Melting Iron(fe) Or Treating Molten Iron Patents (Class 75/507)
  • Patent number: 9005332
    Abstract: A process for producing pig iron or liquid primary steel products is provided. Charge materials containing iron ore and, if appropriate, additions are reduced in at least one reduction unit by means of a reducing gas, and at least parts thereof are smelted in a smelting unit, with coal being added and with formation of the reducing gas. Reducing gas from the smelting unit and/or top gas from the reduction unit are/is subjected to cleaning. The process water obtained during the wet cleaning is degassed and in the process volatile organic compounds are removed from the process water.
    Type: Grant
    Filed: April 12, 2011
    Date of Patent: April 14, 2015
    Assignee: Siemens Vai Metals Technologies GmbH
    Inventors: Kurt Lukschander, Ulrike Schmidt
  • Patent number: 8999033
    Abstract: The present invention provides a method for producing direct reduced iron and/or hot metal using high-moisture content carbonaceous material, including: agglomerating carbonaceous material from the high-moisture content carbonaceous material with a metal oxide-bearing material to form an agglomerate suitable for use in a direct reduction and/or hot metal producing process. The method also includes distilling the high-moisture content carbonaceous material. The method further includes dry quenching the carbonaceous material obtained from the distilling step. The method still further includes drying the high-moisture content carbonaceous material with energy from a hot off gas from a furnace for producing direct reduced iron and/or hot metal prior to the distilling step.
    Type: Grant
    Filed: December 14, 2011
    Date of Patent: April 7, 2015
    Assignee: Midrex Technologies, Inc.
    Inventors: Masahiko Tetsumoto, Todd Astoria
  • Publication number: 20150013497
    Abstract: A process for recovering iron/steel from scrap mill scales and fines is disclosed. A process in accordance with embodiments of the present invention comprises mixing mill scales and fines with coke or other carbon containing fines and sealing the mixture in a container. The container is charged into a cupola or blast furnace, where the components react to form molten iron/steel. The recovery process in accordance with an embodiment of the present invention is performed integral to cupola or blast furnace operations and the recovered metal is collected at the base of the furnace as molten iron/steel.
    Type: Application
    Filed: October 3, 2014
    Publication date: January 15, 2015
    Inventors: Henry H. HOFFMAN, Jeffrey J. Hoffman
  • Publication number: 20140298955
    Abstract: A top-blowing lance includes a refining oxygen gas blowing nozzle having a plurality of ejection openings through which oxygen gas is blown into an iron bath in a reaction vessel, the ejection openings being disposed along a circular orbit at intervals, and a burner nozzle having an axis coaxial with the central axis of the circular orbit, forming a flame inside the refining oxygen gas blowing nozzle, and having ejection openings for blowing a powder heated by the flame into the iron bath, wherein an indicator A that indicates the positional relationship between the ejection openings of the refining oxygen gas blowing nozzle and the ejection openings of the burner nozzle satisfies the specified conditions.
    Type: Application
    Filed: October 16, 2012
    Publication date: October 9, 2014
    Inventors: Goro Okuyama, Naoki Kikuchi, Yuichi Uchida, Yukio Takahashi, Shingo Sato, Kenji Nakase, Yasutaka Ta, Yuji Miki
  • Patent number: 8845779
    Abstract: The object of the present invention is to provide a process for producing molten iron through the efficient reduction of iron oxide having various chemical compositions and various shapes, or through the efficient melting of scrap iron or reduced iron having various shapes and various chemical compositions, the process being used in cases where the amount of iron necessary per furnace is not so large as in blast furnace processes. Specifically, the present invention provides a process for producing molten iron comprising the steps of: supplying carbon-containing molten iron to a holding container, heating the molten iron using heat of a combustion reaction of a gas mixture containing a fuel gas and a combustion-supporting gas, thereby storing the heat therein, and adding a carbon source and an iron-containing material that contains iron oxide and/or scrap iron to the heated and heat-stored molten iron, thereby converting the iron-containing material to molten iron.
    Type: Grant
    Filed: September 7, 2009
    Date of Patent: September 30, 2014
    Assignee: ISTC Co., Ltd.
    Inventor: Teruyoshi Hiraoka
  • Patent number: 8834600
    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.
    Type: Grant
    Filed: June 11, 2004
    Date of Patent: September 16, 2014
    Assignee: The University of Leeds
    Inventors: Animesh Jha, Pailo Antony Malpan, Vilas Dattatray Tathavadkar
  • Patent number: 8828117
    Abstract: A method for reducing tundish and ladle nozzle clogging in a steel making process by introducing an additive into molten steel containers used in steel making at predetermined times. The additives introduced are oxides of iron which contain between 10% and 30% of oxygen by weight. By adding the oxides of iron in a controlled manner using a cored wire apparatus, clogs in tundish or ladle nozzles in the steel making process are avoided and the steel flows more smoothly with less interruptions due to clogged nozzles. A preferred embodiment uses oxides of iron contained in a cored wire which can be introduced at a predetermined rate and readily mix with molten steel, provide better distribution of dissolved oxygen in the steel to oxidize inclusions, and facilitate removal of the inclusions before the inclusions can cause nozzle clogging.
