Abstract: There are provided a method of manufacturing an Fe/Ni-containing material having a low content of sulfur (S) from an Fe/Ni/SO4-containing liquid waste, a ferronickel mass using the Fe/Ni-containing material, and a method of manufacturing the ferronickel mass. The method of manufacturing an Fe/Ni-containing material from an Fe/Ni-containing liquid waste includes: removing SO4 from an Fe/Ni/SO4-containing liquid waste by adding an SO4 neutralizing agent to the liquid waste so that pH of the liquid waste can be maintained to a pH level of 0.5 to 2.5; precipitating Fe and Ni in the form of hydroxide [(Ni,Fe)(OH)] by adding NaOH to the SO4-free solution; washing the precipitate with water; and manufacturing an Ni/Fe-containing material by filtering and drying the washed Ni/Fe-containing sludge.

Abstract: A manufacture method of briquette for use as metal stock is provided which increases the efficiency of drying porous masses so as to shorten a drying time, and which provides a simplified constitution for reducing an installation area of a system and for reducing the running cost and initial cost of the system. The porous masses are formed by compression molding a recyclable material containing metallic powder. The compression molded porous masses are fed into a tubular member, into which hot air is blown for drying the porous masses.

Abstract: Methods of producing a plurality of particle aggregates having a specified number of member particles are provided according to embodiments of the present invention. Specific methods include stimulating a plurality of particles with an aggregation stimulus to form a plurality of particle aggregates and then quenching the aggregation stimulus in order to inhibit further particle aggregation. An individual particle aggregate of the produced plurality of particle aggregates has member particles including at least a first member particle and a second member particle. Member particles of particle aggregates are optionally subjected to fusion to stabilize the particle aggregates. Produced particle aggregates having a specified number of member particles may be purified to enrich for particular aggregates.

Abstract: The invention relates to a process for producing binderless briquettes from metal chips and metal dusts in which the metal chips are pressed into a cup-shaped form and the upwardly open cavity produced as a result is filled with metal dust, after which the opening is closed with a cover consisting of pressed metal chips.

Abstract: The present invention relates to an apparatus for manufacturing molten iron. The present invention provides an apparatus for manufacturing molten iron including a charge container receiving the supply of reducing material in which hot fine direct reduced iron from multiple fluidized-bed reactors are mixed; at least one pair of roller presses to which the fine direct reduced iron is supplied to undergo roll pressing, thereby producing continuous compacted material having lumped portions adjacent to each other; a crusher crushing the compacted material produced by the roller presses; and a melter-gasifier to which is charged crushed compacted material that is crushed by the crusher. Each of the pair of roller presses include pressed portions and protruded lines formed between the pressed portions.

Abstract: A solidified product (B) is produced by charging a dust (11) generated in a steel making process and containing iron and an oxide thereof as a principal component into a mold (7) and by subjecting it to a pressure molding. A raw material charged to the mold is a mixed granulated product (11p) prepared by mixing the dust and a powder containing carbon as a principal component and by granulating the resultant mixture.

Abstract: An apparatus and process for forming compacted powder metal parts having a non-axial undercut feature. An undercut die is located between the upper and the lower dies and contains a plurality of shaped punches aligned in a circular pattern. Each of the shaped punches contains a working edge. The working edges converge to form an inner circumference which creates the undercut feature. The edges of the shaped punches slide with respect to each other to change the size of the inner circumference from a maximum diameter position to a minimum diameter position. During compaction, the rotation of the shaped punches alters the inner circumference to its minimum diameter position thereby forming an undercut in the final compacted part. The retraction of the shaped punches to its maximum diameter position enables the unimpeded removal of the part from the tool set.

Abstract: There are provided a method of manufacturing an Fe/Ni-containing material having a low content of sulfur (S) from an Fe/Ni/SO4-containing liquid waste, a ferronickel mass using the Fe/Ni-containing material, and a method of manufacturing the ferronickel mass. The method of manufacturing an Fe/Ni-containing material from an Fe/Ni-containing liquid waste includes: removing SO4 from an Fe/Ni/SO4-containing liquid waste by adding an SO4 neutralizing agent to the liquid waste so that pH of the liquid waste can be maintained to a pH level of 0.5 to 2.5; precipitating Fe and Ni in the form of hydroxide [(Ni,Fe)(OH)] by adding NaOH to the SO4-free solution; washing the precipitate with water; and manufacturing an Ni/Fe-containing material by filtering and drying the washed Ni/Fe-containing sludge.

