Abstract: A process for converting organic wastes into a reducing agent-coke substitute (“RACS”). More specifically, a process for producing a reducing agent-coke substitute from a mixed waste material containing economically recoverable metals and organic based materials is described. In accordance with one aspect, the process comprises blending mixed waste material with a metal-containing smelter by-product, processing the blend of mixed waste material and smelter by-product through a heated mixing device to convert the blend into reducing agent-coke substitute.

Abstract: The process for producing the sponge iron includes the steps of preparing a sandwich of at least two layers wherein the at least two layers includes a first layer (10) of iron oxide source which content is carbon free or comprises of only self-contaminant carbon or carbonaceous and second layer (12) is a mixture of iron oxide source and carbon source and subjecting the sandwich of at least two layers to a pyrolysis process in a non-oxidative environment at temperature between 950° C. to 1900° C. for a period between 10 minutes to 36 hours. The carbon source in the second layer (12) is equal to or more than stoichiometric weight of carbon according to a predominant reaction. The non-oxidative pyrolysis occurs in a reactor. The sandwich of two layers is placed in a moving carrier (16) such as tray to accommodate the sandwich of two layers in the reactor.

Abstract: One aspect is a method for producing an alloy, whereby the alloy includes at least a first metal and a second metal, whereby firstly a powder metallurgical route and subsequently a melt metallurgical route is used sequentially in order to generate the alloy from the, at least, first metal and the second metal. The method includes grinding the first metal into a first metal powder, grinding the second metal into a second metal powder, mixing the first metal powder and the second metal powder to produce a blended powder, generating a blended body from the blended powder by the powder metallurgical route, and generating the alloy by melting the blended body by the melt metallurgical route.

Abstract: The present technology provides an illustrative apparatus for recycle electric arc furnace (EAF) dust and method of use related to the same. The apparatus has a heat controlling region coupled to a separation volume and includes at least one magnet and a cooling region. The heating controlling region operates at a temperature sufficient to transform at least some of the EAF dust into a mixture of gaseous zinc and one or more additional metals. The magnet separates the iron-rich material from the mixture of gaseous zinc and one or more additional metals and the cooling region condenses the gaseous zinc.

Abstract: A process for converting organic wastes into a reducing agent-coke substitute (“RACS”). More specifically, a process for producing a reducing agent-coke substitute from a mixed waste material containing economically recoverable metals and organic based materials is described. In accordance with one aspect, the process comprises blending mixed waste material with a metal-containing smelter by-product, processing the blend of mixed waste material and smelter by-product through a heated mixing device to convert the blend into reducing agent-coke substitute.

Abstract: Methods and apparatus are disclosed for condensing vapour phase compounds or elements, typically metals such as magnesium, obtained by reduction processes.

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: The present invention is based on a novel electric induction furnace design that enables the removal of zinc-containing filter dust (FD) originating from the production of steel (alloy or non-alloy) and the production of cast iron with galvanized steel scrap, using a novel process based on the carbothermal reduction of the metal oxides present in the FD, performed at the temperature at which the materials are melted inside the electric induction furnace. The electric induction furnace of the invention incorporates an electric arc or plasma beam generator to melt all the inorganic non-metallic material. The incorporation of this generator also enables the use of large volumes of molten slag.

Abstract: Disclosed is a process and apparatus for the treatment of divided metal residues contaminated by one or more organic compounds, including mixing, inside a chamber, of metal residues with at least one calcium/magnesium compound capable of reacting exothermically with water; exothermic reaction of the at least one calcium/magnesium compound with the water that the metal residues contain; rise in temperature of the metal residues subject to an exothermic reaction; dehydration of the metal residues during this exothermic reaction; oxidation of the organic compounds during the mixing, by bringing the metal residues contaminated by one or more organic compounds mixed with the at least one calcium/magnesium compound into contact with a gas stream containing at least partly oxygen; and removal from the chamber of a handleable dehydrated treated product having a residual content of organic compounds of less than 1% by weight of the treated product.

Abstract: A process for producing a foamed slag on austenitic stainless melts in an electric arc furnace. A mixture of metal oxides and carbon is introduced into the furnace, the metal oxide is reduced by the carbon below the slag at the metal/slag interface, and the resulting gases bring about the foaming of the slag by bubble formation. The mixture to be charged, which is added in the form of preforms such as briquets or pellets, contains iron oxide, iron carriers, carbon and the required binders in addition to nickel oxide.

