Iron(fe) Patents (Class 75/433)
  • Patent number: 9163879
    Abstract: A partially-reduced iron producing apparatus includes: an exhaust gas circulating device which supplies an oxygen-containing gas to raw-material pellets to be heated by a heat of ignition raw-material pellets, the oxygen-containing gas made by circulating part of an exhaust gas discharged from the raw-material pellets by use of the heat of the ignition raw-material pellets heated in a heating furnace and mixing the discharged exhaust gas with air; and a liquid-tar separating device which is provided in the exhaust gas circulating device and which separates a tar component in the exhaust gas from the exhaust gas as a liquid tar.
    Type: Grant
    Filed: September 20, 2013
    Date of Patent: October 20, 2015
    Assignee: PRIMETALS TECHNOLOGIES JAPAN, LTD.
    Inventors: Susumu Kamikawa, Hideaki Mizuki, Hideki Ito, Keiichi Sato, Khanhson Pham
  • Patent number: 9062365
    Abstract: A method of manufacturing a metal part according to the present invention includes heating a shaped product of stainless steel to 600° C. or more in an oxygen-free atmosphere and heat-treating the shaped product in an oxygen atmosphere after the heating.
    Type: Grant
    Filed: September 13, 2012
    Date of Patent: June 23, 2015
    Assignee: NHK SPRING CO., LTD.
    Inventors: Ryuichi Kawatake, Takashi Maruyama
  • Publication number: 20150122082
    Abstract: The invention relates to a method for processing slags of non-ferrous metallurgy, containing iron and valuable metals, to produce clean slag that is free of detrimental substances and valuable metals and suitable as it is for use as a raw material or construction material. Slag is reduced in a reduction furnace (18) with the help of reducing agents (19) so far that at least 5% of the iron of the slag is reduced into metal. At the same time, some of the valuable metals, such as zinc, lead, arsenic and cadmium, vaporize. The contents of the reduction furnace (18) are continuously mixed to prevent separation of a metallic phase from the slag. The generated slag-metal mixture (21) is tapped off from the reduction furnace (18), cooled, crushed and ground to a finer size. Finally, a metal fraction (26) is separated from a clean slag (25).
    Type: Application
    Filed: April 15, 2013
    Publication date: May 7, 2015
    Inventors: Maija-Leena Metsarinta, Jussi Liipo, Pekka Kurki, Madeleine Scheidema
  • Publication number: 20150093285
    Abstract: The present invention relates to a magnetic material, which contains at least one transition metal (TM), at least one rare earth metal (RE) and tungsten, wherein the proportion of transition metal (TM) is 60 to 90% by mass, the proportion of rare earth metal (RE) is 10 to 20% by mass, and the proportion of tungsten (W) is 5 to 25% by mass, in each case in relation to the total mass of the magnetic material.
    Type: Application
    Filed: April 19, 2013
    Publication date: April 2, 2015
    Inventors: Stefan Hinderberger, Christian Wegierski, Peter Barth, Gerhard Schneider, Arne Huber, Juergen Oberle, Dagmar Goll, Friederike Koeppen, Lars Bommer, Roland Stein, Markus Raith, Alberto Martinez-Limia, Roman Karimi, Ingrid Wuehrl, T-akashi Shigematsu
  • Publication number: 20150013496
    Abstract: The invention relates to a pelletising feed containing chromite ore, at least one nickel salt, and silicon carbide as the only carbonaceous material and the only reducing agent. The invention also relates to process for manufacturing the pelletising feed comprising the steps providing chromite, at least one nickel salt and silicon carbide, and mixing chromite, at least one nickel salt and silicon carbide. The invention also relates to use of the pelletising feed as a starting material for the manufacture of sintering feed. The invention also relates to a sintering feed in the form of pellets containing the pelletising feed. The invention also relates to sintered pellets containing the sintering feed. The invention also relates to process for manufacturing the sintered pellets. The invention also relates to use of the sintered pellets as a component of smelting feed. The invention also relates to smelting feed comprising sintered pellets.