Abstract: A method for manufacturing molten iron including the steps of producing reducing material of mixed hot fine direct reduced iron and calcined additives, the reducing material being produced from multiple fluidized beds; charging the reducing material to at least one pair of roller presses; roll pressing the reducing material through the one pair of roller presses to produce continuous compacted material having protrusions formed on pressed surfaces; crushing the compacted material; charging the crushed compacted material to a coal packed bed; and supplying oxygen to the coal packed bed to manufacture molten iron, wherein in the producing compacted material, the compacted material is formed such that acute and obtuse angles are formed between a center line formed along a length of a cross section that is cut along a lengthwise direction perpendicular to an axial direction of the roller presses and connecting lines that connect grooves closest to each other across the cross sectional area.

Abstract: In a method of producing a reduced iron cast, a cast of a powder which includes total iron of 40% or more and an atomic molar amount of fixed carbon of 0.7 to 1.5 times the atomic molar amount of oxygen compounded with metal oxide reduced in a carbon monoxide atmosphere at 1200° C. is reduced in a rotary hearth furnace. The method includes: producing, in an atmosphere at a maximum temperature of 1200° C. to 1420° C. at a ratio of carbon monoxide to carbon dioxide of 0.3 to 1.2 in the reduced material, a reduced iron-containing material in which a ratio of metal iron is 50 mass % or more and a ratio of carbon is 5 mass % or less; and compression-molding the reduced iron-containing material at a temperature of 500° C. to 800° C. by a roller-type mold.

Abstract: The invention relates to a process for producing binderless briquettes from metal chips and metal dusts in which the metal chips are pressed into a cup-shaped form and the upwardly open cavity produced as a result is filled with metal dust, after which the opening is closed with a cover consisting of pressed metal chips.

Abstract: The present invention discloses a composition for a desulfurizer with a high sulfur capacity and a process for making the same. The composition comprises the active components of three kinds of iron oxides and is used in the desulfurizer to remove hydrogen sulfide from the gaseous and liquid state feed stocks. The process for preparing the composition comprises the following steps: (1) mixing a solid ferrous compound with a solid hydroxide at a molar ratio of iron to hydroxyl being in the range from 1:2 to 1:3; (2) kneading the mixture feeds obtained in step (1) and making them react completely; (3) drying the products obtained in step (2) in the air; (4) washing and filtering the feeds obtained in the step (3); (5) naturally drying or baking the solids obtained in step (4) to form a composition for a desulfurizer with a high sulfur capacity.

Abstract: A method of making a treating wash includes mixing brass granules with acetone, mixing carbon nanotube material, iron pyrite granules and copper granules in the acetone brass mixture, and straining the liquid from the remaining solid material. Methods of treating materials such as brass granules, iron pyrite granules, carbon nanotube material, and brass granules comprises washing the materials in the treating wash, followed by straining and drying the materials.

Abstract: Processes for making rigid, binder free agglomerates of powdered metal are disclosed. The agglomerates have a low tap density. Articles that contain binder free agglomerates made from electrochemically active powder are also disclosed.

Abstract: A composite alloy that contains TiC is made using a green binder system of titanium sponge granules and a liquid phase binder system comprising titanium, nickel, and aluminum. The alloy has a mass of less than 5 grams per cubic centimeter. The alloy may be bonded to a hard substrate to provide an armor tile.

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

Abstract: A method for the production of ore comprising a proportion of fines, additives and green agglomerates optionally containing a binder, provided with an outer coating consisting of a combustible containing fine-grained carbon, such as coke. According to the method, the ore is mixed with the additives and the optionally available binder. The mixture is pelletized and the green agglomerates thus formed are coated with the combustible, whereby the combustible is introduced into an agglomeration drum. In order to enable continual production of homogeneous-quality green agglomerates, the mixture is pelletized in the agglomeration drum and the combustible is added in an area of the longitudinal extension of the agglomeration drum where the size of the green agglomerates formed in the agglomeration drum is sufficient for further processing.

Abstract: The present invention relates to an apparatus for manufacturing compacted irons of the reduced materials containing fine reduce irons and an apparatus for manufacturing molten irons provided with the same. The apparatus for manufacturing compacted irons according to the present invention includes a couple of rollers for compacting reduced materials containing fine reduced irons and manufacturing compacted irons, a guide chute for guiding compacted irons which are discharged from the couple of rollers; and crushers for crushing compacted irons which are guided into the guide chute. A guiding surface of the guide chute, which guides the compacted irons, includes a straight slanted surface and a curved slanted surface.

Abstract: A manufacturing method of briquette for use as metal stock is provided which is adapted for effective reduction of a drying time of a porous mass such that the quantity of energy required for the drying process may be reduced. A porous mass is formed by compressing cotton-like aggregates containing metal grinding dust under pressure. The resultant porous mass is immediately dipped in a heated solidification assistant. Subsequently, the porous mass impregnated with the solidification assistant is immediately transported to a drying furnace for drying.

