EA026994B1 - Method of manufacturing a composite product (embodiments) and method of manufacturing a molten metal (embodiments) - Google Patents

Abstract

Methods of manufacturing a composite product and methods of manufacturing a molten metal are disclosed. The methods of manufacturing a composite product comprising (a) a polymeric material binder and a carbon-bearing material or (b) the polymeric material binder and a metal-bearing material comprise heating and mixing the components of the composite product and thereafter forming the heated mixture into a final product shape in the form of pellets, granules, blocks, pigs, patties, plugs, or pucks, with the heating step being sufficient to melt at least a part of the polymeric material binder to facilitate forming the product. The methods of manufacturing a molten metal comprise charging the composite product having required properties into a metallurgical furnace in a high temperature processing plant.

Description

The present invention relates to methods for producing composite products and to methods for producing molten metal.

The present invention relates, in particular, although in no way exclusively, to methods for producing composite products obtained from regenerated products.

The present invention relates, in particular, although in no way exclusively, to methods for producing composite products suitable for use in high temperature methods.

The term high-temperature methods in this context means methods that occur at temperatures above 400 ° C, usually at least 600 ° C.

Examples of high temperature processes are those carried out in metallurgical furnaces, such as steelmaking furnaces. In such methods, the composite products of the present invention are intended to provide metal-containing components or energy sources, or both.

Other examples of high temperature methods are those carried out in power plants and in kilns, such as kilns in the production of cement, requiring heat from fossil fuels or fossil fuels. In such methods, the composite products of the present invention are intended to provide an energy source as a substitute for fossil fuels.

The present invention is not limited to methods for producing composite products suitable for use in high temperature processes. For example, the composite products of the present invention can be used as building materials or as materials for protecting buildings and structures, as well as wear-resistant materials (for example, abrasion resistant or corrosion resistant), such as an alternative to timber products and steel products.

The present invention is based on the use of a polymeric material as a binder for bonding particles of a metal-containing material and / or carbon-containing material in a composite product comprising (a) a polymeric material and a metal-containing material, or (b) a polymeric material and a carbon-containing material, or (c) a polymeric material and metal-containing material and carbon-containing material.

The present invention is also based on the preparation of such composite products by combining heating and mixing the components of the composite product, wherein the heating step is sufficient to melt at least a portion of the polymer binder to facilitate molding of the products.

The present invention provides a method for producing a composite product in the form of (a) a polymeric binder and a metal-containing material or (b) a polymeric binder and a carbon-containing material, comprising heating and mixing the components of the composite product and then converting the heated mixture into the form of the final product, the heating step being sufficient to melt at least a portion of the polymer binder to facilitate molding of the product.

The heating and stirring steps can be performed in the order described in the previous paragraph, or in the reverse order, or simultaneously.

The term metal-containing material in this context means any material that can be processed in the high-temperature method, such as a high-temperature metallurgical method, carried out in a metallurgical furnace to obtain a metal product. The term metal, as used in this context, includes metal alloys. Steelmaking, in particular steelmaking in electric arc furnaces, is one of the metallurgical processes of particular interest to the applicant. Other metallurgical methods include, for example, making steel in oxygen converters and methods for producing cast iron. The present invention is not limited to high temperature metallurgical methods. The metal-containing material may be a regenerated (reusable) material.

A method of obtaining a composite product comprising a polymeric binder and a metal-containing material may include mixing other materials, such as materials that are a carbon source other than the polymeric binder, with the metal-containing material and the polymeric material.

Other carbon sources may include any one or more sources selected from biomass, fly ash, rubber, paper, coke breeze, charcoal fines, coal fines, toners for printers and photocopiers, and any other suitable organic material. It should be noted that, as a rule, in addition to the carbon content in the form of carbon black, toners contain metal-containing particles (iron oxides) and polymer material. Other carbon sources may be reclaimed materials. Other carbon sources may be fresh materials.

Other materials may include calcined lime, dolomite, and magnesite.

