Abstract: A cored wire for refining molten metal includes a reactive core material that is in the form of a solid rod. A non-reactive particulate material radially surrounds the solid core material, and an exterior metal jacket radially surrounds the particulate material. The particulate material may include wood or other material that when introduced into the molten metal, undergoes thermal decomposition to release carbon dioxide, hydrocarbons, or combinations thereof as a shroud around the core material.

Abstract: Stabilized volatile briquettes and processes and apparatuses for making and using the same are provided. The stabilized volatile briquette includes a volatile material and a thermoplastic binder material such that the thermoplastic binder material binds the volatile material together to define a briquette that is stable. The process includes mixing a volatile waste material and a thermoplastic binder material to form a briquette mixture, shearing the briquette mixture, extruding the briquette mixture to form a thermoplastic briquette extrusion, and hardening the thermoplastic briquette extrusion to form a stabilized volatile briquette. The apparatus includes an extruder, a heating portion operably connected to the extruder, and a heated die operably connected to the heating portion such that the extruder, the heating portion, and the heated die are configured to gradually heat a thermoplastic binder material such that the thermoplastic binder material binds a provided volatile material together.

Abstract: Methods and systems for producing direct reduced iron having increased carbon content, comprising: providing a reformed gas stream from a reformer; delivering the reformed gas stream to a carbon monoxide recovery unit to form a carbon monoxide-rich gas stream and a hydrogen-rich gas stream; and delivering the carbon-monoxide-rich gas stream to a direct reduction furnace and exposing partially or completely reduced iron oxide to the carbon monoxide-rich gas stream to increase the carbon content of resulting direct reduced iron. The carbon monoxide-rich gas stream is delivered to one of a transition zone and a cooling zone of the direct reduction furnace. Optionally, the method further comprises mixing the carbon monoxide-rich gas stream with a hydrocarbon-rich gas stream.

Abstract: Method for producing nano sized ferrite particles from a metallurgical slag, the method including the steps of: a) providing a ladle with a molten slag including CaO, SiO2, FeO, and at least one of MnO, Cr2O3, V2O3. b) oxidizing the slag at a temperature in the interval of 1573K-1773K (1300-1500° C.) for 10-90 minutes, c) removing at least a portion of the slag from the ladle d) cooling the removed slag portion to a temperature below 373K (100° C.), e) extracting nano sized manganese ferrite and/or chromium ferrite and/or vanadium ferrite particles from the cooled portion.

Abstract: An iron production furnace equipment (1) has a melting reactor (2) into which iron oxide-containing raw material (4) and slag formers (5) are added. A melter arrangement (22) melts the iron oxide-containing raw material and transforms the melted raw material into liquid slag (6) A smelting reduction reactor (3) is connected to the melting reactor by a slag transfer arrangement (10). The smelting reduction reactor comprises a heater arrangement (30) for heating the slag. Means (32) for supplying a reductant (7) for reducing the iron oxide in the slag into a liquid iron melt (8) and for producing a combustible gas mixture (11) comprising at least one of CO and H2. A gas connection (12) is connected between the smelting reduction reactor and the melter arrangement. The melter arrangement in turn comprises a combuster (28) combusting the gas mixture. The combustion heat is used for purpose of melting.

Abstract: A method of producing a mold steel, the method including a first process of preparing a molten steel A that is obtained after vacuum refining and has a component composition including from 0.005% to 0.1% by mass of C, from 1.0% to 5.0% by mass of Ni, from 3.0% to 8.0% by mass of Cr, more than 0% but less than or equal to 2.0% by mass of Mo, more than 0% but less than or equal to 3.5% by mass of Cu, and more than 0% but less than or equal to 2.0% by mass of Al, in which an amount of O is 0.005% by mass or less and an amount of N is 0.03% by mass or less; a second process of reducing the amount of O and the amount of N in the molten steel A, by slag refining the molten steel A, to obtain a molten steel B; and a third process of casting the molten steel B, is provided.