Abstract: A process for producing a ferronickel product from a mixed nickel iron hydroxide product, said process including the steps of: providing a mixed nickel iron hydroxide product; pelletising the mixed nickel iron hydroxide product to produce nickel iron hydroxide pellets; calcining the nickel iron hydroxide pellets to produce mixed nickel iron oxide pellets; and reducing the nickel iron oxide pellets with one or more reducing gases at high temperatures to produce ferronickel pellets.

Abstract: Steelmaking dusts produced during the manufacture of iron and steel by means of a melting furnace and containing iron and iron oxides as a principal component are mixed, and granulated, with a powder containing carbon as a principal component to provide mixed granules. The mixed granules are, after having impregnated with water before the molding thereof, molded under pressure within a mold assembly to provide briquettes, which are solidified bodies of the steelmaking dusts. The briquettes are reused as a raw material to be charged into the melting furnace. When the dusts having a concentration of zinc enhanced are dezinced, reduction in amount of dezincing treatment and increase of the efficiency of the dezincing treatment can be achieved.

Abstract: For collecting fine particles from fume generated in the process of thermal cutting or welding of a metal material and solidifying them, a fume disposal system comprises a fume introducing chamber 25 which is connected to a cutting machine body through a suction duct 2 and into which suctioned fume is introduced; a bug filter 24 for separating and collecting fine particles from the fume introduced into the fume introducing chamber 25; a hopper 22 for storing the separated, collected fine particles; a screw conveyor for conveying the fine particles stored in the hopper 22 to a molding chamber; and a pressurizing device 38 for pressurizing the fine particles fed into the molding chamber to reduce the volume thereof.

Abstract: A method for the recovery of the secondary metallurgy (LF) slag from a plant for the production of steel comprises a cooling step of the slag, by means of the passage of air and/or other gas, a breakdown step, i.e. transformation of several phases present in the mass into powder and a step of drawing the powder.

Abstract: An apparatus and process for forming compacted powder metal parts having a non-axial undercut feature. An undercut die is located between the upper and the lower dies and contains a plurality of shaped punches aligned in a circular pattern. Each of the shaped punches contains a working edge. The working edges converge to form an inner circumference which creates the undercut feature. The edges of the shaped punches slide with respect to each other to change the size of the inner circumference from a maximum diameter position to a minimum diameter position. During compaction, the rotation of the shaped punches alters the inner circumference to its minimum diameter position thereby forming an undercut in the final compacted part. The retraction of the shaped punches to its maximum diameter position enables the unimpeded removal of the part from the tool set.

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 invention relates to the separation of metals in Fe-bearing zinc leaching residues, in particular neutral and weak acid leach residues. The process comprises the steps of: preparing agglomerates containing, besides the Zn leaching residue, at least 5 wt % of carbon and 2 to 10 wt. % of S; fuming said agglomerates in a static bed at a temperature above 1250° C., thereby producing a reduced Fe-bearing phase and Zn-bearing fumes; and extracting said Zn-bearing fumes. The high S content of the feed allows for a relatively high operating temperature without production of molten phases. This guarantees fast reduction and fuming kinetics, and permits the use of a compact technology such as a static bed furnace.

Abstract: A solidified product (B) is produced by charging a dust (11) generated in a steel making process and containing iron and an oxide thereof as a principal component into a mold (7) and by subjecting it to a pressure molding. A raw material charged to the mold is a mixed granulated product (11p) prepared by mixing the dust and a powder containing carbon as a principal component and by granulating the resultant mixture.

Abstract: The present invention discloses a composition for a desulfurizer with a high sulfur capacity and a process for making the same. The composition comprises the active components of three kinds of iron oxides and is used in the desulfurizer to remove hydrogen sulfide from the gaseous and liquid state feed stocks. The above-mentioned composition comprises cubic ferroferric oxide in the form of crystalline phase (Fe3O4), amorphous ferric oxide (Fe2O3) and amorphous ferric oxide monohydrate (Fe2O3.H2O). The composition has a sulfur capacity of at least 40%.

Abstract: A method and composition for removing sulfur from molten ferrous material, particularly molten iron. The desulfurization agent includes reclaimed magnesium scrap, a gas-producing compound and a calcium compound.

