WO2020251491A2

WO2020251491A2 - Production of metal alloys from ores and metal melting direct current (dc) furnace systems

Info

Publication number: WO2020251491A2
Application number: PCT/TR2020/050446
Authority: WO
Inventors: Yılmaz KARAKAŞ
Original assignee: Karakas Arge Teknoloji Ulastirma Gemi Mad Met San Ve Tic AS
Current assignee: Karakas Arge Teknoloji Ulastirma Gemi Mad Met San Ve Tic AS
Priority date: 2019-06-12
Filing date: 2020-05-22
Publication date: 2020-12-17
Anticipated expiration: 2021-12-12
Also published as: WO2020251491A3

Abstract

This invention is related to direct current furnace systems employed in production of iron & steel, low carbon ferro chrome, high carbon ferro chrome, ferro manganese, pig iron, ferrosilicon, silicium metal, other ferro alloys and non-ferrous metals.

Description

PRODUCTION OF METAL ALLOYS FROM ORES AND

METAL MELTING DIRECT CURRENT (DC) FURNACE SYSTEMS

TECHNICAL FIELD

PRIOR ART Among the systems employed for melting mine ores, we may basically and primarily mention about furnace systems. The purpose herein is to expose the ores charged into furnace to high temperature, and to ensure that they are melted down and moulded under the effects of this temperature. In addition, alloys are also ensured to be prepared by bringing several materials together.

If and when we diversify the metal melting furnaces in terms of heat source used therein, then and in this case, natural gas and electrical furnaces come to the forefront. In reverberant furnaces as a type of natural gas furnaces, a portion of heat is directly transferred from flame to metal, while another portion of heat is reflected from furnace walls, and exerts an effect on metal. In this system, metal is melted down by heat energy taken from natural gas fired by a burner inside the furnace. However, use of fossil fuels paves the way for some disadvantages. Included in these disadvantages are interaction of combustible products with ore melt, and existence of toxic and dangerous ingredients in chimney gas, and low efficiency and high investment, operating and maintenance costs in some furnaces, and unit prices of fossil fuels. In melting furnaces operating with electrical energy, induction furnaces are used, in addition to resistance furnaces and arc furnaces. Particularly induction furnaces are more preferable among furnace systems because of their advantages such as sensitive heat values, metal purity, efficiency, environmental friendliness and less- noisiness. Induction current (turbulent current) refers to and stands for electric current induced by a magnetic field related to the adjacent magnetic or electric current in a conductor. In an induction current separator, strong permanent magnets are generally used to generate this field. The passing of ore through a series of magnets having different magnetic poles generates Lorentz forces which continuously revolve the piece of ore and force it to stray away from its current course. If the ore remains in the magnetic field generated by alternative current for a certain period of time, its resistance against reverse induction current generated by the field will cause the ore to be heated up. This is called induction heating, and is used in some metallurgy applications. Induction heating is started to be used for melting purposes in industry starting from 1930s. In our day, these furnaces are used not only in iron and steel, but also mostly in non-ferrous metals. Two general approaches are observed to be used in design of induction based furnaces. In the first one, solid metal is directly heated and melted in a coreless induction furnace by means of induction currents. In the second one, metal melt is further melt down to the high temperature at the bottom of channel induction furnace, and the superheated metal melt further melts down also the ingots or other scraps fed from the top of furnace (RECYCLING AND IMPROVEMENT OF ALUMINUM - Post-graduate thesis - Necdet iZGi). DEFINITION OF INVENTION

The present invention is related to a system developed in order to eliminate the aforementioned disadvantages and to bring new advantages to the relevant technical field.

Purpose of this invention is to create a system for producing metal alloys directly or out of processed ores, for use in production and smelting of all components such as High Carbon Ferrochrome (HC FeCr), Low Carbon Ferrochrome (LC FeCr), Ferro Silicochrome (FeSiCr), Ferro Nickel (FeNi), High Carbon Ferromanganese (HC FeMn), Low Carbon Ferromanganese (LC FeMn), Ferro Silicomanganese (FeSiMn), Ferrosilicon (FeSi), Metallic Silicium (Si) and Pig Iron and Steel out of ores. The system is also used for recovery and refining of precious metal oxides (Cr203, MnO, NiO, Fe203, etc.) remaining in slags arising out of production of these components.

