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.

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.

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.

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.

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.

Abstract: The subject matter of the invention is a molded body containing titanium, a method for the production thereof, and the use thereof.

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.

Abstract: The present invention relates to a process for improving energy supply when heating and melting a scrap bulk wherein a preheated oxidizing gas with addition of fossil fuels melts a channel into the scrap bulk and further energy supply occurs through this channel. A significant improvement of the process is achieved by supplying hot blast to the scrap bulk from the top.

Abstract: Provided herein are materials that can achieve up to 14% hydrogen absorption by weight in ambient conditions, which is a marked improvement over the hydrogen absorption values found in the prior art. Further provided are experimental conditions necessary to produce these materials. In order to produce the hydrogen storage material, a transition metal (or Lithium) is vaporized in a pi bond gas in conditions that permit only a few bonding collisions to occur between the vaporized transition metal atoms and pi bond gas molecules before the resulting bonded material is collected.

Abstract: A composite product and a method of manufacturing the composite product are disclosed. The composite product includes (a) a polymeric material binder and a metal-bearing material or (b) the polymeric material binder and a carbon-bearing material. The 5 method includes heating and mixing the components of the composite product and thereafter forming the heated mixture into a final product shape, with the heating step being sufficient to melt at least a part of the polymeric material binder to facilitate forming the product.

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. Chromium oxide, manganese oxide, zinc oxide and 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.

Abstract: A molten bath-based direct smelting process includes controlling the process conditions in a direct smelting vessel so that molten slag in a molten bath of metal and slag in the vessel has a viscosity in a range of 0.5-5 poise in an operating temperature range for the process.

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

Abstract: 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.

Abstract: In one aspect, the present invention is directed to methods and apparatuses for recovering target metals from scrap. In some embodiments, the methods comprise dissolving a portion of a mixed metal scrap into a molten salt to form a molten salt and metal mixture, the scrap including a target metal species and at least one contaminant metal species; bubbling a gas through the molten salt and metal mixture to form a gas and metal vapor mixture comprising target metal vapors; and condensing at least a portion of the target metal vapors.

Abstract: A method of production for a super alloy comprising the steps of: boring a hole at a depth ranging from about 12 kilometers to about 20 kilometers to create a shaft; manufacturing the shaft, where the shaft includes at least one guide way; maneuvering a super alloy production device to the base of the shaft; exposing a mixture of metals within the super alloy production device to extreme temperature and extreme pressure within the shaft; combining the mixture of metals within the super alloy production device to form a super alloy; removing the super alloy from the shaft with the super alloy production device; and incorporating the super alloy into at least one industrial device.

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.

Abstract: Process for melting scrap metal in a furnace comprising the steps of feeding a charge of solid scrap metal to the furnace, supplying fuel and an oxygen-rich oxidant to the furnace and combusting the fuel with the oxidant to generate heat inside the furnace, melting the charge of solid scrap metal in the furnace by means of the heat, withdrawing the molten metal from the furnace. Following the step of feeding the charge of solid scrap metal to the furnace, the fuel is combusted with the oxidant so as to generate one or more visible flames in the furnace above the charge and before the step of withdrawing the molten metal from the furnace, the fuel is combusted with the oxidant so as to generate flameless combustion in the furnace above the molten metal.

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.

Abstract: A metal composite comprising a spinodal structure having at least one ductile phase and method of making same is disclosed. The metal composite is formed by forming an alloy comprising a positive heat of mixing in the liquid state; purifying the alloy; and forming a network structure of the alloy comprising at least one ductile sub-network.

Abstract: An object of the present invention is to produce briquettes that have high strength even when the amounts of binder and water used are decreased as much as possible. A method for producing briquettes that achieve this object includes a step of forming primary granules by using a powder containing a metal oxide and at least one of zinc oxide, lead oxide, and titanium oxide and a step of compressing the primary granules still containing the at least one of zinc oxide, lead oxide, and titanium oxide so as to mold the primary granules into secondary granules.

Abstract: Burner assembly for use in industrial heating and melting applications of material susceptible to oxidation at elevated temperatures is comprised of a flow passage of oxidant surrounded by an annular flow passage of fuel whereby the oxidant is substantially contained inside the fuel layer up to at least 5 oxidant nozzle diameters downstream of the burner outlet in order to minimize contact between the oxidant and the furnace load.