    Type: Application
    Filed: November 15, 2011
    Publication date: January 15, 2015
    Inventors: Helge Krogerus, Pasi Mäkelä
  • Patent number: 8920535
    Abstract: A separation and recovery method that enables titanium and tungsten to be separated and recovered from a used DeNOx catalyst in high yield. Specifically, a method of separating and recovering metal elements that includes a first heating step of heating a DeNOx catalyst containing titanium, tungsten, vanadium and iron in a chlorine atmosphere, thereby removing the vanadium and the iron from the DeNOx catalyst, and a second heating step, performed after the first heating step, of heating the DeNOx catalyst in a chlorine atmosphere while the catalyst is exposed to a gas of a hydrocarbon compound (excluding CH4) or an oxygen-containing carbon compound, thereby volatilizing the tungsten and the titanium from the DeNOx catalyst, and recovering the tungsten and the titanium from the DeNOx catalyst.
    Type: Grant
    Filed: April 23, 2013
    Date of Patent: December 30, 2014
    Assignees: Mitsubishi Heavy Industries, Ltd., National University Corporation Akita University
    Inventors: Masashi Kiyosawa, Katsumi Nochi, Norihisa Kobayashi, Kozo Iida, Katsuyasu Sugawara, Yuuki Mochizuki
  • 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
  • Patent number: 8911700
    Abstract: A process and an installation for reducing particulate material containing iron oxide are shown, wherein the material containing iron oxide is at least partially reduced with reducing gas in a reducing zone and the waste gas produced during the reduction is drawn off and subsequently subjected to CO2 cleaning in a CO2 separating device (1), in which a tail gas containing CO2 is separated. The tail gas is subjected to combustion and subsequent dewatering in a dewatering device (5), the substitute gas thereby formed being used as a substitute for inert gas.
    Type: Grant
    Filed: February 3, 2010
    Date of Patent: December 16, 2014
    Assignee: Siemens Vai Metals Technologies GmbH
    Inventors: Robert Millner, Jan-Friedemann Plaul, Kurt Wieder
  • Publication number: 20140345425
    Abstract: A method of starting a smelting process in a smelting vessel includes heating frozen slag and forming molten slag and draining molten slag from a forehearth connection via a forehearth and establishing a clear flow path through the forehearth connection and thereafter hot starting the smelting process.
    Type: Application
    Filed: December 6, 2012
    Publication date: November 27, 2014
    Inventors: Jacques Pilote, Rodney James Dry, Hendrikus Koenraad Albertus Meijer
  • 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
  • Patent number: 8845780
    Abstract: The present technology provides an illustrative apparatus for recycle electric arc furnace (EAF) dust and method of use related to the same. The apparatus has a heat controlling region coupled to a separation volume and includes at least one magnet and a cooling region. The heating controlling region operates at a temperature sufficient to transform at least some of the EAF dust into a mixture of gaseous zinc and one or more additional metals. The magnet separates the iron-rich material from the mixture of gaseous zinc and one or more additional metals and the cooling region condenses the gaseous zinc.
    Type: Grant
    Filed: August 16, 2011
    Date of Patent: September 30, 2014
    Assignee: Empire Technology Development LLC
    Inventor: Ezekiel Kruglick
  • Patent number: 8834599
    Abstract: In a method and a device for operating a smelting reduction process, at least part of an export gas from a blast furnace or a reduction unit is thermally utilized in a gas turbine and the exhaust gas of this gas turbine is used in a waste heat steam generator to generate steam. The remaining part of the export gas is fed to a CO2 separation apparatus, the tail gas thereby obtained being fed to a waste heat steam generator and burned for additional steam generation. The combustible components of the tail gas are sent for thermal utilization in a steam generator, so that the overall energy balance of the thermal use of the export gas is improved. In addition, a further part of the export gas is qualitatively improved by the CO2 separation apparatus, so as to generate a high-quality reduction gas which can be supplied for metallurgical use.
    Type: Grant
    Filed: September 29, 2009
    Date of Patent: September 16, 2014
    Assignee: Siemens Vai Metals Technologies GmbH
    Inventors: Robert Millner, Johannes Leopold Schenk, Kurt Wieder
  • Publication number: 20140224069
    Abstract: The present invention provides a process for the preparation of pre-melted calcium aluminate for iron and steel treatment and protection by the fusion of aluminum dross residues, usually referred to as non-metallic products (NMP) containing variable levels of aluminum (Al) and aluminum nitride (AlN) with calcium carbonate at high temperature, under oxidizing atmosphere. It further relates to the purification of the molten calcium aluminate from some contaminants present in the dross residue.