Another purpose of this invention is to cover systems which constitute the melting furnace systems (Smelter) employed in production and melting of metal alloys out of ores. These contain the kinds of refractories used therein, their pattern and usage types, cooling applications, electrical systems, electrical transfer copper assemblies used, principles of transfer of electrical energy, electricity generating plasma power unit, and applications used by melting Smelter systems for discharging of the produced metals and their slags.

Drawings

Applications of this present invention which are briefly summarized in the preceding paragraph and are to be thoroughly described in more details hereinbelow may be understood with reference to the example applications of the invention as depicted in the drawings attached hereto. However, it should also be clearly stated that the drawings attached hereto depict and describe only the typical applications of this invention, and as the invention may also permit other equipotent applications for this reason, the drawings will in no event be assumed to have limited or restricted the scope of this invention.

Drawing 1 is a general view of melting furnace covered by this invention.

Drawing 2 is a general view of the invented system.

Drawing 3 indicates the use of the invented system with displacement of anode and cathode.

Drawing 4 indicates the bending movements of smelter during casting in the invented system. Drawing 5 indicates the electrode stepping out of smelter during casting by smelter in the invented system.

Drawing 6A indicates the plain pattern type on the bottom body of smelter.

Drawing 6B indicates the front view of the plain pattern type on the bottom body of smelter.

Drawing 7A indicates the ring pattern type on the bottom body of smelter.

Drawing 7B indicates the front view of the ring pattern type on the bottom body of smelter.

Drawing 7C indicates the front view of copper bar assembly at the midst of the ring pattern.

Drawing 8 indicates the use of oxide based refractory material instead of carbon material in the top layer refractory pattern.

Drawing 9A indicates the type of pattern with refractory materials in furnace.

Drawing 9B indicates the application of expansion forging in the type of pattern with refractory materials in furnace.

Drawing 10A indicates the top view of laying of fully conductor copper material by being contacted with refractory materials inside smelter.

Drawing 10B indicates the front view of the type of assembly of refractory and copper metals inside smelter.

Drawing 10C indicates the front view of assembly of copper on the bottom base of smelter as well.

Drawing 10D indicates the front view of conductivity provided from outside the smelter body as well.

Drawing 11 indicates the front view of laying of the bottom base of smelter by using oxide based refractory material with low thermal conductivity and no electrical conductivity.

Drawing 12A indicates the application types and designed of copper or conductor metals in the invention.

Drawing 12B indicates the perspective view of copper or conductor metals in the invention.

Drawing 12C indicates the perspective and front view of alternative structuring of copper or conductor metals in the invention. Drawing 13 indicates the front view of plain refractory pattern in smelter, and with several electrodes used and applied in this pattern.

Drawing 14 indicates the version of multi-electrode system layed by using ring pattern in the invention.

Drawing 15 indicates the rectangular 3-electrode smelter structure.

Drawing 16 indicates the front view of internal pattern of smelter in the invention.

For the sake of clarity, if and when possible, identical reference numbers are used in order to refer to the identical elements used jointly in the drawings. Drawings are not scaled and may be further simplified for clarification purposes. It is believed that the elements and specifications of an application may be usefully included in or transferred to other applications as well, without any further description thereon. Description of Details in Drawings

Descriptions of reference numbers indicated in the drawings are listed below:

