Method and apparatus for making feedstock for steel making

A method for the production of a composite feedstock for steelmaking, comprising the steps of:

• placing solid oxidants in a molding box of a casting machine, the molding box being disposed on a conveyor;
• pouring molten iron onto the solid oxidants to form a blend while the molding box is moving on the conveyor, the ratio between an average linear pouring speed of the molten iron and a linear movement speed of the molding box being in the range of 3:10 and 6:10;
• and
• subjecting the blend to a distributed mechanical force perpendicular to an upper surface of the blend to prevent the oxidants from floating in the iron.

A pig caster for the manufacture of a composite feedstock for steelmaking, the pig caster comprising:

• a least one molding box disposed upon a conveyor;
• a device for pouring molten metal into the molding box;
• a device for placing solid oxidant onto the molding box;
• at least one atomizer for spraying a cooling agent into the molding box and any contents of the molding box;
• and
• a device adapted to apply a mechanical force to the oxidizer within the molding box to prevent the oxidizer from floating in the metal.

A method for the production of steel by charging a furnace having a capacity with layers of scrap;

• a composite charge stock manufactured by pouring molten iron onto solid oxidants to form a blend, during the formation of which the solid oxidants are prevented by the application of a mechanical force from floating in the iron;
• and fluxing components, the charging followed by heating, melting, and oxygen blowing, wherein the furnace is charged in two batches:
• the first batch comprising combination of the charge stock and the scrap in an amount between 2% and 32% of the furnace capacity, the charge stock being layered with the scrap in a ratio between approximately 1:0:1 and approximately 1:20, and at least partial melting of the combination;
• the second batch comprising addition to the combination of the first batch of a combination comprising a further layer of scrap beneath a further layer of charge stock.