    Type: Grant
    Filed: June 29, 2011
    Date of Patent: September 9, 2014
    Inventor: Gregory L. Dressel
  • Publication number: 20140230606
    Abstract: Ironmaking method and installation with recirculation of exhaust gas as a reduction gas and whereby part of the exhaust gas is purged upstream and/or downstream of a CO/CO2 separation unit, said purged exhaust gas being subjected to a water gas shift reaction for H2 generation.
    Type: Application
    Filed: September 28, 2012
    Publication date: August 21, 2014
    Inventors: Xavier Traversac, Richard Dubettier-Grenier, Sebastien De Limon, Philippe Court
  • Patent number: 8771397
    Abstract: A steelmaking plant including a pressurized direct reduction reactor for continuous production of hot direct reduced iron with a batch-melting furnace and a standby cooler, all three being capable of being situated side-by-side, with such DRI being able to be alternatively fed to the furnace or to the cooler. The furnace is selectively charged through a diverter valve by a pneumatic transport system with the hot DRI being entrained in a carrier gas fed into a receiving bin (having an upper DRI/gas disengagement space and a lower DRI buffer portion). A pressurized charge of the DRI accumulated in such disengaging/buffer bin is periodically fed down into a dosing/depressurization bin which in turn depressurizes the DRI and feeds a batch of DRI down into the furnace. Upon sensing that the buffer portion is full, the DRI is then pneumatically diverted to the cooler, such as during furnace maintenance shut down.
    Type: Grant
    Filed: April 17, 2008
    Date of Patent: July 8, 2014
    Assignees: HYL Technologies, S.A. de C.V., Danieli & C. Officine Meccaniche, S.p.A.
    Inventors: Gilberto Garza-Rodriguez, Andrea Tavano, Octavio Jorge Becerra-Novoa
  • Patent number: 8771399
    Abstract: A method and composition for removing sulfur from molten ferrous material, particularly molten iron. The desulfurization agent includes one or more pucks or briquettes of deoxidizing and/or desulfurization agent. The pucks or briquettes of deoxidizing and/or desulfurization agent include at least one deoxidizing metal and at least one ferrous metal.
    Type: Grant
    Filed: March 10, 2010
    Date of Patent: July 8, 2014
    Assignee: Magnesium Technologies Corporation
    Inventor: Thomas H. Bieniosek
  • Publication number: 20140165784
    Abstract: The invention relates to a process for producing an iron- and/or tungsten containing powder or powder agglomerate including the steps of: a) mixing at least a first powder fraction comprising a tungsten carbide containing powder, and at least a second powder fraction comprising an iron oxide powder and/or a tungsten oxide containing powder and optionally an iron powder, the weight of the first fraction being in the range of 50-90% by weight of the mix and the weight of the second fraction being in the range of 10-50% by weight of the mix, b) heating the mix of step a) to a temperature in the range of 400-1300° C., preferably 1000-1200° C. The invention also relates to an iron- and/or tungsten containing powder or powder agglomerate.
    Type: Application
    Filed: February 10, 2014
    Publication date: June 19, 2014
    Applicant: MINPRO AKTIEBOLAG
    Inventor: Johan Arvidsson
  • Publication number: 20140123809
    Abstract: An object of the present invention is to provide a method for producing an alloy recycled material by effectively removing carbon from a carbon-containing alloy, which is produced as scrap or sludge of an R—Fe—B based permanent magnet, a used magnet, or the like. The method of the present invention as a means for resolution is characterized in that a carbon-containing R—Fe—B based permanent magnet alloy is subjected to an HDDR treatment to remove carbon. An alloy recycled material produced by the method of the present invention contains a reduced amount of carbon. Therefore, in the case where it is recycled for the production of a magnet, even when an increased amount is subjected to high-frequency heating in a vacuum melting furnace, a non-negligible increase in the amount of carbon contained in the produced magnet can be avoided.
    Type: Application
    Filed: June 29, 2012
    Publication date: May 8, 2014
    Applicant: HITACHI METALS, LTD.
    Inventors: Katsuyoshi Furusawa, Atsushi Kikugawa
  • Publication number: 20130333518
    Abstract: An environmentally friendly flux for molten steel desulfurization includes CaO and Al2O3 so that [CaO]/[Al2O3] is within a range of 1.6 to 3.0, and includes one or more alkali metal oxides of Na2O, K2O, and Li2O, and SiO2 so that [SiO2]/[R2O] is within a range of 0.1 to 3, [R2O] is within a range of 0.5 mass % to 5 mass %, and [SiO2] is within a range of 0.05 mass % to 15 mass % in a case in which the [CaO], the [Al2O3], the [SiO2], and the [R2O] represent the mass % of CaO, the mass % of Al2O3, the mass % of SiO2, and the total amount of the mass % of Na2O, the mass % of K2O, and the mass % of Li2O respectively.
