Including Consolidation Of Solid Carbon(c) Containing Material With Reducible Iron(fe) Compound Patents (Class 75/504)
  • Patent number: 8974571
    Abstract: A partially-reduced iron producing apparatus includes: a supplying device laying ignition raw-material pellets on an endless-grate; a heating furnace heating the ignition raw-material pellets; another supplying device laying the raw material pellets on the ignition raw-material pellets; and an exhaust gas circulation device supplying an oxygen-containing gas to the raw-material pellets. The oxygen containing gas is made by circulating part of an exhaust gas discharged from the raw-material pellets and mixing it with air. A partially-reduced iron is produced by thermally reducing the raw-material pellets in a bed height direction thereof through separate combustion and heating regions. The combustion region formed on an upstream side in a travelling direction of the endless grate by supplying the oxygen-containing gas having a high oxygen concentration.
    Type: Grant
    Filed: December 31, 2012
    Date of Patent: March 10, 2015
    Assignee: Mitsubishi-Hitachi Metals Machinery, Inc.
    Inventors: Susumu Kamikawa, Hiroshi Nakajima, Keiichi Sato, Khanhson Pham
  • Patent number: 8961650
    Abstract: A reduction furnace includes a pellet material supplying device forming on a grate an ignition carbon material layer having a predetermined height; an ignition device; and an exhaust gas circulation device supplying an oxygen-containing gas comprising circulated exhaust gas mixed with air, to a packed bed of the pellets heated by a combustion heat of the ignition carbon material layer. A partially-reduced iron is produced by thermally reducing the pellets through a combustion region for the ignition carbon material layer and a heating region, the combustion region formed upstream in a travelling direction of the grate by supplying a gas having a high oxygen concentration, the heating region formed downstream of the combustion region by supplying a gas having a low oxygen concentration.
    Type: Grant
    Filed: December 4, 2012
    Date of Patent: February 24, 2015
    Assignee: Mitsubishi-Hitachi Metals Machinery, Inc.
    Inventors: Susumu Kamikawa, Hiroshi Nakajima, Keiichi Sato, Khanhson Pham
  • Publication number: 20150004049
    Abstract: Process for the manufacture of ferrochrome alloy comprising the steps of providing a pelletising feed, wherein the pelletising feed comprises chromite ore and silicon carbide as the only carbonaceous material and the only reducing agent; pelletising the pelletising feed to obtain pellets; sintering the pellets to obtain sintered pellets; mixing the sintered pellets with external reducing agent to obtain smelting feed; and smelting the smelting feed.
    Type: Application
    Filed: November 15, 2011
    Publication date: January 1, 2015
    Applicant: Outotec Oyj
    Inventors: Pasi Mäkelä, Helge Krogerus
  • Patent number: 8906131
    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: Grant
    Filed: April 19, 2012
    Date of Patent: December 9, 2014
    Inventor: John J. Simmons
  • Patent number: 8690987
    Abstract: Carbon iron composite is produced by feeding a formed product of a carbon-containing substance and an iron-containing substance into a carbonization furnace, carbonizing the formed product in a carbonization zone, blowing a coolant gas into the furnace through a coolant-gas-blowing tuyere disposed in a cooling zone to cool carbon iron composite, exhausting a furnace gas through an outlet in a top portion, and discharging the carbon iron composite through a lower portion of the cooling zone.
    Type: Grant
    Filed: July 28, 2010
    Date of Patent: April 8, 2014
    Assignee: JFE Steel Corporation
    Inventors: Takeshi Sato, Tetsuya Yamamoto, Hidekazu Fujimoto, Takashi Anyashiki
  • Patent number: 8679222
    Abstract: The process for producing the sponge iron includes the steps of preparing a sandwich of at least two layers wherein the at least two layers includes a first layer (10) of iron oxide source which content is carbon free or comprises of only self-contaminant carbon or carbonaceous and second layer (12) is a mixture of iron oxide source and carbon source and subjecting the sandwich of at least two layers to a pyrolysis process in a non-oxidative environment at temperature between 950° C. to 1900° C. for a period between 10 minutes to 36 hours. The carbon source in the second layer (12) is equal to or more than stoichiometric weight of carbon according to a predominant reaction. The non-oxidative pyrolysis occurs in a reactor. The sandwich of two layers is placed in a moving carrier (16) such as tray to accommodate the sandwich of two layers in the reactor.
    Type: Grant
    Filed: March 26, 2010
    Date of Patent: March 25, 2014
    Assignee: IOP Specialists SDN. BHD.
    Inventor: Kin Onn Low
  • Publication number: 20130291685
    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.
    Type: Application
    Filed: October 16, 2012
    Publication date: November 7, 2013
    Applicant: NU-IRON TECHNOLOGY, LLC
    Inventor: NU-IRON TECHNOLOGY, LLC
  • Patent number: 8333823
    Abstract: A method and system for producing metallic iron nuggets may include providing multiple layers of agglomerates, such as briquettes, balls and extrusions, of a reducible mixture of reducing material (such as carbonaceous material) and of a reducible iron bearing material (such as iron oxide) on a hearth material layer (such as carbonaceous material) and providing a coarse overlayer of carbonaceous material over at least some of the agglomerates. Heating the agglomerates of reducible mixture to 1425° C. or 1400° C. or 1375° C. results in formation of an intermediate product of one or more metallic iron nuggets, which may have a sulfur content of less than 0.03%, and slag, which may have less than 5% mass MgO, which may have a ratio of percent by weight sulfur in the slag over percent by weight sulfur in the metallic nuggets of at least about 12 or at least about 15.