    Type: Application
    Filed: February 11, 2014
    Publication date: August 14, 2014
    Applicant: 9255-8444 QUEBEC INC. dba METKEM INNOVATION
    Inventor: Ghyslain Dubé
  • 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: 20140150606
    Abstract: A method of manufacturing direct reduction iron and a reduction firing apparatus. The apparatus has a reduction furnace including a left chamber, a right chamber, a material containing device, a step mechanism, a slag distributing device, a charging device, heating burners, a fume extraction path, a charging device, a material receiving tank and a slag discharging path. The method includes the following steps: distributing and charging the slag in the material containing device; carrying and sending the material containing device through a preheating station, a heating station and a reduction station sequentially. Meanwhile, heating the material to be reduced by a combustion of fuel with the heating burners; discharging the reduced material into the material receiving tank; placing the material device from which the material is discharged into the feeding side of the other chamber, then a next work circulation begins.
    Type: Application
    Filed: June 4, 2013
    Publication date: June 5, 2014
    Inventor: Jinlong Zhan
  • Publication number: 20140123809
    Abstract: An object of the present invention is to provide a method for producing an alloy recycled material by effectively removing carbon from a carbon-containing alloy, which is produced as scrap or sludge of an R—Fe—B based permanent magnet, a used magnet, or the like. The method of the present invention as a means for resolution is characterized in that a carbon-containing R—Fe—B based permanent magnet alloy is subjected to an HDDR treatment to remove carbon. An alloy recycled material produced by the method of the present invention contains a reduced amount of carbon. Therefore, in the case where it is recycled for the production of a magnet, even when an increased amount is subjected to high-frequency heating in a vacuum melting furnace, a non-negligible increase in the amount of carbon contained in the produced magnet can be avoided.
    Type: Application
    Filed: June 29, 2012
    Publication date: May 8, 2014
    Applicant: HITACHI METALS, LTD.
    Inventors: Katsuyoshi Furusawa, Atsushi Kikugawa
  • Patent number: 8551396
    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.
    Type: Grant
    Filed: April 18, 2008
    Date of Patent: October 8, 2013
    Assignee: University of Virginia Patent Foundation
    Inventors: Bellave S. Shivaram, Adam B. Phillips
  • Patent number: 8500866
    Abstract: Upon cooling to 15 to 45° C., a process for the treatment of raw product gas generated by pressure gasification of solid fuels comprises the removal of HCN and NH3 in a preliminary stage, of H2S and COS and possibly other sulfur-containing compounds in a first stage and of CO2 in a second stage by physisorption with cold oxygenate, and the pure product gas is supplied to the direct reduction of iron ore as reduction gas and/or as fuel gas. An improvement of the process consists in that recycle gas loaded with CO2 and steam, which is branched off from the circuit of the recycle gas of the direct reduction of iron ore, is admixed to the desulfurized product gas upon removal of the steam contained therein.
    Type: Grant
    Filed: May 23, 2008
    Date of Patent: August 6, 2013
    Assignee: Lurgi Clean Coal Technology (Proprietary) Limited
    Inventor: Gerhard Schmitt
  • Publication number: 20130192421
    Abstract: The invention relates to a method of agglomerating iron oxide-containing residual substances, in particular scale and mill scale, wherein the residual materials and the paper sludge are dried and comminuted and agglomerates are produced by means of hot briquetting from the mixture comprising the residual substances and the paper sludge. In this way, mill scale briquettes of high strength and density can be produced which in steelmaking processes can then be charged into an electric arc furnace for the purpose of recycling the iron contained in the residual substances.
    Type: Application
    Filed: July 2, 2011
    Publication date: August 1, 2013
    Applicant: RHM Rohstoff-Handelsgesellschaft mbH
    Inventors: Udo Meynerts, Seulo Henrique Seabra Da Rocha, Michael Maurer
  • Patent number: 8486329
    Abstract: A process for the production of a semi-solidified iron alloy slurry having a crystallized solid phase and a residual liquid phase, wherein a material having a hypoeutectic cast iron composition is used, and an additive agent having a boiling point that is lower than at least a crystallization initiation temperature of primary crystals of the material is added to a melt of the material when the melt temperature is within a specific temperature range of not lower than the crystallization initiation temperature of the primary crystals and not greater than a temperature that is 50° C. higher than the crystallization initiation temperature, to thereby simultaneously conduct the stirring of the melt by the boiling of the additive agent and the cooling of the melt to a temperature falling within a semi-solidification temperature range thereof.