    Type: Application
    Filed: March 30, 2012
    Publication date: December 19, 2013
    Inventors: Masamitsu Wakoh, Akihiro Matsuzawa, Katsuhiro Fuchigami, Kohsuke Kume, Yuji Ogawa
  • Patent number: 8597398
    Abstract: The invention is directed to a method of making liquid metal compositions containing a large number of solid particles per unit volume, without external heat removal, which solid particles act as nuclei for grains when the metal is solidified. A method of forming a metal solid includes the step of partially removing a solute of a liquid metallic solution which is at its liquidus temperature to partially solidify a metal solvent component, thereby forming a solid fraction, wherein there is essentially no reduction in temperature of the liquid metallic solution and solid fraction. The method further includes the step of subsequently lowering the temperature of the liquid metallic solution and solid fraction to solidify the remaining liquid metallic solution and thereby form a solid that includes the solid fraction formed during the step of partial solute removal. In an embodiment, the method further includes turbulence from gas evolution which aids in solid particle formation and grain refinement.
    Type: Grant
    Filed: March 17, 2010
    Date of Patent: December 3, 2013
    Assignee: Massachusetts Institute of Technology
    Inventors: Merton C. Flemings, David V. Ragone
  • Publication number: 20130287619
    Abstract: In one embodiment, a neutron shielding material is formed of boron-adding stainless steel of either austenite-ferrite two-phase stainless steel or ferritic stainless steel, the austenite-ferrite two-phase stainless steel containing, in mass %, B: 0.5% to 2.0%, Ni: 3.0 to 10.0%, and Cr: 21.00 to 32.00%, the ferritic stainless steel containing, in mass %, B: 0.5% to 2.0%, Ni: 4.0% or less, and Cr: 11.00 to 32.00%, and the boron-adding stainless steel being well in ductility and thermal conduction property.
    Type: Application
    Filed: June 12, 2013
    Publication date: October 31, 2013
    Inventors: Masanori Kibata, Yuuji Saito, Motoji Tsubota, Yoshitaka Doken, Makoto Sato, Shunichi Hatano, Masanori Ishiga, Go Ono
  • Publication number: 20130260164
    Abstract: A steel plate is provided which has excellent hydrogen induced cracking resistance. The steel plate is suitable for use in a line pipe. The steel plate satisfies a predetermined composition. In a composition of an inclusion contained in the steel and having a width of 1 ?m or more, the ratio (RES/CaS) of the mass of an REM sulfide (RES) to that of a Ca sulfide (CaS) is equal to or more than 0.05, a Zr content of the inclusion is in a range of 5 to 60%, and a Nb content of the inclusion is 5% or less.
    Type: Application
    Filed: March 15, 2013
    Publication date: October 3, 2013
    Applicant: KABUSHIKI KAISHA KOBE SEIKO SHO (Kobe Steel, Ltd.)
    Inventor: KABUSHIKI KAISHA KOBE SEIKO SHO (Kobe Steel, Ltd.)
  • Publication number: 20130239751
    Abstract: A method for producing nodular cast iron by using a nodulizer and a spheroidizing device, the method including spheroidizing, the spheroidizing including the following steps: a) placing an integrated rare earth magnesium ferrosilicon nodulizer coated with a rectangular steel tube at a preset position inside a spheroidizing ladle, disposing a strut head on the spheroidizing ladle, and fixing the strut head; b) inputting a ferrosilicon inoculant into the spheroidizing ladle; c) inputting melted iron into the spheroidizing ladle for spheroidizing; and d) removing the strut head from the spheroidizing ladle after spheroidizing.
    Type: Application
    Filed: April 23, 2013
    Publication date: September 19, 2013
    Applicant: TIANJIN WANLU LIMITED COMPANY OF SCIENCE AND TECHNOLOGY
    Inventor: TIANJIN WANLU LIMITED COMPANY OF SCIENCE AND TECHNOLOGY
  • Publication number: 20130195712
    Abstract: There is provided a method for obtaining a pure melt in which the impurities Mn, Al, Ti, Pb, Zn, and B are removed from molten cast iron and depletion of useful C and Si is suppressed, the method wherein an excess oxygen flame having a theoretical combustion ratio of fuel and oxygen (amount of oxygen (volume)×5/amount of fuel (volume)) of 1 to 1.5 is directly exposed to the surface of pre-melted molten cast iron, the temperature of the molten cast iron is held at 1250° C. or more and less than 1500° C. while the melt surface is superheated and an acidic slag is brought into contact with the melt, and an oxygen-containing gas is injected into the interior of the molten cast iron.
    Type: Application
    Filed: January 24, 2011
    Publication date: August 1, 2013
    Applicants: KIMURA CHUZOSHO CO., LTD., MIE PREFECTURE, SENSHU CORPORATION, NANIWA ROKI CO., LTD., HITACHI METALS, LTD., KINOSHITA MANUFACTORY CO., LTD.
