Abstract: A process for recovering pig iron from iron-containing concentrates produced from iron-containing ores and sands by forming agglomerates and reducing them in a natural gas smelter, in which the process makes maximum utilization of heat created in and by the process.

Abstract: The present invention relates to a zero-waste process for extraction of alumina from different types of bauxite ores and red mud residues and of titanium dioxide from ilmenite. Iron oxide is first reduced to metallic iron above the melting point of C-saturated cast iron alloy which yields a high-C iron alloy and an Al and Ti metal oxide rich slag which is then treated with alkali carbonate to form alkali aluminates and titanates. The alkali aluminates are separated by water leaching from which the hydroxide of alumina is precipitated by bubbling C02. The residue from water leaching is treated with sulphuric acid and Ti02 is precipitated via a hydrolysis route. The process recovers most of the metal values and generates only small quantities of silicious residues at pH 4-5 which can be used for soil conditioning.

Abstract: 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.

Abstract: The present invention relates to a desulfurizing agent of improved oxidation resistance, ignition resistance and productivity, and a method for manufacturing the desulfurizing agent. The desulfurizing agent may include a plurality of magnesium-aluminum alloy grains with grain boundaries, and a compound of one selected from consisting of magnesium and aluminum and one selected from consisting of alkaline metal and alkaline earth metal, the compound exists in the grain boundaries and is not inside but outside of the magnesium-aluminum alloy grains.

Abstract: A method for producing molten iron by melting an iron source material using an iron bath-type melting furnace comprising a top-blowing lance at an upper part of the furnace, a bottom-blowing tuyere in the bottom of the furnace and a tap hole at a lower part on the side of the furnace, the method comprising: a melting process of melting the iron source material, wherein the melting process has at least one tapping process of discharging the molten iron and the slag through the tap hole while holding a position of the furnace in generating the molten iron, and the tapping process continues or interrupts generation of the molten iron and continues top-blowing of the oxygen-containing gas to thereby keep a temperature of the molten iron in the furnace at or above a pre-set lowest temperature of the molten iron.

Abstract: A method of inoculating magnesium (Mg) on compacted graphite iron (CGI) comprises: providing a partition having a predetermined height on the bottom of a ladle so as to divide the interior of the ladle into a first space and a second space; laminating an Mg inoculant and a cover in order in the second space; and tapping liquid CGI cast iron onto the first space, whereby the Mg inoculant becomes in contact with the liquid CGI iron after the liquid CGI tapped onto the first space goes over the partition toward the second space and after the cover is melted by the liquid CGI. According to the method, the deviation of density of Mg is minimized, and a secondary inoculating process can thus be omitted.

Abstract: This invention relates to a waste treatment furnace and method comprising: Generating a molten metal bed, which moves in a forward direction, such as to define a closed circuit in a cyclical and continuous manner, the surface of said bed comprising at least one essentially-slag-free segment. Loading waste onto the aforementioned essentially-slag-free segment, the waste being dragged by the molten metal bed such that it floats in the mentioned forward direction. Retaining the waste on the surface of the molten metal bed as it moves in the mentioned forward direction. Treating the waste under the effect of the constant and continuous heat exchange generated by the movement of the molten metal bed beneath the waste retained thereon.

Abstract: A process for producing molten iron with a combination of a moving-hearth reducing furnace and an iron bath-type melting furnace that includes charging a bedding carbonaceous material on a hearth of the moving-hearth reducing furnace and placing carbonaceous material-containing agglomerates containing a powdery iron oxide source and a powdery carbonaceous reductant on the bedding carbonaceous material; thermally reducing the carbonaceous material-containing agglomerates while moving the hearth in the moving-hearth reducing furnace to generate solid reduced iron and simultaneously thermally carbonizing the bedding carbonaceous material to generate char; hot-forming the solid reduced iron and the char into agglomerates without substantial cooling; continuously charging the agglomerates into the iron bath-type melting furnace from thereabove; and blowing oxygen-containing gas into the iron bath-type melting furnace to melt the solid reduced iron and to thereby generate molten iron.