    Type: Grant
    Filed: March 12, 2009
    Date of Patent: July 16, 2013
    Assignee: Kogi Corporation
    Inventors: Syuichi Shikai, Yasushi Fujinaga, Minoru Sasaki, Toshio Ohkado, Susumu Nishikawa
  • Publication number: 20130081516
    Abstract: Metallic iron is produced from a composition formed from a mixture of iron ore particles and particles of a reductant made of a biomass material, a coal or coke in a particulate form together with a flux and is processed in a loose, un-agglomerated non-pelletized, non-briquetted form in a reducing furnace to produce metallic iron directly from the ore. An excess of biomass or coal or coke reductant can be used to provide CO and H that can be recovered as a synthetic gas and converted to electrical or other energy. Metallic iron nuggets or slabs can be produced from manganiferous ores or concentrates. Manganese can be caused to enter the nugget or slab or the slag by adjusting the furnace temperature. Titaniferous ores or concentrates can be used to produce metallic iron slabs or nuggets and a titanium-rich slag.
    Type: Application
    Filed: April 19, 2012
    Publication date: April 4, 2013
    Inventor: John J. Simmons
  • Publication number: 20130019714
    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: Application
    Filed: January 5, 2011
    Publication date: January 24, 2013
    Applicant: SMS SIEMAG AKTIENGESELLSCHAFT
    Inventors: Johann Reichel, Lutz Rose
  • Publication number: 20130019716
    Abstract: A process and an apparatus for reducing charge materials containing iron ore or for producing pig iron or liquid primary steel products in a smelting unit are provided, the charge materials being at least partially reduced in at least one reduction unit by means of a reducing gas and optionally at least some of the at least partially reduced charge materials being melted in a smelting unit while supplying coal or coke and gas containing oxygen, while simultaneously forming the reducing gas, and the reducing gas or a reducing gas generated externally being supplied to the reduction unit. In the event of an interruption in the production of pig iron or primary steel products, the at least one reduction unit is emptied and the at least partially reduced charge materials are introduced into at least one vessel and kept under a non-oxidizing shielding gas atmosphere.
    Type: Application
    Filed: December 1, 2010
    Publication date: January 24, 2013
    Inventors: Thomas Eder, Robert Millner, Jan-Friedemann Plaul, Norbert Rein, Karl Zehetbauer
  • Publication number: 20120312125
    Abstract: A method of ironmaking using full-oxygen hydrogen-rich gas which includes hot transferring and hot charging the high-temperature coke, sinter and pellet into the ironmaking furnace through transferring and charging device, and injecting oxygen and hydrogen-rich combustible gas at a predetermined temperature into the ironmaking furnace through the oxygen tuyere and the gas tuyere disposed at the ironmaking furnace, respectively. It also provides an apparatus for ironmaking using full-oxygen hydrogen-rich gas which includes a raw material system, a furnace roof gas system, a coke oven gas injecting system, a dust injecting system, a slag dry-granulation and residual heat recovering system and an oxygen system. Additionally an apparatus and method for hot transferring and hot charging of ironmaking raw material is disclosed.
    Type: Application
    Filed: August 30, 2010
    Publication date: December 13, 2012
    Applicants: CENTRAL IRON & STEEL RESEARCH INSTITUTE, SHANDONG TIEXIONG METALLURIGICAL TECHNOLOGY CO LTD., SHANDONG COKING GROUP CO., LTD.
    Inventors: Yuanhong Qi, Qingtao Wang, Dingliu Yan, Peimin Guo
  • Publication number: 20120297926
    Abstract: The invention relates to a method for producing an agglomerated product containing alumina which is useful as a component to be incorporated into a synthetic slag as used in steel making. The product is formed from powdered aluminium dross which is formed with water into pellets or briquettes and wherein the components of the pellets or briquettes are allowed to react at elevated pressure to release ammonia. The pellets or briquettes may then be calcined.