    Inventors: Toshitake Kanno, Ilgoo Kang, Takao Fujikawa, Hiromitsu Takeuchi, Kiyoshi Kinoshita, Hirotoshi Murata, Nobuya Yamamoto, Tatsuo Atsumi
  • Publication number: 20130177469
    Abstract: Methods comprising providing a composition comprising iron and a high melting point element; heating the composition to an elevated temperature up to about 3,500° F.; holding the composition at the elevated temperature for a time sufficient for the heat's temperature to stabilize; and allowing the composition to cool or solidify. Methods comprising providing a master alloy comprising iron and up to about 30% by weight of a high melting point element; and adding the master alloy to a heat of steel. Compositions comprising an alloy of iron and high melting point element in which the alloy is up to about 30% by weight of the high melting point element. Compositions comprising an alloy of iron and high melting point element having a substantially uniform microstructure.
    Type: Application
    Filed: December 21, 2012
    Publication date: July 11, 2013
    Inventors: James D. Ruhlman, Charles Scherrer, Randall W. Schudalla
  • Patent number: 8470069
    Abstract: A method of using scrap rubber and other scrap materials, such as tires or parts or pieces of tires, to manufacture or melt steel and other metals in a furnace is disclosed. The scrap rubber may be used as a carbon source for the manufacture of steel and other metals, and may be used as an energy source to melt the scrap metal used to make the steel and other metals. The net benefit of this method includes reducing the amount of scrap rubber, such as tires, to be sent to a waste disposal facility or landfill, thereby improving the environment. In addition, by increasing the use of scrap rubber as a source of energy for steel or metal production, less energy is required from other sources.
    Type: Grant
    Filed: April 4, 2012
    Date of Patent: June 25, 2013
    Inventor: Franklin Leroy Stebbing
  • Publication number: 20130142688
    Abstract: The present invention provides a high-strength steel sheet including: C: 0.03 to 0.25 mass %, Si: 0.1 to 2.0 mass %, Mn: 0.5 to 3.0 mass %, P: not more than 0.05 mass %, T.O: not more than 0.0050 mass %, S: 0.0001 to 0.01 mass %, N: 0.0005 to 0.01 mass %, acid-soluble Al: more than 0.01 mass %, Ca: 0.0005 to 0.0050 mass %, and a total of at least one element of Ce, La, Nd, and Pr: 0.001 to 0.01 mass %, with a balance including iron and inevitable impurities, in which the steel sheet contains a chemical component on a basis of mass that satisfies 0.7<100×([Ce]+[La]+[Nd]+[Pr])/[acid-soluble Al]?70 and 0.
    Type: Application
    Filed: February 23, 2012
    Publication date: June 6, 2013
    Inventors: Kenichi Yamamoto, Hideaki Yamamura, Yuzo Takahashi, Osamu Kawano, Kohsuke Kume, Junji Haji, Daisuki Maeda, Yoshihiro Suwa
  • Publication number: 20130081516
    Abstract: Metallic iron is produced from a composition formed from a mixture of iron ore particles and particles of a reductant made of a biomass material, a coal or coke in a particulate form together with a flux and is processed in a loose, un-agglomerated non-pelletized, non-briquetted form in a reducing furnace to produce metallic iron directly from the ore. An excess of biomass or coal or coke reductant can be used to provide CO and H that can be recovered as a synthetic gas and converted to electrical or other energy. Metallic iron nuggets or slabs can be produced from manganiferous ores or concentrates. Manganese can be caused to enter the nugget or slab or the slag by adjusting the furnace temperature. Titaniferous ores or concentrates can be used to produce metallic iron slabs or nuggets and a titanium-rich slag.
    Type: Application
    Filed: April 19, 2012
    Publication date: April 4, 2013
    Inventor: John J. Simmons
  • Publication number: 20130036868
    Abstract: A process for producing pig iron or liquid primary steel products is provided. Charge materials containing iron ore and, if appropriate, additions are reduced in at least one reduction unit by means of a reducing gas, and at least parts thereof are smelted in a smelting unit, with coal being added and with formation of the reducing gas. Reducing gas from the smelting unit and/or top gas from the reduction unit are/is subjected to cleaning. The process water obtained during the wet cleaning is degassed and in the process volatile organic compounds are removed from the process water.
    Type: Application
    Filed: April 12, 2011
    Publication date: February 14, 2013
    Inventors: Kurt Lukschander, Ulrike Schmidt
  • Publication number: 20130032005
    Abstract: A method for producing compacts containing iron oxide from undersized oxidic iron carriers may include producing a mixture which comprises undersized oxidic iron carriers, bentonite as a binder and water, pressing the mixture and hardening the green compacts obtained by the pressing, as well as to the compacts produced by the method and to the use of the compacts as lump iron carriers. The mixture may be subjected to a kneading process lasting at least 3 minutes and up to 30 minutes, prior to the pressing. The compacts may thus be produced without a maturing process.
    Type: Application
    Filed: March 21, 2011
    Publication date: February 7, 2013
    Inventors: Christian Boehm, Hado Heckmann
  • Patent number: 8343255
    Abstract: When the density (DO) of the inclusions whose major axis exceeds 5 ?m observed in the axis position of a section perpendicular to the axial direction of a forged product is made 70 nos/cm2 or below and the radius of the forged product is made R, the ratio of the density (DR) of the inclusions whose major axis exceeds 5 ?m observed in the R/3 position from the axis position toward the radial direction and the density DO satisfies an inequality (1) below. 0.5?DR/DO?1.