    Type: Grant
    Filed: July 30, 2010
    Date of Patent: December 18, 2012
    Assignee: Nu-Iron Technology, LLC
    Inventors: Iwao Iwasaki, Richard F. Kiesel, David J. Englund, Dave Hendrickson
  • Patent number: 8092574
    Abstract: In a method of producing a reduced iron cast, a cast of a powder which includes total iron of 40% or more and an atomic molar amount of fixed carbon of 0.7 to 1.5 times the atomic molar amount of oxygen compounded with metal oxide reduced in a carbon monoxide atmosphere at 1200° C. is reduced in a rotary hearth furnace. The method includes: producing, in an atmosphere at a maximum temperature of 1200° C. to 1420° C. at a ratio of carbon monoxide to carbon dioxide of 0.3 to 1.2 in the reduced zone, a reduced iron-containing material in which a ratio of metal iron is 50 mass % or more and a ratio of carbon is 5 mass % or less; and compression-molding the reduced iron-containing material at a temperature of 500° C. to 800° C. by a roller-type mold.
    Type: Grant
    Filed: September 2, 2008
    Date of Patent: January 10, 2012
    Assignee: Nippon Steel Corporation
    Inventor: Tetsuharu Ibaraki
  • Patent number: 8088195
    Abstract: The present invention provides a method for efficiently manufacturing a titanium oxide-containing slag from a material including titanium oxide and iron oxide, wherein a reduction of titanium dioxide is suppressed and the electric power consumption is minimized. The method includes the steps of: heating a raw material mixture including titanium oxide, iron oxide, and a carbonaceous reductant, or the raw material mixture further including a calcium oxide source, in a reducing furnace; reducing the iron oxide in the mixture to form reduced iron; feeding the resultant mixture to a heating melting furnace; heating the resultant mixture in the heating melting furnace to melt the reduced iron and separate the reduced iron from a titanium oxide-containing slag; and discharging and recovering the titanium oxide-containing slag out of the furnace.
    Type: Grant
    Filed: November 7, 2007
    Date of Patent: January 3, 2012
    Assignee: Kobe Steel Ltd.
    Inventors: Hidetoshi Tanaka, Itsuo Miyahara, Hiroshi Uemura, Takao Harada, Hiroshi Sugitatsu, Isao Kobayashi
  • Patent number: 8021460
    Abstract: A method for producing metallic iron nodules by assembling a shielding entry system to introduce coarse carbonaceous material greater than 6 mesh in to the furnace atmosphere at location(s) where the temperature of the furnace atmosphere adjacent at least partially reduced reducible iron bearing material is between about 2200 and 2650° F. (1200 and 1450° C.), the shielding entry system adapted to inhibit emission of infrared radiation from the furnace atmosphere and seal the furnace atmosphere from exterior atmosphere while introducing coarse carbonaceous material greater than 6 mesh into the furnace to be distributed over the at least partially reduced reducible iron bearing material, and heating the covered at least partially reduced reducible iron bearing material in a fusion atmosphere to assist in fusion and inhibit reoxidation of the reduced material during fusion to assist in fusion and inhibit reoxidation of the reduced material in forming metallic iron nodules.
    Type: Grant
    Filed: September 29, 2009
    Date of Patent: September 20, 2011
    Assignee: Nu-Iron Technology, LLC
    Inventors: Rodney L. Bleifuss, David J. Englund, Iwao Iwasaki, Andrew J. Lindgren, Richard F. Kiesel
  • Patent number: 8012237
    Abstract: A process for producing molten iron is a process in which while an inert gas is blown into a molten iron layer in an iron bath type melting furnace through bottom-blown tuyeres provided in a hearth bottom thereof to stir the molten iron layer, a carbon material, an additive flux, and solid reduced iron obtained by heating reduction of carbon composite iron oxide briquettes are charged into the above melting furnace, and top blowing of an oxygen-containing gas is performed through a top-blown lance provided for the melting furnace, so that the solid reduced iron is melted by combustion heat obtained by combusting the carbon material and/or carbon in molten iron to form molten iron.
    Type: Grant
    Filed: September 18, 2008
    Date of Patent: September 6, 2011
    Assignee: Kobe Steel, Ltd.
    Inventors: Hideaki Fujimoto, Tsuyoshi Mimura, Takao Harada, Masataka Tateishi, Kiminori Hajika, Hiroshi Sugitatsu
  • Patent number: 7985389
    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.