    Type: Application
    Filed: January 26, 2011
    Publication date: November 29, 2012
    Applicant: BUMATECH (PTY) LIMITED
    Inventor: Samuel Hewitt
  • Publication number: 20120282130
    Abstract: A carbothermic reduction method is provided for reducing a rare earth element-containing oxide including at least one of neodymium (Nd) and praseodymium (Pr) and possibly other rare earth elements (La, Ce, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Sc, and Y) as alloying agents in the presence of carbon and a source of a reactant element including one or more of silicon, germanium, tin, lead, arsenic, antimony and bismuth to form a rare earth element-containing intermediate alloy as a master alloy for making permanent magnet material. The process is a more efficient, lower cost and environmentally friendly technology than current methods of manufacturing rare earth metals. The intermediate material is useful as a master alloy for making a permanent magnet material comprising at least one of neodymium and praseodymium, and possibly other rare earth metals as alloying additives.
    Type: Application
    Filed: April 18, 2012
    Publication date: November 8, 2012
    Inventors: Karl A. Gschneidner, JR., Frederick A. Schmidt, Ralph W. McCallum
  • Publication number: 20120279356
    Abstract: A process and a device for charging a primary product for pig iron into a smelting unit are provided. According to the process and device, some of the primary product that has been formed by reducing oxidic iron carriers is stored in the hot state in a reservoir tank before being supplied into the storage device or charging device that is directly connected to the smelting unit.
    Type: Application
    Filed: October 6, 2010
    Publication date: November 8, 2012
    Inventors: Thomas Eder, Robert Millner, Jan-Freidemann Plaul, Norbert Rein, Andreas Scherney, Karl Zehetbauer
  • Publication number: 20120192677
    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.
    Type: Application
    Filed: January 28, 2011
    Publication date: August 2, 2012
    Inventors: Albert Calderon, Terry James Laubis, Richard Owen McCarthy
  • Publication number: 20120118107
    Abstract: A process and an apparatus for producing sponge iron from iron-oxide-containing material in lump form by direct reduction in a reduction shaft using a reducing gas, wherein the entire reducing gas is introduced by means of a number of reducing gas distribution ducts in a star-like arrangement or arranged parallel to one another, preferably into the lower quarter of the reduction shaft, and evenly distributed over the entire cross-section of the reduction shaft.
    Type: Application
    Filed: January 19, 2012
    Publication date: May 17, 2012
    Inventor: Bogdan Vuletic
  • Patent number: 8133296
    Abstract: In order to allow a significant reduction of the steel production cost when producing stainless steel with the alloying elements chromium and nickel, according to the invention, it is proposed to perform the intermediate production of ferrochrimium and ferronickel in two separate direct reduction processes based on low-cost chromium ore and nickel ore in two SAF (3, 4) arranged in parallel on the primary side of a processing converter (6).
    Type: Grant
    Filed: October 22, 2008
    Date of Patent: March 13, 2012
    Assignee: SMS Siemag Aktiengesellschaft
    Inventors: Johann Reichel, Lutz Rose
  • Publication number: 20120031235
    Abstract: A thermal system for separating out co-mingled metals in almost pure form, the system including a tunnel kiln having temperature zones through which the co-mingled metals are conveyed and progressively heated until at least one metal of the co-mingled metals melts thereby separating the melted metal from the other metal or metals of the co-mingled metals. The system includes molten metal catch basins for collecting the melted metal which are arranged beneath a conveyor on which the co-mingled metals are transported within the kiln. The catch basins are tapped to the outside of the kiln so that as the various metals melt out at progressively higher temperatures, they can be collected into cast iron chills or other collection devices to form pure ingots.
    Type: Application
    Filed: August 6, 2010
    Publication date: February 9, 2012
    Inventor: Scott W. Frame
  • Publication number: 20120003115
    Abstract: A process for the production of a semi-solidified iron alloy slurry having a crystallized solid phase and a residual liquid phase, wherein a material having a hypoeutectic cast iron composition is used, and an additive agent having a boiling point that is lower than at least a crystallization initiation temperature of primary crystals of the material is added to a melt of the material when the melt temperature is within a specific temperature range of not lower than the crystallization initiation temperature of the primary crystals and not greater than a temperature that is 50° C. higher than the crystallization initiation temperature, to thereby simultaneously conduct the stirring of the melt by the boiling of the additive agent and the cooling of the melt to a temperature falling within a semi-solidification temperature range thereof.