Abstract: There is proposed a method for preliminary treatment of molten iron wherein heat source for dissolving scrap is ensured sufficiently to improve iron yield while decreasing phosphorus concentration efficiently by suppressing the amount of flux solvent used in the process of desiliconization, dephosphorization and decarburization. In the method for preliminary treatment of molten iron by conducting desiliconization and dephosphorization of molten iron with a converter type container, molten iron is first charged into the converter type container to conduct desiliconization and then intermediate slag removal is conducted, and subsequently a lime-based flux solvent is added to the container while blowing oxygen to conduct dephosphorization of the molten iron, and thereafter newly untreated molten iron is charged into the container to conduct desiliconization, and subsequently the above treatments are repeatedly conducted with the same container.

Abstract: A method of starting a molten-bath based melting process includes commencing supplying cold oxygen-containing gas and cold carbonaceous material into a main chamber of a smelting vessel within at most 3 hours after completing a hot metal charge into the vessel and igniting the carbonaceous material and heating the main chamber and molten metal in the main chamber.

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.

Abstract: During the production of non-stainless steel, slag containing a high proportion of metal oxides, primarily iron oxide, is formed during the smelting of the solid material in the electric arc furnace. The concentration of the iron oxide often reaches values of more than 20%. This slag has a poor foaming capability and does not permit the typical characteristics of a carbon steel slag to be achieved. In order to cause such a slag to foam, according to the invention it is proposed to load the electric arc furnace with pellets or briquettes (8) which consist of a defined mixture of an iron oxide carrier and an iron carrier as ballast material, of carbon as reducing agent and also of a binder material, which react in the electric arc furnace in a reducing manner, floating under the slag (7) in the steel melt (6). The reaction gases (12) produced in this way consist primarily of carbon monoxide and advantageously support the foaming of the slag.

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.

Abstract: The invention refers to metallurgy, in particular to making low (LH) and specified (SH) hardenability steels in electric arc, induction furnaces or oxygen converters. A metallurgical unit is loaded with metal charge consisting of iron carbon alloy, scrap with a specified content of manganese, silicon, chrome, nickel and copper, providing for the final content of each of them of not more than 0.

Abstract: A cored wire injection with a filling of iron oxide and mineral carbonate provides an improved method and apparatus for increasing and maintaining dissolved oxygen in the steelmaking process, while also providing a method for forming carbon dioxide for stirring and carbon oxidation in the molten steel bath. The method and apparatus are particularly useful for low carbon steel production by lowering the tap oxygen content in the furnace and preventing high amounts of iron oxide in the slag. Injecting a cored wire containing a mineral carbonate in the ladle after the furnace melting process provides sources of oxygen and a method of stirring the steel and reducing the partial pressure of CO needed to lower the carbon content.

Abstract: A molten bath-based direct smelting process comprises controlling the process conditions in a direct smelting yessel 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 when the slag temperature is in a range of 1400-1550° C. in the molten bath in the vessel.

Abstract: A process for extracting metal values from ores or residues is disclosed. The process mentioned above is mainly suitable for aluminoferrous ores such as bauxite, titanoferrous ores such as ilmenite, or residues such as red mud waste. The process involves pulverizing the ore and/or residue and mixing with a carbonaceous material, followed by smelting the iron values and slag in the mixture to yield molten iron and oxides of aluminum and titanium. The process is simple, cost-effective, and provides effective extraction of high purity metal values.

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.

Abstract: A method of desulfurizing steel including steps of forming a slag over a molten metal, drawing a vacuum to less than 5 torr over the slag and molten metal, stirring the molten metal and slag, and deoxidizing and desulfurizing the molten metal and slag to degas the steel reducing at least sulfur, nitrogen, oxygen, and hydrogen contents, and reducing activity of oxygen in the molten metal to less than 30 ppm. The method includes forming a slag composition after degassing the steel comprising CaO between about 50 and 70% by weight, SiO2 between about 20 and 28% by weight, CaF2 between about 5 and 15% by weight, MgO not more than 8% by weight, Al2O3 not more than 1% by weight, and a combination of FeO+MnO not more than 2% by weight, where the sum of CaO+CaF2+SiO2+MgO is at least 85% by weight.