Abstract: Process of treating filter dust (3) of the type produced in aluminium recycling processes in a recycling system for recycling the metal (1) of salt slag recycling (2), including at least a pyrolysis step (31) in which the filter dust (30) enter a rotating auger where it is heated to a temperature of not less than 500° C. and not more than 600° C.; and in which the organic and toxic substances breakdown in this heating and part of the carbon and other combustibles burn in the controlled presence of air, this air being mixed with the dust by the movement of the rotating auger (310); in which organic materials are oxidized due to the oxygen provided; and in which the solid result of the pyrolysis step (31) is added to the general salt slag recycling process (2).

Abstract: The disclosed invention provides an improved method that utilizes a liquid ladle slag in combination with a crushed material, such as a refractory brick, and alumina ladle brick or an aluminum dross, to manufacture a calcium aluminate product that can be used in the steel refining process.

Abstract: The disclosure is directed to a process for producing separable iron and titanium oxides from an ore containing titanium oxide and ferric oxide, comprising: (a) forming agglomerates comprising carbon-based materials and the ore, the quantity of carbon of the agglomerates being sufficient for, at an elevated temperature, reducing ferric oxide to ferrous oxide and forming a ferrous oxide-rich molten slag, (b) introducing the agglomerates onto a carbon bed of a moving hearth furnace; (c) heating the agglomerates in the moving hearth furnace to a temperature sufficient for reducing and melting the agglomerates to produce a ferrous oxide-rich molten slag; (d) metallizing the ferrous oxide of the molten slag by reaction of the ferrous oxide and the carbon of the carbon bed at a furnace temperature sufficient for maintaining the slag in a molten state; and (e) solidifying the slag after metallization of the ferrous oxide to form a matrix of titanium oxide-rich slag having a plurality of metallic iron granules distri

Abstract: The invention relates to a process for producing a material based on silver-carbon, that involves the steps of: (i) providing a suspension of carbon particles; and (ii) supplying a solution of a silver compound and of a reducing agent, such that a silver-containing precipitate is deposited onto the carbon particles, where the carbon particles have a mean diameter of 200 nm or greater. The invention further relates to a material obtainable by this process and to the use of the material in circuit breakers for low-voltage power engineering.

Abstract: The disclosed invention provides an improved method that utilizes a liquid ladle slag in combination with a crushed material, such as a refractory brick, an alumina ladle brick or an aluminum dross, to manufacture a calcium aluminate product that can be used in the steel refining process.

Abstract: A molded body containing titanium, a method for the production thereof, and the use thereof.

Abstract: The present invention is directed to cobalt compounds and methods for making such metal oxide compositions, specifically, metal oxide compositions having high surface area, high metal/metal oxide content, and/or thermal stability with inexpensive and easy to handle materials.

Abstract: A method of treating a spent potliner after use in an aluminum smelting process, the method comprising crushing and classifying the spent potliner, placing the classified and crushed spent potliner in a furnace at a temperature greater than 450° C., heating the spent potliner to a temperature greater than 450° C., mixing the heated spent potliner with water to produce reaction gases and residue, burning the reaction gases, mixing the residue with water in a well ventilated area for a period of weeks to cure the residue. The method also embraces blending the cured residue with other chemicals and minerals to provide specific mineral products.

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: The disclosure is directed to a process for producing separable iron and titanium oxides from an ore containing titanium oxide and ferric oxide, comprising: (a) forming agglomerates comprising carbon-based materials and the ore, the quantity of carbon of the agglomerates being sufficient for, at an elevated temperature, reducing ferric oxide to ferrous oxide and forming a ferrous oxide-rich molten slag, (b) introducing the agglomerates onto a carbon bed of a moving hearth furnace; (c) heating the agglomerates in the moving hearth furnace to a temperature sufficient for reducing and melting the agglomerates to produce a ferrous oxide-rich molten slag; (d) metallizing the ferrous oxide of the molten slag by reaction of the ferrous oxide and the carbon of the carbon bed at a furnace temperature sufficient for maintaining the slag in a molten state; and (e) solidifying the slag after metallization of the ferrous oxide to form a matrix of titanium oxide-rich slag having a plurality of metallic iron granules distri

Abstract: Acid mine drainage is treated to form a wet meal-containing precipitate. Such wet metal containing precipitate is dried and processed to form a powder which contains one or more metals. The powder (alone or in combination with other metal powders or other additives) is then compressed (e.g., pressed in a die, rolled, extruded) and sintered to form a desired sintered metal article. In some embodiments, the sintered metal article may be subjected to one or more secondary processes (e.g., oil impregnation, resin impregnation, metal infiltration, copper infiltration, heat treating, steam oxidizing, plating and secondary machining) to alter the strength, configuration or other property of the pressed metal article.

