A concentric ring gas atomization nozzle with isolated gas supply manifolds is provided for manipulating the close-coupled atomization gas structure to improve the yield of atomized powders.

A method for producing a water-atomized metal powder, comprising applying water to a molten metal stream, dividing the molten metal stream into a metal powder, and cooling the metal powder, wherein the metal powder is further subjected to secondary cooling with cooling capacity having a minimum heat flux point (MHF point) higher than the surface temperature of the metal powder in addition to the cooling and the secondary cooling is performed from a temperature range where the temperature of the metal powder after the cooling is not lower than the cooling start temperature necessary for amorphization nor higher than the minimum heat flux point (MHF point).

A magnesium-based alloy powder is made of a magnesium-based alloy that contains 0.2 mass % to 5 mass % of calcium, wherein the magnesium-based alloy powder has an average particle diameter of 100 m to 1,500 m, wherein the magnesium-based alloy powder has a particle average aspect ratio of 0.5 to 1, wherein the magnesium-based alloy powder has an apparent density of 0.2 g/cm.sup.3 to 1.2 g/cm.sup.3, and wherein the mean value of hardness variation index values obtained by dividing the difference of the maximum value and the minimum value of micro Vickers hardnesses taken at 10 measurement points in a particle cross section by the maximum value is 0.3 or less.

A low-sulfur granulated metallic unit having a mass fraction of sulfur between 0.0001 wt. % and 0.08 wt. % is disclosed herein. Additionally or alternatively, the granulated metallic unit can comprise a mass fraction of phosphorous of at least 0.025 wt. %, a mass fraction of silicon between 0.25 wt. % and 1.5 wt. %, a mass fraction of manganese of at least 0.2 wt. %, a mass fraction of carbon of at least 0.8 wt. %, and/or a mass fraction of iron of at least 94.0 wt. %.

A low-carbon granulated metallic unit having a mass fraction of carbon between 0.1 wt. % and 4.0 wt. % is disclosed herein. Additionally or alternatively, the granulated metallic unit can comprise a mass fraction of phosphorous of at least 0.025 wt. %, a mass fraction of silicon between 0.25 wt. % and 1.5 wt. %, a mass fraction of manganese of at least 0.2 wt. %, a mass fraction of sulfur of at least 0.0001 wt. %, and/or a mass fraction of iron of at least 94.0 wt. %.

Systems and methods for using a liquid hot metal processing unit to produce granulated metallic units (GMUs) are disclosed herein. In some embodiments of the present technology, a liquid hot metal processing system for producing GMUs comprises a liquid hot metal processing unit including a granulator unit. The granulator unit can include a tilter positioned to receive and tilt a ladle, a controller operably coupled to the tilter to control tilting of the ladle, a tundish positioned to receive the molten metallics from the ladle, and a reactor positioned to receive the molten metallics from the tundish. The reactor can be configured to cool the molten metallics to form granulated metallic units (GMUs).

Reduced-waste systems and methods for granulated metallic units (GMUs) production are disclosed herein. A representative method can include receiving a first supply of molten iron and producing GMUs by granulating the molten iron poured onto a target material of a reactor. The method can include removing residual fines of the GMUs via a classifier based on a threshold particle size and mixing the residual fines with a second supply of molten iron to produce additional GMUs.

Treating cooling water in industrial production facilities and associated systems, devices, and methods are disclosed herein. The system can comprise a cooling tower with a first and second cell, each having a housing to receive return water and a sump below to maintain supply water configured to directly contact molten metal. The system includes an inlet and an inlet line to provide return water to the cooling tower and an outlet and an outlet line to direct supply water back to the industrial production facility. The inlet, outlet, and cooling tower form a closed-loop network. Additionally, a blowdown line is fluidically coupled to the outlet to divert a portion of the supply water away from the closed-loop network.

A low-carbon granulated metallic unit having a mass fraction of carbon between 0.1 wt. % and 4.0 wt. % is disclosed herein. Additionally or alternatively, the granulated metallic unit can comprise a mass fraction of phosphorous of at least 0.025 wt. %, a mass fraction of silicon between 0.25 wt. % and 1.5 wt. %, a mass fraction of manganese of at least 0.2 wt. %, a mass fraction of sulfur of at least 0.0001 wt. %, and/or a mass fraction of iron of at least 94.0 wt. %.

Reduced-waste systems and methods for granulated metallic units (GMUs) production are disclosed herein. A representative method can include receiving a first supply of molten iron and producing GMUs by granulating the molten iron poured onto a target material of a reactor. The method can include removing residual fines of the GMUs via a classifier based on a threshold particle size and mixing the residual fines with a second supply of molten iron to produce additional GMUs.