FORM-2
THE PATENTS ACT, 1970
(39 of 1970)
AND
THE PATENTS RULES, 2003 COMPLETE SPECIFICATION
(See Section 10; Rule 13)
1. TITLE OF THE INVENTION:
"A novel method of obtaining ferro carbon from a mixture of different ferrous scrap product"
2. APPLICANT:
(a) NAME: MASSCORP LIMITED.
(b) NATIONALITY: AN INDIAN COMPANY INCORPORATE UNDER
THE COMPANIES ACT, 1956.
(c) ADDRESS: MASSCORP HOUSE, PLOT NO.38/5,
D III BLOCK, MIDC, CHINCHWAD,
PUNE-411019, MAHARASHTRA, INDIA.
The following specification describes the nature of the invention and the manner in which it is to be performed:-

3. PREAMBLE TO THE DESCRIPTION
Field of Invention
The present invention relates to a novel method of obtaining ferro carbon from a mixture of different ferrous scrap product.
Background of the Invention & the Related Art
The recycling of scrap is a vast business all over the world. The scrap is a term used to describe recyclable and other materials left over from every manner of product consumption. The recyclable material from the scrap amounts to a goods quantity of raw material feedstock for the industrial manufacturing around the world. The recycling of scrap is a vast business all over the world.
The steel melting is predominantly done in the following process routes:
Basic Route:
Ore + Coke + Heat + Additives = Hot Metal (Pig Iron)→Fe + C (4%)← Oxygen = Liquid Steel.
Various improvements in this couple of century old steel making continued through the bessemer converter, the open hearth, the LD converter, the fiore, the EOF etc. All these processes required the ore, the reducing agent, the carbon and the oxygen. The other steel making inputs like direct reduced iron (DRI) were produced by mixing ore and the reductant in the rotary kiln at 750° C (Fe2 O3 + C)

or ore and Gas (Fe2 O3 + C2 H4). This DRI is used to make the steel by melting in the induction or arc furnace. In the later years, it is indentified that, if %C is available in DRI, the melting can be assisted by the oxygen and innovations are happening in this field now.
Electric Route
A) Scrap + ElecArc + Fluxes → Liquid Steel
B) Scrap + Coke + ElecArc + Oxygen + Fluxes → Liquid Steel
C) Scrap + Pig Iron + ElecArc +Oxygen + Fluxes → Liquid Steel
D) Scrap + Sponge Iron + Pig Iron + ElecArc +Oxygen + Fluxes → Liquid Steel
E) Scrap + Sponge Iron + Induction heat + Fluxes → Liquid Steel
When we closely look at all the above various process routes, it is visible that, the oxygen assisted melting is practiced for the faster melting and the heat energy given by the oxygen is more economical than from the electric power. Naturally, one works towards the power saving and the potential earning from the carbon credit.
The oxygen cannot be used ''without carbon" in the scrap mix or in the molten bath. Hence, the carbon availability to assist the faster melting through oxygen lancing is a prerequisite.
E.g. 1M3 of oxygen can replace 3.5 units of power input. The saving on Rs./ton of melting.
3.5 KWH = Rs. 19.25 1M3 of oxygen = Rs. 10.25

For the melter, 9 Rs/ M3 oxygen usage is the benefit. The oxygen utilization can go upto 60M /tonne in the hot metal route or 35M /tonne in the scrap +coke+pig iron mixture.
Hence, the necessity of carbon percentage in the furnace input is advantageous. This has lead to an innovative way of increasing percentage of carbon in the scrap leading to:
• Faster Melting and productivity
• Lower cost
• Lower usage of national resources
4. DESCRIPTION OF THE INVENTION
The invention under consideration describes a novel method of obtaining ferro carbon from a mixture of different ferrous scrap product.
The process under consideration is very simple and gives benefits to all the steel
melters.
Another inherent, but hidden benefit to the buyers is as described below:
The process under consideration insulates from the volatility of the inputs like -hot metal/pig iron, which rock when the government changes the iron ore policy and/or China/Australia declare unilateral price increase on coke. The product & the process under consideration is approximately 90% protected by the scrap,

