FORM-2
THE PATENTS ACT, 1970
(39 of l970)
AND
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See Section 10; Rule 13)
1. TITLE OF THE INVENTION:
"A novel method of obtaining ferro nickel 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, M1DC, 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 nickel 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.
Nickel is widely used in the special steel application when the toughness and the hardnability are demanded.
The pure Nickel is an import commodity. The price of which is controlled by LME and the volatility of price is very high. To site an example, the price of Nickel increased in 2006-2008 from 12000$/tonne to 52000$/tonne.
The alloys steel producers faced enormous difficulty in adjusting to this volatility and recovering it from the end users.
One of the alternatives to address this volatility is by recycling Nickel based scrap. The nickel based scrap is generated mostly from the stainless steel tooling

application alloys used in the mining, the drilling, the hot die application etc. These are solid rods, blocks, rolls, and drills etc., which are used for re-melting to recover Nickel available. However such scrap is generated from
a) Wide geographies.
b) Different compositions depending on different applications.
c) Individual collection centers cannot generate adequate quantity of known specification scrap as to help alloys steel producers in knowing the input alloy content and controlling the cost.
However this is practiced to some extent.
We believed that if we can,
a) Generate a known, certifiable Nickel mixed scrap in large quantities.
b) Compact such scrap into chargeable size bundles into furnace.
c) Such bundle, when compacted gives good density - helping the number of charges into the furnace.
It benefits the melting shop.
In the Electric arc furnace the system that is followed, is to charge virgin Nickel into the liquid ladle @ 1670° C. But this brings down the liquid temperature to 1630° C and it reduces to 1590° C when it reaches refining furnace. Again it has to be heated to 1630° C in refining furnace for around 10 minutes (at the rate of 4 to 5° C/minute).
Whereas, if this Nickel can be added in arc furnace, we save around 10 minutes in every 70 minutes cycle.

It is also realized that, if we can select Ni-Cr scrap, while preparing this bundles, and charged into arc furnace, the chrome recovery comes to 80-85% of input, for chrome, while nickel recovery is close to 100%.
The chrome scrap when charged directly into the arc furnace has got a tendency to get oxidized during arcing and the recovery goes down to 30%. Hence melters prefer to charge virgin Ferro chrome into the Refining furnace and gain recovery but lose time to bring up temperature of liquid metal.
This time loss and usage of costly virgin Ferro chrome can be done away with chrome scrap when added into the scrap mix before compacting.
The nickel & chrome combination is the highest consumption in the Alloys steel industry and this innovative product shall help the industry to
a) Use recycled product.
b) Save Cost.
c) Save time.
4. DESCRIPTION OF THE INVENTION
In the process under consideration for manufacturing of the ferro nickel, 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, nickel scrap is taken. Then, the nickel scrap is segregated. Further, the said nicke] scrap is shredded. Next is the mixing of both the metals i.e. the light weight M.S. scrap &

the nickel scrap. Next to this, is the mixing thoroughly of the nickel 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 nickel is ready.
The salient advantages of the ferro nickel 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 nickel obtained with the help of the above referred process are as follows:
MASSPRO FERRO NICKEL:- Ni 1.5% - 5% max
Chrome 4.25% - 8% max Balance Fe
The flowchart specifying the process of obtaining the ferro nickel with help of the above process is enclosed herewith.

5. We claim:
1. A novel method of obtaining ferro nickel from a mixture of different ferrous scrap product.
2. A novel method of obtaining ferro nickel 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 nickel 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 nickel scrap being taken then segregated & shredded.
4. A novel method of obtaining ferro nickel from a mixture of different ferrous scrap product as claimed in claim nos. 1, 2 & 3, both, the light weight M.S. scrap & the nickel scrap mixed thoroughly alongwith the nickel additives and the predetermined quantity batches (say 5 MT) of above referred mixed scrap being made.
5. A novel method of obtaining ferro nickel 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 nickel 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 nickel.
7. A novel method of obtaining ferro nickel 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 nickel having the following salient advantages:

• Known Input
• Faster Melting
• Lower power consumption
• Charge weight/M3 is better than Heavy Melting and Shredded scrap.
8. A novel method of obtaining ferro nickel 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 nickel having the following product specifications: