A method of starting a molten-bath based melting process includes establishing a sufficiently large and stable “hot zone” for ignition of oxygen and coal in a main chamber of a smelting vessel by independent means, i.e. independently of and before supplying cold oxygen and coal into the main chamber.
    Type: Application
    Filed: December 6, 2012
    Publication date: October 30, 2014
    Inventors: Jacques Pilote, Rodney James Dry, Hendrikus Koenraad Albertus Meijer
  • Publication number: 20140318313
    Abstract: Provided is a method for increasing the rate of recovery of valuable metals when waste batteries batteries are treated by a dry process. The valuable metal recovery method in the dry step S20 includes a melting step ST21 including melting waste batteries to form a melt, a slag separation step ST22 including separating slag from the melt, and an alloy separation step ST23 including separating an alloy of valuable metals from the melt, wherein the slag has an aluminium oxide content of 20% by weight to less than 75% by weight and an iron content of 5% by weight to 40% by weight, calculated as metallic iron, and silicon oxide and calcium oxide are added as fluxes in the melting step ST21 so that the slag can have a melting point of at least 1,500° C., preferably at most 1,650° C.
    Type: Application
    Filed: November 28, 2011
    Publication date: October 30, 2014
    Applicant: SUMITOMO METAL MINING CO., LTD.
    Inventors: Jun-ichi Takahashi, Kazuhiro Mori
  • Patent number: 8871000
    Abstract: The present invention relates generally to a smelting operation or the like, by which molten metal is produced from a metal oxide after metal oxide agglomerates are directly reduced and melted with a carbonaceous material in an electric heating and melting furnace. More specifically, the present invention relates to an electric furnace for producing molten metal that has material recycling capability, especially in-process material recycling capability.
    Type: Grant
    Filed: November 29, 2011
    Date of Patent: October 28, 2014
    Assignee: Midrex Technologies, Inc.
    Inventor: Masahiko Tetsumoto
  • Patent number: 8870999
    Abstract: A ladle that can melt and freeze castable metal in a specific manner so that high quality liquid metal and metal alloys may be produced with minimum oxide and hydrogen content. Upon introduction of a quantity of molten metal into the ladle, staged heating and cooling of the molten metal promotes the liberation of previously-dissolved gases from the castable metal, resulting in significant decreases in as-cast porosity.
    Type: Grant
    Filed: November 4, 2011
    Date of Patent: October 28, 2014
    Assignee: GM Global Technology Operations LLC
    Inventors: Qigui Wang, Hengcheng Liao, Lei Zhao, Ye Pan
  • Patent number: 8845779
    Abstract: The object of the present invention is to provide a process for producing molten iron through the efficient reduction of iron oxide having various chemical compositions and various shapes, or through the efficient melting of scrap iron or reduced iron having various shapes and various chemical compositions, the process being used in cases where the amount of iron necessary per furnace is not so large as in blast furnace processes. Specifically, the present invention provides a process for producing molten iron comprising the steps of: supplying carbon-containing molten iron to a holding container, heating the molten iron using heat of a combustion reaction of a gas mixture containing a fuel gas and a combustion-supporting gas, thereby storing the heat therein, and adding a carbon source and an iron-containing material that contains iron oxide and/or scrap iron to the heated and heat-stored molten iron, thereby converting the iron-containing material to molten iron.
    Type: Grant
    Filed: September 7, 2009
    Date of Patent: September 30, 2014
    Assignee: ISTC Co., Ltd.
    Inventor: Teruyoshi Hiraoka
  • Publication number: 20140260804
    Abstract: A method of decarburizing a molten alloy may generally comprise injecting a first gas comprising at least one of argon, carbon dioxide, and oxygen through a first fluid-conducting portion of a tuyere into the molten alloy below the surface of the molten alloy, and injecting a second gas comprising at least one of argon and carbon dioxide through a second fluid-conducting portion of the tuyere into the molten alloy below the surface of the molten alloy. The tuyere may comprise an inner portion concentrically aligned within an outer portion to define an annulus therebetween. The first gas may be injected through the inner portion, and the second gas may be injected through the annulus.