Abstract: The invention relates to a layered filter structure, said filter element comprises—a first layer, said first layer comprising a porous metal layer;—a second layer, said second layer comprising a self-supporting layer of sintered short metal fibers. The first and the second layer are sintered together. The layered filter structure is in particular suitable as surface filtration medium, for example for the filtration of liquids or gases.

Abstract: A method of preparing a composite cathode active material having superior cell characteristics includes mixing and milling starting material, carbon and an organic complexing agent. The mixture is heated at a first temperature in an inert atmosphere to form a composite precursor, and then the precursor is ground and heated at a second temperature in an inert atmosphere to produce a carbon-containing composite cathode material having high electronic conductivity The said composite cathode has a general formula of LiFe1-xMxPO4—C, within 0?x<1, M is selected from the group consisting of Co, Ni, V, Cr, Mn and a mixture thereof.

Abstract: The present invention relates to a process of treating filter powders (3) of the type produced in aluminum recycling processes in a recycling system for recycling the metal (1) of saline slag recycling (2), comprising at least a pyrolysis step (31) in which the filter powders (30) enter a rotating auger where they are heated to a temperature of not less than 500° C. and not more than 600° C.; and in which the organic and toxic substances breakdown in this heating and part of the carbon and other combustibles burn in the controlled presence of air, this air being mixed with the powder by the movement of the rotating auger; in which organic materials are oxidized due to the oxygen provided; and in which the solid result of the pyrolysis step (31) is added to the general saline slag recycling process (2).

Abstract: The disclosed invention provides an improved method that utilizes a liquid ladle slag in combination with a crushed material, such as a refractory brick, an alumina ladle brick or an aluminum dross, to manufacture a calcium aluminate product that can be used in the steel refining process.

Abstract: A method of improving the sintering of mineral bearing ore which comprises the addition of an aqueous solution of a transition metal sulfate, preferable copper sulfate, to the sinter base mix or to the sinter trim feed is disclosed.

Abstract: A method of producing reduced iron pellets including reducing raw material pellets to obtain reduced iron pellets, and rolling the reduced iron pellets at a temperature ranging between 800 and 1200° C. sufficiently such that the reduced iron pellets undergo sintering.

Abstract: A method is provided by which rice hull ash is pelletized for use in steelmaking. The rice hull ash is blended with lime or dolime, and also with a mixture of water and molasses. This generates heat as the lime and water react to form lime hydroxide, a known binder. The heat thus generated reduces the energy required for drying the pellets.

Abstract: A sintered alloy that enables the reducing of coefficient of friction and the sealing of pores on a surface thereof and a method of manufacturing the same. A sintered alloy body includes a resin film layer and pores. The pores define a porosity ranging from 2 to 35 volume %, each having an inlet portion and an inside portion, defining a pore inlet diameter and a pore inside diameter respectively. The pore inlet diameter ranges from 10 to 200 &mgr;m, and an average ratio of the pore inlet diameter to the pore inside diameter is at least. Solid lubricant is dispersed in the resin film layer. After forming the layer 3, it is pressed against the sintered alloy body. Thus, the layer enters into the pores to closely contact them, thereby sealing the pores, reducing the coefficient of friction due to the solid lubricant.

Abstract: The invention relates to a method of regulating a roasting furnace in fluidized bed roasting. Part of the roasting furnace grate is separated off into a separate grate section, known as the overflow grate, where the nozzles and the amount of roasting gas blown through them can be regulated independently of the main grate. It is advantageous to position the separately regulated grate in the section of the furnace where the overflow aperture is located.

Abstract: Nanostructured non-stoichiometric materials are disclosed. Novel magnetic materials and their applications are discussed. More specifically, the specifications teach the use of nanotechnology and nanostructured materials for developing novel magnetic devices and products.