1- Electrode

1a- Electrode holder

1 b- Electrode tower

2- Raw materials feeding

3- Gas chimney

4- Copper conductor

5- Trap plate

6- Trap concrete

7- Side shell plate

10- Metal / slag removal hole

11 - Discharge feeder

12- Refractory brick

12a- Oxide brick

12b- Graphite brick

12c- Carbon brick

13- Bottom shell plate 15- Electric transformer

16- Copper bars

17- Cable

18- Electrical insulation material

19- Steel block

20- Copper ring

20a- Copper shaft

20b- Ring Bar

20c- Copper shaft assembly screw

21 - Air cooling duct

22- Expansion forging

S- Smelter

DETAILED DESCRIPTION OF INVENTION

The preferred alternatives referred to in this detailed description of the invention are depicted and described herein solely for the sake of clarity and in such manner not to lead to any restrictive or limiting effect thereon. This invention is related to a system used for production and smelting of all components such as High Carbon Ferrochrome (HC FeCr), Low Carbon Ferrochrome (LC FeCr), Ferro Silicochrome (FeSiCr), Ferro Nickel (FeNi), High Carbon Ferromanganese (HC FeMn), Low Carbon Ferromanganese (LC FeMn), Ferro Silicomanganese (FeSiMn), Ferrosilicon (FeSi), Metallic Silicium (Si) and Pig Iron and Steel out of ores, characterized in that the ores kept in smelter (S) shown in Drawing 1 are melted through conversion of AC current to DC current in an electric transformer (15) shown in Drawing 2 and Drawing 3, fit for the smelter (S) shown in Drawing 1 , and through transmission of DC current to electrode (1 ) and anode (4) connected to electrode tower (1 b) by means of electrode holder (1 a) by using copper bars (16) and cables (17). The system covered by this invention is also used for recovery and refining of precious metal oxides (Cr203, MnO, NiO, Fe203, etc.) remaining in slags arising out of production of these components. The invention further covers systems which constitute the melting furnace systems (Smelter) employed in production and melting of metal alloys out of ores. These contain the kinds of refractories used therein, their pattern and usage types, cooling applications, electrical systems, electrical transfer copper assemblies used, principles of transfer of electrical energy, electricity generating plasma power unit, and applications used by melting Smelter systems for discharging of the produced metals and their slags. Specifications of metals and refractories employed in Smelter (S) system:

Copper; in the form of copper ring bar (20b) or cable (17), particularly preferred electrolytic copper,

Steel, stainless steel, copper plate and aluminium plate are used in shell plates (7, 13) of smelter (S).

Out of refractory bricks (12) used in internal surface of smelter (S), oxide bricks (12a) are alumina based, magnesium based, silicium carbide, chammote (fireclay), carbon based, and graphite based. These materials are used in brick form, powder forged form, concrete casting or extrusion form. Oxide bricks (12a) used therein do not have electrical conductivity, and have a low thermal conductivity (<10 W/m.K). Carbon brick (12c) and graphite brick (12b) refractories used therein have electrical conductivity, and the Carbide based ones of them have a high thermal conductivity. Thermal conductivity is low in the carbon based ones (<15 W/m.K), but high in the graphite based ones (generally 80-300 W/m.K). In the invention, refractory oxide materials, some nitride and carbide based materials in brick or concrete form, heat resistant plastic based composite materials, and wood based materials are used in electrical insulation materials employed in the smelter (S) melting systems. Smelter (S) used for production out of ore is comprised of the main components shown in Drawing 1. Included among them are side shell plate, bottom shell plate and trap plate made of metal sheets, as well as metal / slag removal hole (10), electrical insulation material (18), raw materials feeding (2), gas chimney (3), air cooling duct (21 ), various oxide/carbide/carbon/graphite based refractory bricks (12) laid inside smelter (S), electrode (1 ) (cathode or anode, variable depending on the purpose of use), and copper conductor (4) (anode or cathode, variable depending on the purpose of use).

Smelter (S) operates according to the direct current (DC) electricity principle. Direct current (DC) is generated in an electrical transformer (15) of smelter (S). Alternative current (AC) electrical power used in electrical network lines is converted into direct current (DC) by electrical transformer (15) of smelter (S). Smelter (S), electrical transformer (15) system and its characteristics, refractory bricks (12) and their characteristics, pattern and assembly types constitute an integrity.

In electrical transformer (15), direct current is generated as 6, 12 and 24 PULSES according to electricity principles. Outlet electric power is entirely insulated. This means to say that for the employees working with ANODE and CATHODE separately, the operating power is not dangerous and do not lead to an electric shock risk, regardless of the voltage and current used therein. However, if a person or an employee contacts both anode and cathode at the same time, it is dangerous. With this safety, DC power generating electrical transformer (15) is designed between 25 and 1200 Volt range. The voltage to be chosen varies according to the targeted applications. In applications, no upper limit (cap) is imposed on current values. The generally used current value changes between 100 Amperes and 500,000 Amperes. In the use of electrical transformer (15), the system is designed as voltage fixed - ampere variable, ampere fixed - voltage variable or ampere / voltage independent variable. Electrical transformer (15) is manufactured through design of power ratios of smelter (S) depending on the applications. In installation of electrical transformer (15), DIODE, THYRISTOR or electronic DC converters are employed for generation of DC current. These systems are cooled down by air, gas, incombustible fluid or water. Electrical power is transmitted from electrical transformer (15) through metal conductors or copper metal. Whatever the type of conductors used therein, it is transmitted by electrical cable (17), preferably copper bar (16) or flexy systems. Conductor systems are designed as air-cooled, gas-cooled or liquid-cooled (water or another type of fluid).

