Abstract: A continuous process provides direct reduction of iron ore in a solid state. Briquettes of iron ore fragments and biomass are transported through a preheating chamber and preheated to a temperature of at least 400° C. The preheated briquettes are transported through a heating/reduction chamber that has an anoxic environment, and iron ore and biomass in the briquettes are exposed to electromagnetic energy in the form of microwave energy under anoxic conditions. Microwave energy generates heat within iron ore, and biomass acts as a reductant and reduces iron ore in a solid state, as the briquettes move through the heating/reduction chamber.

Abstract: A method of introducing carbon to an Electric Arc Furnace (EAF) used for melting steel, and a composition of matter including carbon, and made in a briquette form. The composition comprises between 45 and 96 weight percent of a carbon-containing material, between 2 and 30 weight percent of a basic oxide, and between 2 and 25 weight percent of a binder material. The method comprises mixing between 45 and 96 weight percent of a carbon-containing material, between 2 and 30 weight percent of a basic oxide, and between 2 and 25 weight percent of a binder material to form a solid material mixture; compressing individual portions of the solid material mixture into compressed briquettes; curing the compressed briquettes into solid briquettes; and adding the solid briquettes into the molten steel in the electric arc steelmaking furnace.

Abstract: Iron and molybdenum containing pellets and a process for producing the pellets are disclosed. A green pellet is produced from mixing an iron containing powder, a molybdenum oxide powder, and a carbonaceous powder. The green pellets can be reduced at a temperature in the range of 400-1500° C. The pellets can be briquetted.

Abstract: Iron and molybdenum containing agglomerates and a process for producing the agglomerates is are disclosed. A green agglomerate is produced from mixing an iron containing powder, a molybdenum oxide powder, and a carbonaceous powder. The green agglomerates can be reduced at a temperature in the range of 400-1500° C.

Abstract: In a method for producing pressed articles containing coal particles, before being mixed with a binder system containing water, at least a subset of the coal particles is subjected to at least two impregnation steps in which it is impregnated with at least one substance. The pressed articles may be used, for example, in methods of pig iron production in a packed bed or in methods for producing carbon carriers for methods of pig iron production in a packed bed.

Abstract: A method for producing pressed articles containing coal particles, pressed articles obtained from such method, and the use of such pressed articles in methods for producing pig iron in a fixed bed or for producing carbon carriers for methods for producing pig iron in a fixed bed, are provided. To this end, a partial amount of the coal particles to be processed into pressed articles is impregnated with a substance before the material to be processed into pressed articles is mixed with a binder system containing water and finally being processed into pressed articles.

Abstract: The present invention is one or more processes for producing separable iron and titanium oxides from an ore comprising titanium oxide and iron oxide, comprising: (a) forming agglomerates comprising carbon-based material and the ore, the quantity of carbon of the agglomerates being at least sufficient for forming a ferrous oxide-containing molten slag, at an elevated temperature; (b) introducing the agglomerates onto a bed of carbon-based material in a moving hearth furnace, wherein the carbon-based materials used for both the agglomerates and the bed have a low sulfur content; (c) heating the agglomerates in the moving hearth furnace to a temperature sufficient for liquefying the agglomerates to produce a liquid comprising ferrous oxide-containing slag; (d) metallizing the ferrous oxide of the 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 liquid state; (e) solidifying the slag after metallization of the ferrous oxide to

Abstract: The invention relates to a method for producing an agglomerate, which is used as a blast furnace feed material, by mixing a fine material containing metal and/or metal oxide, a mineral binder, which comprises a mineral raw material and a lime-based material, and optionally other additives to form a mass and solidifying the mass to form an agglomerate, wherein a raw material comprising a silicon oxide fraction of at least 40 wt %, a fine grain fraction of less than 4 ?m of at least 20 wt %, and a grain size fraction of less than 1 ?m of at least 10 wt % is used as the mineral raw material. The invention further relates to a blast furnace feed material that can be produced by means of the method according to the invention, and to a pre-mixture for producing the blast furnace feed material.