    Type: Application
    Filed: March 12, 2013
    Publication date: September 18, 2014
    Applicant: ATI PROPERTIES, INC.
    Inventors: Roy J. Matway, Kenneth G. Malencia, Jay E. Rupert
  • Patent number: 8834600
    Abstract: The present invention relates to a zero-waste process for extraction of alumina from different types of bauxite ores and red mud residues and of titanium dioxide from ilmenite. Iron oxide is first reduced to metallic iron above the melting point of C-saturated cast iron alloy which yields a high-C iron alloy and an Al and Ti metal oxide rich slag which is then treated with alkali carbonate to form alkali aluminates and titanates. The alkali aluminates are separated by water leaching from which the hydroxide of alumina is precipitated by bubbling C02. The residue from water leaching is treated with sulphuric acid and Ti02 is precipitated via a hydrolysis route. The process recovers most of the metal values and generates only small quantities of silicious residues at pH 4-5 which can be used for soil conditioning.
    Type: Grant
    Filed: June 11, 2004
    Date of Patent: September 16, 2014
    Assignee: The University of Leeds
    Inventors: Animesh Jha, Pailo Antony Malpan, Vilas Dattatray Tathavadkar
  • Publication number: 20140245864
    Abstract: A dross processing system crucible comprising a substantially vertical inner wall having an upper end, a lower end, an outer surface, and an inner surface, a bottom having an upper surface and a lower surface, the upper surface affixed to the lower end of the inner wall. A blockable port is disposed in the bottom, and a thermal insulating material covers the outer surface of the vertical inner wall and the lower surface of the bottom. An outer vessel is affixed to the upper end of the substantially vertical inner wall, and the thermal insulating material is disposed between the outer surface of the inner wall and the outer vessel.
    Type: Application
    Filed: March 4, 2013
    Publication date: September 4, 2014
    Inventor: Charles Clayton WYCUFF
  • Patent number: 8795408
    Abstract: A method and a device control the introduction of several metals into a cavity configured to melt the metals in the form of ingots. In particular, the method is configured to control the introduction of several metals into a cavity for melting the metals so as to dip-coat a steel strip with the metals in liquid metal form. Whereby a first metal is introduced in the form of at least a first ingot having a high content of the first metal and a second metal is introduced in the form of at least a second ingot formed as an alloy of the first metal and the second metal. The second metal content of the second ingot is chosen from a range of significant contents for ensuring an intended overall flow rate for combined melting of the ingots, the range of significant contents being chosen in a limited interval of sequentially increasing values so as to minimize differences between melting points of the ingots.
    Type: Grant
    Filed: November 14, 2008
    Date of Patent: August 5, 2014
    Assignee: Siemens VAI Metals Technologies SAS
    Inventors: Arnaud D'Halluin, Benjamin Grenier
  • Publication number: 20140208896
    Abstract: In an implementation, an apparatus for separation and recovery of a molten metal (106) from a slag (108) includes a device (400) attached to a slag ladle (100). The device (400) having a lower edge (404) and free edge (402) is fitted over a part of the slag-ladle (100) holding the molten metal (106) and the slag (108). The device (400) acts as a barrier for the flow of molten iron (106) such that the slag (108) is allowed to flow over the device (400) while the molten metal (106) is retained in the slag-ladle (100). The device (400) has a sluice gate (406) and a chute (408) for indicating the flow of the slag (108) in the form of a pipe-like stream.
    Type: Application
    Filed: September 27, 2012
    Publication date: July 31, 2014
    Inventor: Ramchandra Harisa Tupkary
  • Publication number: 20140202597
    Abstract: One embodiment provides an article, comprising: an inner container having a cavity, the inner container comprising a ceramic; and an outer container, the outer container comprising a susceptor; wherein at least a portion of an outer surface of the inner container is in contact with an inner surface of the outer container, and wherein the inner container is removable from the mold. Methods of melting using the present article are also provided.
