Abstract: A method of producing a silicon-and-carbon-enriched cast iron melt. The method can include melting an initial cupola charge in a cupola, conducting the molten metal to a mixing vessel, increasing the silicon and carbon content of the molten metal by a substantially continuous addition of granular silicon carbide having a purity of greater than 94% and a size of less than ⅜″ to the mixing vessel while simultaneously agitating the molten metal to an extent sufficient to bring the silicon carbide into solution with the molten metal, and conducting the silicon-and-carbon-enriched molten metal away from the mixing vessel.

Abstract: Metallic particles capable of causing iron or other desired first metal to break free from its oxide are coated with a refractory that inhibits incineration of the metallic particles. The coated metallic particles are added to the molten metal bath as a means for treating the molten metal bath by increasing the yield of the first metal from the bath.

Abstract: An alloy having two constituents: a crystal structure of orderly solid iron-based solution; a non-metallic phase at least partially soluble in iron including particles which are uniformly dispersed in the volume of the first phase and are of suitable size. In a preferred embodiment, the alloy contains iron with dissolved and bonded carbon as the first phase, which forms the crystal structure, and material partially soluble in iron, for example structurally free molecular carbon, is taken as the second non-metallic phase. The alloy preferably contains the components at the following ratios, % by mass: carbon in a dissolved and in a bonded state: 0.01-1.00; free carbon: 0.01-2.24; iron: balance. The ratio of free carbon to that of carbon in a dissolved and in a bonded state ranges from 0.01 to 20. The alloy Is preferably produced by melting out low carbon semi-product, overheating the semi-product above a liquidus temperature, for example by 20-70° C.

Abstract: A method and composition for removing sulfur from molten ferrous material, particularly molten pig iron. The desulfurization agent includes a magnesium particle coated with a heat absorbing compound. The heat absorbing compound absorbs heat around the magnesium particle to reduce the rate the magnesium particle vaporizes in the molten iron. The particle size of the magnesium particle is at least about twice the particle size of the heat absorbing compound. A bonding agent can be used to bond the particles of the heat absorbing compound to the particle of magnesium.

Abstract: A method and composition for removing sulfur from molten ferrous material, particularly molten pig iron. The desulfurization agent includes a magnesium particle coated with a heat absorbing compound. The heat absorbing compound absorbs heat around the magnesium particle to reduce the rate the magnesium particle vaporizes in the molten iron. The particle size of the magnesium particle is at least about twice the particle size of the heat absorbing compound. A bonding agent can be used to bond the particles of the heat absorbing compound to the particle of magnesium.

Abstract: A method of producing iron from iron carbide is disclosed. Solid iron carbide is injected into a molten bath comprising molten iron and slag and dissolves in the molten bath. An oxygen-containing gas is injected into a gas space above the surface of the molten bath to cause combustion of at least a portion of combustible material in the gas space. In addition splashes and/or droplets of molten iron and/or slag are ejected upwardly from the molten bath into the gas space above the quiescent bath surface to form a transition zone. The transition zone is a region in which heat generated by combustion of combustible material is transferred to the splashes and/or droplets of molten iron and/or slag and thereafter is transferred to the molten bath when the splashes and/or droplets of molten iron and/or slag return to the molten bath.

Abstract: A dispersion strengthening method for metallic melts that are used to form large articles. The method comprises adding nanophase particles into a molten metallic melt and dispersing the nanophase particles in the metallic melt. The nanophase particles comprising particles with diameters in the range of about 5 nanometers to about 100 nanometers. The step of dispersing the nanophase particles in the metallic melt spaces the particles from each other with an average interparticle spacing (IPS) in a range from about 10 nanometers to about 500 nanometers.

Abstract: Disclosed is a process for desulphurization of a pig iron melt for further processing wherein the melt is brought into close contact with a ground solid slag. As desulphurizing agent, the slag accumulating in secondary steelmaking with a basicity of at least 4, an iron content in the range of 4 to 6 wt.-% and a phosphorous content in the range .ltoreq.0.4 wt.-%, is used in ground form or the slag is used together with calcium carbide and magnesium as a solid mixture in ground form.

Abstract: A method for purifying iron carbide begins by feeding ore to a reaction chamber. A mixture of iron, iron oxides, gangue, and iron carbides is extracted from the reaction chamber. The temperature of the mixture is then adjusted to a range of 400.degree.-500.degree. C. The mixture, at the adjusted temperature, is subjecting to a first magnetic field for separating the mixture into a magnetic fraction including iron and iron oxides from a non-magnetic fraction including gangue and iron carbides. This is followed by a cooling of the non-magnetic fraction of gangue and iron carbides below the Curie temperature of iron carbide. The gangue and iron carbides are subjecting to a second magnetic field for separating the iron carbides, that become magnetic, from the gangue that remains non-magnetic.

Abstract: A method of making an engineering ferrous metal comprising the steps of adding to liquid engineering ferrous metal solid alloy carbide particles and thereafter permitting the ferrous metal to solidify. The alloy carbide particles are coated with iron or an iron alloy to allow wetting to occur between the powder and the liquid ferrous metal and the particles have a density which matches that of the ferrous metal to provide a uniform distribution of the carbide particles in the ferrous metal. A roll may be made having at least a shell made of metal by such a method by centrifugal casting or electroslag remelting.

Abstract: The desulfurization agent for molten iron is made up of 70 to 95% commercial calcium carbide, 5 to 25% silicon dioxide, 0 to 10% of a metal oxide, and 0 to 5% calcium fluoride. The metal oxides are iron oxides and manganese oxides. The desulfurizing agent has been found to reduce the amount of calcium carbide in the resulting slag.

Abstract: The present invention provides an agent for desulphurizing iron containing calcium carbide and a metallic component, wherein the calcium carbide and the metallic component are present in such a form that the bulk densities and grain sizes thereof lie in the same range.The present invention also provides a process for producing this agent, as well as a process for desulphurizing iron using this agent.