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1. WO2011002467 - SLAG CONTROL IN A CHANNEL INDUCTION FURNACE

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[ EN ]

WHAT IS CLAIMED IS:

1. A method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material which comprises:

providing a channel induction furnace having a headspace and containing a molten metal bath;

forming and maintaining a slag layer on the molten bath;

feeding at least one waste material into a channel induction furnace so that the at least one waste material is supported by the slag layer; and

allowing the at least one waste material to react in the channel induction furnace to produce at least one of a molten metal product that passes into the molten metal bath, a vapor phase metal product that passes into the headspace of the channel induction furnace and a slag product that is added to the slag layer;

wherein the slag layer has a thickness and the method further comprises:

maintaining the thickness of the slag layer at a level so that the thickness is sufficient to support the at least one waste material by the slag layer while minimizing heat transfer through the slag layer.

2. A method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 1 , wherein the thickness of the slag layer is controlled by periodically removing a portion of the slag layer from the channel induction furnace.

3. A method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 2, wherein the slag layer has a fluidity which is controlled by heating the slag layer and adjusting the chemistry of the slag layer.

4. A method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 3, wherein the slag layer has a basic chemistry.

5. A method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 1, wherein the thickness of the slag layer is controlled by continuously removing a portion of the slag layer from the channel induction furnace.

6. A method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 5, wherein the slag layer has a fluidity which is controlled by heating the slag layer and adjusting the chemistry of the slag layer.

7. A method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 1 , wherein the thickness of the slag layer is controlled to be below about 5 inches.

8. A method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 7, wherein the thickness of the slag layer is controlled to be below about 4 inches.

9. A method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 8, wherein the thickness of the slag layer is controlled to be below from about 2 to 4 inches.

10. A method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 9, wherein the thickness of the slag layer is controlled to be about 2 inches.

11. A method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material which comprises:

providing a channel induction furnace having a headspace and containing a molten metal bath;

forming and maintaining a slag layer on the molten bath;

feeding at least one waste material into a channel induction furnace so that the at least one waste material is supported by the slag layer; and

allowing the at least one waste material to react in the channel induction furnace to produce at least one of a molten metal product that passes into the molten metal bath, a vapor phase metal product that passes into the headspace of the channel induction furnace and a slag product that is added to the slag layer;

wherein the slag layer has a thickness and the method further comprises:

maintaining the thickness of the slag layer at a level so that the thickness is sufficient to support the at least one waste material by the slag layer while minimizing the resistance of vapor phase components from transferring through the slag layer.

12. A method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 11, wherein the thickness of the slag layer is controlled by periodically removing a portion of the slag layer from the channel induction furnace.

13. A method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 12, wherein the slag layer has a fluidity which is controlled by heating the slag layer and adjusting the chemistry of the slag layer.

14. A method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 13, wherein the slag layer has a basic chemistry.

15. A method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 11 , wherein 77

the thickness of the slag layer is controlled by continuously removing a portion of the slag layer from the channel induction furnace.

16. A method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 15, wherein the slag layer has a fluidity which is controlled by heating the slag layer and adjusting the chemistry of the slag layer.

17. A method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 11 , wherein the thickness of the slag layer is controlled to be below about 5 inches.

18. A method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 17, wherein the thickness of the slag layer is controlled to be below about 4 inches.

19. A method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 18, wherein the thickness of the slag layer is controlled to be below from about 2 to 4 inches.

20. A method of processing at least one of a molten metal product, a vapor phase metal product and a slag product from at least one waste material according to claim 19, wherein the thickness of the slag layer is controlled to be about 2 inches.