Abstract: The invention relates to an extrusion device (1) for compacting metal parts, in particular shavings (3), for example made of Fe, Cu, Mg or alloys of these elements or other low melting metals or their alloys, into homogenous extrusion mouldings with at least one extrusion unit with an extrusion die (5) formed by a die housing (9) which forms a die cavity (8) and has a guide arrangement for an extrusion element (7) adjustable by a drive device (6), and with an inlet opening (28) for the shavings (3) in the die housing (9), whereby a compression channel (18) is arranged opposite a front face of the extrusion element (7) facing the mould cavity (8) and adjacent to the mould cavity (8) in the direction of a passage surface (15) for a material strand (2).

Abstract: A slag conditioner for extending the life of a BOF vessel lining utilizing recycled blast furnace filter cake dewatered by contact with a hot slag; its process of production, and method of use.

Abstract: The invention concerns a method for upgrading steel plant dust to recuperate industrially reusable compounds. Said method comprises an attrition and dilution step, a solid/liquid separating and solid washing step, an acid leaching step, and acid purification step comprising a carburizing reaction or a carburizing and decalcification reaction. Said method is characterised in that it comprises an oxidation/neutralisation step which includes a step oxidizing iron into iron oxyhydroxides and/or iron oxides and a neutralizing reaction of the reaction medium.

Abstract: Self-reducing agglomerates are provided for use in the production of metal. The agglomerates comprise a mixture of iron oxide containing particles and particles of a reducing agent bonded by use of a pre-gel. The agglomerates are produced by a method and apparatus that provides for mixing and curing thereof. The agglomerates may then be used for reduction thereof for the production of iron.

Abstract: A method for producing an improved charging stock for use in further metallurgical processes including the steps of providing a source of molten metal of known composition, providing a source of solid particulate material of a known composition which is compatible with the molten metal, combining the molten metal source with the solid particulate material source to produce a combined stream and forming the combined stream into a plurality of uniformly sized metal billets for use in further metallurgical processes.

Abstract: The present invention relates to a method for manufacturing a diamond composite from diamond particles, comprising the steps of forming a work piece, heating the work piece and controlling the heating temperature and heating time so that a certain desired amount of graphite is created by graphitization of diamond particles, thereby creating an intermediate body, and infiltrating silicon or silicon alloy into the intermediate body. The invention also relates to a diamond composite produced by this method.

Abstract: Specific recycle materials are blended with hot slag and wet sludge to make a recyclable steelmaking revert. The specific recycle materials are kish, lime, glass, ferro-manganese and the like. The specific materials are blended with the slag and sludge individually or in any desirable combination to form a steelmaking revert. After the recycle materials are blended with the slag and sludge, the recycle blend slag/sludge mixture is allowed to rest to bring the moisture content to less than 10% by weight. The steelmaking revert and process for making the same reduce the need for steelmaking raw materials by employing recycle materials from land fills. Thus, the cost of steel production is reduced.

Abstract: An apparatus for producing reduced iron, and a compact drying method for application to the apparatus are disclosed. The apparatus comprises a pelletizer or a briquetter for mixing and agglomerating coal as a reducing agent and iron ore as iron oxide to form compacts, a dryer for drying the compacts, a circular rotary hearth type reducing furnace for reducing the dried compacts in a high temperature atmosphere, a first heat exchanger for performing heat exchange between a hot off-gas discharged from the reducing furnace and combustion air to be supplied to the reducing furnace, and coolers for cooling the hot off-gas. A second heat exchanger for heating drying air is disposed on an exit side of the first heat exchanger. The drying air heated by the second heat exchanger is supplied to the dryer to dry the compacts with the drying air scant in moisture. Consequently, highly efficient, stable drying in the dryer can be performed, and high quality reduced iron can be produced stably.

Abstract: The wet granulated iron ore is initially conducted through a drying zone. The ore leaves the drying zone at a temperature of 120-400° C. The ore is then heated in direct contact with hot gas to temperatures of 700-1,100° C. before being delivered to a reduction zone. The ore coming out of the drying zone is fully or partially guided through a separating device so as to separate the ore into fine and coarse grain fractions. The fine-grained ore fraction is conveyed to a granulating device so as to produce an iron ore granulate which is conducted to the drying zone. The coarse-grained ore fraction is heated to temperatures of 700-1,100° C. before it is guide into the reduction zone.

Abstract: A method of processing flue dust that contains one or more compounds from a first group of zinc, lead and cadmium compounds, and contains iron compounds, involves heating the flue dust to cause a substantial portion of one or more of the compounds of the first group to become gas-borne. A carbonaceous material is introduced to the remaining flue dust, and the flue dust/carbonaceous material mixture is heated to cause a substantial portion of the remaining compounds from the first group to become gas-borne while retaining a substantial portion of the iron in a non-gas-borne condition. The gas-borne compounds are separated from the non-gas-borne compounds.

