Abstract: A process for drying fine tailings is provided. The process, which may use a pipeline reactor system, comprises providing an in-line flow of the fine tailings; continuously introducing a flocculent solution to cause dispersion and commence flocculation of the fine tailings and may comprise rapid turbulent mixing; subjecting the fine tailings to flocculation and water release conditioning in-line to cause formation and rearrangement of floes and increasing the yield shear stress to form flocculated fine tailings while avoiding over-shearing of the flocs; and depositing the fine tailings to allow the release of water, formation of a non-flowing fine tailings deposit and drying of the non-flowing fine tailings deposit. The process enables effective in-line dispersion, flocculation and water release, resulting in reliable deposition and drying of the fine tailings deposit.

Abstract: Methods and systems for processing an iron ore tailings byproduct are described. In one embodiment, a method for processing an iron ore tailings byproduct includes sizing particles within a slurry of the iron ore tailings byproduct to separate particles from the slurry having a dimension less than a predetermined size. After sizing, the method may further include centrifugating the particles less than the predetermined size into centrifugated concentrate and tails portions. The centrifugated concentrate portion may be separated into separated concentrate and tails portions. Finally, in certain embodiments, the separated concentrate portion may be de-watered to a remaining composition of matter comprising iron in greater proportion than in the iron ore tailings byproduct. Generally, using the systems and methods described herein, iron that would have otherwise been un-recovered is extracted from the iron ore tailings byproduct.

Abstract: The present invention is directed to provide a production method for carbonaceous material-containing metal oxide briquettes, capable of ensuring sufficient strength of briquettes while using a metal oxide material containing a large amount of fine particles, such as steel mill dust. This method comprises a mixing step of mixing a metal oxide material A containing a large amount of fine particles with a carbonaceous material B in a mixer 15, to form a powdery mixture E, a compacting step of compacting the powdery mixture E using a briquette machine 17 to form compacts F, a classifying step of classifying the compacts F into an oversize fraction G and an undersize fraction H, using a sieve 18, and collecting the oversize fraction G as product briquettes, and a compact circulating step of returning a part of the compacts F to the mixer 15 or the briquette machine 17, as a recycle material.

Abstract: A method of producing an ore slurry includes pulverizing and classifying steps as well as an ore slurry condensing step, wherein the slurry condensing step uses as a flocculant solution a diluted solution of the flocculant that satisfies the conditions of: (A) a flocculant molecular weight of 8×106 to 20×106 and (B) a flocculant dilution ratio of 0.1 to 0.5 g/L, and with respect to the added amount of the flocculant, a flocculant solution having an amount corresponding to 50 to 150 g of the flocculant amount per ton of dried solid components of the ore slurry is added to the ore slurry so as to be made in contact therewith for a sufficient period of time, with the temperature of the slurry being set in a range from 35 to 45° C. upon transporting the slurry from the condensing step to the next process.

Abstract: A method of enriching the iron content of low grade iron ore bearing materials has been developed which produces a high iron ore concentrate suitable for processing into pig iron and steel. The process includes reducing the low grade iron ore bearing materials to a fine particulate form and treating a water slurry of this material by applying a combination of ultrasonic treatments in a plurality of high and low intensity magnetic separation operations to remove interfering materials and concentrate magnetic and paramagnetic iron bearing materials into a high grade ore stock.

Abstract: Systems and methods for processing sludge from a fume scrubbing system that scrubs fumes from a steelmaking converter in a manner that separates/isolates a significant portion of the metallic iron particles in the sludge and prepares these particles for convenient handling. In an exemplary system, the system includes separating equipment that isolates metallic iron particles in the sludge and forming equipment that forms the isolated particles into briquettes that have relatively high mechanical resistance that allow the briquettes to maintain their integrity during handling and storage. The high-metallic-iron-content briquettes can be recycled in the steelmaking process, for example, as charging material for a basic oxygen converter or an electric arc furnace. Water used in the system can be recycled and reused within the system, thereby making the system environmentally friendly.

Abstract: A method and an apparatus for treating return ores using plasma, capable of treating sintered return ores generated in a sintering process in a steel maker or return ores (iron ores) employed in other ironmaking process such as FINEX. The method of treating return ores using plasma includes: providing return ores sorted out by a sorting process; and bonding the return ores by fusing and agglomerating the return ores using plasma. Also, an apparatus for treating return ores using plasma includes a plasma heating device used to fuse and agglomerate sorted return ores. The return ores of a predetermined grain size are fusion-bonded and agglomerated using a flame of a plasma heating device. Particularly, the return ores can be treated in a massive amount to enhance productivity of a fusion-bonding process of the return ores. Furthermore, a great amount of sintered return ores generated in the sintering process can be subjected to a fewer number of re-treatment processes.