Smelter (S) and electrical transformer (15) are sine qua non integral parts and components of each other. The basically used assembly/installation example is shown in Drawing 2. Drawing 3 indicates the use of the invented system with displacement of anode and cathode.

Smelter (S) is employed in 3 different forms depending on the specifications of application. As shown in Drawing 4, drawing A indicates a fixed smelter (S), drawing B indicates a 0-90° angled bendable smelter (S) and drawing C indicates a >90° angled bendable smelter (S). Thus, molten ore inside smelter (S) can be discharged with the downslope. In smelter (S), in models A and B of Drawing 4, electrode (1 ) is at the same axis with smelter (S) during metal / slag discharge operation, as further demonstrated in Drawing 4. However, in model C of again Drawing 4 showing the smelter (S), electrode (1 ) gets out of smelter (S) during discharging and casting operation, as further demonstrated in Drawing 5.

Refractory bricks (12) may be laid up on the bottom shell plate of smelter (S) either plainly bottom-up as shown in Drawing 6A and Drawing 6B or in a ring form as shown in Drawing 7A and Drawing 7B. Bricks may be laid in one or more brickwork rows / layers. Number and thickness of rows of refractory brick (12) are designed according to the production applications. As shown in Drawing 7C, it is also used by installing a copper shaft (20a) at the midst of a ring-shaped pattern so as to ensure electrical conductivity. Copper shaft (20a) is fixed by an assembly screw (20c) to the steel block (19) at the top by using a screw or other assembly form. This type of pattern form is fit for melting steel in electric arc furnaces.

Bottom shell plate is entirely and electrically insulated and separated from side shell plate and trap plate by means of an electrical insulation system. It is insulated so as to ensure that it does no more have any electricity transfer or transmission capacity. This is a fundamental requirement in installation of bottom shell plate and refractory bricks (12). Even electrical conductive refractory materials are assembled and installed as such inside smelter (S).

As seen in Drawing 6B, in the top layer of pattern of refractory bricks (12), fully carbon based carbon brick (12c) refractory may be used, or as shown in Drawing 7B, partially graphite based graphite bricks (12b) and carbon bricks (12c) may be used together. This is applied according to the specifications of the metal alloy produced therein. During production of high temperature metal liquefied on carbon based material, graphite material at the lower layers of carbon material protects carbon by cooling it down quickly. At the same time, electrical current of anode is transferred from graphite brick (12b) and carbon brick (12c) into smelter (S). Carbon and graphite materials are materials with electrical conductivity.

In some applications, as shown in Drawing 8, in top layer refractory brick (12) pattern, oxide based oxide brick (12a) refractory material is used in place of carbon brick (12c). Inside smelter (S), for the sake of electrical conductivity, graphite brick (12b) or carbon brick (12c) refractory material is used at the same top layer. Again graphite brick (12b) material is used for the purpose of cooling of lower base of smelter (S).

Refractory bricks (12) may be laid as also shown in Drawing 9A and as explained before. At the same time, as seen in Drawing 9B, expansion forging (22) may be applied between brick layers. By doing so, refractory expansions occurring in large smelter (S) systems will have been compensated. However, this expansion forging (22) should not prevent electrical conductivity of graphite and carbon based refractory materials. This expansion forging may further be applied also on different layers of refractory brick (12) patterns inside smelter (S).

