A DC plasma arc furnace, a method of co-processing waste and metal, a method of producing energy by processing material using the furnace, and the products produced by the furnace are provided. Metal may be efficiently processed by the furnace via an increased organic content in other feedstock fed into the furnace.

A method for continuous estimation an instantaneous weight of a graphite electrode being consumed in an electric arc furnace. The method includes the steps of continuously sensing a hydraulic pressure acting on a mast holding the graphite electrode; converting each one of the sensed hydraulic pressures to a corresponding weight of the graphite electrode; and determining from the corresponding weights of the graphite electrode the instantaneous weight of the graphite electrode.

A method for continuous estimation an instantaneous weight of a graphite electrode being consumed in an electric arc furnace. The method includes the steps of continuously sensing a hydraulic pressure acting on a mast holding the graphite electrode; converting each one of the sensed hydraulic pressures to a corresponding weight of the graphite electrode; and determining from the corresponding weights of the graphite electrode the instantaneous weight of the graphite electrode.

Apparatus for melting metal material comprising a container for metal material, by way of example, but not limited to, metal scrap, DRI, cast iron, supplied in an electric arc-type melting furnace, and a plurality of electrodes to melt the metal material, which can be inserted in said container.

Apparatus for melting metal material comprising a container for metal material, by way of example, but not limited to, metal scrap, DRI, cast iron, supplied in an electric arc-type melting furnace, and a plurality of electrodes to melt the metal material, which can be inserted in said container.

Apparatuses for interfacing with an electrode provided with a melting furnace including a vessel and an electrode. In some embodiments, a support assembly (50) supports the electrode outside of the vessel, and includes a cart (102) or similar apparatus that permits or facilitates selective vertical movement of the electrode and selective transverse movement of the electrode. In some embodiments, a push assembly (52) interfaces with a rear face of the electrode outside of the vessel, and is operable to apply a pushing force onto the rear face. The push assembly can include one or more tracks (e.g., threaded screw) that supports a body between opposing arms of a fixed frame. The body can translate along the tracks to apply a pushing force onto the electrode.

Apparatuses for interfacing with an electrode provided with a melting furnace including a vessel and an electrode. In some embodiments, a support assembly (50) supports the electrode outside of the vessel, and includes a cart (102) or similar apparatus that permits or facilitates selective vertical movement of the electrode and selective transverse movement of the electrode. In some embodiments, a push assembly (52) interfaces with a rear face of the electrode outside of the vessel, and is operable to apply a pushing force onto the rear face. The push assembly can include one or more tracks (e.g., threaded screw) that supports a body between opposing arms of a fixed frame. The body can translate along the tracks to apply a pushing force onto the electrode.

A sealing system for isolating the environment inside a vitrification container from the outside environment comprises a vitrification container with a lid. The lid comprises two or more electrode seal assemblies through which two or more electrodes may be operatively positioned and extend down through the lid into the vitrification container. The electrodes may move axially up and down through the electrode seal assemblies or lock into place. The electrode seal assemblies each comprise a housing having two halves with recessed ring grooves. Sealing rings with a split may be placed into the grooves. Gas galleries may be machined or cast into the housing such that they are adjacent to the ring grooves. The gas galleries distribute gas onto the external faces of the sealing rings causing a change in pressure resulting in the sealing rings compressing onto the electrodes and forming a seal.

A sealing system for isolating the environment inside a vitrification container from the outside environment comprises a vitrification container with a lid. The lid comprises two or more electrode seal assemblies through which two or more electrodes may be operatively positioned and extend down through the lid into the vitrification container. The electrodes may move axially up and down through the electrode seal assemblies or lock into place. The electrode seal assemblies each comprise a housing having two halves with recessed ring grooves. Sealing rings with a split may be placed into the grooves. Gas galleries may be machined or cast into the housing such that they are adjacent to the ring grooves. The gas galleries distribute gas onto the external faces of the sealing rings causing a change in pressure resulting in the sealing rings compressing onto the electrodes and forming a seal.

A method for forming a protective antioxidative barrier on the furnace electrodes using a chemically altered cooling liquid containing an antioxidant additive. This method can be applied to electrodes used in electric arc furnaces and ladle metallurgy furnaces. The method can involve spraying the cooling liquid onto the electrode, thereby forming the protective antioxidative barrier and reducing the oxidation of the electrode.