    Type: Grant
    Filed: July 20, 2009
    Date of Patent: January 1, 2013
    Assignee: Kobe Steel, Ltd.
    Inventors: Takashi Abiko, Michio Nishihara, Eiji Otsuki, Shunsuke Hori, Tomoya Shinozaki, Tetsushi Deura
  • Publication number: 20120301383
    Abstract: The present invention relates to new compositions of matter, particularly metals and alloys, and methods of making such compositions. The new compositions of matter exhibit long-range ordering and unique electronic character.
    Type: Application
    Filed: March 20, 2012
    Publication date: November 29, 2012
    Inventor: Christopher J. Nagel
  • Publication number: 20120267015
    Abstract: Provided are: a non-oriented electrical steel sheet having outstanding magnetic properties and comprising, as percentages by weight, from 1.0 to 3.0% of Al, from 0.5 to 2.5% of Si, from 0.5 to 2.0% of Mn, from 0.001 to 0.004% of N, from 0.0005 to 0.004% of S and a balance of Fe and other unavoidably incorporated impurities, wherein the Al, Mn, N and S are included so as to satisfy the compositional formulae {[Al]+[Mn]}?3.5, 0.002?{[N]+[S]}?0.006, 300?{([Al]+[Mn])/([N]+[S])}?1,400; and a production method therefor. By optimising the Al, Si, Mn, N and S added components in this way, the distribution density of coarse inclusions is increased, thereby making it possible to improve crystal-grain growth properties and domain wall mobility and so produce the highest grade of non-oriented electrical steel sheet having superior magnetic properties, low hardness, and superior customer workability and productivity.
    Type: Application
    Filed: December 28, 2010
    Publication date: October 25, 2012
    Applicant: POSCO
    Inventors: Jae-Hoon Kim, Jae-Kwan Kim, Yong-Soo Kim, Won-Seog Bong
  • Patent number: 8287804
    Abstract: In the method for recovering a metal from a target that contains a metal and a metal oxide, the target contains a sintered body of the metal oxide after being heated under a condition of melting the metal without melting or decomposing the metal oxide. The target is heated in an upper crucible of a two-level crucible that includes the upper crucible with a through hole-formed in a bottom surface thereof, and a lower crucible disposed below the through hole, the size of the through hole being set such that it does not allow the sintered body of the metal oxide contained in the target to pass therethrough, and the melted metal is caused to flow into the lower crucible, so that the metal is separated from the metal oxide.
    Type: Grant
    Filed: December 8, 2009
    Date of Patent: October 16, 2012
    Assignee: Tanaka Holdings Co., Ltd
    Inventors: Toshiya Yamamoto, Takanobu Miyashita, Kiyoshi Higuchi, Yasuyuki Goto
  • Publication number: 20120152061
    Abstract: The present invention provides a method for producing direct reduced iron and/or hot metal using high-moisture content carbonaceous material, including: agglomerating carbonaceous material from the high-moisture content carbonaceous material with a metal oxide-bearing material to form an agglomerate suitable for use in a direct reduction and/or hot metal producing process. The method also includes distilling the high-moisture content carbonaceous material. The method further includes dry quenching the carbonaceous material obtained from the distilling step. The method still further includes drying the high-moisture content carbonaceous material with energy from a hot off gas from a furnace for producing direct reduced iron and/or hot metal prior to the distilling step.
    Type: Application
    Filed: December 14, 2011
    Publication date: June 21, 2012
    Applicant: MIDREX TECHNOLOGIES, INC.
    Inventors: MASAHIKO TETSUMOTO, TODD ASTORIA
  • Publication number: 20120125151
    Abstract: An integrated steelmaking plant design is disclosed for efficiently merging the continuous operation of a reduction reactor producing hot DRI with the batch operation of at least one DRI melting furnace. The direct reduction reactor is adapted for producing hot DRI for its consumption in a DRI melting furnace or for producing cold DRI when the continuous production of DRI will exceed the DRI consumption rate of the melting furnace or when it suffers long-term operational delays. The reduction reactor has a DRI cooling zone within the same reactor vessel which is selectively operable for cooling the DRI in the same reactor vessel when the hot DRI produced in said reactor will not be consumed by the DRI melting furnace and when the capacity of the hot DRI bin feeding the melting furnace is insufficient to accumulate the amount of hot DRI which will not be consumed.
    Type: Application
    Filed: May 8, 2010
    Publication date: May 24, 2012
    Inventors: Jorge Octavio Becerra-Novoa, Ronald Victor Manuel Lopez-Gomez, Alessandro Martinis, Andrea Tavano
  • Publication number: 20120087824
    Abstract: The object of the present application is to define an alloy, which presents the mechanical and physical properties of the gray iron alloy, with a wide interface range of the CGI's tensile strength. This new alloy, flake graphite based, is a High Performance Iron (HPI) alloy. Therefore, besides its high tensile strength, the HPI alloy presents excellent machinability, damping vibration, thermal conductivity, low shrink tendency and good microstructure stability (compatible with gray iron alloys). Said HPI's characteristics are obtained by a specific interaction among five metallurgical fundaments: chemical analysis; oxidation of the liquid metal; nucleation of the liquid metal; eutectic solidification and eutectoidic solidification.