    Type: Grant
    Filed: August 12, 2008
    Date of Patent: July 26, 2011
    Assignee: Cardero Resource Corporation
    Inventor: Glenn E. Hoffman
  • Patent number: 7842119
    Abstract: A solidified product (B) is produced by charging a dust (11) generated in a steel making process and containing iron and an oxide thereof as a principal component into a mold (7) and by subjecting it to a pressure molding. A raw material charged to the mold is a mixed granulated product (11p) prepared by mixing the dust and a powder containing carbon as a principal component and by granulating the resultant mixture.
    Type: Grant
    Filed: February 17, 2006
    Date of Patent: November 30, 2010
    Assignees: NTN Corporation, Daiwa Steel Corporation
    Inventors: Katsutoshi Muramatsu, Norio Misaki
  • Patent number: 7632335
    Abstract: Method and system for producing metallic nuggets includes providing reducible mixture (e.g., reducible micro-agglomerates; reducing material and reducible iron bearing material; reducible mixture including additives such as a fluxing agent; compacts, etc.) on at least a portion of a hearth material layer. In one embodiment, a plurality of channel openings extend at least partially through a layer of the reducible mixture to define a plurality of nugget forming reducible material regions. Such channel openings may be at least partially filled with nugget separation fill material (e.g., carbonaceous material). Thermally treating the layer of reducible mixture results in formation of one or more metallic iron nuggets. In other embodiments, various compositions of the reducible mixture and the formation of the reducible mixture provide one or more beneficial characteristics.
    Type: Grant
    Filed: December 7, 2005
    Date of Patent: December 15, 2009
    Assignee: Nu-Iron Technology, LLC
    Inventors: Iwao Iwasaki, Michael J. Lalich, Robert C. Beaudin, Richard F. Kiesel, Andrew J. Lindgren, Rodney L. Bleifuss
  • Patent number: 6630010
    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.
    Type: Grant
    Filed: March 28, 2001
    Date of Patent: October 7, 2003
    Assignee: Midrex International B.V. Zurich Branch
    Inventors: Shuzo Ito, Yasuhiro Tanigaki, Shoichi Kikuchi, Osamu Tsuge, Isao Kobayashi, Keisuke Honda, Koji Tokuda, Hidekazu Okamoto
  • Patent number: 6605130
    Abstract: Pellets incorporated with a carbonaceous material of the present invention contain a carbonaceous material and iron ore mainly composed of iron oxide. The maximum fluidity of the carbonaceous material in softening and melting, and the ratio of iron oxide particles of 10 &mgr;m or smaller in the iron ore are within the range above a line which connects in turn points A, B and C shown in FIG. 1, including the line. This permits the production of pellets incorporated with a carbonaceous material having excellent thermal conductivity and high strength. Reduction of the pellets incorporated with a carbonaceous material produces reduced iron having high strength after reduction and a low fines ratio with improved productivity.
    Type: Grant
    Filed: November 15, 2001
    Date of Patent: August 12, 2003
    Assignee: Kobe Steel, Ltd.
    Inventors: Yoshimichi Takenaka, Shoji Shirouchi, Masakata Shimizu, Kazuya Miyagawa
  • Patent number: 6602320
    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.
    Type: Grant
    Filed: April 10, 2001
    Date of Patent: August 5, 2003
    Assignees: Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.), Midrex International B.V.
    Inventors: Kojiro Fuji, Hidetoshi Tanaka, Shoichi Kikuchi, Takaya Kitajima, Osamu Tsuchiya
  • Patent number: 6592648
    Abstract: A process of reduction of iron ore and/or waste oxides in the form of agglomerate containing carbonaceous reductant on the hearth of a furnace includes providing a bed of agglomerates on the hearth of a furnace, the bed having a height of at least about 40 mm and having at least four layers of agglomerates. The carbonaceous reductant contains sufficient volatile matter, the volatile matter having a weight of at least about 10% of the weight of the reductant. The bed of agglomerates is heated with a radiant heat source having a temperature of at least about 1450° C. to cause the top of the bed to reach a temperature in the range of 1350° C. to 1530° C. to 1500° C. to reduce iron oxides in the iron ore and/or waste oxides to metallic iron.
    Type: Grant
    Filed: April 30, 2001
    Date of Patent: July 15, 2003
    Assignee: McMaster University
    Inventors: Wei-kao Lu, Dianbing Huang
  • Patent number: 6592647
    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.
    Type: Grant
    Filed: August 8, 2001
    Date of Patent: July 15, 2003
    Assignee: Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.)
    Inventors: Mitsutaka Hino, Isao Kobayashi, Shoichi Kikuchi
  • Patent number: 6592649
    Abstract: The present invention provides a method of producing metallic iron nuggets with a high yield and good productivity, and more particularly a method which can produce metallic iron nuggets which have a high Fe purity and are excellent in transporting and handling due to a large grain diameter with a high yield and good productivity, when they are produced by reducing and melting raw material containing iron oxide such as iron ore and carbonaceous reducing agent such as coke.
    Type: Grant
    Filed: June 28, 2001
    Date of Patent: July 15, 2003
    Assignee: Midrex International B.V. Zurich Branch
    Inventors: Shoichi Kikuchi, Yasuhiro Tanigaki, Koji Tokuda, Osamu Tsuchiya, Shuzo Ito
  • Patent number: 6506231
    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.