Abstract: The present invention provides a process for cold briquetting and pelletization of ferrous or non-ferrous or mineral fines using iron bearing hydraulic mineral binders for metallurgical applications, said process consisting the steps of: mixing 80-95% by Wt. of a metallurgical/mineral/carbonaceous/oil contaminated dust/fines/sludge with 3-10% by Wt. of an iron bearing hydraulic mineral binder and optionally with 2-6% by Wt. water and 0.05 to 0.20% by Wt. of a surface active agent to form a homogenized dry mix/slurry, pelletizing/compacting the dry mix/slurry to form an agglomerated mass, and curing the agglomerated mass for 3-20 days by exposing the agglomerated mass to atmospheric air for 10-14 hours followed by moisture treatment.

Abstract: A nonfired agglomerated ore which is satisfactory in reduction property in the shaft of a blast furnace and excellent in rapid heating bursting property and a production method thereof are provided. A carbon containing nonfired agglomerated ore for blast furnace which is prepared in such a way that iron oxide and a carbonaceous material are blended with each other to prepare a mixture, a binder is added to the mixture, and the mixture is kneaded, formed, and cured, wherein the agglomerated ore contains carbon in the content of 80 to 120% of the theoretical carbon quantity required to reduce the reducible oxygen in the iron ores to form metallic iron, and the binder is selected so that the crushing strength may be 7,850 kN/m2 or more at room temperature.

Abstract: The object of this process is to remove heavy metals and other elements and compounds from the Coal Combustion Products (CCP), ore, or other material by processing and recovery of the individual elements and/or compounds in a marketable form leaving an inert residual meeting the ground water quality standards.

Abstract: The present invention provides a reducing furnace of the rotary hearth-type and a method for reducing a metal oxide simplified in the process from dehydration to molding, according to which a moisture-rich powdery raw material is reduced at low cost. The present invention also provides an operation method whereby dusts or sludge generated in the refining or processing of metal are economically recycled. A powdery mixture having a moisture content of 100% or higher relative to the total mass of a metal oxide-containing powder and a carbon-containing powder is made into a slurry and mixed by stirring. Thereafter, the slurry is dehydrated to a moisture content of 16 to 26% and compression-molded into articles. The cylindrical or granular shaped articles having a thickness or diameter of 30 mm or less thus obtained are fed to a zone the atmospheric temperature of which is 1170° C. or lower in the furnace and reduced through calcination by a rotary hearth reducing furnace thereby to provide a metal.

Abstract: The present invention provides a process for cold briquetting and pelletization of ferrous or non-ferrous or mineral fines using iron bearing hydraulic mineral binders for metallurgical applications, said process consisting the steps of: mixing 80-95% by Wt. of a metallurgical/mineral/carbonaceous/oil contaminated dust/fines/sludge with 3-10% by Wt. of an iron bearing hydraulic mineral binder and optionally with 2-6% by Wt. water and 0.05 to 0.20% by Wt. of a surface active agent to form a homogenized dry mix/slurry, pelletizing/compacting the dry mix/slurry to form an agglomerated mass, and curing the agglomerated mass for 3-20 days by exposing the agglomerated mass to atmospheric air for 10-14 hours followed by moisture treatment.

Abstract: Ferrous metal briquettes made from ferrous metal particles and an alkaline metal silicate, for adding to ferrous melts to recycle the particles.

Abstract: Ultrafine composite metal particles comprising a surfactant sheath and an organic compound sheath that surround a metal core in which metal atoms obtained by reduction precipitation from an organic metal compound have agglomerated, the particle diameter being 1 to 100 nm. The ultrafine composite metal particle may comprise a surfactant sheath that surrounds a metal core in which metal atoms obtained by reduction precipitation from an inorganic metal compound have agglomerated. The ultrafine composite metal particles are obtained by forming an ultrafine particle precursor by producing a colloidal solution of an organic metal compound or an inorganic metal compound in a nonaqueous solvent using a surfactant, and by reducing the ultrafine particle precursor by adding a reducing agent to this colloidal solution, thus forming ultrafine composite metal particles with a diameter of 1 to 100 nm and having at least a surfactant sheath around a metal cored.

Abstract: Shaped bodies containing particulate iron materials, such as cast pellets, briquettes and the like, with sufficient strength to withstand temperatures of up to at least 1000° C. can be obtained by using a fully hydrated high-alumina cement as the binder. The strength of the pellets at elevated temperatures can be further enhanced by adding small amounts of bentonite, silica fume or other suitable supplementary cementing materials, and super plasticizer. The iron particulate materials, typically having a size range of from about 0.01 mm to 6 mm, include ore fines, sinter fines, BOF and EAF dusts, mill scale, and the like. Powdered carbonaceous material, such as ground coal or coke, may also be added to the pellets. The shaped bodies are suitable for use in blast furnaces, basic oxygen furnaces, and in DRI processes.

