In the present invention the torch movement period is 20-40 seconds, with the torch movement period being the time required to move plasma torches (which heat the surface of molten metal in the casting mold) one time. The average heat input amount at multiple sites, which are obtained by dividing the initial solidification portion (which is where the molten metal makes contact with the casting mold and first solidifies) into multiple sites in the circumferential direction of the casting mold, is 1.0-2.0 MW/m.sup.2. The molten metal advection time, which is the time required for electromagnetically stirred molten metal to travel the length of the torch heating region of the surface of the molten metal in the lengthwise direction of the casting mold, is 3.5 seconds or less.

A plasma cutting system includes a power supply that outputs first and second plasma cutting currents. A torch is connected to the power supply and includes a first cathode that receives the first plasma cutting current, a first electrode and swirl ring, a second cathode that receives the second plasma cutting current, and a second electrode and swirl ring. The torch simultaneously generates a first and second plasma arcs from the electrodes. A gas controller is configured to separately control a flow of a first plasma gas to the first swirl ring and a flow of a second plasma gas flow to the second swirl ring. A torch actuator moves the torch during cutting, and includes a motor having a hollow shaft rotor for rotating the torch during cutting. A motion controller is operatively connected to the torch actuator to control movements of the torch during cutting.

A plasma cutting system includes a power supply that outputs first and second plasma cutting currents. A torch is connected to the power supply and includes a first cathode that receives the first plasma cutting current, a first electrode and swirl ring, a second cathode that receives the second plasma cutting current, and a second electrode and swirl ring. The torch simultaneously generates a first and second plasma arcs from the electrodes. A gas controller is configured to separately control a flow of a first plasma gas to the first swirl ring and a flow of a second plasma gas flow to the second swirl ring. A torch actuator moves the torch during cutting, and includes a motor having a hollow shaft rotor for rotating the torch during cutting. A motion controller is operatively connected to the torch actuator to control movements of the torch during cutting.

In the present pelletizing apparatus, the induration of iron ore concentrate pellets is achieved in a tunnel furnace heated by plasma torches, wherein the generation of CO2 by the conventional iron ore pelletizing processes is reduced by using electricity powered plasma torches instead of burning natural gas, heavy oil or pulverized coal in burners, thereby reducing considerably industrial pollution of the atmosphere.

In the present pelletizing apparatus, the induration of iron ore concentrate pellets is achieved in a tunnel furnace heated by plasma torches, wherein the generation of CO2 by the conventional iron ore pelletizing processes is reduced by using electricity powered plasma torches instead of burning natural gas, heavy oil or pulverized coal in burners, thereby reducing considerably industrial pollution of the atmosphere.

Methods of sequestering toxin particulates are described herein. In a primary processing chamber, a carbon source of toxin particulates may be combined with plasma from three plasma torches to form a first fluid mixture and vitrified toxin residue. Each torch may have a working gas including oxygen gas, water vapor, and carbon dioxide gas. The vitrified toxin residue is removed. The first fluid mixture may be cooled in a first heat exchange device to form a second fluid mixture. The second fluid mixture may contact a wet scrubber. The final product from the wet scrubber may be used as a fuel product.

Methods of sequestering toxin particulates are described herein. In a primary processing chamber, a carbon source of toxin particulates may be combined with plasma from three plasma torches to form a first fluid mixture and vitrified toxin residue. Each torch may have a working gas including oxygen gas, water vapor, and carbon dioxide gas. The vitrified toxin residue is removed. The first fluid mixture may be cooled in a first heat exchange device to form a second fluid mixture. The second fluid mixture may contact a wet scrubber. The final product from the wet scrubber may be used as a fuel product.

Methods of making a fuel fluid are disclosed. A first working fluid and a second working fluid may be provided. The first working fluid may be exposed to a first high voltage electric field to produce a first fluid plasma, and the second working fluid may be exposed to a second high voltage electric field to produce a second fluid plasma. The first fluid plasma and the second fluid plasma may be contacted to form a fluid plasma mixture, which is transported to a heat exchange device. The fluid plasma mixture may be cooled to form a fuel fluid; and the fuel fluid may be collected.

Methods of making a fuel fluid are disclosed. A first working fluid and a second working fluid may be provided. The first working fluid may be exposed to a first high voltage electric field to produce a first fluid plasma, and the second working fluid may be exposed to a second high voltage electric field to produce a second fluid plasma. The first fluid plasma and the second fluid plasma may be contacted to form a fluid plasma mixture, which is transported to a heat exchange device. The fluid plasma mixture may be cooled to form a fuel fluid; and the fuel fluid may be collected.

A method and apparatus are described for supplying municipal solid waste (MSW), and/or other types of solid waste comprising both organic waste material and inorganic waste material, into a plasma gasifier reactor (PGR) in which the solid waste is to be processed.