Abstract: The invention relates to a preparation method for stainless steel slags and modified steelworks slags for recovery of metal. In order to create a dry preparation method which guarantees a low wear and energy efficient comminution and de-agglomeration of stainless steel slags and modified steelworks slags as well as a selective separation of a metal fraction and a silicate fraction and which can be variable in relation to the different slag compositions and different requirements upon the quality of the metal fraction and the at least one silicate fraction, a roller mill is used at least for the comminution. The slags are supplied with a feed grain size of up to approximately 150 mm. The use of an air swept roller mill is advantageous, in which the comminution and de-agglomeration, if necessary drying, and at the same time a separation into an extensively mineral-free metal fraction and a virtually metal-free silicate fraction are brought together.

Abstract: Systems and methods for processing sludge from a fume scrubbing system that scrubs fumes from a steelmaking converter in a manner that separates/isolates a significant portion of the metallic iron particles in the sludge and prepares these particles for convenient handling. In an exemplary system, the system includes separating equipment that isolates metallic iron particles in the sludge and forming equipment that forms the isolated particles into briquettes that have relatively high mechanical resistance that allow the briquettes to maintain their integrity during handling and storage. The high-metallic-iron-content briquettes can be recycled in the steelmaking process, for example, as charging material for a basic oxygen converter or an electric arc furnace. Water used in the system can be recycled and reused within the system, thereby making the system environmentally friendly.

Abstract: A raw material for sintering of 100% in total is blended so as to adjust iron-containing dust and/or sludge to 60% or more, and coarse grains having a grain size of 2 mm or larger to 20% or more on the weight basis, one-third or less of the total amount of addition of coke breeze is added as a fuel, the blend is kneaded and granulated using a vibration kneading granulator to thereby produce granulated grains, the residual portion of the total amount of addition of coke breeze is added to the granulated grains, the blend is subjected to exterior coating granulation using a rolling type granulator, thus-granulated raw material for sintering is screened, and a fraction having a grain size of 1 mm or larger is used for sintering, making it possible to sinter microparticulate dust and microparticulate sludge as main raw materials, which have conventionally been used only to a limited amount of use.

Abstract: In a method and a system for sorting shredder residues of metal-containing wastes, in particular from vehicle body shells, shredder residues are separated into a shredder light fraction and a non-ferromagnetic fraction. The method and system provide for a raw-granulate fraction being produced during the sorting of the shredder light fraction and the shredder heavy fraction in preliminary processes and a main process, by separating out at least one ferromagnetic fraction, a nonferrous-metal fraction, a fiber fraction, and a sand fraction, and the raw-granulate fraction being split up in a refining process.

Abstract: The present invention is directed to provide a production method for carbonaceous material-containing metal oxide briquettes, capable of ensuring sufficient strength of briquettes while using a metal oxide material containing a large amount of fine particles, such as steel mill dust. This method comprises a mixing step of mixing a metal oxide material A containing a large amount of fine particles with a carbonaceous material B in a mixer 15, to form a powdery mixture E, a compacting step of compacting the powdery mixture E using a briquette machine 17 to form compacts F, a classifying step of classifying the compacts F into an oversize fraction G and an undersize fraction H, using a sieve 18, and collecting the oversize fraction G as product briquettes, and a compact circulating step of returning a part of the compacts F to the mixer 15 or the briquette machine 17, as a recycle material.

Abstract: The present invention relates a flotation reagent for sulfidic ores, containing at least one compound of formula (1), wherein R2, R3, R4, R5, R6 and R7, independent of one another, represent hydrogen or groups containing 1 to 15 carbon atoms or groups containing oxygen or nitrogen, and at least another compound serving as collector and containing at least one sulfur atom that is directly bound to a carbon or phosphorus atom, wherein the carbon or phosphorus atom is directly bound to at least another sulfur atom or an oxygen atom.

Abstract: A method of making steel in an electric arc furnace is provided. The method comprises the steps of charging a steelmaking furnace with an iron source, wherein the iron source is melted and refined in the steelmaking furnace during a campaign, providing a source of lime that is screened by a first screening device, compacting the lime material adjacent to the steelmaking furnace to a predetermined size, charging the compacted lime to the steelmaking furnace within a short period of time to avoid degradation of the compacted lime, and adding additional fluxing agents and additives to the steelmaking furnace to produce refined steel in the campaign.

Abstract: In a method of the magnetic loading of a sintering material, magnetically susceptible sinterable substances of high magnetization and fine substances of slidable dropping at low speed are segregated in great amounts in an upper portion of a sintering material layer deposited on a pallet. More of magnetically susceptible sinterable substances such as mill scale, returned ore and the like of good magnetic attachment and fine substances of low drop speed are caused to be segregated in the upper portion of that layer. A magnetic force is applied to a starting sintering material, during movement of the latter having been facilitated in its particle size segregation on a sloping chute, by means of a cylindrical magnetic drum having built therein a permanent magnet and disposed downwardly of the sloping chute.

