Apparatus for the production or refining of metals, and related processes

An electroslag-cold hearth system for refining or producing a metal or metal alloy, comprising a cold hearth vessel capable of holding a pool of liquid metal and an overlying slag layer;

• a power supply for electrically heating the slag layer;
• an ingot mold that communicates with the cold hearth through a flow-over dam that allows the liquid metal to flow from the hearth to the ingot mold while substantially preventing the flow of inclusions to the ingot mold;
• a consumable electrode situated above the cold hearth and laterally off-set from the ingot mold;
• and a non-consumable electrode in contact with the slag layer, wherein the non-consumable electrode comprises a portion of the cold hearth vessel and the ingot mold, and wherein the non-consumable electrode is electrically separated from the cold hearth vessel and the ingot mold by an insulator.

An electroslag-cold hearth system for refining titanium or a titanium alloy, comprising:

• a cold hearth vessel for melting and holding a pool of molten liquid titanium or titanium alloy;
• a calcium-based liquid slag layer overlying the pool of molten liquid titanium or titanium alloy;
• a consumable electrode formed of titanium or titanium alloy, having an end in contact with the liquid slag layer;
• an ingot mold for receiving the molten titanium or titanium alloy, laterally off-set from the consumable electrode, and situated below a portion of the liquid slag layer;
• a power supply for electrically heating the liquid slag layer and the consumable electrode;
• a flow-over dam between the cold hearth vessel and the ingot mold;
• and
• a non-consumable, electrically conductive electrode, in contact with the liquid slag layer, and electrically coupled to the power supply for providing additional thermal energy to the slag layer.

An electroslag-cold hearth system for electrolytically producing titanium or a titanium alloy, comprising:

• a cold hearth vessel for melting and holding a pool of molten liquid titanium or titanium alloy;
• a calcium-based liquid slag layer overlying the cold hearth vessel;
• a source for containing at least one titanium salt in liquid or gaseous form, wherein the salt can be electrochemically reduced to the titanium or titanium alloy when introduced into the liquid slag layer;
• an ingot mold for receiving the molten titanium or titanium alloy, laterally off-set from the cold hearth vessel, and communicating therewith;
• a power supply for electrically heating the liquid slag layer;
• a flow-over dam between the cold hearth vessel and the ingot mold;
• a consumable electrode formed of titanium or titanium alloy, and positioned so that it can be lowered into contact with the liquid slag layer, to allow for the refining of the titanium or titanium alloy while additional titanium or titanium alloy material is being electrolytically produced from the salt;
• and
• a non-consumable, electrically conductive electrode, in contact with the slag layer, and electrically coupled to the power supply for providing additional thermal energy to the liquid slag layer.