    Type: Application
    Filed: August 5, 2011
    Publication date: July 24, 2014
    Applicant: Crucible Intellectual Property, LLC
    Inventor: Theodore A. Waniuk
  • Patent number: 8771399
    Abstract: A method and composition for removing sulfur from molten ferrous material, particularly molten iron. The desulfurization agent includes one or more pucks or briquettes of deoxidizing and/or desulfurization agent. The pucks or briquettes of deoxidizing and/or desulfurization agent include at least one deoxidizing metal and at least one ferrous metal.
    Type: Grant
    Filed: March 10, 2010
    Date of Patent: July 8, 2014
    Assignee: Magnesium Technologies Corporation
    Inventor: Thomas H. Bieniosek
  • Publication number: 20140178244
    Abstract: A method for desulfurizing a metal alloy comprises heating the metal alloy to a molten state. A gaseous desulfurizing compound is bubbled through the molten alloy to form a solid sulfur-containing waste phase and a molten reduced-sulfur alloy phase. The solid waste phase and the molten reduced-sulfur alloy phase are separated. The gaseous desulfurizing compound includes a constituent element selected from the group: alkali metals, alkaline earth metals, and rare earth metals.
    Type: Application
    Filed: December 20, 2012
    Publication date: June 26, 2014
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: Mario P. Bochiechio, John Joseph Marcin, Kirk C. Newton, Michael A. Kmetz
  • Publication number: 20140174256
    Abstract: Provided is a method for stabilizing the degree of oxidation of molten battery waste, and definitively separating slag and alloy. The method is provided with a pre-oxidation step (ST20) for roasting and oxidizing battery waste; and a drying step (S20) for melting the battery waste oxidized in the pre-oxidation step, and separating and recovering the slag and the valuable metal alloy. By providing the pre-oxidation step (ST20) for oxidizing the battery waste by roasting in advance of the drying step (S20), it is possible to stably obtain the optimal degree of oxidization in a melting step (ST21), and to improve the slag-alloy separation efficiency.
    Type: Application
    Filed: February 15, 2012
    Publication date: June 26, 2014
    Applicant: SUMITOMO METAL MINING CO., LTD.
    Inventors: Jun-ichi Takahashi, Kazuhiro Mori, Toshirou Tan
  • Publication number: 20140123812
    Abstract: Methods for degassing and for removing impurities from molten metals are disclosed. These methods can include operating an ultrasonic device in a molten metal bath, and adding a purging gas into the molten metal bath through the tip of the ultrasonic device.
    Type: Application
    Filed: January 16, 2014
    Publication date: May 8, 2014
    Applicant: Southwire Company
    Inventors: Victor F. Rundquist, Kevin S. Gill
  • Publication number: 20140109638
    Abstract: A method is described for reducing the carbon footprint of any commercially important industrial conversion process. The output of this conversion process can be combustible fuels, chemicals, electricity or heat energy. In its broadest form, a carbon negative module outputs energy to a conversion energy and this energy replaces conventional fossil-fuel based energy. A sequesterable carbonaceous solid is produced by the carbon negative process which represents a net carbon withdrawal from the atmosphere.
    Type: Application
    Filed: December 23, 2013
    Publication date: April 24, 2014
    Applicant: Cool Planet Energy Systems, Inc.
    Inventors: Vital AELION, Daren DAUGAARD, Wilson HAGO
  • Publication number: 20140109724
    Abstract: The invention relates to a method for producing a ferroalloy containing nickel. From a fine-grained raw material containing iron and chromium and a fine-grained raw material containing nickel, a mixture is formed with binding agent, the mixture is agglomerated so that first formed objects of desired size are obtained. The objects formed are heat treated in order to strengthen the objects so that the heat treated objects withstand conveyance and loading into a smelter furnace. Further, the objects are smelted under reducing circumstances in order to achieve ferrochromenickel, a ferroalloy of a desired composition containing at least iron, chromium and nickel.