which is globally generated & traded and the carbon required comes from the "recycling" and not from the prime product.
In the product under consideration i.e. ferro carbon the ferrous is taken from the scrap and the carbon coming from the selected high carbon content chips of Pig Iron + Carbon additives if carbon percentage needs to be increased.
In the process under consideration for manufacturing of the ferro carbon, light weight M.S. scrap is taken. The said light weight M.S. scrap is then segregated. Further, the said light weight M.S. scrap duly segregated is then shredded. Alongwith, above mentioned the light weight M.S. scrap's process, sponge iron spillage scrap is taken. Then, the sponge iron spillage scrap is segregated. Further, the said sponge iron spillage scrap is shredded. Next is the mixing of both the metals i.e. the light weight M.S. scrap & the sponge iron spillage scrap. Next to this, is the mixing thoroughly of the carbon additives in the above mentioned scrap mixture.
Further, the predetermined quantity batches (say 5 MT) of above referred mixed scrap are made.
Then, a sample of the above mixture (say 10 kg.) is picked up for sample processing from each of the batch. The above mentioned sample mixture is then melted in the laboratory scale furnace & a cup sample is collected. Then a spectro analysis of the liquid (melted) metal sample is conducted. In the spectro analysis the chemical composition of the above mixture is determined. After knowing the chemical composition the decision about the addition of metal and of the other components is made.

Further, based on the decision about the addition of metal and of the other components, actually the additional metal &/or other components are added in the above referred individual batch of predetermined quantity (say 5 MT). Then, the above batch of predetermined quantity (say 5 MT) is compacted into a chargeable bundle sizes to furnaces for melting & hence, the ferro carbon is ready.
The salient advantages of the ferro carbon obtained with the help of the above process are as follows:
• Known Input
• Faster Melting
• Lower power consumption
• Charge weight/M3 is better than Heavy Melting and Shredded scrap.
The Product Specifications of the ferro carbon obtained with the help of the above referred process are as follows:
MASSPRO FERRO CARBON: - Fe 85% - 95%
Carbon 1% - 9% max.
The flowchart specifying the process of obtaining the ferro carbon with help of the above process is enclosed herewith.

5. We claim:
1. A novel method of obtaining ferro carbon from a mixture of different ferrous scrap product.
2. A novel method of obtaining ferro carbon from a mixture of different ferrous scrap product as claimed in claim no. 1, light weight M.S. scrap being taken, then segregated & shredded.
3. A novel method of obtaining ferro carbon from a mixture of different ferrous scrap product as claimed in claim nos. 1 & 2, alongwith, above mentioned the light weight M.S. scrap's, the sponge iron spillage scrap being taken then segregated & shredded.
4. A novel method of obtaining ferro carbon from a mixture of different ferrous scrap product as claimed in claim nos. 1, 2 & 3, both, the light weight M.S. scrap & the sponge iron spillage scrap mixed thoroughly alongwith the carbon additives and the predetermined quantity batches (say 5 MT) of above referred mixed scrap being made.
5. A novel method of obtaining ferro carbon from a mixture of different ferrous scrap product as claimed in claim nos. 1, 2, 3, & 4, a sample of the above mixture (say 10 kg.) being picked up for sample processing from each of the batch, further the said sample mixture being melted in the laboratory scale furnace & a cup sample being collected, then, a spectro analysis of the liquid (melted) metal sample being conducted & the chemical composition of the above mixture being determined, further based on the chemical composition the decision about the addition of metal and of the other components being made.

6. A novel method of obtaining ferro carbon from a mixture of different ferrous scrap product as claimed in claim nos. 1, 2, 3, 4 & 5, based on the decision as mentioned in claim 4 above, actually the additional metal &/or other components being added in the above referred individual batch of predetermined quantity (say 5 MT), further, the above batch of predetermined quantity (say 5 MT) being compacted into a chargeable bundle sizes to furnaces for melting & hence, the ferro carbon.
7. A novel method of obtaining ferro carbon from a mixture of different ferrous scrap product as claimed in claim nos. 1, 2, 3, 4, 5 & 6, being able to obtain the ferro carbon having the following salient advantages:

• Known Input
• Faster Melting
• Lower power consumption
• Charge weight/M is better than Heavy Melting and Shredded scrap.
8. A novel method of obtaining ferro carbon from a mixture of different
ferrous scrap product as claimed in claim nos. 1, 2, 3, 4, 5, 6 & 7, being
able to obtain the ferro carbon having the following product specifications:
FERRO CARBON: -
Fe 85% - 95% Carbon 1% - 9% max.