Abstract: A method for producing carbon composite metal oxide briquettes includes a mixing step of adding a binder to a metal oxide raw material and a carbonaceous material and mixing the metal oxide raw material, the carbonaceous material, and the binder by a mixer to prepare a powder mixture, and a forming step of forming the powder mixture into carbon composite metal oxide briquettes by using a briquetting machine, in which, in the mixing step, a batch mixer is used as the mixer.

Abstract: Coal particles to be processed into compressed articles are impregnated with a substance before being mixed with a binder system containing water and finally being processed into compressed articles.

Abstract: A method for recycling steelmaking dusts has a granulating step of mixing steelmaking dusts, containing as a principal component iron and oxides thereof produced during the steelmaking in a melting furnace, with a powder containing carbon as a principal component and granulating the resultant mixture to provide mixed granules, a water impregnating step of immersing the mixed granules in a water to allow them to be impregnated with the water, a solidifying step of molding the water impregnated, mixed granules under pressure within a mold assembly to provide a solid body of the steelmaking dusts, a step of transporting the solid body of the steelmaking dusts as a raw material to be charged into the melting furnace, an enhancing step of increasing the concentration of zinc in the dusts, and a dezincing step of dezincing the dusts during a period from acquisition of the steelmaking dusts out of the melting furnace to the solidifying step.

Abstract: The present invention provides a method and facility for preventing crumbling and powderization of green pellets when producing high strength green pellets using a powder feedstock and using the pellets in a rotary hearth reducing furnace and for efficiently reducing the same. It comprises kneading by a kneader 5 a feedstock of a powder of a fine particle size (20 to 80 wt % having size of not more than 10 ?m) including a metal oxide and carbon-bearing powder fed from a feed storage tank 1 and producing green pellets by a pan type pelletizer 7. The green pellets are screened by a pellet screen 9, then dried by a pellet dryer 11 and reduced by firing in a rotary hearth reducing furnace 13. At that time, the green pellets are continuously conveyed to prevent crumbling.

Abstract: A method is provided for producing an agglomerated material that is used for producing metallic iron by heat reduction in a moving hearth-type reducing furnace, wherein the agglomerated material can have a high mechanical strength without increases in the binder content and the moisture content of the material mixture. The method for producing an agglomerated material used for producing metallic iron, wherein the agglomerated material is produced by agglomerating a material mixture containing an iron-oxide-containing material, a carbonaceous reducing agent, a binder, and moisture; drying the material mixture; and charging and heating the material mixture in a moving hearth-type reducing furnace to reduce the iron oxide contained in the material mixture with the carbonaceous reducing agent, wherein a carbohydrate is used as the binder and the material mixture is left to stand prior to the agglomeration.

Abstract: A method of making metallic iron in which a compact, containing iron oxide such as iron ore or the like and a carbonaceous reductant such as coal or the like, is used as material, and the iron oxide is reduced through the application of heat, thereby making metallic iron. In the course of this reduction, a shell composed of metallic iron is generated and grown on the surface of the compact, and slag aggregates inside the shell. This reduction continues until substantially no iron oxide is present within the metallic iron shell. Subsequently, heating is further performed to melt the metallic iron and slag. Molten metallic iron and molten slag are separated one from the other, thereby obtaining metallic iron with a relatively high metallization ratio.

Abstract: The present invention provides a method and facility for preventing crumbling and powderization of green pellets when producing high strength green pellets using a powder feedstock and using the pellets in a rotary hearth reducing furnace and for efficiently reducing the same. It comprises kneading by a kneader 5 a feedstock of a powder of a fine particle size (20 to 80 wt % having size of not more than 10 ?m) including a metal oxide and carbon-bearing powder fed from a feed storage tank 1 and producing green pellets by a pan type pelletized 7. The green pellets are screened by a pellet screen 9, then dried by a pellet dryer 11 and reduced by firing in a rotary hearth reducing furnace 13. At that time, the green pellets are continuously conveyed to prevent crumbling.