Abstract: In order to allow a significant reduction of the steel production cost when producing stainless steel with the alloying elements chromium and nickel, according to the invention, it is proposed to perform the intermediate production of ferrochrimium and ferronickel in two separate direct reduction processes based on low-cost chromium ore and nickel ore in two SAF (3, 4) arranged in parallel on the primary side of a processing converter (6).

Abstract: A process for producing a semi-solidified slurry of an iron alloy including the steps of pouring a melt of an iron alloy into a semi-solidified slurry producing vessel 30 and cooling the melt therein to obtain a semi-solidified slurry having a crystallized solid phase and a residual liquid phase, wherein a hypereutectoid or hypoeutectic cast iron composition containing 0.8-4.3 wt. % C is used as a material, a melt of the composition is poured into the semi-solidified slurry producing vessel in a predetermined amount at a time, a temperature of the melt when poured into the semi-solidified slurry producing vessel is controlled to be not lower than a crystallization initiation temperature of the composition and not greater than a temperature that is 50° C. higher than the crystallization initiation temperature, and a cooling rate of the melt poured into the semi-solidified slurry producing vessel is controlled not to exceed 20° C. per minute.

Abstract: Efficient coordination of processing (by desulphurizing) and moving hot metal from a direct smelter, producing hot metal on a continuous basis, to an electric arc furnace or furnaces, operating on a batch basis, is disclosed. The invention includes the use of hot metal storage devices, such as ladles, that are large enough to supply hot metal for a small number, preferably two or three, of electric arc furnace batch operations.

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.

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

Abstract: A method and device for the purification and separation of purified metal from a metal mother liquid having a specific density and comprising one or more foreign element(s). The method includes: providing in a column device a starting material including metal crystals and a metal mother liquid including at least one foreign element; applying a temperature difference between a relatively hot zone at the upper end of the column and a relatively cool zone at the lower end of the column; a separation step wherein at least a part of the metal crystals is separated from the metal mother liquid by rising of the metal crystals to the upper surface of the metal mother liquid; and a further separation step wherein purified metal floating on the upper surface of the metal mother liquid is discharged from the column device.

Abstract: A process for tapping a steel furnace with a reduced amount of entrained slag is disclosed. During tapping, particles of a slag foaming agent are added. The foaming agent may include calcium carbide and/or other chemicals. The agent foams the slag to decrease its density during tapping and/or to disrupt initial vortex formation at the tap.

Abstract: In order to allow a significant reduction of the steel production costs when producing stainless steel with the alloying elements chromium and nickel, according to the invention, it is proposed to perform the intermediate production of ferrochromium and ferronickel in two separate direct reduction processes based on low-cost chromium ore and nickel ore in two SAF (3, 4) arranged in parallel on the primary side of a processing converter (6).

Abstract: A method for producing liquid ferroalloy by direct processing of manganese and chromium bearing iron compounds, by the steps: of mixing carbonaceous reductant, fluxing agent, and a binder with materials such as iron sands, metallic oxides, manganese-iron ore concentrates and/or chromium-iron ore concentrates and silica sands, to form a mixture; forming agglomerates from the mixture; feeding the agglomerates to a melting furnace with other materials; melting the feed materials at a temperature of from 1500 to 1760 C and forming a slag and hot metal; removing the slag; and tapping the hot metal as liquid ferroalloy.

Abstract: A process for producing steel and for obtaining slag having a high content of additional elements such as vanadium in a two-step process. Liquid pig iron is initially blown onto a high-grade slag at a lower temperature, the slag being further processed separately after tapping, while the pig iron is supplied to at least one additional converter in which it is blown at a higher temperature to form steel. A high-grade slag is generated while shortening the steel production process using the process in that the intermediate metal product that is tapped from the first converter is subjected to a heating and/or holding phase before being supplied to the second converter.

Abstract: Method and plant for pre-heating, transforming and melting a metal charge comprising metal scrap, in an electric arc furnace associated with a tunnel to transport, pre-heat and discharge the scrap. The furnace comprises a hearth and a roof through which the electrodes pass. The method provides that the furnace is weighed at least periodically in order to detect the quantity of discharged scrap present inside the furnace itself, that the temperature of the liquid bath inside the furnace is detected at least periodically and that at least the discharge delivery of the scrap inside the furnace is detected by weighing and is regulated in order to maintain the temperature of the liquid bath around a pre-determined value.