Abstract: A method for use in production of metallic iron nodules comprising providing a reducible mixture into a hearth furnace for the production of metallic iron nodules, where the reducible mixture comprises a quantity of reducible iron bearing material, a quantity of first carbonaceous reducing material of a size less than about 28 mesh of an amount between about 65 percent and about 95 percent of a stoichiometric amount necessary for complete iron reduction of the reducible iron bearing material, and a quantity of second carbonaceous reducing material with an average particle size greater than average particle size of the first carbonaceous reducing material and a size between about 3 mesh and about 48 mesh of an amount between about 20 percent and about 60 percent of a stoichiometric amount of necessary for complete iron reduction of the reducible iron bearing material.

Abstract: During the production of non-stainless steel, slag containing a high proportion of metal oxides, primarily iron oxide, is formed during the smelting of the solid material in the electric arc furnace. The concentration of the iron oxide often reaches values of more than 20%. This slag has a poor foaming capability and does not permit the typical characteristics of a carbon steel slag to be achieved. In order to cause such a slag to foam, according to the invention it is proposed to load the electric arc furnace with pellets or briquettes (8) which consist of a defined mixture of an iron oxide carrier and an iron carrier as ballast material, of carbon as reducing agent and also of a binder material, which react in the electric arc furnace in a reducing manner, floating under the slag (7) in the steel melt (6). The reaction gases (12) produced in this way consist primarily of carbon monoxide and advantageously support the foaming of the slag.

Abstract: A method for producing liquid pig iron or liquid steel intermediate products from fine-particled material containing iron oxide. The fine-particled material is prereduced in at least one prereduction stage and reduced in a final reduction stage to sponge iron. The sponge iron is melted in a melt-down gasification zone, with carbon carriers and oxygen-containing gas supplied. A CO- and H2-containing reduction gas is generated and introduced into the final reduction stage, is converted there, is drawn off and introduced into at least one prereduction stage, converted there and drawn off. A first quantity fraction of the fine-particled material containing iron oxide is introduced into a melt-down gasification zone via at least one prereduction stage and one final reduction stage, and a further quantity fraction of the fine-particled material containing iron oxide is introduced into the melt-down gasification zone directly or together with the carbon carriers and the oxygen-containing gas.

Abstract: A method for producing pig iron by direct processing of ferrotitania sands, by the steps of: (a) mixing carbonaceous reductant, a fluxing agent, and a binder with titanium-containing materials selected from iron sands, metallic oxides, and/or iron ore concentrates, to form a mixture; (b) forming agglomerates from the mixture (c) introducing the agglomerates to a melting furnace; (d) melting the agglomerates at a temperature of from 1500 to 1760 C and forming hot metal with a slag thereon; (e) removing the slag; (f) tapping the hot metal; and (g) recovering the titanium and vanadium values.

Abstract: A process for producing desulphurised iron in a solid form. The process includes (a) direct smelting an iron-containing metalliferous feed material and producing molten iron; (b) desulphurising molten iron produced in the direct smelting (a); and (c) casting desulphurised molten iron from the desulphurisation (b) into a solid form, such as pigs.

Abstract: A process for direct smelting metalliferous feed material in a direct smelting vessel and producing process outputs of molten metal, molten slag, and an off-gas from the vessel is disclosed. The process includes controlling pressure in the direct smelting vessel by controlling off-gas pressure in an off-gas stream supplied to a fluidised bed pretreatment apparatus while the process is operating in the “hold” and “idle” process states.

Abstract: A method for manufacturing metallic iron from a raw material mixture containing a carbonaceous reducing agent and an iron oxide-containing material, has a step of determining a target temperature of initial molten slag formation corresponding to a predetermined target carbon concentration in the metallic iron, the initial molten slag containing a gangue component, an unreduced iron oxide, and an ash component of the carbonaceous reducing agent, and being first produced in the raw material mixture by heating thereof; a step of preparing the raw material mixture producing a composition of the initial molten slag corresponding to the target temperature; and a step of heating the raw material mixture to reduce and melt the raw material mixture and to produce the initial molten slag. By this manufacturing method, metallic iron having a target carbon concentration can be efficiently manufactured.