Abstract: This invention belongs to ferrous metallurgy field, and in particular relates to a lime-based additive for steel smelting which is used in the electric furnace refining and steel casting process for carbureting and deoxidation and the preparation method thereof. The lime-based additive for steel smelting comprises lime-based material and carbonaceous material, wherein the content of the lime-based material is 40-80 wt % relative to the total amount of the additive, and the remaining is the carbonaceous material; the lime-based material is a passivated CaO powder with a low flowability, or the mixture of the passivated CaO powder and CaCO3 powder, and the carbonaceous material is at least one of the coke, graphite, semi-coke powder and coal with carbon content not less than 85 wt %. When the additive has a shape of pellet, and it further comprises 1-5 wt % of agglomerant which has a microstructure of strip, streak or dendritic, and is at least one of MgO, Al2O3, and CaCO3.

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: Method and system for producing metallic nuggets includes providing reducible mixture (e.g., reducible micro-agglomerates; reducing material and reducible iron bearing material; reducible mixture including additives such as a fluxing agent; compacts, etc.) on at least a portion of a hearth material layer. In one embodiment, a plurality of channel openings extend at least partially through a layer of the reducible mixture to define a plurality of nugget forming reducible material regions. Such channel openings may be at least partially filled with nugget separation fill material (e.g., carbonaceous material). Thermally treating the layer of reducible mixture results in formation of one or more metallic iron nuggets. In other embodiments, various compositions of the reducible mixture and the formation of the reducible mixture provide one or more beneficial characteristics.

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: Cotton-like aggregates (B) including grinding chips from an iron-based metal and a grinding fluid containing oil and water are compression molded for forming a brittle compact (C) having the fibrous grinding chips roughly sheared and excessive water and oil removed therefrom. The brittle compact (C) is crushed for further finely shearing the grinding chips and the resultant grinding chips are mixed with a solidification assistant (D) for producing an iron-based powder material (E) containing the solidification assistant (D).

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 method for producing an iron oxide pellet including the steps of adding water to a raw material mixture comprising iron oxide which serves as a primary component, a carbonaceous material in an amount sufficient for reducing the iron oxide, an organic binder in an amount sufficient for binding the iron oxide and the carbonaceous material, and an inorganic coagulant in an amount of not less than 0.05 mass % and less than 1 mass %; pelletizing the resultant mixture to thereby obtain a green pellet; and drying the green pellet until the moisture content is reduced to equal to or less than 1.0 mass %. The thus-produced iron oxide pellet is charged in a reducing furnace for reduction to thereby obtain a reduced iron pellet.

Abstract: The invention is a method of making metallized iron agglomerates by combining iron/steel particles and a reductant material with a cellulose fiber binder material, compacting the combination to form a solid agglomerate, and reducing the iron portions of the agglomerate in a direct reduction furnace. The cellulose fiber binder material provides an agglomerate having improved strength and lower overall cost than comparable agglomerates using binders known in the art.

Abstract: A method of processing flue dust, where the flue dust contains one or more compounds from a first group of zinc, lead and cadmium compounds, and contains one or more compounds from a second group of iron, silicon, calcium, magnesium and aluminum compounds, includes mixing the flue dust with a carbonaceous material, heating the flue dust/carbonaceous material mixture under non-turbulent conditions to cause a substantial portion of the compounds from the first group to become gas-borne while retaining a substantial portion of the compounds of the second group in a non-gas-borne condition, and separating the gas-borne compounds from the non-gas-borne compounds.

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: In a method of producing molten pig iron (13) or molten steel pre-products from charging substances formed of iron ore (4), preferably in the shape of lumps and/or pellets, and optionally of fluxes (5), the charging substances are directly reduced to sponge iron in a reduction zone (2), the sponge iron is charged into a melt-down gasifying zone (12) and, there, is melted under the supply of carbon carriers (10) and an oxygen-containing gas, wherein a CO—H2-containing reducing gas is generated that is withdrawn from the melt-down gasifying zone (12) and introduced into the reduction zone (2), is reacted there and is withdrawn as a topgas, wherein the topgas is subjected to scrubbing and the sludges thus separated are at least partially agglomerated. To utilize the agglomerates thus formed while expending as little energy as possible, the agglomerates are recirculated into the reduction zone (2).

Abstract: Iron-rich material waste products, such as electric arc furnace dust, are formed with an organic binder into discrete shapes, such as briquettes and/or other solid shapes. The shapes can then be used in iron and steel making processes and the iron and heavy metal values in the waste product recovered.

