Abstract:
A process for producing metals from a metalliferous feed material in an electric furnace is disclosed. The process includes the steps of forming a molten bath having a metal layer and a slag layer on the metal layer in the furnace and supplying electrical energy to the furnace and converting the electrical energy to thermal energy and thereby contributing to the heat input requirements of the process. The process also includes injecting a carrier gas and a solid carbonaceous material into the molten bath via one or more than one solids injection lance/tuyere and causing molten material to be projected from the molten bath as splashes, droplets, and streams into a space above a nominal quiescent surface of the molten bath and forming a transition zone. The process also includes injecting an oxygen-containing gas into the furnace via one or more than one oxygen-containing gas injection lance/tuyere and post-combusting reaction gases released from the molten bath and thereby further contributing to the heat requirements of the process. In this process the ascending and thereafter descending splashes, droplets, and streams of molten material in the transition zone facilitate heat transfer to the molten bath and the transition zone minimises heat loss from the furnace via the side walls in contact with the transition zone.
Abstract:
A non-mechanical valve (3) for controlling the flow of fluidisable solids is disclosed. The valve (3) comprises a pipe having an upstream leg (5) with a solids inlet (13) at an upper end, a downstream leg (7) with a solids outlet (14) at an upper end, and a base section (9) interconnecting lower ends of the legs (5, 7). The valve (3) further comprises a means for introducing aeration gas into each of the legs (5, 7) to maintain fluidised flow of solids through the valve (3) and a means for adjusting the flow of aeration gas to the legs (5, 7) to control the solids flow through the valve (3).
Abstract:
A process for at least partially reducing iron oxides comprises forming a bed of reactants on a hearth of a rotary hearth furnace, the reactants comprising (a) mixture of iron ore fines and particulate carbonaceous material and/or (b) micro-agglomerates of iron ore fines and particulate carbonaceous material. The mixture and/or the micro-agglomerates are heated in the rotary hearth furnace to at least reduce the iron oxides. The "micro-agglomerates" are agglomerates that are less than 1400 microns (and preferably more than 500 microns) in diameter. The at least partially reduced product is preferably used in the production of metallic iron. An apparatus for at least partially reducing iron oxides is also claimed. The process permits operation of the rotary hearth furnace without requiring pelletisation of iron oxide fines and coal.
Abstract:
An industrially realistic process for alkaline leaching of a titaniferous material is disclosed. The process comprises the following process steps: (I) leaching the titaniferous material with an alkaline leachant to bring impurities in the titaniferous material into solution; and (II) treating the leachant to enhance the effectiveness of the leachant in the removal of impurities in step (I). In particular, step (II) may involve the heating of the leachant or adding additives such as sodium silicate or lime to cause the precipitation of alumina and silica.
Abstract:
A reactor for introducing a gas into a fluid comprises a mixing tank (12, 43) for the fluid and a partition means (13, 45) for dividing the tank into at least two chambers (21, 89) and (23, 91). The reactor further comprises a first pump means (14, 47) located in one of the chambers for circulating the fluid downwards in one chamber and then upwards in the other chamber and an aerator assembly (29, 49) for aerating a sidestream of the fluid and introducing the aerated fluid into the tank for mixing the aerated fluid with the circulating fluid in the tank. The aerator assembly (29, 49) comprises a bank of venturi aerators (38, 57) each having an aerator inlet; an aerator outlet; and a constriction intermediate the aerator inlet and the aerator outlet for creating a region of reduced pressure in the fluid, the constriction being elongate in a section transverse to the direction of flow of the fluid through the constriction; and a means for introducing the gas into the constriction to aerate the fluid.
Abstract:
A smelting vessel (4) for producing molten metal includes a refractory lined hearth that in use is in contact with molten slag or molten metal in the smelting vessel, and the hearth includes a plurality of heat pipes (2.1) positioned in a refractory lining of at least a part of the hearth for cooling the refractory lining.
Abstract:
A molten bath-based direct smelting process comprises controlling the process conditions in a direct smelting vessel so that molten slag in a molten bath of metal and slag in the vessel has a viscosity in a range of 0.5-5 poise when the slag temperature is in a range of 1400-1550° C. in the molten bath in the vessel.