    Type: Application
    Filed: December 20, 2013
    Publication date: April 24, 2014
    Applicant: OUTOKUMPU OYJ
    Inventors: Tuomo MÄKELÄ, Pekka NIEMELÄ
  • Publication number: 20140102256
    Abstract: A method for recovering valuable metals is provided in which the degree of oxidation of molten waste batteries is stabilized and separation between slag and an alloy is ensured. The method includes a roasting step (ST10) in which waste batteries are roasted beforehand at a low temperature of 300° C. or higher but lower than 600° C., an oxidation step (ST20) in which the waste batteries are oxidized by roasting at 1,100-1,200° C., and dry step (S20) in which the waste batteries that were oxidized in the oxidation step are melted, and slag and an alloy of valuable metals are separated from each other and recovered. By conducting the roasting step (ST10), organic carbon, which impairs the stability of the oxidation step (ST20) and which is contained, in plastic components, etc., is removed in advance prior to the oxidation step (ST20), and the efficiency of slag/alloy separation can be improved.
    Type: Application
    Filed: February 15, 2012
    Publication date: April 17, 2014
    Applicant: SUMITOMO METAL MINNING CO., LTD.
    Inventors: Kazuhiro Mori, Toshirou Tan, Jun-ichi Takahashi
  • Publication number: 20140090798
    Abstract: Described herein is a method of melting a bulk metallic glass (BMG) feedstock, comprising: heating at least a portion of the BMG feedstock to temperatures slightly below a solidus temperature of the BMG, wherein the portion remains a solid at the temperatures slightly below the solidus temperature and wherein a temperature distribution of the portion is essentially uniform; heating the portion of the BMG feedstock to temperatures above a liquidus point.
    Type: Application
    Filed: September 28, 2012
    Publication date: April 3, 2014
    Inventors: THEODORE A. WANIUK, Joseph Stevick, Sean O'Keeffe, Dermot J. Stratton, Joseph C. Poole, Matthew S. Scott, Christopher D. Prest
  • Publication number: 20140090796
    Abstract: Described herein is a method of melting a bulk metallic glass (BMG) feedstock, comprising: feeding the BMG feedstock into a crucible; melting a first portion of the BMG feedstock to form molten BMG, while maintaining a second portion of the BMG feedstock solid; wherein the second portion and the crucible hold the molten BMG.
    Type: Application
    Filed: September 28, 2012
    Publication date: April 3, 2014
    Inventors: Theodore A. WANIUK, Joseph STEVICK, Sean O'KEEFFE, Dermot J. STRATTON, Joseph C. POOLE, Matthew S. SCOTT, Christopher D. PREST
  • Publication number: 20140090797
    Abstract: Described herein is a device comprising a crucible, a movable base and a heater; wherein the heater is configured to melt BMG to form molten BMG feedstock in the crucible; wherein the movable base configured to slide along a length of the crucible; wherein the movable base and the crucible are configured to hold the molten BMG feedstock.
    Type: Application
    Filed: September 28, 2012
    Publication date: April 3, 2014
    Inventors: Theodore A. Waniuk, Joseph Stevick, Sean O'Keeffe, Dermot J. Stratton, Joseph C. Poole, Matthew S. Scott, Christopher D. Prest
  • Publication number: 20140090518
    Abstract: The method is used to obtain metals, noble metals, and rare earth metals from scrap. The aim of the invention is to provide a method that allows an efficient recovery even from electronic scrap. This is achieved in that the scrap and carbon-containing materials (A) are oxidized with oxygen containing gases (11) in the presence of alkaline materials under overall reducing conditions with an overall lambda of <1 in an updraft gasifier (2) with a bulk material moving bed, said gasifier having a reduction zone (13) and an oxidation zone (7). The resulting syngas is drawn at the upper part (16) of the updraft gasifier, and the metals, noble metals, and rare earth metals are bound at least partly to the alkaline materials as oxides and/or in elementary form. Finally, said metals are obtained from the process as an enriched mixture (B) by means of physical separation methods.
