Feed material composition and handling in a channel induction furnace

1. A method of continuously processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material which comprises:

providing a furnace having a headspace, opposite ends and containing a molten metal bath;

operating the furnace so that the surface of the molten metal bath is not under turbulent conditions;

forming and maintaining a slag layer on the molten metal bath;

feeding at least one waste material into the furnace at one of the opposite ends and into the slag layer that floats on the molten metal bath so that the at least one waste material is engulfed by the slag layer;

allowing the at least one waste material to react in the furnace to replenish the slag layer that floats on the molten metal bath and produce at least one of a molten metal product that passes into the molten metal bath, and a vapor phase metal product that passes into the headspace of the furnace;

removing a portion of the slag layer as a slag product from another of the opposite ends of the furnace so as to cause the slag layer and the at least one waste material fed into the slag layer to move across the surface of the molten metal bath; and

continuously maintaining the thickness of the slag layer at a level so that the thickness is sufficient to support the at least one waste material in the slag layer,

wherein the step of feeding at least one waste material into the furnace comprises feeding discrete masses or volumes of waste material into the furnace in a manner that avoids the formation of islands of waste material in or on the slag layer.

2. A method of continuously processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 1 , wherein the step of feeding at least one waste material into the furnace comprises allowing a previously fed discrete mass or volume of waste material to move with the slag layer to a position whereat a subsequent fed discrete mass or volume of waste material will not contact the previously fed discrete mass or volume of waste material.

3. A method of continuously processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 1 , wherein the step of feeding at least one waste material into the furnace comprises feeding discrete masses or volumes of waste material into the furnace at different locations.

4. A method of continuously processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 3 , wherein the step of feeding at least one waste material into the furnace comprises providing the furnace with a plurality of waste material feed inlets and feeding discrete masses or volumes of waste material into the furnace through different ones of the plurality of waste material feed inlets.

5. A method of continuously processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 3 , wherein the step of feeding at least one waste material into the furnace comprises providing the furnace with a waste material feed inlet and directing discrete masses or volumes of waste material into the furnace through the waste material feed inlet so that individual discrete masses or volumes of the waste material land in different positions within the furnace.

6. A method of continuously processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 5 , wherein the step of directing discrete masses or volumes of waste material into the furnace comprises contacting the discrete masses or volumes of waste materials with a chute or deflector.

7. A method of continuously processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 3 , wherein the step of feeding at least one waste material into the furnace comprises feeding discrete masses or volumes of waste material into the furnace while rotating the furnace.

8. A method of continuously processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 3 , wherein the step of feeding at least one waste material into the furnace comprises mechanically repositioning discrete masses or volumes of waste material within the furnace.

9. A method of continuously processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 8 , wherein the step of repositioning discrete masses or volumes of waste material within the furnace comprises pushing the discrete masses or volumes of waste material with an elongated tool.

10. A method of continuously processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 3 , wherein the step of feeding at least one waste material into the furnace comprises manually repositioning discrete masses or volumes of waste material within the furnace.

11. A method of continuously processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material which comprises:

providing a furnace having a headspace, opposite ends and containing a molten metal bath;

operating the furnace so that the surface of the molten metal bath is not under turbulent conditions;

forming and maintaining a slag layer on the molten metal bath;

feeding at least one waste material into the furnace at one of the opposite ends and into the slay layer that floats on the molten metal bath so that the at least one waste material is engulfed in the slag layer;

allowing the at least one waste material to react in the furnace to replenish the slag layer that floats on the molten metal bath and to produce at least one of a molten metal product that passes into the molten metal bath, and a vapor phase metal product that passes into the headspace of the furnace;

removing a portion of the slag layer as a slag product from another of the opposite ends of the furnace so as to cause the slag layer and the at least one waste material fed into the slag layer to move across the surface of the molten metal bath; and

continuously maintaining the thickness of the slag layer at a level so that the thickness is sufficient to support the at least one waste material by the slag layer,

wherein islands of waste material that are formed in or on the slag layer are mechanically or manually broken up.

12. A method of continuously processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material claim 11 , wherein the step of breaking up islands of waste material comprises contacting the islands of waste material with an elongated tool.

13. A method of continuously processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material which comprises:

providing a furnace having a headspace, opposite ends and containing a molten metal bath;

operating the furnace so that the surface of the molten metal bath is not under turbulent conditions;

forming and maintaining a slag layer on the molten metal bath;

feeding at least one waste material into the furnace at one of the opposite ends and into the slay layer that floats on the molten metal bath so that the at least one waste material is engulfed in the slag layer;

allowing the at least one waste material to react in the furnace to replenish the slag layer that floats on the molten metal bath and to produce at least one of a molten metal product that passes into the molten metal bath, and a vapor phase metal product that passes into the headspace of the furnace;

removing portion of the slag layer as a slag product from another of the opposite ends of the furnace so as to cause the slag layer and the at least one waste material fed into the slag layer to move across the surface of the molten metal bath; and

continuously maintaining the thickness of the slag layer at a level so that the thickness is sufficient to support the at least one waste material by the slag layer,

wherein the at least one waste material is screened to remove fines before being fed into the furnace.

14. A method of continuously processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material which comprises:

providing a furnace having a headspace, opposite ends and containing a molten metal bath;

operating the furnace so that the surface of the molten metal bath is not under turbulent conditions;

forming and maintaining a slag layer on the molten metal bath;

feeding at least one waste material into the furnace at one of the opposite ends and into the slay layer that floats on the molten metal bath so that the at least one waste material is engulfed in the slag layer;

allowing the at least one waste material to react in the furnace to replenish the slag layer that floats on the molten metal bath and to produce at least one of a molten metal product that passes into the molten metal bath, and a vapor phase metal product that passes into the headspace of the furnace;

removing a portion of the slag layer as a slag product from another of the opposite ends of the furnace so as to cause the slag layer and the at least one waste material fed into the slag layer to move across the surface of the molten metal bath; and

continuously maintaining the thickness of the slag layer at a level so that the thickness is sufficient to support the at least one waste material by the slag layer,

wherein the at least one waste material is fed into the furnace together with a heat-conducting metal material.

15. A method of continuously processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 14 , wherein the at least one waste material and the heat-conducting metal material are admixed together.

16. A method of continuously processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 15 , wherein the at least one waste material and the heat-conducting metal material comprise a loose admixture.

17. A method of continuously processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 14 , wherein the heat-conducting metal material comprises iron.

18. A method of continuously processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 14 , wherein the heat-conducting metal material comprises a waste material.

19. A method of continuously processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 18 , wherein the heat-conducting metal material comprises a machining waste.

20. A method of continuously processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 19 , wherein the heat-conducting metal material comprises iron borings.