    Type: Grant
    Filed: June 26, 2001
    Date of Patent: January 14, 2003
    Assignee: Kabushiki Kaisha Kobe Seiko Sho
    Inventors: Takuya Negami, Kazuo Kunii, Shinichi Inaba, Masataka Shimizu, Isao Kobayashi, Yoshimichi Takenaka, Toshihide Matsumura, Akira Uragami, Takashi Kujirai, Osamu Tsuchiya, Kimio Sugiyama, Shuzo Ito, Shoichi Kikuchi
  • Patent number: 6475264
    Abstract: A process for direct smelting a metalliferous feed material is disclosed. The process includes the steps of partially reducing metalliferous feed material and substantially devolatilising coal in a pre-reduction vessel and producing a partially reduced metalliferous feed material and char. The process also includes direct smelting the partially reduced metalliferous feed material to molten metal in a direct smelting vessel using the char as a source of energy and as a reductant and post-combusting reaction gas produced in the direct smelting process with pre-heated air or oxygen-enriched air to a post-combustion level of greater than 70% to generate heat required for the direct smelting reactions and to maintain the metal in a molten state.
    Type: Grant
    Filed: March 21, 2000
    Date of Patent: November 5, 2002
    Assignee: Technological Resources Pty Ltd
    Inventor: Rodney James Dry
  • Patent number: 6387153
    Abstract: A procedure for holding production of molten metal in a direct smelting process is disclosed. In situations where it is necessary to hold metal production and there is a continuing available supply of oxygen-containing gas and solid carbonaceous material, the hold procedure includes the steps of stopping supply of metalliferous feed material, continuing to inject oxygen-containing gas and solid carbonaceous material into the vessel and generating heat within the vessel to maintain the temperature of the molten bath above a temperature at which the bath freezes. In situations where it is necessary to hold production and there is a continuing supply of oxygen-containing gas but no available solid carbonaceous material, the hold procedure includes the steps of stopping supply of metalliferous feed material and injecting oxygen-containing gas and gaseous or liquid combustible material into the vessel and generating heat within the vessel to maintain the bath temperature.
    Type: Grant
    Filed: October 10, 2000
    Date of Patent: May 14, 2002
    Assignee: Technological Resources Pty Ltd
    Inventor: Peter Damian Burke
  • Patent number: 6372016
    Abstract: An apparatus for producing reduced iron, and a compact drying method for application to the apparatus are disclosed. The apparatus comprises a pelletizer or a briquetter for mixing and agglomerating coal as a reducing agent and iron ore as iron oxide to form compacts, a dryer for drying the compacts, a circular rotary hearth type reducing furnace for reducing the dried compacts in a high temperature atmosphere, a first heat exchanger for performing heat exchange between a hot off-gas discharged from the reducing furnace and combustion air to be supplied to the reducing furnace, and coolers for cooling the hot off-gas. A second heat exchanger for heating drying air is disposed on an exit side of the first heat exchanger. The drying air heated by the second heat exchanger is supplied to the dryer to dry the compacts with the drying air scant in moisture. Consequently, highly efficient, stable drying in the dryer can be performed, and high quality reduced iron can be produced stably.
    Type: Grant
    Filed: July 5, 2000
    Date of Patent: April 16, 2002
    Assignee: Mitsubishi Heavy Industries, LTD
    Inventors: Susumu Kamikawa, Kouichi Hirata, Hironori Fujioka, Hideaki Mizuki, Keiichi Sato
  • Publication number: 20010049980
    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.
    Type: Application
    Filed: June 26, 2001
    Publication date: December 13, 2001
    Applicant: KABUSHIKI KAISHA KOBE SEIKO SHO
    Inventors: Takuya Negami, Kazuo Kunii, Shinichi Inaba, Masataka Shimizu, Isao Kobayashi, Yoshimichi Takenaka, Toshihide Matsumura, Akira Uragami, Takashi Kujirai, Osamu Tsuchiya, Kimio Sugiyama, Shuzo Ito, Shoichi Kikuchi
  • Patent number: 6302938
    Abstract: A carbonaceous material is controlled such that the amount of carbon is from 7 to 60 mass % based on the total amount of iron and Zn in a starting mixture comprising one or more of ducts containing iron oxide and Zn oxide and a binder in an amount to bond the dusts, and water is added to prepare green pellets incorporated with the carbonaceous material. Then, dry pellets prepared by drying the thus prepared green pellets into a reduction furnace, the dry pellets are heated by heat transfer, mainly, radiation such that a temperature elevation rate is from 3 to 13° C./sec within a temperature range from 150 to 900° C. of the pellets, thereby reducing Zn oxide and evaporating Zn, as well as reducing iron oxide to produce reduced iron pellets.
