Abstract: A process and apparatus for improving metal production in ironmaking and steelmaking processes is disclosed. The use of an inert metallic conductor in the slag-containing crucible and the addition of a transition metal oxide to the slag are the disclosed process improvements.

Abstract: This invention provides a method and apparatus whereby steel of various compositions may be produced from iron ore and coal through a series of stages without the intermediate production of liquid iron. A reforming reactor receives top gases from the steel making reactors, and converts them to high reduction potential gases which are returned to the steel making reactors. The iron ore and reductants, such as coal, are charged to a controlled atmosphere reactor which may be an inclined rotary cylindrical shaft. From the controlled atmosphere reactor the charge is moved to a potential shift reactor which is inclined or vertical and encounters increasing heat and rising gases for converting the carbonized sponge into a semi-molten state. The charge then passes to a high temperature reactor where it encounters the reducing gases from the reforming reactor and preheated oxygen to create temperature in which steel is made.

Abstract: A process for smelting metallurgical waste material containing at least one iron compound, at lest one heavy metal, and at least one toxic element. The waste material and a reductant are introduced into a furnace. Heat is applied to the waste material and to the reductant to form a melt under reducing conditions whereby volatilization of the heavy metal occurs and a matte or speiss is formed in which the toxic element is stabilized. Fuel and an oxidizing gas are introduced into the melt by submerged injection to create a submerged oxidizing region. The melt is circulated to the submerged oxidizing region and is oxidized causing volatilization of the toxic element stabilized in the matte or speiss.

Abstract: A method of making iron involves using waste polymer material as a solid fuel charged to an iron melting vessel and/or using gaseous decomposition products from pyrolysis of waste polymer material as a gaseous fuel supplied to the vessel. Relatively large quantities of waste polymer materials can thereby be disposed of without landfill usage, while a substantial portion of their energy value is recovered for heating and melting the iron-bearing material in the vessel. The waste polymer material may comprise reaction injection molding compounds and precursors thereof, sheet mold compounds and precursors thereof, car fluff (i.e., non-metallic residue from the recycling of automobiles), scrap rubber tires and the like. Waste sheet molding compounds including calcium carbonate filler can be charged to the iron-making vessel such that the calcium carbonate therein is released and functions as a flux at the iron-making temperature involved to remove impurities from the iron.

Abstract: Prereduced iron oxides are supplied to a smelting vessel (1) for the production of iron or steel by directing a hot reducing offgas from the vessel (1) into a vertical riser duct (8) without substantial cooling of the offgas and by way of inlet (16), particulate iron oxide containing material is entrained in the hot reducing offgas as the gas is conveyed upwardly through the duct (8). The hot gas heats the entrained material to a temperature at which partial reduction of the iron oxide occurs, the hot gas thereby, losing sensible heat. Additional materials may be introduced to the duct (8) for entrainment in the gas. Particulate material is separated in a cyclone (9) from the gas and the separated partially reduced material is introduced to the smelting vessel by way of passage (12).

Abstract: There is disclosed a process for recovering valuable metals from a dust containing zinc comprising mixing the dust containing zinc with a reductant and a flux for regulating the basicity of slag, forming the mixture into pellets with a pelletizer, charging the pellets into a shaft type preheating-prereducing furnace provided with a preheating zone at the upper part and with a reducing zone at the lower part and removing, in the preheating zone, moisture and ignition loss components in the pellets, while prereducing in the reducing zone, the pellets under such conditions that a reduction of iron oxide is made to proceed selectively while the reduction of zinc oxide is suppressed to the possible minimum, charging the prereduced pellets into a melting furnace to melt and reduce them in the furnace, separating zinc, or zinc and lead, by evaporation followed by condensation to recover them, and separating iron and lead, or iron, according to the difference in their specific gravities to recover the iron as a molte

Abstract: The present invention relates to an overall direct smelting process which provides for separating the carburization function from the heating function to permit separate control of the individual functions. One embodiment of the smelting reactor is divided into a carburization/smelting section and a heating section with a substantial recirculation of the molten product from the heating section back to the carburization/smelting section. The heating section also serves as a slag/metal separation section. Carburization is achieved by injection of solids (fine coal mixed with slagging agents), where desired. Gas generating solids or inert gases are injected into a lift pipe to provide a motive force for circulation of the molten metal. The circulation rate through the system is a function of the injected solid composition, the mass flow rate of the solids injected into the lift pipe and the lift pipe geometry.

Abstract: An ash-containing fuel feedstock comprising petroleum coke and/or heavy liquid hydrocarbonaceous fuel, wherein said ash comprises compounds of V, Ni, and Si in admixture with an iron-containing additive, is subjected to partial oxidation to produce a hot raw effluent stream of synthesis gas, reducing gas, or fuel gas with entrained molten slag. The hot raw effluent gas steam is cooled and coarse slag is separated. The coarse slag is heated to a temperature in the range of about 1900.degree. F. to 2600.degree. F. and above the melting point of said slag while in contact with reducing gas in a thermal reduction zone to produce a molten bath of slag comprising the following separable immiscible phases in wt. %.(a) a dense metal phase in the amount of about 0.1 to 5.0 which precipitates to the bottom comprising a nickel-iron alloy containing about 5 to 60 wt. % of nickel;(b) a sulfur encapsulated slag phase in the amount of about 5.

Abstract: Metal oxide ore is subjected to smelting reduction to obtain the molten metal by a method which comprises prereducing said ore in solid state in a prereduction furnace, thereafter melting said ore and carrying out final reduction thereof in a smelting reduction furnace, and at the same time introducing gas generated in said smelting reduction furnace and having reductive capability into said prereduction furnace, the rate of prereducing said ore in said prereduction furnace being controlled at a value with a maximum of the order of 33 percent for raising the rate of utilization of energy to a maximum limit.