Abstract: A method of solidifying a steel-making slag is performed by subjecting a mixture of a steel-making slag containing at least about 50% by weight of a powdery steel-making slag having a particle size not greater than about 5 mm and a substance containing at least about 30% by weight of SiO2 (e.g., a fly ash and/or the fine powder of a granulated blast furnace slag) to a hydration reaction. The resulting solidified material contains at least about 20% of a tobermorite phase, has high strength and is suitable as an inorganic material useful as a roadbed material, building and civil engineering materials, etc.

Abstract: This invention provides a method to control the off gas emission of sulfur dioxide from a mineral ore roaster by grinding a sulfur-containing mineral ore, adding sodium sesquicarbonate to the mineral ore, and roasting the ore and sodium sesquicarbonate at an elevated temperature.

Abstract: A process for producing fired pellets by granulating finely-ground iron ore and subjecting the resulting granules sequentially to drying, dehydration, preheating, and firing, wherein said process comprises adding an additive to said finely-ground iron ore at the time of granulation, said additive reacting with iron ore to form a compound which has a melting point lower than the preheating temperature. Owing to the additive (or sintering auxiliary) added in a small amount to iron ore powder, it is possible to produce preheated pellets by using the existing grate kiln without increasing the amount of preheating energy. The resulting preheated pellets have improved strength and produce no adverse effect on finished pellets.

Abstract: A method is provided for improving the efficiency of a basic oxygen furnace operation and/or regulating its rate of molten iron consumption to accommodate interruptions in downstream production. The method comprises the steps of combining a wet scrubber sludge with hot slag to provide a slag/sludge mixture, commencing a steelmaking operation of the basic oxygen furnace (BOF), and introducing the slag/sludge mixture into the BOF during the steelmaking operation so that the BOF produces a desired quantity and quality of steel in a manner that is more efficient than without the slag/sludge mixture. Also provided is a system for improving the efficiency of a BOF operation. The system comprises a mixer and an introduction mechanism. The mixer is connected to a source of wet scrubber sludge and a source of hot slag. The mixer is adapted to combine the wet scrubber sludge with the hot slag to provide a slag/sludge mixture.

Abstract: A flux which contains irreversibly dehydrated K2AlF5, for soldering light metal materials, in particular aluminum. The flux has the advantages of forming a very uniform flux coating on the workpiece or workpieces to be soldered and exhibiting outstanding flow of the solder. An appropriate soldering process, an aqueous flux suspension and preparation processes for the flux are also disclosed.

Abstract: The invention is directed to a process for dehydrating and recycling back into a BOF converter wet BOF scrubber sludge to produce a steelmaking revert having an improved flow rate when handled in a recycle stream. Wet sludge is combined with hot BOF slag to provide a slag/sludge mixture. The wet sludge causes the mixture to have a moisture content greater than 10% water by weight, and the hot slag, having a temperature below the molten liquid state, vaporizes the water in the mixture and reduces the moisture content to about 4% water by weight or less. The dehydrated mixture has improved flow rate properties when it is recycled as a steelmaking revert.

Abstract: A stable aqueous solution comprising a water soluble salt of a magnesium compound is used to reduce deposits in kilns or furnaces used to make iron ore agglomerates, known as pellets, during iron ore calcination.

Abstract: A melting furnace for reforming steel-making slag so as to be available, for example, to roadbed ballast by mixing steel-making dust with the slag in molten states, which is provided with a fuel oxygen burner for melting the slag and the dust, a slag charging port for charging the slag in molten state into the furnace, a dust feeder for supplying the dust into the furnace, a slag feeder for supplying the slag in powdered state into the furnace, a storage portion for storing a molten mixture of the slag and the dust in a quantity corresponding to a tilting angle of the furnace body and an outlet port for discharging the molten mixture, and is possible to dispose the slag efficiently whether the slag is in the powdered or molten state.

Abstract: A method of preparing a high temperature superconductor. A method of preparing a superconductor includes providing a powdered high temperature superconductor and a nanophase material. These components are combined to form a solid compacted mass with the material disposed in the polycrystalline high temperature superconductor. This combined mixture is rapidly heated, forming a dispersion of nanophase size particles without a eutectic reaction. These nanophase particles can have a flat plate or columnar type morphology.