Abstract: Embodiments described herein comprise a system and method for the recycling and recovery of components and metals found within lithium ion batteries. The process includes the safe and effective means of disposing of batteries, including lithium thylnel cloride, lithium ion, conventional designs, in a manner that utilizes a process of alloying to chemically capture the by product.

Abstract: A process for producing metal compounds directly from underground mineral deposits including steps of forming a borehole at a site into a mineral deposit containing metal compounds, inserting a slurry-forming device having a nozzle into the borehole adapted to direct pressurized water through the nozzle into the mineral deposit, supplying pressured water through the nozzle into the mineral deposit forming a mineral slurry containing metal compounds, extracting the mineral slurry containing metal compounds through the borehole, leaching the mineral slurry converting the metal compounds to a soluble form in a leach solution, and removing metals and metal compounds by treating the leach solution with an extraction treatment removing the metal products. Steps of leaching the mineral slurry and removing metal products are performed at a location remote from the borehole site. In one alternative, the step of removing metal products from mineral slurry is accomplished by pyrometallurgical processes.

Abstract: A process for recovering metal from a process material comprising the metal and a component that is more volatile than the metal, which process comprises: transporting the process material in a retort provided in a furnace, the retort being operated under vacuum and at a temperature sufficient to cause sublimation of the component from the process material thereby producing purified metal; depositing the component that has been sublimed on a cool surface; removing purified metal from the retort; and removing deposited component from the cool surface.

Abstract: Since oxidation loss can be reduced even if collected printing plates are directly melted together with fresh ingots, a high melting yield approximately equal to a melting yield in the case of melting recycled ingots can be obtained. The present invention is a melting method for melting collected printing plates 35 and fresh ingots 37 by a burner 19 in a melting furnace 13, the collected printing plates 35 being collected used lithographic printing plates 36 and/or scraps 33 including offcuts of lithographic printing plates, the method including a first injection step of firstly injecting the collected printing plates 35 in the melting furnace 13 such that a pile of the collected printing plates 35 is formed on a hearth 13B of the melting furnace 13, and a second injection step of injecting the fresh ingots 37 on the pile of the collected printing plates 35 so as not to substantially expose the pile, wherein the fresh ingots are melted in flames of the burner.

Abstract: A hard metal material and a method of manufacturing a component of the hard metal material are disclosed. The hard metal material comprises 5-50 volume % particles of a refractory material dispersed in a host metal. The method comprises forming a slurry of 5-50 volume % particles of the refractory material dispersed in a liquid host metal in an inert atmosphere and pouring the slurry into a mould and forming a casting of the component.

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.

Abstract: A target consisting essentially of a CoCrPt-based metal or a CoCrPtRu-based metal, and one or more metal oxides selected from the group consisting of SiO2, Cr2O3, CoO, TiO2 and Ta2O5, is heated in an upper crucible of a two-level crucible that includes the upper crucible with a through hole formed in a bottom surface, and a lower crucible disposed below the through hole. The target is heated at a temperature of from 1400 to 1790° C. if the target does not contain both TiO2 and Ta2O5. The target is heated at a temperature of from 1400 to 1630° C. if the target contains TiO2 but does not contain Ta2O5. The target is heated at a temperature of from 1400 to 1460° C. if the target contains Ta2O5. The metal thereby melted is caused to flow into the lower crucible, so that the metal is separated from the metal oxide.

Abstract: This invention relates to a waste treatment furnace and method comprising: Generating a molten metal bed, which moves in a forward direction, such as to define a closed circuit in a cyclical and continuous manner, the surface of said bed comprising at least one essentially-slag-free segment. Loading waste onto the aforementioned essentially-slag-free segment, the waste being dragged by the molten metal bed such that it floats in the mentioned forward direction. Retaining the waste on the surface of the molten metal bed as it moves in the mentioned forward direction. Treating the waste under the effect of the constant and continuous heat exchange generated by the movement of the molten metal bed beneath the waste retained thereon.