    Type: Application
    Filed: March 12, 2009
    Publication date: January 5, 2012
    Applicant: Kogi Corporation
    Inventors: Syuichi Shikai, Yasushi Fujinaga, Minoru Sasaki, Toshio Ohkado, Susumu Nishikawa
  • Publication number: 20110283837
    Abstract: In a method and a device for operating a smelting reduction process, at least part of an export gas from a blast furnace or a reduction unit is thermally utilized in a gas turbine and the exhaust gas of this gas turbine is used in a waste heat steam generator to generate steam. The remaining part of the export gas is fed to a CO2 separation apparatus, the tail gas thereby obtained being fed to a waste heat steam generator and burned for additional steam generation. The combustible components of the tail gas are sent for thermal utilization in a steam generator, so that the overall energy balance of the thermal use of the export gas is improved. In addition, a further part of the export gas is qualitatively improved by the CO2 separation apparatus, so as to generate a high-quality reduction gas which can be supplied for metallurgical use.
    Type: Application
    Filed: September 29, 2009
    Publication date: November 24, 2011
    Inventors: Robert Millner, Johannes Leopold Schenk, Kurt Wieder
  • Patent number: 8038766
    Abstract: A direct reduction process for a metalliferous material includes supplying the metalliferous material, a solid carbonaceous material, an oxygen-containing gas, and a fluidizing gas into a fluidized bed in a vessel and maintaining the fluidized bed in the vessel, at least partially reducing metalliferous material in the vessel, and discharging a product stream that includes the partially reduced metalliferous material from the vessel. The process comprises (a) reducing the metalliferous material in a solid state in a metal-rich zone in the vessel; (b) injecting the oxygen-containing gas into a carbon-rich zone in the vessel with a downward flow in a range of ±40° to the vertical and generating heat by reactions between oxygen and the metalliferous material (including metallized material), the solid carbonaceous material and other oxidizable solids and gases in the fluidized bed, and (c) transferring heat from the carbon-rich zone to the metal-rich zone by movement of solids within the vessel.
    Type: Grant
    Filed: May 20, 2005
    Date of Patent: October 18, 2011
    Assignee: Outotec Oyj
    Inventors: Andreas Orth, Heinz Eichberger, Donald Keith Philp, Jeantine Van Gemund, legal representative, Rod Dry
  • Publication number: 20110197712
    Abstract: A system of coal gasification and direct ironmaking which is effective in attaining both heat recovery in a coal-based direct ironmaking process and a reduction in equipment investment in a coal gasification process. The system is characterized by being equipped with: a waste heat boiler (16) for recovering heat of gas exhausted from a coal gasification furnace; a heater (7) provided in exhaust gas lines (1a and 1b) of a heat reduction furnace (1) in the coal-based direct ironmaking process and superheating the steam generated by and exhausted from the waste heat boiler (16); and a superheated steam line (23) for supplying the steam superheated by the heater (7) as an oxidant to the coal gasification furnace (10).
    Type: Application
    Filed: September 25, 2009
    Publication date: August 18, 2011
    Applicant: Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.)
    Inventors: Masataka Tateishi, Masahiro Motoyuki
  • Publication number: 20110179910
    Abstract: A process for producing agglomerates from fine-grained iron carriers and at least one binder as a charge material for a metallurgical process is shown. In at least one further agglomeration step, the agglomerates are coated with a layer, comprising iron carriers and at least one binder, and heated in such a way that the binder is cured in the region of the surface of the agglomerates. In a process for producing liquid pig iron or liquid primary steel products from charge materials and possibly additions and agglomerates, the agglomerates are preheated in a reducing zone, which has a preheating stage, in such a way that the agglomerates completely harden in the preheating stage.
    Type: Application
    Filed: August 17, 2009
    Publication date: July 28, 2011
    Inventors: Christian Boehm, Hado Heckmann, Hans Herbert Stiasny, Johannes Leopold Schenk
  • Publication number: 20110154950
    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.
    Type: Application
    Filed: July 1, 2010
    Publication date: June 30, 2011
    Applicant: Air Products and Chemicals, Inc.
    Inventors: Jin Cao, Russell James Hewertson, Xiaoyi He
  • Publication number: 20110120266
    Abstract: A process for energy-and emission-optimized iron production and an installation for carrying out the process. A first partial amount of a generator gas produced in a melter gasifier is used as a first reducing gas in a first reduction zone. A second partial amount is fed to at least one further reduction zone as a second reducing gas. In addition, after CO2 scrubbing, a partial amount of top gas removed from the first reduction zone is admixed with the generator gas after the latter leaves the melter gasifier, for cooling the generator gas.