    Type: Grant
    Filed: July 10, 2000
    Date of Patent: October 16, 2001
    Assignee: Kabushiki Kaisha Kobe Seiko Sho
    Inventors: Tsunao Kamijo, Kazuya Miyagawa, Yoshimichi Takenaka, Masakata Shimizu, Shoji Shirouchi, Haruhisa Iwakiri
  • Patent number: 6284018
    Abstract: Molten iron is prepared by (1) providing iron oxide and a carbonaceous reducing agent, (2) preparing a shaped product from the carbonaceous reducing agent and the iron oxide, (3) preparing solid reduced iron from the shaped product, wherein the solid reduced iron has a metallization of at least 60%, a specific gravity of at least 1.7, and a carbon content of at least 50% of the theoretical amount required for reducing the iron oxide remaining in the solid reduced iron, and, (4) before substantial cooling occurs, heating the solid reduced iron in an arc heating-type melting furnace at a high temperature. The molten iron can be prepared efficiently from iron ores of relatively low iron content without causing erosion of refractories, at high energy and high reduction efficiencies, and by a simple operation in a simple facility.
    Type: Grant
    Filed: June 27, 2000
    Date of Patent: September 4, 2001
    Assignee: Kabushiki Kaisha Kobe Seiko Sho
    Inventors: Akira Uragami, Shuzo Ito, Koji Tokuda
  • Patent number: 6267799
    Abstract: A method and an apparatus for producing metals and metal alloys from metal oxides in a metallurgical vessel containing a molten bath having a metal layer and a slag layer is disclosed. The method is characterized by injecting a carrier gas and a solid carbonaceous material and/or metal oxides into the molten bath from a side of the vessel that is in contact with the molten bath or from above the molten bath so that the solids penetrate the molten bath and cause molten metal to be projected into the gas space above the molten bath to form a transition zone. The method is also characterized by injecting an oxygen-containing gas into the gas space to post-combust reaction gases released from the molten bath into the transition zone.
    Type: Grant
    Filed: April 17, 2000
    Date of Patent: July 31, 2001
    Assignee: Technological Resources Pty. Ltd.
    Inventors: John Alexander Innes, Robin John Batterham, Rod James Dry
  • Patent number: 6264725
    Abstract: According to a process for producing pig iron (10) from fine-particulate iron oxide carriers and lumpy iron-containing material in a meltdown gasifying zone (9) of a melter gasifier (3), the iron-containing material is melted in a bed (13) formed of solid carbon carriers, under the supply of carbon-containing material and oxygen-containing gas while simultaneously forming a reducing gas. Fine-particulate iron-oxide carriers, such as iron-containing fine ore and ore dust and oxidic iron fine dust, are introduced into a reducing gas stream leaving the melter gasifier (3), and the reducing gas is separated from the fine-particulate material formed thereby. The separated fine-particulate material is introduced into the meltdown gasifying zone (9) via a dust recirculation line (26, 27, 28, 29) and through a dust burner (30), and the reducing gas is used for reducing iron-oxide-containing material.
    Type: Grant
    Filed: April 7, 1999
    Date of Patent: July 24, 2001
    Assignee: Voest-Alpine Industrieanlagenbau GmbH
    Inventors: Josef Stockinger, Michael Nagl
  • Patent number: 6241804
    Abstract: A process and apparatus for producing iron briquettes and/or cold iron sponge, in which charge materials (3) which contain lumpy material containing iron oxide are introduced into the reduction zone (2) of a reduction reactor (1), then a hot reduction gas introduced in a feed zone below the reduction zone flows through the charge materials, which are reduced to hot iron sponge which passes through a gas feed zone (8), which is downstream of the reduction zone (2). Reduction gas is introduced into the reduction reactor (1). After the gas has flowed through the reduction zone (2), it is extracted from the reduction reactor (1) as a top gas. To produce cold iron sponge, hot iron sponge is cooled by cooling gas in a cooling zone (10) downstream of the gas feed zone (8) and the sponge is discharged from the reactor (1) through a product-discharge zone (11) downstream of the cooling zone (10).
    Type: Grant
    Filed: July 27, 1999
    Date of Patent: June 5, 2001
    Assignee: Voest-Alpine Industrieanlagenbau GmbH
    Inventor: Gerald Rosenfellner
  • Patent number: 6241803
    Abstract: A method for manufacturing reduced iron pellets comprises the steps of heating iron oxide pellets incorporating carbonaceous material to yield reduced iron pellets having an apparent density of not more than 4.0 g/cm3, cooling the hot reduced iron pellets by using water at an average cooling rate between 1,500° C./min and 500° C./min, when the surfaces of the reduced iron pellets are cooled from 650° C. to 150° C. The method described above does not require expensive facilities for processing briquettes and can manufacture the reduced iron pellets having high degree of metallization, superior crushing strength, and an apparent density of not more than 4.0 g/cm3.
    Type: Grant
    Filed: January 19, 2000
    Date of Patent: June 5, 2001
    Assignee: Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.)
    Inventor: Kojiro Fuji
  • Patent number: 6214087
    Abstract: A method for producing solid metal product is disclosed including the steps of providing carbon and metal bearing compounds in compacts, coating the compacts with treatment materials, encapsulating the compacts with carbonaceous containing materials to form a residual layer, and treating the residual layer before introduction of the compacts into a furnace. The compacts contain carbon containing metal bearing compounds, and are coated with mixtures of carbonaceous materials dispersed within a binder material such as a viscous liquid, molasses, alcohol, or fuel oil. The coated compacts are treated to form a hardened outer residual layer. The outer residual layer provides for a sacrificial outer coating on the compacts that reacts with any oxidizing gaseous components within the furnace, while the carbon containing metal bearing compounds within the compacts are heated and metallized inside the compounds.