    Type: Application
    Filed: February 12, 2009
    Publication date: April 12, 2012
    Applicant: TEKSID DO BRASIL LTDA.
    Inventors: Otto Luciano Mol de Oliveira, Jefferson Pinto Villafort
  • Patent number: 8152894
    Abstract: A method of using scrap rubber and other scrap materials, such as tires or parts or pieces of tires, to manufacture or melt steel and other metals in a furnace is disclosed. The scrap rubber may be used as a carbon source for the manufacture of steel and other metals, and may be used as an energy source to melt the scrap metal used to make the steel and other metals. The net benefit of this method includes reducing the amount of scrap rubber, such as tires, to be sent to a waste disposal facility or landfill, thereby improving the environment. In addition, by increasing the use of scrap rubber as a source of energy for steel or metal production, less energy is required from other sources.
    Type: Grant
    Filed: February 8, 2011
    Date of Patent: April 10, 2012
    Inventor: Franklin Leroy Stebbing
  • Patent number: 8142541
    Abstract: A method for when preheating a ladle for use in steelmaking where less fuel is consumed in heating the ladle efficiently accurately to a controlled temperature. A temperature of a preheating process is varied by controlling a burner of the heating unit based on measurements of refractories of the ladle taken by a pyrometer. The heating unit includes an emissive coating for reducing heat loss and efficient heating during the preheating process. The heating unit also includes valve mechanisms for accurately varying a flame size of the burner of the heating unit during an idle stage of the preheating process.
    Type: Grant
    Filed: June 11, 2008
    Date of Patent: March 27, 2012
    Assignee: Nucor Corporation
    Inventor: Gregory S. Galewski
  • Publication number: 20120055288
    Abstract: A process for making a precipitation hardenable stainless steel alloy is described. The process includes the step of melting a martensitic steel alloy having the following composition in weight percent, about Carbon ?0.03 max. Manganese ?1.0 max. Silicon ?0.75 max. Phosphorus 0.040 max. Sulfur 0.020 max. Chromium 10-13 Nickel 10.5-11.6 Titanium 1.5-1.8 Molybdenum 0.25-1.5? Copper ?0.95 max. Aluminum ?0.25 max. Niobium ?0.3 max. Boron 0.010 max. Nitrogen 0.030 max. and the balance being iron and usual impurities. The process also includes the step of adding calcium to the alloy while molten. The calcium combines with available sulfur and oxygen to form calcium base inclusions selected from the group consisting of calcium sulfides, calcium oxides, calcium oxysulfides, and combinations thereof. In a further step, the alloy is processed to remove at least a portion of the calcium base inclusions. The alloy is then solidified.
    Type: Application
    Filed: November 10, 2011
    Publication date: March 8, 2012
    Inventors: Robert Wayne Krieble, William Joseph Martin, Thomas Constantine Zogas, David Elmer Wert, Paul Michael Novotny
  • Publication number: 20120024112
    Abstract: A method for reducing tundish and ladle nozzle clogging in a steel making process by introducing an additive into molten steel containers used in steel making at predetermined times. The additives introduced are oxides of iron which contain between 10% and 30% of oxygen by weight. By adding the oxides of iron in a controlled manner using a cored wire apparatus, clogs in tundish or ladle nozzles in the steel making process are avoided and the steel flows more smoothly with less interruptions due to clogged nozzles. A preferred embodiment uses oxides of iron contained in a cored wire which can be introduced at a predetermined rate and readily mix with molten steel, provide better distribution of dissolved oxygen in the steel to oxidize inclusions, and facilitate removal of the inclusions before the inclusions can cause nozzle clogging.
    Type: Application
    Filed: June 29, 2011
    Publication date: February 2, 2012
    Inventor: Gregory L. Dressel
  • Publication number: 20120014828
    Abstract: In a non-oriented electrical steel sheet, Si: not less than 1.0 mass % nor more than 3.5 mass %, Al: not less than 0.1 mass % nor more than 3.0 mass %, Ti: not less than 0.001 mass % nor more than 0.01 mass %, Bi: not less than 0.001 mass % nor more than 0.01 mass %, and so on are contained. (1) expression described below is satisfied when a Ti content (mass %) is represented as [Ti] and a Bi content (mass %) is represented as [Bi]. [Ti]?0.8×[Bi]+0.
    Type: Application
    Filed: May 25, 2010
    Publication date: January 19, 2012
    Applicant: NIPPON STEEL CORPORATION
    Inventors: Masafumi Miyazaki, Hideaki Yamamura, Takeshi Kubota, Yousuke Kurosaki, Kazuto Kawakami, Kazumi Mizukami, Takeaki Wakisaki
  • Publication number: 20120000317
    Abstract: The invention is directed to a method of making liquid metal compositions containing a large number of solid particles per unit volume, without external heat removal, which solid particles act as nuclei for grains when the metal is solidified. A method of forming a metal solid includes the step of partially removing a solute of a liquid metallic solution which is at its liquidus temperature to partially solidify a metal solvent component, thereby forming a solid fraction, wherein there is essentially no reduction in temperature of the liquid metallic solution and solid fraction. The method further includes the step of subsequently lowering the temperature of the liquid metallic solution and solid fraction to solidify the remaining liquid metallic solution and thereby form a solid that includes the solid fraction formed during the step of partial solute removal. In an embodiment, the method further includes turbulence from gas evolution which aids in solid particle formation and grain refinement.