Abstract: A process for continuous refining of steel via multiple distinct reaction vessels for melting, oxidation, reduction, and refining for delivery of steel continuously to, for example, a tundish of a continuous caster system, and associated apparatus.

Abstract: A method of cold starting a molten bath-based direct smelting process for producing molten iron in a vessel (3) is disclosed. The method includes a step of preheating the vessel before supplying solid feed materials into the vessel. The method also includes a subsequent step of supplying an oxygen-containing gas and solid feed materials including material for forming slag, iron-containing feed material, and carbonaceous material into the vessel and generating heat and forming a bath of molten material that includes molten iron and molten slag in the vessel.

Abstract: Molten steel is refined in an electric furnace by using iron scrap as a main iron source, and is tapped into a separate refining vessel. Thereafter, metallic-Al containing material and CaO are added onto a bath surface of the molten steel, and an oxygen containing gas is supplied to the molten steel. Thereby, a nitrogen-removal reaction utilizing an AlN formation reaction is caused to proceed. Consequently, even in the case of molten steel having a low carbon content, a low-nitrogen steel can be refined and produced at low costs.

Abstract: A method for manufacturing molten iron that improves charging and discharge of the fine iron ore, and an apparatus for manufacturing molten iron using the same. The apparatus for manufacturing molten iron includes i) at least one fluidized-bed reduction reactor that reduces fine iron ore and converts the fine iron ore into reduced iron, ii) a fine iron ore charging bin that supplies the fine iron ore to the fluidized-bed reduction reactor, iii) a fine iron ore charging line that directly connects the fine iron ore charging bin to each of the fluidized-bed reduction reactors, and directly charges the fine iron ore into each of the fluidized-bed reduction reactor, iv) a melter-gasifier into which lumped carbonaceous materials and the reduced iron are charged and oxygen is injected, the melter-gasifier manufacturing molten iron, and v) a reducing gas supply line that supplies a reducing gas discharged from the melter-gasifier to the fluidized-bed reduction reactor.

Abstract: A process for producing liquid steel is disclosed. Carbon monoxide and oxygen may be combusted in a high temperature reactor. Iron and iron oxide materials, along with scrap steel if desired, may be placed in the high temperature reactor. Carbon dioxide produced in the high temperature reactor may be circulated through a back reactor vessel. Coke masses may be placed in the back reactor vessel. The coke may be formed by circulating heated carbon monoxide counter current to crushed coal in a rotary kiln. The carbon dioxide circulated through the back reactor vessel reacts with the coke to form carbon monoxide. The carbon monoxide may be conveyed to the high temperature reactor to be combusted with oxygen to produce the heat for forming the liquid steel.

Abstract: A process for producing liquid steel is disclosed. Carbon monoxide and oxygen may be combusted in a high temperature reactor. Iron and iron oxide materials, along with scrap steel if desired, may be placed in the high temperature reactor. Carbon dioxide produced in the high temperature reactor may be circulated through a back reactor vessel. Coke masses may be placed in the back reactor vessel. The coke may be formed by circulating heated carbon monoxide counter current to crushed coal in a rotary kiln. The carbon dioxide circulated through the back reactor vessel reacts with the coke to form carbon monoxide. The carbon monoxide may be conveyed to the high temperature reactor to be combusted with oxygen to produce the heat for forming the liquid steel.

Abstract: A method for making molten iron includes the steps of feeding a raw material mixture containing an iron oxide material and a carbonaceous reductant into a heating reduction furnace to reduce iron oxide in the raw material mixture with the carbonaceous reductant into solid reduced iron; transporting the solid reduced iron to a melting furnace; and combustion of a carbonaceous material supplied as fuel to melt the solid reduced iron in the melting furnace for producing molten iron. After the metallization of the solid reduced iron is enhanced to at least 60%, the solid reduced iron is transported to the melting furnace. The amounts of oxygen and the carbonaceous material supplied to the melting furnace are controlled so that the secondary combustion ratio of CO gas in the melting furnace is reduced to 40% or less. The heat transfer efficiency of the secondary combustion heat to the molten iron is preferably increased to at least 60%.