Abstract: The invention provides complexes in which ligands (e.g., calixarene-related compounds) are coordinated to a metal colloid, e.g. a gold colloid. In exemplary embodiments, two or more ligands complexed to the metal colloid are larger than the metal colloid, thus providing an accessible metal center. The complexes can be immobilized on a substrate. The complexes of the invention are useful as tunable and highly robust isolated metal colloids that find use in binding of molecules and catalysis of chemical reactions.

Abstract: A method of making a nanoparticle reinforced metal matrix component is provided. The method involves solid state processing nanoparticles into a metal matrix material at solid state processing conditions to form a master alloy. At least a portion of the master alloy is added to a mass of metal melt to produce the nanoparticle reinforced metal matrix component.

Abstract: The present invention relates to a method of operating a converter, in particular a Peirce-Smith converter or a converter with similar design or mode of operation, and to an apparatus, for instance a plant, for carrying out the method. The method comprises the step of: loading the converter with a starting material comprising said metal, the metal in the starting material being chemically bound at least in part to at least one compound substance, in particular sulphur; maintaining a temperature within the converter interior space, which is above the melting temperature of the starting material; and supplying an oxygen-containing process gas into the converter interior space through injection nozzles arranged in the wall of the converter, the gas supplied through the injection nozzles comprising carbon dioxide, preferably very cold, technically pure carbon dioxide, as well as oxygen gas and/or air.

Abstract: The present invention relates to new compositions of matter, particularly metals and alloys, and methods of making such compositions. The new compositions of matter exhibit long-range ordering and unique electronic character.

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.

Abstract: The present invention relates to the use of liquid-crystal displays (LCDs), and to processes for the recycling thereof. The processes according to the invention are characterised in that the LCDs are employed at least partly as replacement for other raw materials. In general, the LCDs are thermally treated here at a temperature in the range from 900 to 1700° C.

Abstract: In the method for recovering a metal from a target that contains a metal and a metal oxide, the target contains a sintered body of the metal oxide after being heated under a condition of melting the metal without melting or decomposing the metal oxide. The target is heated in an upper crucible of a two-level crucible that includes the upper crucible with a through hole-formed in a bottom surface thereof, and a lower crucible disposed below the through hole, the size of the through hole being set such that it does not allow the sintered body of the metal oxide contained in the target to pass therethrough, and the melted metal is caused to flow into the lower crucible, so that the metal is separated from the metal oxide.

Abstract: A method for introducing a cored wire into a bath of molten metal includes extracting the cored wire from a reel, and making it run into the molten metal bath, one part of the path traveled by the cored wire being formed in a guide tube with a distal end at a defined height above the metal bath's surface. The cored wire is driven and straightened under conditions practically not altering its substantially circular cross section and allowing it to be vertically introduced and penetrate into the depth of the bath. Elements for driving the cored wire from a reel, a guide tube for guiding the cored wire, and elements for straightening the cored wire are placed in front of its entry into the guide tube, the straightening elements giving the cored wire a straight direction without altering its circular cross section.

Abstract: A method recovers noble metals from noble metal-containing compositions and includes steps of (i) providing a noble metal-containing composition containing an adsorption agent that is based on an inorganic material and is functionalized by organic groups and has at least one noble metal adsorbed to it, and (ii) ashing of the noble metal-containing composition provided in step (i) in order to adjust a residual carbon content of at most 10% by weight, relative to the total weight of the noble metal-containing composition after ashing, to obtain an ashed composition.

Abstract: Aspects of the present invention refer to a MHP process do produce rough ferro-nickel product and that may include the steps of mixing nickel hydroxide with an iron source and slagging agents, putting the mixture in contact with a reducing agent producing a ferronickel alloy, and producing a roasted product that has disseminated ferronickel alloy inside the structure.

Abstract: A carbonaceous-based metallizing method and apparatus wherein a metallic oxide is converted into a carbon-containing, metallized intermediate that is melted in an induction channel furnace to produce liquid metal from said metallic oxide. In the application of iron ore in the form of fines or concentrate, using low-cost coal will greatly reduce capital and operating costs by virtue of eliminating agglomeration of ore, cokemaking, and blast furnace operation. The liquid iron so produced is efficiently converted into steel in a steelmaking furnace such as a basic oxygen furnace (BOF), especially when it is physically integrated to the induction channel furnace wherein the liquid iron is directly poured into the integrated BOF by the induction channel furnace, producing low-cost steel, little heat loss, and minimum emissions.