    Type: Application
    Filed: March 17, 2010
    Publication date: January 5, 2012
    Inventors: Merton C. Flemings, David V. Ragone
  • Publication number: 20110284135
    Abstract: Design and fabrication processes and compositions for iron-based bulk metallic glass materials or amorphous steels. Examples of bulk metallic glasses based on the described compositions may contain approximately 59 to 70 atomic percent of iron, which is alloyed with approximately 10 to 20 atomic percent of metalloid elements and approximately 10 to 25 atomic percent of refractory metals. The compositions can be designed using theoretical calculations of the liquidus temperature to have substantial amounts of refractory metals, while still maintaining a depressed liquidus temperature. The alloying elements are molybdenum, tungsten, chromium, boron, and carbon may be used. Some of the resulting alloys are ferromagnetic at room temperature, while others are non-ferromagnetic. These amorphous steels have increased specific strengths and corrosion resistance compared to conventional high strength steels.
    Type: Application
    Filed: July 29, 2011
    Publication date: November 24, 2011
    Applicant: THE REGENTS OF THE UNIVERSITY OF CALIFORNIA
    Inventors: Kenneth S. Vecchio, Justin Cheney
  • Publication number: 20110256017
    Abstract: A product including an iron casting alloy including iron, niobium and compacted graphite structures.
    Type: Application
    Filed: March 31, 2011
    Publication date: October 20, 2011
    Applicant: BorgWarner Inc.
    Inventor: David M. Decker
  • Publication number: 20110247458
    Abstract: A method is provided for influencing the properties of cast iron by adding magnesium to the cast iron melt and measuring the oxygen content of the cast iron melt. Magnesium is added to the cast iron melt until the oxygen content of the cast iron melt is approximately 0.005 to 0.2 ppm at a temperature of approximately 1,420° C. A sensor for measuring the oxygen content in cast iron melts contains an electrochemical measuring cell containing a solid electrolyte tube.
    Type: Application
    Filed: June 24, 2011
    Publication date: October 13, 2011
    Applicant: HERAEUS ELECTRO-NITE INTERNATIONAL N.V.
    Inventor: Danny HABETS
  • Publication number: 20110243784
    Abstract: In the method for recovering a metal from a target that contains a metal and a metal oxide, the target contains a sintered body of the metal oxide after being heated under a condition of melting the metal without melting or decomposing the metal oxide. The target is heated in an upper crucible of a two-level crucible that includes the upper crucible with a through hole-formed in a bottom surface thereof, and a lower crucible disposed below the through hole, the size of the through hole being set such that it does not allow the sintered body of the metal oxide contained in the target to pass therethrough, and the melted metal is caused to flow into the lower crucible, so that the metal is separated from the metal oxide.
    Type: Application
    Filed: December 8, 2009
    Publication date: October 6, 2011
    Applicant: TANAKA HOLDINGS CO., LTD.
    Inventors: Toshiya Yamamoto, Takanobu Miyashita, Kiyoshi Higuchi, Yasuyuki Goto
  • Publication number: 20110203415
    Abstract: A method of suppressing slag foaming that can grasp a state of slag foaming in the continuous melting furnace and accurately suppress the slag foaming so as to enable continuous production of molten metal in a stable state. This method includes charging of a suppressor into slag in the furnace, measuring a flow rate of a flue gas discharged from the continuous melting furnace during blowing of the slag over time, increasing a charging speed rate of the suppressor if the flue gas flow rate has an increasing tendency and decreasing the charging speed rate of the suppressor if the flue gas flow rate has a decreasing tendency.
    Type: Application
    Filed: July 15, 2008
    Publication date: August 25, 2011
    Applicant: Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.)
    Inventor: Masataka Tateishi
  • Publication number: 20110167963
    Abstract: A dual outlet injector is disclosed for use in a dual lance or dual port desulfurization station, whereby reagent from a given injector vessel may be injected into two separate supply pipes respectively corresponding to the dual lances or dual ports. The dual outlet injector enables a desulfurization station to be configured comprising only one supply vessel for powdered magnesium reagent and only one supply vessel for a carrier reagent such as powdered lime.
    Type: Application
    Filed: June 30, 2009
    Publication date: July 14, 2011
    Applicant: ESM GROUP INC.
