Method and device for repairing the spout sleeve of a metallurgical vessel fitted securely within the refractory lining of the vessel in which the sleeve is repaired by applying mortar to the casting channel of the sleeve with a mortar dispenser inserted into the casting channel, which upon removing the mortar dispenser from the casting channel calibrates the latter over the entire length of the channel. The mortar dispenser is driven rotating coaxially to the casting channel during the mortar application and, after a defined time, is removed from the casting channel, still rotating. The method is particularly suitable for repairing the inner sleeve of a casting ladle with a slide closure adjoining the ladle spout, maintenance of which is automatically carried out in a maintenance station of the casting facility. Repair of the inner sleeve is also carried out automatically here during the maintenance of the slide closure.

A measurement system is provided for predicting a future status of a refractory lining that is lined over an inner surface of an outer wall of a metallurgical vessel and exposed to a heat during which the refractory lining is exposed to molten metal. The system includes one or more laser scanners and a processor. The laser scanners are configured to conduct a plurality of laser scans of the refractory lining when the metallurgical vessel is empty. At least one of the laser scanners is configured to laser scan the refractory lining prior to the heat to collect data related to pre-heat structural conditions of the refractory lining. At least one of the laser scanners is configured to laser scan the refractory lining after the heat to collect data related to post-heat structural conditions of the refractory lining. The processor is configured to predict the future status of the lining.

Apparatus and method are provided for life cycle wear monitoring of a consumable refractory in an electric induction furnace used for heating and melting materials by accumulating laser imaging data of the refractory's inner surface periodically over the refractory's life cycle while the furnace is utilized in a foundry environment and processing the accumulated imaging data for comparative analysis with previous laser imaging data of the refractory's inner surface.

Apparatus and method are provided for life cycle wear monitoring of a consumable refractory in an electric induction furnace used for heating and melting materials by accumulating laser imaging data of the refractory's inner surface periodically over the refractory's life cycle while the furnace is utilized in a foundry environment and processing the accumulated imaging data for comparative analysis with previous laser imaging data of the refractory's inner surface.

An exemplary embodiment of the invention provides a method of preparing a reinforced refractory joint between refractory sections of a vessel used for containing or conveying molten metal, e.g. a metal-contacting trough. The method involves introducing a mesh body made of metal wires into a gap between metal-contacting surfaces of adjacent refractory sections of a vessel so that the mesh body is positioned beneath the metal conveying surfaces, and covering the mesh body with a layer of moldable refractory material to seal the gap between the metal-contacting surfaces. Other embodiments relate to a vessel formed by the method and a vessel section with a pre-positioned mesh body suitable for preparing a sealed joint with other such sections.

An exemplary embodiment of the invention provides a method of preparing a reinforced refractory joint between refractory sections of a vessel used for containing or conveying molten metal, e.g. a metal-contacting trough. The method involves introducing a mesh body made of metal wires into a gap between metal-contacting surfaces of adjacent refractory sections of a vessel so that the mesh body is positioned beneath the metal conveying surfaces, and covering the mesh body with a layer of moldable refractory material to seal the gap between the metal-contacting surfaces. Other embodiments relate to a vessel formed by the method and a vessel section with a pre-positioned mesh body suitable for preparing a sealed joint with other such sections.

Jacketed rotary converter. The converter includes an inclined pot mounted for rotation about a longitudinal axis, a refractory lining for holding a molten alloy pool, an opening in a top of the pot for introducing feed, a lance for injecting oxygen-containing gas, a heat transfer jacket for the pot adjacent the refractory lining, and a coolant system to circulate a heat transfer medium through the jacket to remove heat from the alloy pool in thermal communication with the refractory lining. Also disclosed is a PGM converting process using the jacketed rotary converter. The process can also include low-or no-flux converting; refractory protectant addition; slag separation; partial feed pre-oxidation; staged slagging; and/or smelting the slag in a secondary furnace with primary furnace slag.

Jacketed rotary converter. The converter includes an inclined pot mounted for rotation about a longitudinal axis, a refractory lining for holding a molten alloy pool, an opening in a top of the pot for introducing feed, a lance for injecting oxygen-containing gas, a heat transfer jacket for the pot adjacent the refractory lining, and a coolant system to circulate a heat transfer medium through the jacket to remove heat from the alloy pool in thermal communication with the refractory lining. Also disclosed is a PGM converting process using the jacketed rotary converter. The process can also include low-or no-flux converting; refractory protectant addition; slag separation; partial feed pre-oxidation; staged slagging; and/or smelting the slag in a secondary furnace with primary furnace slag.

Integrated PGM converting process. The process includes smelting a catalyst material in a primary furnace, smelting the primary furnace slag in a secondary furnace, converting the collector alloys from the primary and secondary furnaces in a converter to recover PGM enriched alloy and converter slag, separating the recovered converter slag into first and second converter slag portions, and supplying the first converter slag portion to the secondary furnace for smelting with the primary furnace slag. The process can also include low- or no-flux converting; refractory protectant addition; magnetic slag separation; partial feed pre-oxidation; staged slagging; and/or jacketing the converter.

The process includes melting an initial collector alloy charge to start a converter cycle, introducing feed and injecting oxygen into the alloy pool, allowing ferrous slag to collect, terminating feed introduction and oxygen injection to tap the slag, repeating the feed introduction/oxygen injection/slag tapping sequence a plurality of times, and then tapping the alloy to end the cycle. A delay before non-final slag tappings allows any entrained alloy to settle back into the alloy pool, but the final slag tapping is commenced promptly and alloy is optionally entrained. Slag from the final tapping that may contain entrained alloy can be recycled to the converter, e.g., in a subsequent cycle. The process can also include low- or no-flux converting; refractory protectant addition; slag separation; partial feed pre-oxidation; smelting the slag in a secondary furnace with primary furnace slag; and/or jacketing the converter.