    Type: Application
    Filed: May 3, 2012
    Publication date: April 3, 2014
    Applicant: ECOLOOP GMBH
    Inventors: Thomas Stumpf, Leonhard Baumann, Roland Möller
  • Publication number: 20140083252
    Abstract: A gas stream containing both hydrocarbon and hydrogen is separated into a hydrogen-rich fraction and a hydrocarbon-rich fraction. Then at least one sub-quantity of the hydrocarbon-rich fraction is subjected to at least one operation from the group oxidation using technically pure oxygen and reforming using CO2 and H2O. The result is introduced at least as a component of a reduction gas into a reduction unit containing the metal oxides. As a result of the at least one operation, the hydrocarbon content in the reduction gas on entry into the reduction unit is below 12% by volume.
    Type: Application
    Filed: May 7, 2012
    Publication date: March 27, 2014
    Applicant: SIEMENS VAI METALS TECHNOLOGIES GMBH
    Inventors: Christian Boehm, Robert Millner
  • Publication number: 20140083638
    Abstract: Disclosed is a vessel for melting and casting meltable materials. The vessel may be a surface temperature regulated vessel for providing a substantially non-wetting interface with the molten materials. In one embodiment, the vessel may include one or more temperature regulating channels configured to flow a fluid therein for regulating a surface temperature of the vessel such that molten materials are substantially non-wetting at the interface with the vessel. Disclosed also includes systems and methods for melting and casting meltable materials using the vessel.
    Type: Application
    Filed: September 27, 2012
    Publication date: March 27, 2014
    Inventors: Theodore A. Waniuk, Joseph Stevick, Sean O'Keeffe, Dermot J. Stratton, Joseph C. Poole, Matthew S. Scott, Christopher D. Prest
  • Publication number: 20140069234
    Abstract: Provided is a method for improving the recovery rate of valuable metals such as cobalt when drying the battery waste of lithium ion batteries and the like. A second alloy excellent in terms of iron-cobalt separation performance and containing a small amount of iron is obtained by performing: a pre-oxidation step (ST20) for roasting and pre-oxidizing battery waste containing aluminium and iron; a melting step (ST21) for obtaining a molten product by melting the battery waste after the pre-oxidation step; a first slag separation step (ST22) for separating and recovering first slag containing aluminium oxide from the molten product; a second oxidation step (ST23) for oxidizing a molten first alloy after the first slag separation step; and a second slag separation step (ST24) for separating and recovering a second slag containing iron from a second alloy after the second oxidation step (ST23).
    Type: Application
    Filed: February 15, 2012
    Publication date: March 13, 2014
    Applicant: SUMITOMO METAL MINING CO., LTD.
    Inventors: Jun-ichi Takahashi, Kazuhiro Mori, Toshirou Tan
  • Publication number: 20140060250
    Abstract: Provided is a method in which, when discarded batteries such as lithium-ion batteries are treated by a dry process, slag having a reduced viscosity is obtained to heighten the recovery of valuable metals. The method for recovering valuable metals includes a dry process (S20) which includes a melting step (ST21), a slag separation step (ST22), and an alloy separation step (ST23), the slag having an aluminum oxide content of 5 mass % or higher but less than 20 mass % and an iron content in terms of metallic iron amount of 20-40 mass %. Furthermore, silicon oxide and calcium oxide are added as a flux in the melting step (ST21) so that the slag has a melting point of 1,400° C. or lower, and the melting step (ST21) is conducted at 1,400° C. or lower. Thus the recovery of the alloys can be heightened.