In the invention, as shown in Drawing 9A and Drawing 9B, lower base of smelter (S) is cooled down by air current passing through air cooling duct (21 ). Bottom, side shell plates and trap plate of smelter (S) are cooled down by air, direct or indirect water / incombustible fluid. Water and incombustible fluid coolants may either exert their cooling effects with the help of a duct contacting the body, or be applied by direct contact to the body. This may be in the form of water/fluid side pouring or spraying. However, this directly applied water or fluid cooling effect should not lead to side shell plate and lower base electrical conductivity (contact). For the sake of quicker transmission of electricity in smelter (S), graphite brick (12b) or carbon brick (12c) refractory materials may be laid as shown in Drawing 10A through a tight contact with quick conductor copper or another different conductor material. This copper material is laid by contacting the fully conductor refractory materials inside smelter (S). Drawing 10B indicates the assembly form and type of refractory bricks (12) and copper ring (20). Copper material may be installed in ring form over all of the refractory pattern layers inside smelter (S) or may cover all rings. In the invention, copper ring (20) may be installed as such, or may also be fitted on the lower base of smelter (S) as demonstrated in Drawing

IOC. Here, while copper ring (20) is on the internal bottom surface of smelter (S), the ring bar (20b) used for energy connection are on the external bottom surface thereof. Again, for conductivity purposes, copper or conductor metal material (such as steel, stainless steel and aluminium) may also be installed on the external part of smelter (S). As will be seen in parts B and C of Drawing 10D, a copper ring (20) coating the external surface of smelter (S) may be applied separately and individually or jointly and at the same time together with another copper ring (20) placed on its external bottom surface. Thus, as seen in Drawing

IOD, conductivity is provided from outside the body of smelter (S). As seen, application types and designs of copper or conductor metals are shown as an example in Drawing 12A and Drawing 12B. As also seen herein, copper ring (20) may be applied either in fully circular form or in half-moon form. In another alternative application, copper ring (20) applicable in a plan circular plate form takes energy via ring bar (20b).

In the invention, as also seen in Drawing 11 , oxide based oxide brick (12c) refractory material having a low thermal conductivity and having no electrical conductivity may also be laid on lower base of smelter (S). Thus, heat flow will be directed towards side walls of smelter (S). By doing so, smelter (S) may be run and operated under the side wall cooling effects. This smelter (S) system developed for use in high capacity production of metal alloys may, as shown in Drawing 13, be also used with more than one electrode (1 ) as well. Drawings 13A, 13B and 13C demonstrate a 3-electrode (1 ) plain refractory brick (12) patterned system. As also seen in Drawing 13C, in practice, carbon bricks (12c) may be installed and laid also in the form of forged carbon or uncooked carbon block. Here, in the application shown in Drawing 13B, first row is laid as carbon brick (12c), while second and third rows are laid as graphite brick (12b).

Multi-electrode (1 ) system may also be laid by application of ring-shaped pattern as seen in Drawing 14A and Drawing 14B. Smelters (S) to be used in practice may be designed round, or may be in square, rectangular or different shapes and dimensions. A rectangular 3-electrode (1 ) smelter (S) is shown in Drawing 15A and Drawing 15B.

Smelter (S) base brick pattern may either be plain, or be round or oval as seen in Drawing 16 as well. This may be arranged entirely depending on the field of application and according to wishes.

Claims

1. This invention is related to a direct current smelter furnace system used for production and smelting of all components such as High Carbon Ferrochrome (HC FeCr), Low Carbon Ferrochrome (LC FeCr), Ferro Silicochrome (FeSiCr), Ferro Nickel (FeNi), High Carbon Ferromanganese (HC FeMn), Low Carbon Ferromanganese (LC FeMn), Ferro Silicomanganese (FeSiMn), Ferrosilicon (FeSi), Metallic Silicium (Si) and Pig Iron and Steel out of ores, characterized in that the ores kept in smelter (S) are melted through conversion of AC current to DC current in an electric transformer (15) fit for the smelter (S), and through transmission of DC current to electrode (1 ) connected to electrode tower (1 b) by means of electrode holder (1a) by using copper bars (16) and cables (17) and also to anode (4) positioned at any place of smelter (S), and also that the system covered by this invention is also used for recovery and refining of precious metal oxides (Cr203, MnO, NiO, Fe203, etc.) remaining in slags arising out of production of these components, and also that the invention further covers the kinds of refractories used therein, their pattern and usage types, cooling applications, electrical systems, electrical transfer copper assemblies used, principles of transfer of electrical energy, electricity generating plasma power unit, and applications used by melting Smelter (S) systems for discharging of the produced metals and their slags, characterized in that it comprises the following:

• The system is comprised of side shell plate, bottom shell plate and trap plate made of metal sheets, as well as metal / slag removal hole (10), electrical insulation material (18), raw materials feeding (2), gas chimney (3), air cooling duct (21 ), various oxide/carbide/carbon/graphite based refractory bricks (12) laid inside smelter (S), electrode (1 ) (cathode or anode, variable depending on the purpose of use), and copper conductor (4) (anode or cathode, variable depending on the purpose of use), and • The conductor is copper conductor (4), in the form of copper ring (20) fish plate (20b) or cable (17), particularly preferred electrolytic copper, and

• Steel, stainless steel, copper plate and aluminium plate are used in shell plates (7, 13) of smelter (S), and

• Out of refractory bricks (12) used in internal surface of smelter (S), oxide bricks (12a) are alumina based, magnesium based, silicium carbide, chammote (fireclay), carbon based, and graphite based, and these materials are used in brick form, powder forged form, concrete casting or extrusion form, and

• Oxide bricks (12a) used therein do not have electrical conductivity, and have a low thermal conductivity (<10 W/m.K), and

• Carbon brick (12c) and graphite brick (12b) refractories used therein have electrical conductivity, and the carbide based ones of them have a high thermal conductivity, and thermal conductivity is low in the carbon based ones (<15 W/m.K), but high in the graphite based ones (generally 80-300 W/m.K), and

• In discharging of metal and slag, it may be applied and employed as a fixed smelter (S), or a 0-90° angled bendable smelter (S), or a >90° angled bendable smelter (S), and thus, molten ore inside smelter (S) can be discharged with the downslope, and in smelter (S), in fixed and 0-90° angled positions, electrode (1 ) is at the same axis with smelter (S) during metal / slag discharge operation, but however, in >90° angled position, electrode (1 ) gets out of smelter (S) during discharging and casting operation.

2. A smelter (S) operating according to a direct current (DC) electricity principle developed according to claim 1 , characterized in that alternative current (AC) electrical power used in electrical network lines is converted into direct current (DC) by electrical transformer (15) of smelter (S), and that in electrical transformer (15), direct current is generated as 6, 12 and 24 pulses according to electricity principles, and that outlet electric power is entirely insulated, and that for the employees working with anode and cathode separately, the operating power is not dangerous and do not lead to an electric shock risk, regardless of the voltage and current used therein, unless anode and cathode are contacted at the same time, and that with this safety, DC power generating electrical transformer (15) is designable between 25 and 1200 Volt range, and that though no upper limit (cap) is imposed on current values, the generally used current value changes between 100 Amperes and 500,000 Amperes, and that in the use of electrical transformer (15), the system is designed as voltage fixed - ampere variable, ampere fixed - voltage variable or ampere / voltage independent variable, and that in installation of electrical transformer (15), diode, thyristor or electronic DC converters are employed for generation of DC current, and that these systems are cooled down by air, gas, incombustible fluid or water.

3. A smelter developed according to any one of the claims hereinabove, characterized in that electrical power received from electrical transformer (15) is transmitted through metal conductors or copper metal, and that whatever the type of conductors used therein, it is transmitted by electrical cable (17), preferably copper bar (16) or flexy systems, and that conductor systems are designed as air-cooled, gas-cooled or liquid-cooled (water or another type of fluid.

4. A smelter developed according to any one of the claims hereinabove, characterized in that bottom shell plate is entirely and electrically insulated and separated from side shell plate and trap plate by means of an electrical insulation system, and that it is insulated so as to ensure that it does no more have any electricity transfer or transmission capacity.

5. A smelter developed according to any one of the claims hereinabove, characterized in that refractory bricks (12) may be laid up on the bottom shell plate of smelter (S) either plainly bottom-up or in a ring form, and that bricks may be laid in one or more brickwork rows / layers, and that number and thickness of rows of refractory brick (12) are designed according to the production applications, and that it is also used by installing a copper shaft (20a) at the midst of a ring-shaped pattern so as to ensure electrical conductivity, and that copper shaft (20a) is fixed by an assembly screw (20c) to the steel block (19) at the top by using a screw or other assembly form.