    Type: Application
    Filed: June 24, 2009
    Publication date: May 26, 2011
    Inventors: Thomas Bürgler, Stephan Lackner, Robert Millner, Reinhard Redl, Bernhard Rummer, Herbert Schmid, Johann Wurm, Andreas Zobernig
  • Publication number: 20110079109
    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.
    Type: Application
    Filed: September 1, 2010
    Publication date: April 7, 2011
    Applicant: LINDE AG
    Inventor: Martin Adendorff
  • Publication number: 20110036204
    Abstract: A method for producing reduced iron includes: a step of preparing a mixed raw material; a mixed raw material charging step; and a reducing step. In the step of preparing the mixed raw material, the mixed raw material which contains iron ore (X) containing iron ore with a high content of zinc (A) which contains 0.01 mass % or more of zinc and 50 mass % or more of iron, and a carbonaceous solid reducing material is prepared. In the mixed raw material charging step, the mixed raw material is charged on a movable hearth. In the reducing step, a reduced product is obtained by reducing the mixed raw material charged on the movable hearth by supplying heat to the mixed raw material from above the hearth.
    Type: Application
    Filed: April 22, 2009
    Publication date: February 17, 2011
    Applicant: JFE STEEL CORPORATION
    Inventors: Natsuo Ishiwata, Hiroyuki Hiroha, Koichi Nushiro
  • Publication number: 20110023661
    Abstract: This invention provides a technique for rendering bio-toxicity such as allergy toxicity derived from Ni trace impurity, i.e., nickel toxicity, which is unavoidably present in a bio-Co—Cr—Mo alloy or an Ni-free stainless steel alloy unharmful, characterized in that an element selected from the group consisting of the group 4, 5 and 13 elements of the periodic table, particularly an element selected from the group consisting of the group 4 elements of the periodic table, is added to the alloy composition. The additive element is preferably an element selected from the group consisting of zirconium and titanium, more preferably zirconium.
    Type: Application
    Filed: September 27, 2010
    Publication date: February 3, 2011
    Inventors: Akihiko Chiba, Shingo Kurosu, Naoyuki Nomura
  • Publication number: 20100300246
    Abstract: A method for producing a substantially metallic iron-containing product from iron oxide. The metallic iron produced according to the invention is non-pyrophoric and may be safely shipped and handled without additional process steps. The method of the invention is simple, economical, and produces high quality metallic product which may be used as a feed for Electric Arc Furnace (EAF), Blast Furnaces and Cupolas among other applications.
    Type: Application
    Filed: May 24, 2010
    Publication date: December 2, 2010
    Inventors: James L. Coburn, John L. Sullivan
  • Patent number: 7789936
    Abstract: Methods and systems for removing copper from ferrous scrap are described. Some amounts of copper in ferrous scrap are removed by oxidation and subsequent mechanical impact of the oxidized scrap. Further removal of copper from the solid scrap can be achieved by fluxing the copper oxide below the melting point of ferrous scrap using CaO—SiO2—B2O3— and Na2O—SiO2—B2O3-based slags. Using the invention, copper can be removed from ferrous scrap in a natural, cost-effective, and environmental-friendly manner.
    Type: Grant
    Filed: August 18, 2004
    Date of Patent: September 7, 2010
    Assignee: University of Utah Research Foundation
    Inventors: Weol Dong Cho, Peng Fan
  • Publication number: 20100221137
    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.
    Type: Application
    Filed: April 18, 2008
    Publication date: September 2, 2010
    Applicant: UNIVERSITY OF VIRGINIA PATENT FOUNDATION
    Inventors: Bellave S. Shivaram, Adam B. Phillips
  • Publication number: 20100162852
    Abstract: A direct reduction plant for the production of a metallized product (DRI) by the reduction of iron ores in lump or pellet form, wherein the reducing gas utilized in the DRI reactor contains acid gases such as sulphur compounds and carbon dioxide. The make-up reducing gases are typically produced by partial oxidation of hydrocarbons (syngas) at a high pressure while the DRI reactor is usually operated at a lower pressure. The pressure level of the reducing gas effluent from the DRI reactor (top gas), after cooling and dewatering, is increased to the pressure level of the syngas and the resulting recycle reducing gas is then combined with the make-up syngas and treated in a single acid-gas absorption unit forming a combined stream of clean upgraded reducing gas which thereafter is expanded in a turbine for lowering combined reducing gas pressure to the pressure level of the DRI reactor and is then heated to a temperature preferably above 950° C. and used in the DRI reactor for producing said DRI.