Abstract: In a method of the magnetic loading of a sintering material, magnetically susceptible sinterable substances of high magnetization and fine substances of slidable dropping at low speed are segregated in great amounts in an upper portion of a sintering material layer deposited on a pallet. More of magnetically susceptible sinterable substances such as mill scale, returned ore and the like of good magnetic attachment and fine substances of low drop speed are caused to be segregated in the upper portion of that layer. A magnetic force is applied to a starting sintering material, during movement of the latter having been facilitated in its particle size segregation on a sloping chute, by means of a cylindrical magnetic drum having built therein a permanent magnet and disposed downwardly of the sloping chute.

Abstract: In a method of the magnetic loading of a sintering material, magnetically susceptible sinterable substances of high magnetization and fine substances of slidable dropping at low speed are segregated in great amounts in an upper portion of a sintering material layer deposited on a pallet. More of magnetically susceptible sinterable substances such as mill scale, returned ore and the like of good magnetic attachment and fine substances of low drop speed are caused to be segregated in the upper portion of that layer. A magnetic force is applied to a starting sintering material, during movement of the latter having been facilitated in its particle size segregation on a sloping chute, by use of a cylindrical magnetic drum having built therein a permanent magnet and disposed downwardly of the sloping chute.

Abstract: An iron based product having at least a sufficient total ferrous content by weight to render the product commercially feasible wherein the product is derived by a process comprising the beneficiation of kish slag waste material having a relatively low ferrous material content before beneficiation. The resulting iron based product has a total ferrous content of substantially 90% by weight thereby making it both practical and economical for the reintroduction into iron and/or steel making processes utilizing an injection method or by briquetting at at least a portion of the resulting product. The beneficiation process involves the heating of the waste material to an extent at least sufficient for drying, separating the high sulphur slag from a remainder of the waste material and subsequently classifying the remainder of the waste material, once separated from the high sulphur slag by particle size.

Abstract: A process for producing intermediate grade manganese concentrate from low grade manganiferous ores is disclosed. A low grade manganiferous ore containing silicon, iron, between 1 and 20 per cent manganese and oxides of silicon, iron and manganese is first crushed to reduce the size of the manganiferous ore to a fraction of its original size. The crushed manganiferous ore is then heated to a temperature sufficient to chemically transform the manganese and iron in the manganiferous ore to an artificial magnetic, manganese-iron spinel. The heat treated manganiferous ore is cooled, preferably by air, and then beneficiated by further crushing and grinding to liberate the artificial manganese iron spinel from the silicon and other oxides within the ore. Finally, the artificial manganese-iron spinel is magnetically separated from the silicon and other oxides within the ore to increase the concentration of the manganese and thereby provide an intermediate grade manganese concentrate.

Abstract: A process for the recovery of at least a major proportion of the useful metallic iron values in small sized ferrous slags and drosses in which the slags and drosses are subjected to at least one grinding step in a wet grinding mill. Depending on the size of the slag and dross particles, either a peripheral end discharge rod mill or an axial discharge ball mill is used. In a preferred configuration, two wet grinding stages are used, comprising a peripheral end discharge rod mill followed by a ball mill. Products with different metallic iron contents are recovered by interposing screens with suitably sized openings between and after the grinding mills. This process makes it possible to recover at least about 80% of the metallic iron in the feed material.

Abstract: Iron ore concentrate is converted to magnetic gamma hematite in an autogenous roasting operation which is self-sustaining. The iron ore concentrate is preheated and contained magnetite is oxidized to hematite. Hematite is reduced to magnetite using carbon monoxide. After cooling, the magnetite is oxidatively exothermically converted to magnetic gamma hematite. The thermal energy resulting from the latter step is recycled to the preheating and reduction steps while thermal energy resulting from the cooling step also is recycled to those steps. The magnetic gamma hematite may be subjected to magnetic separation to produce a very low silica high purity iron oxide concentrate, which may be blended with high silica concentrate to provide a pellet feed for making blast furnace feed pellets.

Abstract: Iron ore concentrate is converted to magnetic gamma hematite in an autogenous roasting operation which is self-sustaining. The iron ore concentrate is preheated and contained magnetite is oxidized to hematite. Hematite is reduced to magnetite using carbon monoxide. After cooling, the magnetite is oxidatively exothermically converted to magnetic gamma hematite. The thermal energy resulting from the latter step is recycled to the preheating and reduction steps while thermal energy resulting from the cooling step also is recycled to those steps. The magnetic gamma hematite may be subjected to magnetic separation to produce a very low silica high purity iron oxide concentrate, which may be blended with high silica concentrate to provide a pellet feed for making blast furnace feed pellets.

Abstract: The separation rate of electrostatic precipitators associated with sintering plants is improved in that the exhaust gas is conditioned by means of solid particles. For that purpose, part of the coke breeze as a fuel for the sintering process is branched off, separately ground, supplied to the exhaust gases to be dedusted, collected together with the dust in the electrostatic precipitators and returned to the sintering process.

Abstract: A method for compaction of iron bearing materials includes the steps of accumulating iron and steel plant waste materials, including iron bearing fines, hazardous mill waste products, fines, turnings, borings, sludge, dust, mill scale, and the like; and agglomerating such materials by ram briquetting in a ram briquetter.