    Inventors: Joseph R. Waitlevertch, Larry J. Epps, Michael S. Ross
  • Publication number: 20110154951
    Abstract: The object of the present invention is to provide a process for producing molten iron through the efficient reduction of iron oxide having various chemical compositions and various shapes, or through the efficient melting of scrap iron or reduced iron having various shapes and various chemical compositions, the process being used in cases where the amount of iron necessary per furnace is not so large as in blast furnace processes. Specifically, the present invention provides a process for producing molten iron comprising the steps of: supplying carbon-containing molten iron to a holding container, heating the molten iron using heat of a combustion reaction of a gas mixture containing a fuel gas and a combustion-supporting gas, thereby storing the heat therein, and adding a carbon source and an iron-containing material that contains iron oxide and/or scrap iron to the heated and heat-stored molten iron, thereby converting the iron-containing material to molten iron.
    Type: Application
    Filed: September 7, 2009
    Publication date: June 30, 2011
    Applicant: ISTC CO., LTD.
    Inventor: Teruyoshi Hiraoka
  • Publication number: 20110126671
    Abstract: A method of using scrap rubber and other scrap materials, such as tires or parts or pieces of tires, to manufacture or melt steel and other metals in a furnace is disclosed. The scrap rubber may be used as a carbon source for the manufacture of steel and other metals, and may be used as an energy source to melt the scrap metal used to make the steel and other metals. The net benefit of this method includes reducing the amount of scrap rubber, such as tires, to be sent to a waste disposal facility or landfill, thereby improving the environment. In addition, by increasing the use of scrap rubber as a source of energy for steel or metal production, less energy is required from other sources.
    Type: Application
    Filed: February 8, 2011
    Publication date: June 2, 2011
    Applicant: Rex Enterprises, LLC
    Inventor: Franklin Leroy Stebbing
  • Publication number: 20110094337
    Abstract: A steelmaking plant method and apparatus which includes a pressurized direct reduction reactor for continuous production of hot direct reduced iron (ORI); feeding such DRI to a batch melting furnace or to a standby cooler. The furnace is selectively charged through a diverter valve by a pneumatic transport system with the hot DRI being entrained in a motive carrier gas fed via a first conduit into a receiving bin. A pressurized charge of the DRI accumulated in such disengaging buffer bin is periodically fed via a second conduit down into low dosing/depressurization bin which in turn depressurizes the DRI and feeds a batch of DRI down into the furnace. Upon sensing the capacity of the buffer portion of the receiving bin being filled, the DRI! is then pneumatically diverted from the reactor to the cooler, such as during shut down of the furnace for maintenance or otherwise.
    Type: Application
    Filed: April 17, 2008
    Publication date: April 28, 2011
    Inventors: Gilberto Garza-Rodriguez, Andrea Tavano, Octavio Jorge Becerra-Novoa
  • Publication number: 20110036204
    Abstract: A method for producing reduced iron includes: a step of preparing a mixed raw material; a mixed raw material charging step; and a reducing step. In the step of preparing the mixed raw material, the mixed raw material which contains iron ore (X) containing iron ore with a high content of zinc (A) which contains 0.01 mass % or more of zinc and 50 mass % or more of iron, and a carbonaceous solid reducing material is prepared. In the mixed raw material charging step, the mixed raw material is charged on a movable hearth. In the reducing step, a reduced product is obtained by reducing the mixed raw material charged on the movable hearth by supplying heat to the mixed raw material from above the hearth.
    Type: Application
    Filed: April 22, 2009
    Publication date: February 17, 2011
    Applicant: JFE STEEL CORPORATION
    Inventors: Natsuo Ishiwata, Hiroyuki Hiroha, Koichi Nushiro
  • Publication number: 20100326237
    Abstract: The present invention relates to new compositions of matter, particularly metals and alloys, and methods of making such compositions. The new compositions of matter exhibit long-range ordering and unique electronic character.
    Type: Application
    Filed: February 23, 2010
    Publication date: December 30, 2010
    Inventor: Christopher J. Nagel
  • Publication number: 20100313711
    Abstract: A method for the melting of pig iron in a blast furnace (1) operated with oxygen or in a melt-reduction plant, with a reduction region. Purified crude gas is discharged from the reduction region and is recirculated into the reduction region with the addition of hydrocarbons. The purified crude gas is mixed with hydrocarbons and is also blended with a reduction gas which has a temperature of above 1000° C. and which is generated by partial oxidation of hydrocarbons by means of oxygen gas having an oxygen content of above 90% by volume, in order to form a recirculation gas with a temperature of above 800° C. The recirculation gas is recirculated into the reduction region according to an auto-reforming process.
    Type: Application
    Filed: January 29, 2009
    Publication date: December 16, 2010
    Inventors: Robert Millner, Kurt Wieder, Johann Wurm
  • Publication number: 20100263488
    Abstract: With the production of the secondary steel based on scrap, wherein the scrap (10) is fed in a scrap preheater (2) through a charging device (1), is preheated there and, finally, is brought into a smelting unit (3) and is melted there with primary energy only, the process gases (19), which leave the smelting unit (3), are not used for directly preheating the scrap (10) but are rather used indirectly by heating a gaseous preheatable medium, e.g., air (18) or inert gas, so that energetic, fluidic, and spatial decoupling of preheating and melting and of post-combustion and preheating is achieved.
    Type: Application
    Filed: April 1, 2010
    Publication date: October 21, 2010
    Inventor: Matthias Meyn