Abstract: In a method for treating slags or slag mixtures having iron oxide contents of >5 wt.-%, in particular steelworks slags, in which the steel slags optionally mixed with other slags are charged onto a metal bath, a steel bath having a carbon content of <1.5 wt.-%, preferably <0.5 wt.-%, is used as the metal bath and the steel bath, after the charging of the steel slags, is carburized to above 2.0 wt.-% C, preferably >2.5 wt.-% C, by introducing carbon or carbon carriers.

Abstract: A smelting reduction method comprising (a) charging a carbonaceous material and an ore into a reacting furnace to directly contact the carbonaceous material and the ore; (b) reducing the ore until at least a part of the ore is metallized, the resultant reduced ore containing at least a part of metallized metal being produced; (c) charging the carbonaceous material and the ore containing at least a part of the metallized metal from step (b) into a smelting furnace having a metal bath; and (d) blowing a gas containing 20% or more of oxygen into the metal bath in the smelting furnace to produce molten iron.

Abstract: The present invention refers to an equipment for feeding and distributing charge and fuel in furnaces of rectangular cross section, comprising movable feeding tubes to distribute along the longitudinal section and the cross section of the furnace, both a charge comprised of self-reducing agglomerates, ore, scrap or any other metallic material, and solid fuels of any kind.

Abstract: A method for making molten iron includes the steps of feeding a raw material mixture containing an iron oxide material and a carbonaceous reductant into a heating reduction furnace to reduce iron oxide in the raw material mixture with the carbonaceous reductant into solid reduced iron; transporting the solid reduced iron to a melting furnace; and combustion of a carbonaceous material supplied as fuel to melt the solid reduced iron in the melting furnace for producing molten iron. After the metallization of the solid reduced iron is enhanced to at least 60%, the solid reduced iron is transported to the melting furnace. The amounts of oxygen and the carbonaceous material supplied to the melting furnace are controlled so that the secondary combustion ratio of Co gas in the melting furnace is reduced to 40% or less. The heat transfer efficiency of the secondary combustion heat to the molten iron is preferably increased to at least 60%.

Abstract: An apparatus and method for the direct reduction of iron oxide utilizes a hearth furnace having a vitreous hearth layer of conditioning materials, with the vitreous hearth layer introduced onto a refractory surface of the furnace. The vitreous hearth layer may have upper layers of coating compounds including carbonaceous materials, onto which iron oxide feed material is placed with the carbonaceous materials assisting with segregating the reduced molten iron nuggets from the vitreous hearth layer. The conditioning materials may include compounds such as silicon oxide, magnesium oxide, iron oxides, and aluminum oxide. The conditioning materials are placed in solid or liquid form on the refractory surface, which allows the conditioning materials to raise the melting temperature of the vitreous hearth layer onto which the coating compounds and iron oxide materials are placed.

Abstract: Heat-treated products discharged from a discharge port of a movable hearth type heat treatment furnace, for example a rotary hearth type reduction furnace are discharged to a sorting means, the heat-treated products that foreign substances have been removed, are discharged through a seal leg into which anti-reoxidation gas is blown from a gas blowing nozzle, to a receiving recess of a receiving pan provided within a case having a hopper attached thereto which is a feeding means, and then a scraper is swung to discharge the heat-treated products deposited on the top surface of the receiving recess from the longitudinal ends of the receiving pan and simultaneously to quantitatively feed it to a molten iron-manufacturing furnace 8, which is a downstream side facility, from the bottom side discharge port of the casing having a hopper attached thereto, and in addition, dust removal/cooling means for produced gas of the molten iron-manufacturing furnace and means for regulating the amount of produced gas are provid