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.

Abstract: In order to provide a molten metal in a melting furnace with at least one alloy component or to increase the portion of the latter in the molten metal, a blank mixture has an alloy element containing the alloy component or being made of the latter, from water and a binding agent, and the blank mixture is processed into an alloy blank that can be placed in the melting furnace. At least as much water is added so that the blank mixture can be poured, and at least as much binding agent is added so that the alloy blank has a strength of at least 4/Nmm2 after at the latest seven days setting time at 20° C., preferably at least 5 N/mm2. The blank mixture is poured into a casting mold and setting takes place without applying external pressing, with the alloy blank thus produced being removed from the mold.

Abstract: In a process and apparatus for the reduction of metal oxides (3) to form metalized material by contact with hot reducing gas, which is produced at least partially by catalytic reformation of a mixture of a gas containing carbon dioxide (CO2) and/or steam (H2O) with gaseous hydrocarbons, the heat for the endothermal reformation processes which take place during the reformation is provided at least partially by the combustion of a fuel gas.

Abstract: A treatment ladle comprising a ladle shell containing a generally tubular refractory ladle liner, said ladle being pivotable between a horizontal position and a vertical position, said ladle liner having a first end and a second end with a continuous sidewall therebetween, an interior space being defined between said first and second ends and the continuous sidewall, said ladle liner additionally comprising a pocket for holding a treatment agent, said pocket being located adjacent the first end and in fluid communication with the interior space and located closer to the top than the bottom of the interior space when the ladle is in its horizontal position and closer to the bottom than the top of the interior space when the ladle is in its vertical position, and a spout for receiving and pouring molten metal located closer to the top than the bottom of the interior space when the ladle is in its horizontal and vertical positions, wherein in the horizontal position, a lower volume of the interior space defined

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

Abstract: An apparatus for processing material such as organically coated waste and organic materials including biomass, industrial waste, municipal solid waste and sludge, is provided. The apparatus comprises a rotatable and tillable furnace (1) having a body portion (15), a single material entry point (11) and a tapered portion (13) between said entry point and said body portion of the furnace. The furnace further includes means (25) for rotating the furnace (1) about its longitudinal axis and means (32, 102) for tilting the furnace. The furnace has a closure movable between an open position in which material can be introduced to the furnace (1) and a closed position in which the interior of the furnace is isolated from the external environment. A means at or adjacent said entry point (11) for directs gases in a direction inwardly of said furnace so as to provide a barrier of gas adjacent said opening to inhibit the entrance of oxygen containing atmospheric gas when said closure is in its open position.

Abstract: A method for operating a hearth furnace encompassing a furnace chamber heated by at least one burner, including: a) introducing metal-containing material into the hearth furnace, b) melting the metal-containing material in a first melting phase until a melting bath surface has formed, c) melting the metal-containing material in a second melting phase after the melting bath surface has formed, d) removing and/or holding the melted metal, characterized in that the at least one burner is operated during the phase (b) such that a larger portion of burner capacity is emitted in convection rather than in radiant energy, and that respective portions of convection heat and of radiant heat emitted by the at least one burner are adjusted specifically via adjustment of brightness and/or size, in particular length of a flame of the at least one burner.

Abstract: Various illustrative embodiments of a free-machining aluminum alloy composition and related methods are provided. The aluminum alloy composition can include an aluminum alloy and an effective amount of a graphitic material as a free-machining constituent. Free-machining means the graphitic material is capable of modifying the machining character of the aluminum alloy by affecting the generation of chip-shaped machining debris and/or the friction between the machining tool and the workpiece.

Abstract: Various illustrative embodiments of an apparatus and method for reducing the dissolved hydrogen content of a molten metal alloy are provided. The disclosed embodiments can be utilized for the processing of molten metal alloys such as aluminum, and more particularly, for the removal of dissolved hydrogen from molten metal alloys such as aluminum. Gas permeable diffusers can be employed that are wettable by molten metal. When used as gas injectors, either in combination with ultrasonic oscillation or without, the gas permeable wettable diffusers can provide a high density of ultrafine inert gas bubbles that can be used to rapidly and efficiently reduce the level of dissolved hydrogen within the molten metal.