Abstract: The invention relates to a method for the removal of mercury from gas containing sulphur dioxide and oxygen and from the sulphuric acid vapour contained in the gas. According to the method, the gas is washed with a water solution that contains selenium ions, whereby metallic selenium is formed in the presence of oxygen, which precipitates the mercury in the gas and vapour either as a selenide or in a chlorine-containing environment, as a dichloride of mercury and selenium. Gas washing occurs at a low temperature, below 50° C.

Abstract: A duplex stainless steel containing C, Si, Mn, P, S, Al, Ni, Cr, Mo, N (nitrogen, O (oxygen), Ca, Mg, Cu, B, and W, and the balance Fe and impurities, where a number of oxide-based inclusions, which have a total content of Ca and Mg of 20 to 40% by mass and also have a long diameter of not less than 7 ?m, is not more than a 10 per 1 mm2 of the cross section perpendicular to the working direction, or further, the number of oxide-based inclusions, which have a content of S of not less than 15% by mass and also have a long diameter of not less than 1 ?m, is not more than 10 per 0.1 mm2 of the cross section perpendicular to the working direction. Particularly, the contents of Cu, B and W are desirably 0.2 to 2%, 0.001 to 0.01%, and 0.1 to 4% by mass, respectively.

Abstract: The invention relates to a device for preventing slag from flowing along when tapping a molten metal out of a metal-lurgical vessel, whereby the lap opening of the vessel is formed out of interchangeable pipes, which are located one above the other, made of wear-resistant refractory material, and enclosed by tap framing blocks, whereby the lower end of the lap interchangeable system, which is constructed as described, is formed by a cup block against which a slide that closes the opening rests. According to the invention, axially extending channels that are open at both ends of the pipe are provided in the pipe wall of at least the interchangeable pipe that leads into the interior of the vessel. Said channels are connected to a gas supply at the pipe end facing away from the interior of the vessel.

Abstract: Fume dust is prevented when molten metal is poured into a vessel, and water spray of water mist is introduced into the vessel or onto the molten metal, creating a reduced level of oxygen concentration of about 12% by volume, preferably about 8% by volume, inside the vessel or at the molten metal surface.

Abstract: To be able to produce metal melts using any metal carriers incurring in metallurgical practice as the charging materials, namely in the most diverse quantitative compositions, a plant for producing metal melts is provided with the following characteristic features: an electric arc furnace vessel (1) provided with one charging opening (11, 21) for a metal melt and/or scrap and/or direct reduced metal, in particular direct reduced iron, and/or ore and at least one electrode (16) and one slag tapping means (22), an oxygen-blowing converter vessel (3) provided with one melt tapping means (41), wherein the oxygen-blowing converter vessel (3) and the electric arc furnace vessel (1) form a unit which is connected via an overflow weir (34) and which is rigidly mounted on the foundation and, wherein the bath surface related specifically to the bath volume is smaller in the oxygen-blowing converter vessel (3) than in the electric arc furnace vessel (1) and the oxygen-blowing converter vessel (3) shares a common re

Abstract: A direct smelting process for producing molten iron and/or ferroalloys from a metalliferous feed material is disclosed. The process is a molten bath based process that is carried out in a direct smelting vessel. The process includes the steps of supplying metalliferous feed material, carbonaceous material and fluxes into the vessel; smelting metalliferous feed material to molten iron in the molten bath; and injecting an oxygen-containing gas into the vessel to post-combust gases generated in the process. The process is characterised by controlling the level of molten metal in the vessel by adjusting the pressure in the vessel.

Abstract: A chamber for receiving a downward flow of liquid metal includes a generally horizontal base having a generally planar impact surface. A first faceted sidewall having a plurality of facets formed therein, generally extends upwardly from and encompasses the planar surface to define an interior space. The interior space has an upper opening for receiving the downward flow of liquid metal. A second wall extends inwardly and upwardly from the first faceted wall toward the upper opening. A plurality of buttresses are spaced along the first faceted wall. Each of the buttresses extends between the impact surface and the second faceted wall. The buttresses form a plurality of discrete pockets including at least one facet. The pockets are defined by the buttresses, the impact surface, the first faceted wall and the second wall. The buttresses laterally deflect and divide the radial outward flow into a plurality of discrete flow patterns associated with the plurality of pockets.