Abstract: The invention is a method and apparatus for iron-making/steel-making using a modified rotary hearth furnace, that is a finisher-hearth-melter (FHM) furnace. In the method the refractory surface of the hearth is coated with carbonaceous hearth conditioners and refractory compounds, where onto said hearth is charged with pre-reduced metallized iron. The pre-reduced metallized iron is leveled, then heated until molten, and then reacted with the carbon and reducing gas burner gases until any residual iron oxide is converted to iron having a low sulfur content. Nascent slag separates from the molted iron forming carburized iron nuggets. The nuggets are cooled, and then the iron nuggets and the hearth conditioners, including the refractory compounds, are discharged onto a screen, which separate the iron nuggets from the hearth conditioner.

Abstract: The present invention is directed to a method of producing granular metallic iron, including: heating a formed raw material comprising a carbonaceous reductant and a substance containing iron oxide in a reduction melting furnace to subject the iron oxide contained in the formed raw material to solid-state reduction; and carburizing reduced iron resulting from the solid-state reduction with carbon contained in the carbonaceous in the formed raw material and causing resulting molten metallic iron to coalesce into the granular metallic iron, wherein an atmospheric gas present in proximity to the formed raw material in the carburizing and melting step has a reduction degree of not less than 0.5. The present invention is also directed to a method of producing metallic iron, including forming a deposit layer containing slag produced in the reduction melting process on hearth refractories, thereby protecting the hearth refractories while producing the metallic iron.

Abstract: A direct smelting process for producing iron and/or ferroalloys is provided, which involves injecting feed materials into a molten bath of molten metal in a metallurgical vessel to form an expanded molten bath zone, and injecting oxygen containing gas, wherein the selection of the number of, and position of, the solids injection and oxygen gas injection lances is such that the expanded molten bath zone includes a raised region around the oxygen gas injection region, and such that splashes, droplets and streams of molten material project upwardly from the raised region, and such that a free space forms around a lower end of the oxygen gas injection lance.

Abstract: A method for producing reduced iron comprises agglomerating a raw material mixture containing a carbonaceous reducing agent and an iron oxide-containing material into small agglomerates, heating the agglomerate within a heat reduction furnace, thereby solid reducing the iron oxide in the agglomerate to produce solid reduced iron, or further heating the solid reduced iron, melting the metallic iron produced by the reduction, and coagulating the molten metallic iron while separating the slag component contained in the small agglomerates to provide granular metallic iron, which is characterized by using a agglomerate having a particle size of 10 mm or less or 3-7 mm, preferably less than 6 mm, more preferably 3 mm or more and less than 6 mm as the small agglomerates.

Abstract: A method for heating, reducing and melting a raw material mixture containing carbonaceous reducing agents and an iron oxide-contained substance to manufacture metallic iron, characterized in that a liquid fraction in a solid and liquid coexisting phase of produced slag containing a multi-component gangue is controlled to thereby accelerate melting of solid metallic iron produced.

Abstract: A method of making metallic iron in which a compact, containing iron oxide such as iron ore or the like and a carbonaceous reductant such as coal or the like, is used as material, and the iron oxide is reduced through the application of heat, thereby making metallic iron. In the course of this reduction, a shell composed of metallic iron is generated and grown on the surface of the compact, and slag aggregates inside the shell. This reduction continues until substantially no iron oxide is present within the metallic iron shell. Subsequently, heating is further performed to melt the metallic iron and slag. Molten metallic iron and molten slag are separated one from the other, thereby obtaining metallic iron with a relatively high metallization ratio.

Abstract: A method of making metallic iron in which a compact, containing iron oxide such as iron ore or the like and a carbonaceous reductant such as coal or the like, is used as material, and the iron oxide is reduced through the application of heat, thereby making metallic iron. In the course of this reduction, a shell composed of metallic iron is generated and grown on the surface of the compact, and slag aggregates inside the shell. This reduction continues until substantially no iron oxide is present within the metallic iron shell. Subsequently, heating is further performed to melt the metallic iron and slag. Molten metallic iron and molten slag are separated one from the other, thereby obtaining metallic iron with a relatively high metallization ratio.