Abstract: A method for recovery of metals from essentially metallic fines comprises the following steps: supplying said essentially metallic fines to a flame of a burner (20), bringing said fines to agglomerate by means of heat from the flame without essentially changing the chemical composition thereof, thereby providing an essentially metallic agglomerated product. The agglomerated product is subsequently recovered, preferably in a furnace (30). By means of the method, the recovery of metals is facilitated. An apparatus for performing the method is also provided.

Abstract: The invention concerns an iron powder characterised by spherical form and a porous structure throughout. The powder particles have an average particle diameter between 10 and 300 &mgr;m, a specific surface area of at least 100 m2/kg, a flowability of at least 35 s/50 g, a reactivity of less than 5 minutes and an apparent density lower than about 4 g/cm3. The iron powder is prepared by subjecting a dry powder of essentially spherical iron-containing agglomerates to a heat treatment in a reducing atmosphere at a temperature and time sufficient for obtaining particles essentially consisting of metallic iron and having a porous structure throughout. The obtained particles may then be subjected to sintering at a time and temperature sufficient for obtaining the required strength.

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: The invention relates to a method of utilizing secondary raw materials containing iron, zinc and lead, preferably steelmaking dusts, in a rotary tubular furnace customarily equipped for the rolling process, with basically adjusted rolling slag. By reducing the portion of the carbon carriers in the burden, the energy balance of the rolling process is improved on one hand, and the throughput of the rotary tubular furnace used is increased on the other hand. By improving the quality of the rolling slag, the capability of utilizing the same is favored.

Abstract: Slurries of metallic or ceramic powders are prepared in water which contains gas-eliminating substances such as carbonic acid, hydrogen peroxide, carbonates or hydrogen carbonates. This results in highly porous, solid cakes which may be processed by breaking and/or grinding to yield granules having a low fines content. Depending upon the intended application, the adhesively bound agglomerates may very readily be suspended, used as sintering precursors or as starting substances for solid-state reactions.

Abstract: A metal feedstock from wasted metal products is disclosed. The feedstock is formed by crushing the metal products into pieces; magnetically separating sheet-shaped ferrous scraps and ferrous cast blocks from the crushed pieces; placing the cast blocks between the sheet-shaped scraps to make a sandwich structure; and pressing the sandwich structure to form a metal feedstock.

Abstract: A roadway base comprises oily sludge, steelmaking slag fines, and an additive selected from the group consisting of cement, fly ash, asphaltic emulsion, and mixtures thereof

Abstract: For effectively reprocessing iron-containing residual smelting plant materials (1 to 3), in which iron may be present both in metallic form and in oxidic form, with lowest possible energy expenditure, the residual smelting plant materials (1 to 3) are processed into agglomerates (8,11), the agglomerates (8,11) are charged into an electric arc furnace (10), melted there and reduced, and the resultant melt is refined (FIG. 1).

Abstract: A method of forming a metal feedstock from wasted metal products is disclosed. The method includes the steps of crushing the metal products into pieces; magnetically separating sheet-shaped ferrous scraps and ferrous cast blocks from the crushed pieces; placing the cast blocks between the sheet-shaped scraps to make a sandwich structure; and pressing the sandwich structure to form a metal feedstock.

Abstract: A process and apparatus for separating briquettes and fragments in a product stream resulting from briquetting direct reduced iron. Separating and cooling of the briquettes and fragments are carried out simultaneously in an initial step with use of separating means submerged in a cooling bath. The process enables use of less rugged apparatus following the initial step and the apparatus is not subjected to handling the product stream at the elevated temperatures at which briquetting is carried out. Capital expenditure and equipment maintenance is thus reduced.

Abstract: A cored wire continuously formed by continuously inserting an extruded core inside a continuously roll formed sheath, the peripheral edges of the roll formed sheath joined by a continuous lock seam. Inspection of the partially formed lock seam at a designated process step serves to warn the user of malformed or defective lock seam portions in the finished cored wire.

Abstract: A method for the direct preparation of metal from metal containing ore by applying microwaves, alone or in combination with other heating means, to extract metal from masses made by forming a powder of ore and an optional reducing agent. The method minimizes the expenditure of energy used to refine the metal, the level of contamination introduced into the metal, and the production of environmental pollutants.

Abstract: A process for preparing high carbon content briquettes includes providing a particulate material which includes iron particles including iron oxide in an amount of at least about 4% based on weight of the material, and carbon particles in an amount greater than about 2% based on weight of the material; and subjecting the material to briquetting temperature and pressure so as to provide stable agglomerate briquettes of the material.