Abstract: A tundish impact pad has a non-uniform construction with a long dimension and a short dimension perpendicular to the long dimension, the long dimension of the impact pad disposed aligned with the long dimension of the tundish on the tundish floor. The impact pad is a body of refractory material capable of withstanding continuous contact with molten steel during the entire use cycle of the tundish. The body has a base with an impact surface, an endless outer side wall extending upwardly from the impact surface, and a top surface substantially parallel to the impact surface and connected to the side wall and defining a non-uniform opening. The side wall also has an interior face which is semi-circular about an axis substantially parallel to the impact surface around the entire extent thereof, or channel-shaped, so that molten steel contacting the impact surface flows outwardly, then in turn inwardly then directed upwardly by the side wall interior face, and then flows out the opening.

Abstract: Molten (M) is poured into a receiver (8,28) designed to reduce fume and then out into an open area (P) via an outlet (9,29) designed to cause the metal (M) to flow in a laminar flow. A hood (11) may be present above the receiver (8,28).

Abstract: The present invention pertains to a process for cooling and purifying hot, dust-laden flue gases enriched with dioxins and other toxic components from a melting vessel, e.g., an arc furnace.Both the flue gases A, B generated during charging and those generated during the melting operation are collected, and the toxic components are removed in two ways.The flue gases A collected in the exhaust hoods 2 are fed into the filter 6, while previously blowing an additive 12, on which the toxic components settle before reaching the filter bags, into the flue gas stream A.The hot flue gases B drawn off directly from the arc furnace 1 are introduced into a combustion chamber 3 after passing through a water-cooled section 4, and are subjected to afterburning in the combustion chamber 3 to remove the toxic pollutants. These gases are then intermediately cooled in a second, water-cooled section 5, further cooled by adding more additional cold air A, and fed into the filter 7.

Abstract: A device for detecting slag in molten metal comprises a ladle shroud with a hollow passage that communicates a ladle containing the molten metal to a tundish to allow the molten metal to flow from the ladle to the tundish, and an electrically conductive element positioned in a wall of the hollow passage, so that the element is in electrical contact with the molten metal. If the ladle shroud is electrically conductive, the electrically conductive element is electrically isolated therefrom by an insulating sleeve around the electrically conductive element. Preferably, the electrically conductive element is a steel pin, particularly one where the steel pin has an flanged end in electrical contact with said molten metal, and more particularly where opposite end has a bore therein to accommodate an electrical lead wire to communicate the pin to a voltmeter.

Abstract: A tundish and, more specifically, an impact pad is formed with a bottom impact surface and includes an outer side wall extending upwardly therefrom which fully encloses an interior space or cavity having an upper opening into which molten metal is directed from a ladle shroud. The outer side wall of the pad includes an inner surface extending from the bottom impact surface to the opening of the pad. The inner side wall surface includes an annular portion which extends inwardly and upwardly toward the opening of the pad. In the preferred embodiment, the inner side wall surface curves continuously from the bottom impact surface to a vertical wall defining the opening of the pad. The pad redirects the pouring stream back into itself causing the counter current flows to slow each other down thereby minimizing turbulence and inhibiting high velocity flow within the tundish. The upward flow is further is advantageously directed away from the incoming pouring stream toward the surface of the bath.

Abstract: A method and apparatus is provided for temporarily retaining slag and nonmetallic particles in a tundish while molten metal is being transferred through the tundish to other desired vessels. In particular, a meltable dam is placed into an opening between the chambers in a tundish, and the meltable dam retains an accumulation of molten metal in the pour chamber of the tundish with the slag and nonmetallic particles floating on top of that level such that the slag and nonmetallic particles are above the opening between the chambers of the tundish. The dam then completely melts and allows the transfer of molten metal through the opening. The slag and nonmetallic particles are retained in the pour chamber, however, because the molten metal being transferred into the pour chamber maintains the level in that chamber above the opening until almost all of the metal has been transferred into and through the chamber.