Abstract: A process comprising: charging a raw material compacting substance containing a carbonaceous reducing agent and an iron oxide contained substance into a moving hearth type furnace; reducing the raw material compacting substance to a reducing ratio 30 to 80% within the reducing furnace to thereby form a shell formed of metal iron or forming a state that a shell formed of metal iron or metal iron are stretched around in a network fashion and a carbonaceous reducing agent remains in a clearance therebetween; agglomerating produced slag containing FeO therein; charging the compacting substance reduced into a melting furnace in a state maintaining a high temperature, and carrying out final reducing and melting to obtain molten meal iron.

Abstract: An iron oxide waste agglomerate, preferably a briquette, is provided including 0.03-15 weight percent on a dry basis lignosulfonate binder, 50-99.5 weight percent on a dry basis iron oxide waste, and 0.3-20 weight percent water. The agglomerate can further include 1-40 weight percent on a dry basis carbon source material such as carbon black, coke or coal. The briquette is heated in a furnace where the iron oxide waste is reduced to elemental iron. The binder is effective to prevent the briquettes from crumbling during the reducing opperation. The reduced iron briquette is then dropped into molten steel, thereby recycling iron oxide waste.

Abstract: A process and an apparatus for producing metals from a metalliferous feed material are disclosed. The process includes the steps of partially reducing and at least partially melting a metalliferous feed material in a pre-reduction/melting means and completely reducing the partially reduced feed material in a reduction means. The pre-reduction/melting means is positioned directly above the reduction means and communicates with the reduction means so that at least partially molten, partially reduced feed material flows downwardly into a central region of the reduction means. The reduction means includes a vessel that contains a molten bath having a metal layer and a slag layer on the metal layer. The process includes injecting oxygen-containing gas into the reduction means and post-combusting reaction gas generated in the molten bath and injecting oxygen-containing gas into the pre-reduction/melting means and post-combusting reaction gas discharged from the reduction means.

Abstract: A direct smelting process for producing metals from a metalliferous feed material is disclosed. The process includes forming a molten bath having a metal layer (15) and a slag layer (16) on the metal layer in a metallurgical vessel, injecting metalliferous feed material and solid carbonaceous material into the metal layer via a plurality of lances/tuyeres (11), and smelting metalliferous material to metal in the metal layer. The process also includes causing molten material to be projected as splashes, droplets, and streams into a top space above a nominal quiescent surface of the molten bath to form a transition zone (23).

Abstract: The present invention is an apparatus and method for the direct reduction of iron oxide utilizing a rotary hearth furnace to form a high purity carbon-containing iron metal button. The hearth layer may be a refractory or a vitreous hearth layer of iron oxide, carbon, and silica compounds. Additionally, coating materials may be introduced onto the refractory or vitreous hearth layer before iron oxide ore and carbon materials are added, with the coating materials preventing attack of the molten iron on the hearth layer. The coating materials may include compounds of carbon, iron oxide, silicon oxide, magnesium oxide, and/or aluminum oxide. The coating materials may be placed as a solid or a slurry on the hearth layer and heated, which provides a protective layer onto which the iron oxide ores and carbon materials are placed. The iron oxide is reduced and forms molten globules of high purity iron and residual carbon, which remain separate from the hearth layer.

Abstract: In a method for the production of liquid metal, in particular liquid pig iron (9) or liquid steel pre-products, from metal carriers, in particular partially reduced or reduced sponge iron (3), in a melter gasifier (1) in which with supply of a carbon-containing material at least partially formed of fine coal (16) and coal dust (13) and with supply of oxygen or oxygen-containing gas the metal carriers are melted in a bed (4) of the carbon-containing material at the simultaneous formation of a reducing gas, optionally upon previous final reduction, fine coal (16) and coal dust (13) which are being charged, are mixed with bitumen (20) in the hot state, after undergoing a drying operation, and subsequently are cold-briquetted, and the briquettes (25) thus formed are charged to the melter gasifier (1) in the cold state and in the melter gasifier (1) are subjected to shock-heating.