Abstract: A method for manufacturing coal agglomerates for use in a direct smelting reducing furnace is disclosed, in which a fine coal is agglomerated at a high temperature in a simple manner, or anthracite or low free swelling coal having a low free swelling index is mixed with the fine coal, and the mixture is agglomerated at a high temperature, thereby turning the low quality coal to useful purpose. The present invention is characterized in that a fine coal having a free swelling index of 3.0 or more and a particle size of 8 mm or less, or the fine coal mixed with 70 weight % of anthracite or a low free swelling coal, is maintained at 600.degree. C. or over for 5 minutes or more, thereby manufacturing coal agglomerates for use in a direct smelting reducing furnace.

Abstract: A compressed briquette or other solid shape, object, or article useful as a coke substitute in blast furnaces disclosed as being manufactured so as to comprise a reaction product of fine carbonaceous material (such as coke breeze, coke fines, or petroleum coke), a reactive tar, and polymeric binder.

Abstract: A method for preparing iron bearing green pellets that can be processed in a rotary hearth furnace without degradation and become self-fluxing sponge iron pellets when charged to a submerged arc furnace operating at a lower temperature than the rotary hearth furnace, to produce hot metal having a carbon content from 1% to about 5%.

Abstract: Iron-rich-material waste products, such as electric arc furnace dust, are formed with an organic binder into discrete shapes, such as briquettes. The shapes can then be used in iron and steel making processes and the iron and heavy metal values in the waste product recovered.

Abstract: A process for agglomerating by extrusion, metallurgical by-products and waste products having small particle size, is described. A blend of metallurgical by-products, some of which contain silicates previously treated at high temperatures and thereby being capable of chemically and structurally binding water, optionally mixed with portland cement and/or slag cement, and containing water which has been added in amounts that the silicates and cement present can completely absorb and react with, is further mixed with a hydrocarbonaceous substance. The resulting mixture is subsequently agglomerated by extrusion. The extrudates obtained are shape retaining and sufficiently hard to be handled without breaking, crumbling or dusting, and may be charged to extractive pyrometallurgical installations for recovering value metals contained in the metallurgical by-products and waste products. The extrudates may also be stored without dusting and loss of hardness.

Abstract: Pellets of iron ore or other water insoluble particulate material are made from a mixture of the particulate material, moisture and a pelletizing binder by forming moist green pellets, a water displacing additive is applied to the surface of these pellets after they are substantially wholly formed, and the pellets are then dried. The preferred water displacing additive is a solution of a silicone in an organic solvent.

Abstract: A process and apparatus are described for agglomerating metal-containing fine sized particles of metallurgical waste materials continuously by means of a combustible agglomerating agent. The process and apparatus may be adapted to dust and fine particles of different origins and having any particular particle size range and bulk specific gravity. The agglomerates are obtained by feeding the dust or fine sized particles and a combustible agglomerating agent to a continuous mixer, then to a heated rotatable kiln. The agglomerates are subsequently allowed to fall onto one or more conveyor belts, arranged in sequence. The agglomerates on the conveyor belts may be cooled, either by water or compressed air jets impinging upon them, or by cooling the belt surfaces on which the agglomerates are carried. The agglomerating agent may be a low melting point hydrocarbon such as wax, tar, pitch, or the hydrocarbon may be emulsified with water to form an emulsion and then mixed with the particles.

Abstract: A process is described for the agglomeration of fine particles utilizing a combustible agglomerating agent dispersed in an aqueous emulsion. The process is particularly directed to the handling of fine metal containing particles, originating as by-products or waste products of metallurgical processes, which are to be stored or recycled to metal extractive process steps. The amount of agglomerant added as aqueous emulsion to the particles, is calculated by correlating in an empirical formula the bulk density and the average particle size of the particles, with the emulsified combustible agglomerating agent to be added expressed as weight percent of the particles. The calculated amount of combustible agglomerating agent is emulsified in water, then mixed and blended with the particles, which usually comprise particles of non-uniform size distribution. The aqueous emulsion may also be formed in-situ on the surface of the particles, and the mixture is then blended to form agglomerates.