    Type: Application
    Filed: May 14, 2008
    Publication date: July 1, 2010
    Inventors: Jorge Octavio Becerra-Novoa, Pablo-Enrique Duarte-Escareno, Eugenio Zendejas-Martinez
  • Publication number: 20100154594
    Abstract: A process for melting scrap metal for producing steel which includes the steps of combining a quantity of scrap metal and scrap rubber in an electric arc furnace. Energy is then applied to the quantity of steel and scrap rubber in the furnace to start the combustion of the scrap rubber to add additional heat for melting the scrap metal containing steel.
    Type: Application
    Filed: March 8, 2010
    Publication date: June 24, 2010
    Applicant: Rex Enterprises, LLC
    Inventor: Franklin Leroy Stebbing
  • Publication number: 20090013827
    Abstract: In a method of producing steel using a steel-making vessel, where lime is used as a flux material that is blown, from above, into a steel-making bath along with an oxygen stream, providing a flux material composition of calcium oxide having a particle size of less than 250 mesh, which contains a flow aid material that is a polymeric siloxane, in an amount of less than 0.5 percent by weight of the calcium oxide, and injecting the flux material composition through a lance along with oxygen into the steel-making bath contained in the steel-making vessel.
    Type: Application
    Filed: February 9, 2006
    Publication date: January 15, 2009
    Inventors: Larry D. Wolfe, Richard J. Brelowski
  • Patent number: 7014678
    Abstract: According to the invention, oil-charged mill-scale is treated such that the oil is encapsulated or bound therein. An escape of oil on use in a shaft oven first occurs when the ignition point is reached, thus guaranteeing combustion. Agglomeration of said mixture is by pelleting. A mixture comprising the following is preferably used for encapsulation and chemical binding of the oil: A zinc salt and a calcium salt of a saturated or unsaturated fatty acid, a hydrophobic inducing agent, an amino alcohol and ammonia. The abstract of the disclosure is submitted herewith as required by 37 C.F.R. §1.72(b). As stated in 37 C.F.R. §1.72(b), “A brief abstract of the technical disclosure in the specification must commence on a separate sheet, preferably following the claims, under the heading “Abstract of the Disclosure.” The purpose of the abstract is to enable the Patent and Trademark Office and the public generally to determine quickly from a cursory inspection the nature and gist of the technical disclosure.
    Type: Grant
    Filed: February 3, 2003
    Date of Patent: March 21, 2006
    Inventor: Wolfgang Schwetlick
  • Patent number: 6572674
    Abstract: Steel work gases (blast-furnace gases, coke-oven gases, converter gases, etc.) are burnt with an exhaust gas from a gas turbine, optionally with a supply of natural gas and of air, in a postcombustion section between the outlet of the gas turbine and the inlet of a recovery boiler, the steam from which is utilized especially for producing electrical energy.
    Type: Grant
    Filed: February 7, 2000
    Date of Patent: June 3, 2003
    Assignee: L'Air Liquide - Société Anonyme á Directoire et Conseil de Surveillance pour l'Etude et l'Exploitation des Procédés Georges Claude
    Inventors: Pascal Avart, Jérôme Girard, Geneviève Mure, Emmanuel Pousset
  • Patent number: 6562101
    Abstract: Methods and apparatus for processing electric arc furnace (“EAF”) dust through a basic oxygen furnace (BOF) to recover iron value from the EAF dust and concentrate zinc from the EAF dust into a material useful as a feed in zinc manufacturing processes. The method results in the reduction of the burden for the regulatory tracking of EAF dust. In addition, the method provides economic savings which result from the reduction of processing fees and the recovery of the value of iron and zinc materials. The apparatus involves the use of existing equipment that is used to recover iron value from other materials generated at steel making facilities, or the installation of new equipment for the purpose of iron reuse.
    Type: Grant
    Filed: February 6, 2002
    Date of Patent: May 13, 2003
    Assignee: Heritage Environmental Services, LLC
    Inventors: Kenneth S. Price, Kim Lenti