Abstract: A process and apparatus carries out the direct removal of slag floating on the molten metal within a metallurgical furnace via vacuum suction-tube which is inserted from above through a furnace discharge opening. The tube discharge is connected into an evacuated external slag-cooling chamber, within which the slag stream exiting the suction-tube is granulated by impinging water jets. The water and entrained slag granules descend by gravity through a communicating water-column vacuum-leg, terminating in an atmosphere-exposed pool, within which the granules are collected on a conveyor which dewaters the granules while carrying the slag out of the pool to an external pile or bin. The invention is capable of realizing slow slag discharge at controlled rates over long time periods, as well as in conjunction with the simultaneous and continuous metal withdrawal by a somewhat analagous metal siphon tube into an evacuated metal withdrawal chamber for casting.

Abstract: An automatic molten metal supplying device and supplying method capable of promoting discharge of molten metal retained in a ladle during pouring into an injection sleeve of a die-casting machine, and capable of preventing a residual molten metal from being suspended from the intake/discharge port. A ladle is selectively communicatable with an atmosphere by the opening/closing unit. The opening/closing unit is connected to a molten metal pressurizing mechanism 20 and a residual molten metal removing mechanism 30 through pipes. At the time of pouring, small volume or low pressure fluid is introduced into the ladle by means of the molten metal pressurizing mechanism through the opening/closing unit. After completion of the pouring, large volume or high pressure fluid is introduced into the ladle by the residual molten metal removing mechanism. Since low volume or low pressure fluid is applied into the ladle during pouring, the molten metal can be smoothly discharged from the ladle.

Abstract: A plant for the production of molten metals, includes a melting vessel and a metallurgical vessel receiving the melt from the melting vessel for aftertreating the melt and closed by a lid. The melting vessel has a tap opening for the melt provided on the bottom level of the melting vessel and located on the periphery of the melting vessel. The tap opening is positioned above a pour-in opening of the metallurgical vessel. In order to ensure a continuous melting procedure, the pour-in opening of the metallurgical vessel following the melting vessel is provided above a melt guiding chute arranged within the metallurgical vessel.

Abstract: An apparatus for producing solidified metals of high cleanliness removes floating matter such as oxides from the surface of molten metals prior to melt atomization. The apparatus includes a water-cooled melt vessel having a dam extending from a sidewall of the vessel at an acute angle to the sidewall. The dam extends above a preselected metal surface level of the interior of the vessel to form a floating matter trap region within the apex of the acute angle. There is a passageway through the dam sufficiently remote from the trap region that floating matter in the trap region is not in communication with the passageway. The passageway may be entirely below the metal surface level or extend from below the metal surface level to above the metal surface level, but sufficiently far away that floating matter can be forced away from the passageway, as by the herding action of a plasma torch.

Abstract: A dart-assembly for piercing open a blockage in the opening of a ladle for holding and transporting molten steel is mounted in the outlet bore of a slide-gate associated with the ladle opening. The assembly has an outer steel housing; mounted within the housing is a dart-member having an elongated rod, which rod has a lower threaded end for receiving a threaded nut. The upper end of the rod is provided with a dart-like head-portion which actually contacts and pierces through the blockage in the opening of the ladle when the dart-member is fired. A compression spring is telescopingly mounted about most of the length of the elongated rod of the dart-member, between the enlarged dart-like head-portion and the upper, flat-surface of a stop member.

Abstract: In the manufacture of pig-iron in a shaft furnace, a taphole is closed with hardened plugging compound during making of the iron and is opened for the tapping of the iron and then resealed. The resealing of the taphole comprises inserting hardenable plugging compound into the taphole and, before hardening thereof, driving a hollow tube into the plugging compound. The hollow tube has an open front end. The tube is pulled out at the next tapping. The use of a tube avoids disturbance of the plugging compound and creates a smoother taphole, leading to improved flow of liquid iron.

Abstract: A method and apparatus for the forced production of exceptionally clean steel wherein a metallurgical vessel is insulated and sealed to maintain a neutral environment into which steel is tapped and cleaned by use of gas injection and impurity precipitation and removal.