    Type: Grant
    Filed: March 19, 1999
    Date of Patent: April 10, 2001
    Assignee: Midrex International B.V. Rotterdam, Zurich Branch
    Inventors: Glenn E. Hoffman, David C. Meissner, Kyle J. Shoop
  • Patent number: 6152983
    Abstract: A carbonaceous material is controlled such that the amount of carbon is from 7 to 60 mass % based on the total amount of iron and Zn in a starting mixture comprising one or more of ducts containing iron oxide and Zn oxide and a binder in an amount to bond the dusts, and water is added to prepare green pellets incorporated with the carbonaceous material. Then, dry pellets prepared by drying the thus prepared green pellets into a reduction furnace, the dry pellets are heated by heat transfer, mainly, radiation such that a temperature elevation rate is from 3 to 13.degree. C./sec within a temperature range from 150 to 900.degree. C. of the pellets, thereby reducing Zn oxide and evaporating Zn, as well as reducing iron oxide to produce reduced iron pellets.
    Type: Grant
    Filed: December 17, 1998
    Date of Patent: November 28, 2000
    Assignee: Kabushiki Kaisha Kobe Seiko Sho
    Inventors: Tsunao Kamijo, Kazuya Miyagawa, Yoshimichi Takenaka, Masakata Shimizu, Shoji Shirouchi, Haruhisa Iwakiri
  • Patent number: 6149709
    Abstract: Molten iron is prepared by (1) providing iron oxide and a carbonaceous reducing agent, (2) preparing a shaped product from the carbonaceous reducing agent and the iron oxide, (3) preparing solid reduced iron from the shaped product, wherein the solid reduced iron has a metallization of at least 60%, a specific gravity of at least 1.7, and a carbon content of at least 50% of the theoretical amount required for reducing the iron oxide remaining in the solid reduced iron, and, (4) before substantial cooling occurs, heating the solid reduced iron in an arc heating-type melting furnace at a high temperature. The molten iron can be prepared efficiently from iron ores of relatively low iron content without causing erosion of refractories, at high energy and high reduction efficiencies, and by a simple operation in a simple facility.
    Type: Grant
    Filed: February 20, 1998
    Date of Patent: November 21, 2000
    Assignee: Kabushiki Kaisha Kobe Seiko Sho
    Inventors: Akira Uragami, Shuzo Ito, Koji Tokuda
  • Patent number: 6120577
    Abstract: A process of recovering iron values and separating zinc oxides and other contaminants from steel mill waste metal oxides, such as blast furnace dust, BOF dust, mill scale and oily sludges, characterized by iron metallization levels up to 95% or more and zinc oxide removal in excess of 99%, and including the steps of blending the oxides with coke breeze in an amount sufficient to provide a total carbon content of 16% to 22%, the coke breeze having a particle size of 50% or more plus 60 mesh or larger, briquetting the blend to form briquettes having a thickness ranging from 1/2" to 3/4", and firing the briquettes in a rotary hearth furnace to metallize the iron and evolve zinc and other oxide contaminants.
    Type: Grant
    Filed: March 25, 1998
    Date of Patent: September 19, 2000
    Assignees: LTV Steel Company, Inc., Maumee Research and Engineering, Inc., USX Corporation
    Inventors: Peter J. Koros, Jagjit S. Bajaj, Valdis R. Daiga, Vishwaprakash S. Hegde
  • Patent number: 6083296
    Abstract: A method and an apparatus for producing metals and metal alloys from metal oxides in a metallurgical vessel containing a molten bath having a metal layer and a slag layer is disclosed. The method is characterized by injecting a carrier gas and a solid carbonaceous material and/or metal oxides into the molten bath from a side of the vessel that is in contact with the molten bath or from above the molten bath so that the solids penetrate the molten bath and cause molten metal to be projected into the gas space above the molten bath to form a transition zone. The method is also characterized by injecting an oxygen-containing gas into the gas space to post-combust reaction gases released from the molten bath into the transition zone.
    Type: Grant
    Filed: March 9, 1998
    Date of Patent: July 4, 2000
    Assignee: Technological Resources Pty. Limited
    Inventors: John Alexander Innes, Robin John Batterham, Rod James Dry
  • Patent number: 6063156
    Abstract: A method for producing a molten iron from a compact containing a carbonaceous reductant and an iron oxide is carried out extremely efficiently with a simple operation. The compact is supplied to a molten iron bath or a molten slag on the molten iron bath so as to float on the molten iron bath and/or the molten slag such that a part or most of the compact surface is substantially exposed to a high temperature gas atmosphere in the furnace for taking in a reduced iron generated by the reduction of the iron oxide in the compact.
