A renewable energy powered thermal processing system is formed from a renewable energy source operably connected to an inverter via a charge controller. In one embodiment, a solar renewable energy source is operably connected to the inverter via a solar charge controller. The inverter is connected to a renewable energy storage device and further conditions the current for the thermal processing power supply, which then delivers energy to a thermal processing unit. A supplemental renewable energy source, such as wind, may further be operably connected to the inverter via a supplemental charge controller. As such, the thermal processing unit can be powered solely by renewable energy directly or stored renewable energy within the renewable energy storage device to provide a standalone, grid-independent renewable energy powered thermal processing system. Optionally, a grid tie may further selectively connect the system to an external power grid as a backup source of energy.

A direct reduction system for a direct reduction of iron ore, comprising a reactor having a reduction area and being adapted to be loaded from above with said iron ore; a treatment and feeding line, to process the process gases, thus obtaining a reducing gas mixture, and feed said reducing gas mixture into the reduction area; a line for recovering and treating an exhausted gas exiting the reactor, communicating upstream with the reactor and downstream with said treatment and feeding line; wherein at least one bypass duct is provided, adapted to divert at least one portion of reducing gas mixture from said treatment and feeding line to said recovery and treatment line.

A direct reduction system for a direct reduction of iron ore, comprising a reactor having a reduction area and being adapted to be loaded from above with said iron ore; a treatment and feeding line, to process the process gases, thus obtaining a reducing gas mixture, and feed said reducing gas mixture into the reduction area; a line for recovering and treating an exhausted gas exiting the reactor, communicating upstream with the reactor and downstream with said treatment and feeding line; wherein at least one bypass duct is provided, adapted to divert at least one portion of reducing gas mixture from said treatment and feeding line to said recovery and treatment line.

A process and plant for preheating a metal charge fed in continuous to an electric melting furnace through a preheating tunnel provided with side walls, a vault and a horizontal conveyor, wherein the metal charge is enveloped in countercurrent by fumes or exhaust gases exiting from the electric melting furnace, includes causing an air intake from the surrounding environment through openings along the preheating tunnel to complete the combustion of the fumes or exhaust gases. The intake is regulated by acting on suction fans and/or on the openings, based on measurements by temperature sensors and/or the composition of the outgoing gases in or downstream of the terminal part of the tunnel. The metal charge is enveloped by jets of gas ejected through a plurality of nozzles arranged non-uniformly longitudinally on the vault of the tunnel, with a greater concentration on the top of the vault of the tunnel.

A shuttle kiln (100) according to certain aspects includes at least one flue channel (124) and multiple flue risers (122) in fluid communication with the flue channel (124), and at least one shuttle (104) defining multiple exhaust shafts (140) arranged above the multiple flue risers (122), wherein an aggregate volume of a first exhaust shaft/riser pair (140-1, 122-1) differs from an aggregate volume of a second exhaust shaft/riser pair (140-2, 122-2). Such configuration at least partially compensates for different backpressures that would otherwise be experienced by flue gas exiting a shuttle kiln cavity (138) through different exhaust shafts (140), thereby improving uniformity of flue gas flow and reducing temperature variability within a kiln cavity (138).

Metallurgical plant (10) for treating steelworks by-products, comprising at least one smelting furnace (11) configured to reduce and smelt the reducible metal oxides present in the by-products, generating fumes (F), and an apparatus (12) associated with the smelting furnace (11) to treat said fumes (F). In particular, the apparatus (12) comprises static means for extracting and separating zinc oxide (ZnO) from the fumes (F).

Industrial cars for holding high-temperature materials, such as flat push hot cars for transporting hot coke and deposits, and associated systems and methods are disclosed herein. In some embodiments, an industrial car can include an at least partially enclosed hot box with a base and sidewalls, and one or more of the base or sidewalls can be covered by surface plates. The surface plates can be arranged in a floating configuration with gaps therebetween, such that the surface plates can move relative to one another and thermally expand without exerting excessive compressive force against adjacent surface plates. In some embodiments, the hot box can also include a roof with a first non-curved member and a second non-curved member abutting the first non-curved member. In some embodiments, the industrial car can include one or more emission ducts to remove dust and exhaust from within and around the industrial car.

Industrial cars for holding high-temperature materials, such as flat push hot cars for transporting hot coke and deposits, and associated systems and methods are disclosed herein. In some embodiments, an industrial car can include an at least partially enclosed hot box with a base and sidewalls, and one or more of the base or sidewalls can be covered by surface plates. The surface plates can be arranged in a floating configuration with gaps therebetween, such that the surface plates can move relative to one another and thermally expand without exerting excessive compressive force against adjacent surface plates. In some embodiments, the hot box can also include a roof with a first non-curved member and a second non-curved member abutting the first non-curved member. In some embodiments, the industrial car can include one or more emission ducts to remove dust and exhaust from within and around the industrial car.

A coupling has an opening and a protrusion extending downward from the opening. The protrusion has threads that are preferably positioned outside of the opening. A rotor shaft that connects to the coupling has an internal bore with threads that receives and retains the protrusion, such as by a threaded connection between the two, so the protrusion applies driving force to the shaft.

A slag foaming system for an electric arc furnace utilizing algae is described. The algae may be dried algae in particle form that is injected into the electric arc furnace through a solids injector and may be directed into the slag. Other slag foaming compositions may also be injected into a furnace as a function of furnace parameters to create slag foam while maintaining a high yield of slag without excess iron oxide and reduced carbon and carbon dioxide emission. The algae and slag foaming composition may be used in combination for slag formation and control.