6. A smelter developed according to any one of the claims hereinabove, characterized in that in the top layer of pattern of refractory bricks (12), fully carbon based carbon brick (12c) refractory may be used, or partially graphite based graphite bricks (12b) and carbon bricks (12c) may be used together, and that this is applied according to the specifications of the metal alloy produced therein, and that during production of high temperature metal liquefied on carbon based material, graphite material at the lower layers of carbon material protects carbon by cooling it down quickly, and that at the same time, electrical current of anode is transferred from graphite brick (12b) and carbon brick (12c) into smelter (S) due to electrical conductivity of carbon and graphite materials.

7. A smelter developed according to any one of the claims hereinabove, characterized in that in top layer refractory brick (12) pattern, oxide based oxide brick (12a) refractory material is used in place of carbon brick (12c), and that inside smelter (S), for the sake of electrical conductivity, graphite brick (12b) or carbon brick (12c) refractory material is used at the same top layer, and that again graphite brick (12b) material is used for the purpose of cooling of lower base of smelter (S).

8. A smelter developed according to any one of the claims hereinabove, characterized in that due to the compensability of refractory expansions occurring in large smelter (S) systems, expansion forging (22) may be applied between brick layers in laying of refractory bricks (12), but however this expansion forging (22) should not prevent electrical conductivity of graphite and carbon based refractory materials, and that this expansion forging may further be applied also on different layers of refractory brick (12) patterns inside smelter (S).

9. A smelter developed according to any one of the claims hereinabove, characterized in that lower base of smelter (S) is cooled down by air current passing through air cooling duct (21 ), and that bottom, side shell plates and trap plate of smelter (S) are cooled down by air, direct or indirect water / incombustible fluid, and that water and incombustible fluid coolants may either exert their cooling effects with the help of a duct contacting the body, or be applied by direct contact to the body in the form of water/fluid side pouring or spraying.

10. A smelter developed according to any one of the claims hereinabove, characterized in that for the sake of quicker transmission of electricity in smelter (S), graphite brick (12b) or carbon brick (12c) refractory materials may be laid through a tight contact with quick conductor copper or another different conductor material, and that this copper material is laid by contacting the fully conductor refractory materials inside smelter (S), and that in installation ofrefractory bricks (12) and copper ring (20), the copper material may be installed in ring form over all of the refractory pattern layers inside smelter (S) or may cover all rings, and that copper ring (20) may be installed as such, or may also be fitted on the lower base of smelter (S), and that while copper ring (20) is on the internal bottom surface of smelter (S), the ring bar (20b) used for energy connection are on the external bottom surface thereof, and that again, for conductivity purposes, copper or conductor metal material (such as steel, stainless steel and aluminium) may also be installed on the external part of smelter (S), and a copper ring (20) coating the external surface of smelter (S) may be applied separately and individually or jointly and at the same time together with another copper ring (20) placed on its external bottom surface.

11. A smelter developed according to any one of the claims hereinabove, characterized in that in smelter (S), for the sake of electrical conductivity, copper ring (20) may be applied either in fully circular form or in half-moon form, and that in another alternative application, copper ring (20) applicable in a plan circular plate form takes energy via ring bar (20b).

12. A smelter developed according to any one of the claims hereinabove, characterized in that oxide based oxide brick (12c) refractory material having a low thermal conductivity and having no electrical conductivity may also be laid on lower base of smelter (S), and that thus, heat flow will be directed towards side walls of smelter (S), and by doing so, smelter (S) may be run and operated under the side wall cooling effects.

13. A smelter developed according to any one of the claims hereinabove, characterized in that this smelter (S) system is developed for use in high capacity production of metal alloys and may also be used with more than one electrode (1 ) as well, and that in laying of multi-electrode (1 ) plain refractory brick (12) patterned system, carbon bricks (12c) may be installed and laid also in the form of forged carbon or uncooked carbon block, and that here, first row is laid as carbon brick (12c), while second and third rows are laid as graphite brick (12b), and that multi-electrode (1 ) system may also be laid by application of ring-shaped pattern, and that smelters (S) to be used in practice may be designed round, or may be in square, rectangular or different shapes and dimensions.

14.A smelter developed according to any one of the claims hereinabove, characterized in that smelter (S) base brick pattern may either be plain, or be round or oval.