A method for producing liquid pig iron comprises: i) providing a DRI product with an iron content of at least 75.0 wt. %, a carbon content of at least 0.10 wt. % and a content of acidic and basic slag components, comprising CaO, SiO.sub.2, MgO and Al.sub.2O.sub.3 of max. 15.0 wt. %; ii) supplying the DRI product, adding slag formers, into an electrically operated smelting unit; iii) optionally supplying further iron and/or carbon components into the electrically operated smelting unit; iv) smelting the DRI product and optionally the further iron and/or carbon components in the presence of the slag formers, so that a liquid pig iron phase and a liquid slag phase are formed; v) adjusting the slag phase such that it has a basicity of (CaO+MgO/SiO.sub.2) from 0.95 to 1.5; vi) tapping the liquid pig iron phase; and vii) tapping and granulating the slag phase.

A method for producing liquid pig iron comprises: i) providing a DRI product with an iron content of at least 75.0 wt. %, a carbon content of at least 0.10 wt. % and a content of acidic and basic slag components, comprising CaO, SiO.sub.2, MgO and Al.sub.2O.sub.3 of max. 15.0 wt. %; ii) supplying the DRI product, adding slag formers, into an electrically operated smelting unit; iii) optionally supplying further iron and/or carbon components into the electrically operated smelting unit; iv) smelting the DRI product and optionally the further iron and/or carbon components in the presence of the slag formers, so that a liquid pig iron phase and a liquid slag phase are formed; v) adjusting the slag phase such that it has a basicity of (CaO+MgO/SiO.sub.2) from 0.95 to 1.5; vi) tapping the liquid pig iron phase; and vii) tapping and granulating the slag phase.

Systems and methods are described in which spent pickle liquor from metal cleaning processes is utilized to regenerate a lixiviant used to recover valuable metals from industrial waste and other sources. The spent pickle liquor is neutralized and solvated metals in the spent pickle liquor are precipitated in this process. When the industrial waste is slag from a metal refining process a partially closed metal production process can be implemented, where spent pickle liquor from cleaning of the refined metal is used to regenerate a lixiviant used to recover a different, valuable metal from a waste slag of the process, with precipitated salts from the lixiviant regeneration being returned as a raw material in the metal refining process. As a result waste streams from these processes are dramatically reduced or eliminated.

Systems and methods are described in which spent pickle liquor from metal cleaning processes is utilized to regenerate a lixiviant used to recover valuable metals from industrial waste and other sources. The spent pickle liquor is neutralized and solvated metals in the spent pickle liquor are precipitated in this process. When the industrial waste is slag from a metal refining process a partially closed metal production process can be implemented, where spent pickle liquor from cleaning of the refined metal is used to regenerate a lixiviant used to recover a different, valuable metal from a waste slag of the process, with precipitated salts from the lixiviant regeneration being returned as a raw material in the metal refining process. As a result waste streams from these processes are dramatically reduced or eliminated.

A coke product configured to be used in foundry cupolas to melt iron and produce cast iron products is disclosed herein. In some embodiments, the coke product has a Coke Reactivity Index (CRI) of at least 30% and an ash fusion temperature (AFT) less than 1316 C. Additionally or alternatively, the coke product can comprise (i) an ash content of at least 8.0%, (ii) a volatile matter content of no more than 1.0%, (iii) a Coke Strength After Reaction (CSR) of no more than 40%, (iv) a 2-inch drop shatter of at least 90%, and//or (v) a fixed carbon content of at least 85%.

A molten bath-based direct smelting process includes controlling the process conditions in a direct smelting vessel so that molten slag in a molten bath of metal and slag in the vessel has a viscosity in a range of 0.5-5 poise in an operating temperature range for the process.

A molten bath-based direct smelting process includes controlling the process conditions in a direct smelting vessel so that molten slag in a molten bath of metal and slag in the vessel has a viscosity in a range of 0.5-5 poise in an operating temperature range for the process.

A method for producing blast-furnace blowing coal to be blown through a tuyere into the interior of the blast-furnace body of a blast furnace, wherein: the composition and melting point of the ash from the coal are analyzed in advance; the composition of the blast-furnace slag is analyzed in advance; the blast-furnace slag contains more calcium oxide than the coal ash does; and the coal and the blast-furnace slag are mixed, on the basis of the composition and melting point of the coal ash and the composition of the blast-furnace slag, and in a manner such that the amount of calcium oxide contained in a quaternary system phase diagram including silicon dioxide, magnesium oxide, aluminum oxide and calcium oxide, which are the principal components of the coal ash and the blast-furnace slag, causes the melting point of the ash to be 1400 C. or higher.

A method for producing blast-furnace blowing coal to be blown through a tuyere into the interior of the blast-furnace body of a blast furnace, wherein: the composition and melting point of the ash from the coal are analyzed in advance; the composition of the blast-furnace slag is analyzed in advance; the blast-furnace slag contains more calcium oxide than the coal ash does; and the coal and the blast-furnace slag are mixed, on the basis of the composition and melting point of the coal ash and the composition of the blast-furnace slag, and in a manner such that the amount of calcium oxide contained in a quaternary system phase diagram including silicon dioxide, magnesium oxide, aluminum oxide and calcium oxide, which are the principal components of the coal ash and the blast-furnace slag, causes the melting point of the ash to be 1400 C. or higher.