    Type: Application
    Filed: February 15, 2012
    Publication date: March 6, 2014
    Applicant: SUMITOMO METAL MINING CO LTD
    Inventors: Jun-Ichi Takahashi, Kazuhiro Mori
  • Publication number: 20140060251
    Abstract: A method for the direct reduction of metal oxides with carbon. According to the method, pellets are formed containing a mixture of metal oxides having sequential reduction potentials when heated in the presence of carbon and an amount of carbon sufficient to reduce more easily reduced of the metal oxides yet insufficient to reduce all of the metal oxides. The pellets are heated to a temperature at least sufficient to reduce the more easily reduced metal oxides to produce direct reduction metal while removing sufficient of the carbon in the form of oxides of carbon during the reduction to avoid a subsequent decarburization step in further processing of the direct reduction metal.
    Type: Application
    Filed: April 30, 2012
    Publication date: March 6, 2014
    Inventor: Wei-Kao Lu
  • Publication number: 20140033871
    Abstract: An apparatus for condensing metal vapors has at least one inlet conduit that is cooled to cause a portion of the metal vapor to condense to liquid. The apparatus also has a holding tank that is connected to the inlet conduit that collects condensed liquid metal. The apparatus also has at least one outlet conduit connected to the holding tank that is cooled to cause a portion of the remaining metal vapor to condense to solid metal. The apparatus also has at least one heater that heats the at least one outlet conduit to cause the solid metal to melt to liquid metal and subsequently flow in to the holding tank. The apparatus also has at least one sealing mechanism located at a distal end of the at least one outlet conduit for preventing metal vapor and carrier gas from exiting the outlet conduit during heating of the outlet conduit.
    Type: Application
    Filed: October 4, 2013
    Publication date: February 6, 2014
    Applicant: INFINIUM, INC.
    Inventors: Adam Clayton POWELL, IV, Soobhankar PATI, Jason DOUGLAS, Stephen Joseph DEREZINSKI, Luciano SPIRIDIGLIOZZI, Michael BUCHMAN, Thomas EAGAR
  • Publication number: 20140020510
    Abstract: The present invention discloses a new recovery of base metals from sulphide ores and concentrates, which comprises mixing the base metal's ore with ferric salts, heating the said mixture; adding water to form a pulp, stirring and filtering the pulp.
    Type: Application
    Filed: July 23, 2013
    Publication date: January 23, 2014
    Applicant: VALE S/A
    Inventors: Tiago Valentim BERNI, Antonio Clareti PEREIRA, Felipe Hilario GUIMARÃES
  • Patent number: 8632621
    Abstract: A simple, compact burner achieves a more optimal melting of a solid charge followed by performance of combustion under distributed combustion conditions. The burner achieves this by fluidically bending the flame towards the solid charge during a melting phase with an actuating jet of oxidant, redirecting the flame in a direction away from the charge, and staging injection of oxidant among primary and secondary portions during a distributed combustion phase.
    Type: Grant
    Filed: December 31, 2010
    Date of Patent: January 21, 2014
    Assignee: L'Air Liquide, Societe Anonyme pour l'Etude et l'Exploitation des Procedes Georges Claude
    Inventors: Vivek Gautam, Kenneth Kaiser, Luc Jarry, Remi Pierre Tsiava
  • Patent number: 8623114
    Abstract: A method and system for the copper anode refining is provided in which coherent jet technology is employed to heat the molten blister copper and/or melt scrap copper charges using a melting flame, oxidize the sulfur in the molten blister copper, and reduce the oxygen in the molten blister copper using top-blown coherent jet gas streams from one or more multi-functional, coherent jet lance assemblies. The present system and method employs a microprocessor-based controller operatively controlling the flow of an oxygen-containing gas, an inert gas, a reducing agent and a fuel to the coherent jet lance. The disclosed copper anode refining system and method greatly improves copper production while lowering oxidation/reduction cycle times and minimizing NOx emissions.
    Type: Grant
    Filed: February 15, 2011
    Date of Patent: January 7, 2014
    Assignee: Praxair Technology, Inc.