    Type: Grant
    Filed: December 18, 1997
    Date of Patent: May 16, 2000
    Assignee: Kabushiki Kaisha Kobe Seiko Sho
    Inventors: Takuya Negami, Akira Uragami
  • Patent number: 5891214
    Abstract: The invention relates to a method for increasing the effectiveness of the smelting reduction of oxidic metal carriers, particularly iron ore, and improving the heat efficiency of the charged fuels in the smelting reduction process which takes place in a reaction vessel containing a molten bath with a layer of slag and wherein the reaction gases escaping from the molten bath are afterburned with oxidizing gases, the resulting heat is transferred to the molten bath and the reacting agents, ore and carbon, are fed to the smelt at least partly from the top through the gas space of the reaction vessel, wherein these reacting agents, ore and carbon, are added in a compact form to the molten bath as a composite material with or without further escort substances.
    Type: Grant
    Filed: April 22, 1996
    Date of Patent: April 6, 1999
    Assignee: Technological Resources Pty. Ltd.
    Inventors: John Innes, Gregory Hardie
  • Patent number: 5873925
    Abstract: A process for treating iron-bearing material with a carbonaceous material to form a mixture, wherein the amount of carbonaceous material added exceeds the stoichiometric amount required to reduce the metal oxide to elemental metal. In one embodiment, the process also includes blending an organic binder with the mixture. The mixture is agglomerated using compaction to bond the mixture and form green compacts. The green compacts are loaded into a heated furnace and heated for about 5-12 minutes at a temperature of between about 2100.degree.-2500.degree. F. and at a CO/CO.sub.2 ratio of about 1.5-2.5 proximate the discharge area to reduce the iron oxide containing compacts to compacts containing elemental iron and an excess amount of carbonaceous material wherein the excess amount of carbonaceous material counteracts re-oxidation of the elemental iron. The reduced compacts are then discharged from the furnace.
    Type: Grant
    Filed: February 10, 1997
    Date of Patent: February 23, 1999
    Assignee: Maumee Research & Engineering, Inc.
    Inventors: Franklin G. Rinker, Deane A. Horne, James Alan Thornton
  • Patent number: 5873924
    Abstract: A desulfurization composition contains from about 3% to about 20% particulate metallic aluminum, about 5% to about 30% particulate alumina, about 0.5% to about 12% particulate hydrocarbon material or other gas generating composition and the balance lime plus impurities. Preferably aluminum dross is the source of aluminum and alumina. The desulfurization composition is injected into molten iron from a blast furnace preferably in an amount of 4 to 20 pounds desulfurizer per ton of hot metal. The desulfurizing composition can be injected as a blend or co-injected into the hot metal through a lance using a carrier gas or dumped into the hot metal as it is being poured into the ladle. At least for torpedo ladles, the desulfurization composition can be placed in the ladle before the hot metal is poured into it.
    Type: Grant
    Filed: April 7, 1997
    Date of Patent: February 23, 1999
    Assignees: Reactive Metals & Alloys Corporation, USX Corporation
    Inventors: Brian Mark Kinsman, Leon A. Luyckx, James H. Young, Jr., Robert V. Branion, Jr.
  • Patent number: 5855645
    Abstract: A method for producing a more concentrated iron product from an industrial waste materials stream comprising iron and non-iron constituents such as EAF and basic oxygen furnace dust generally comprising the steps of compacting or briquetting the waste materials stream, roasting the waste materials stream at temperatures above about 980.degree. C. to convert the iron compounds to direct reduced iron, crushing the roasted waste materials stream, separating the iron compounds contained in the waste materials stream by magnetic separation or flotation, and providing the iron compounds back to the EAF or basic oxygen furnace.
    Type: Grant
    Filed: July 26, 1996
    Date of Patent: January 5, 1999
    Assignee: Metals Recycling Technologies Corp.
    Inventors: Allan S. Myerson, Charles W. Sanzenbacher, Peter Robinson, Charles A. Burrows, Paul R. DiBella
  • Patent number: 5849063
    Abstract: A method for producing direct reduced iron or/and pig iron from an industrial waste materials stream such as EAF and blast furnace dust generally comprising the steps of separating the materials contained in the waste materials stream by magnetic separation or flotation, briquetting the iron-containing materials separated during the separation process with carbon, and providing the briquettes to a reduction furnace or/and to a small scale blast furnace or cupola furnace to produce direct reduced iron or/and pig iron, respectively. The exhaust streams from the process are further treated to recover chemical values and to allow the recycle of the exhaust streams to the main process.
    Type: Grant
    Filed: June 26, 1996
    Date of Patent: December 15, 1998
    Assignee: Metals Recycling Technologies Corp.
    Inventors: Allan S. Myerson, Charles W. Sanzenbacher, Peter J. Robinson, Charles A. Burrows, Paul R. DiBella
  • Patent number: 5782957
    Abstract: A process for treating iron-bearing material with a carbonaceous material to form a dry mixture, wherein the amount of carbonaceous material added exceeds the stoichiometric amount required to reduce the metal oxide to elemental metal. In one embodiment, the process also includes blending an organic binder with the dry mixture. The dry mixture is agglomerated to bond the dry mixture and form green compacts. The green compacts are loaded into a heated furnace and heated for about 5-12 minutes at a temperature of between about 2100.degree.-2500.degree. F. to reduce the iron oxide containing compacts to compacts containing elemental iron and an excess amount of carbonaceous material wherein the excess amount of carbonaceous material counteracts re-oxidation of the elemental iron. The reduced compacts are then discharged from the furnace.