    Inventors: David B. George, Arsenio C. Enriquez, Jr., Adrian Christian Deneys, William John Mahoney, Ian Francis Masterson, Stephen Manley, Jesse Cates, Kevin Albrecht
  • Patent number: 8613789
    Abstract: A process for producing particle-reinforced composite materials through utilization of an in situ reaction to produce a uniform dispersion of a fine particulate reinforcement phase. The process includes forming a melt of a first material, and then introducing particles of a second material into the melt and subjecting the melt to high-intensity acoustic vibration. A chemical reaction initiates between the first and second materials to produce reaction products in the melt. The reaction products comprise a solid particulate phase, and the high-intensity acoustic vibration fragments and/or separates the reaction products into solid particles that are dispersed in the melt and are smaller than the particles of the second material. Also encompassed are particle-reinforced composite materials produced by such a process.
    Type: Grant
    Filed: November 10, 2011
    Date of Patent: December 24, 2013
    Assignee: Purdue Research Foundation
    Inventors: Qingyou Han, Zhiwei Liu
  • Publication number: 20130333523
    Abstract: A molten bath-based process for direct smelting metalliferous material and producing molten metal in a direct smelting vessel that contains a molten bath that has a metal layer that is at least 900 mm deep. The process includes selecting operating parameters of the process so that feed material (solid material and carrier gas) is injected from above the metal layer into the metal layer via at least one solids injection lance with sufficient momentum to penetrate to a depth of at least 100 mm below a nominal quiescent surface of the metal layer to cause upward movement of molten material and gas from the metal layer.
    Type: Application
    Filed: February 9, 2012
    Publication date: December 19, 2013
    Applicant: TECHNOLOGICAL RESOURCES PTY. LIMITED
    Inventor: Rodney James Dry
  • Patent number: 8597398
    Abstract: The invention is directed to a method of making liquid metal compositions containing a large number of solid particles per unit volume, without external heat removal, which solid particles act as nuclei for grains when the metal is solidified. A method of forming a metal solid includes the step of partially removing a solute of a liquid metallic solution which is at its liquidus temperature to partially solidify a metal solvent component, thereby forming a solid fraction, wherein there is essentially no reduction in temperature of the liquid metallic solution and solid fraction. The method further includes the step of subsequently lowering the temperature of the liquid metallic solution and solid fraction to solidify the remaining liquid metallic solution and thereby form a solid that includes the solid fraction formed during the step of partial solute removal. In an embodiment, the method further includes turbulence from gas evolution which aids in solid particle formation and grain refinement.
    Type: Grant
    Filed: March 17, 2010
    Date of Patent: December 3, 2013
    Assignee: Massachusetts Institute of Technology
    Inventors: Merton C. Flemings, David V. Ragone
  • Publication number: 20130305882
    Abstract: The subject matter of the invention is a molded body containing titanium, a method for the production thereof, and the use thereof.
    Type: Application
    Filed: July 22, 2013
    Publication date: November 21, 2013
    Applicant: Sachtleben Chemie GmbH
    Inventors: Djamschid AMIRZADEH-ASL, Dieter FUENDERS
  • Publication number: 20130309127
    Abstract: The present invention relates to tailored materials, particularly metals and alloys, and methods of making such materials. The new compositions of matter exhibit long-range ordering and unique electronic character.
    Type: Application
    Filed: April 24, 2013
    Publication date: November 21, 2013
    Applicant: ELECTROMAGNETICS CORPORATION
    Inventor: Christopher J. Nagel
  • Publication number: 20130276581
    Abstract: A method of using scrap rubber and other scrap materials, such as tires or parts or pieces of tires, to manufacture or melt steel and other metals in a furnace is disclosed. The scrap rubber may be used as a carbon source for the manufacture of steel and other metals, and may be used as an energy source to melt the scrap metal used to make the steel and other metals. The net benefit of this method includes reducing the amount of scrap rubber, such as tires, to be sent to a waste disposal facility or landfill, thereby improving the environment. In addition, by increasing the use of scrap rubber as a source of energy for steel or metal production, less energy is required from other sources.
    Type: Application
    Filed: June 24, 2013
    Publication date: October 24, 2013
    Inventor: Franklin Leroy Stebbing