    Type: Grant
    Filed: November 6, 1996
    Date of Patent: July 21, 1998
    Assignee: Maumee Research & Engineering, Inc.
    Inventors: Franklin G. Rinker, Deane A. Horne
  • Patent number: 5695543
    Abstract: A method and system for recovering metal from steel waste products is disclosed. This method and system works on such hazardous and/or toxic wastes as mill scale, flue dust and slag. This method and system operates by mixing the steel waste produce with a flux composition and then melting the mix in a single phase two electrode electric arc furnace. Once the mixture is melted by the heat from the electrodes, the electro-magnetic field induced in the melted mixture serves to enhance the recovery from the steel waste product of useful steel material. Furthermore, this method and system provide a cost effective solution to the hazardous waste disposal problems impacting steel refineries around the world and does so in a manner that removes the toxicity of the waste while producing a variety of useful products, including high grade steel and neutralized fill.
    Type: Grant
    Filed: May 10, 1996
    Date of Patent: December 9, 1997
    Assignee: D & S Technologies, Inc.
    Inventor: Desmond L. Shields
  • Patent number: 5665140
    Abstract: A method for producing iron carbide for use as an iron source in steelmaking is provided. The method can use a wide range of feedstocks without depending on natural gas by using other forms of carbon as the carburizing source. The present method accomplishes the production of iron carbide by mixing together finely divided iron oxide containing feedstocks and carbon, pelletizing the mixture, and heating the pellets to a high temperature under reducing conditions. Preferably, the pellets are heated to a temperature of at least 1100.degree. C. Excess levels of carbon should be used in the process to assure maximum production of iron carbide.
    Type: Grant
    Filed: December 4, 1995
    Date of Patent: September 9, 1997
    Assignee: Allmet Technologies, Inc.
    Inventors: John K. Pargeter, Mark S. Mazanek
  • Patent number: 5516358
    Abstract: A method for producing iron carbide for use as an iron source in steelmaking is provided. The method can use a wide range of feedstocks without depending on natural gas by using other forms of carbon as the carburizing source. The present method accomplishes the production of iron carbide by mixing together finely divided iron oxide containing feedstocks and carbon, pelletizing the mixture, and heating the pellets to a high temperature under reducing conditions. Preferably, the pellets are heated to a temperature of at least 1100.degree. C. Excess levels of carbon should be used in the process to assure maximum production of iron carbide.
    Type: Grant
    Filed: November 17, 1994
    Date of Patent: May 14, 1996
    Assignee: Pro-Tech Reclamation, Inc.
    Inventors: John K. Pargeter, Mark S. Mazanek
  • Patent number: 5486229
    Abstract: A raw material for producing ferrite dust for friction elements and a method of producing reduced ferrite dust, capable of using, as the raw material, various collected sludge and dust which are by-products obtained at iron factories. The sludge has solid components consisting essentially of 35 to 50% total Fe, no more than 2% metallic Fe, 1.0 to 8.0% SiO.sub.2, 0.3 to 2.5% MgO, 1.0 to 6.0% CaO, 1.0 to 5.0% Al.sub.2 O.sub.3, 20 to 40% fixed carbon, and 0.1 to 1.0% ZnO, said sludge having a grain size of 20 to 250 mesh, an apparent specific gravity of 1.2 to 2.0 g/cc, a real specific gravity of 3.3 to 4.3 g/cc, and a porosity of 40 to 65%. The collected dust consists essentially of 50 to 85% true Fe, 20 to 55% FeO, 30 to 55% Fe.sub.3 O.sub.4, 2 to 12% CaO, 1 to 5% SiO.sub.2, 1 to 3% MgO, 1 to 3% MnO, and no more than 1% fixed carbon, 50 to 85% total Fe, 2 to 12% CaO, 1 to 5% SiO.sub.2, 1 to 3% MgO, 1-3% MnO, and no more than 1% fixed carbon.
    Type: Grant
    Filed: July 29, 1993
    Date of Patent: January 23, 1996
    Assignee: Kumsan Material Co., Ltd.
    Inventor: Ki Ju An
  • Patent number: 5350434
    Abstract: The process for making a refined molten steel includes melting preheated solid iron sources and solid carbon sources in a melting vessel with heat generated by electric arc to form a carbon-containing molten material and then melting other preheated solid iron and carbon sources in the carbon-containing molten material by heat generated by combustion reaction in the melting vessel. In the combustion reaction oxygen is fed into the molten material through nozzles located in the melting vessel below the surface of the molten bath. The exhaust gases formed in the melting vessel are used to preheat the solid iron sources and then are burned in an afterburner to reduce pollution. An apparatus for performing the process is also described.
    Type: Grant
    Filed: May 13, 1993
    Date of Patent: September 27, 1994
    Assignee: Metallgesellschaft AG
    Inventor: Bernt Rollinger