- 1,026,994

The method may include controlling the process and selecting a metal-containing material (if present), a carbon-containing material (if present) and a polymeric binder to produce a product having the desired porosity. Situations may arise in which it is desired that the product is non-porous. Other situations may arise in which, due to the occurrence of preferred chemical reactions occurring in a high-temperature process, such as a high-temperature metallurgical process, it may be necessary for the product to have a level of porosity. For example, it may be desirable for a chemical reaction to occur in the product in the furnace, while a level of porosity may be desirable to facilitate the release of volatile reaction products.

The method may include mixing the metal-containing material and the polymer binder to form a uniform dispersion of the metal-containing material in the product.

The method may include mixing a carbon-containing material and a polymeric binder to form a uniform dispersion of the carbon-containing material in the product.

The method may include heating the mixture of product components at a temperature high enough to completely melt the polymer binder. The temperature may be any acceptable temperature, taking into account the specific choice of the polymer binder, other components of the mixture and the requirements of a particular method of forming a composite product. For example, in the case of a polymer binder in the form of low density polyethylene, as a rule, the temperature is 150-175 ° C. The method may include selecting a metal-containing material and a carbon-containing material so that these materials remain solid throughout the entire heating step.

The method may include controlling the process and selecting a metal-containing material (if present), a carbon-containing material (if present), and a polymeric binder to produce a product having the desired density. For example, in the case where the product is a raw material for steel production, it may be preferable that the product has a density that allows the product to remain on the surface in the bath of molten metal formed during the process.

The metal-containing material and the carbon-containing material may be in the form of solid particles.

In a particular example related to steelmaking, the metal-containing material may be in the form of iron-containing particles.

Iron-containing particles can be in the form of finely divided particles.

According to a particular example, the iron-containing particles may be in the form of finely divided particles of secondary scale or dust from a dust collector or other by-products of steel mills or iron mills.

In the context of iron particles for use in the preparation of steel in electric arc furnaces, the term fine particles as used herein refers to particles having a main size of less than 6 mm.

In a broader context of metal-containing particles for use in high temperature processes in metallurgical furnaces, the term fine particles as used herein refers to particles having a main size of less than 6 mm.

The use of a polymeric material as a binder for metal-containing or carbon-containing materials in a composite product of the present invention is not limited to composite products for high-temperature processes carried out in metallurgical furnaces, and extends to high-temperature processes in the general sense that require a composite product according to the invention. In this context, the present invention is not limited to fine particles and extends to metal-containing and carbon-containing materials having a main size of more than 6 mm.

The polymer binder may be any suitable material. An important requirement for a polymeric binder is its ability to act as a binder for other components of the composite product under the specific conditions of transportation of materials and in the operating conditions of the product. For example, specific conditions may include long-term storage in the open air. As another example, specific conditions may include specific material transportation requirements for the product.

The polymer binder may be a regenerated polymer material.

The polymer binder may be a regenerated polyethylene, such as low density polyethylene, or high density polypropylene or regenerated polypropylene.

The carbonaceous material may be in the form of biomass, fly ash, rubber, paper, coke breeze, charcoal fines and fossil fines, used toner for printers and photocopiers, and any other suitable organic material. The carbonaceous material may be a regenerated material. The carbonaceous material may be fresh material.

The method may include any suitable molding step to shape the final product.

- 2 026994

The molding step may be any of the following steps: extrusion, injection molding (including injection molding), and another type of briquetting or extrusion step.

For example, step (c) may include molding the heated mixture to obtain a composite product by extruding the hot mixture.

The extrudate may be in the form of a final product.

Alternatively, extrudate cutting may be required to obtain the shape of the final product. For example, step (c) may include forming a continuous extrudate and then cutting the extrudate leaving the extruder to shape the final product.

In the case where the extrudate leaves the extruder in the form of a continuous bundle (small or large cross section), the method may include cutting the bundle into pieces of shorter length, while the segments of the extrudate of a shorter length form the product.

The shape of the final product may be any acceptable form of any acceptable size.

The shape and size of the shape of the final product can be determined taking into account the requirements of the metallurgical process and the metallurgical furnace in which the product is to be used.

The product may be in the form of pellets.

The product may be in the form of granules.

The product may take the form of larger products, which can be described as blocks, bars, briquettes, plugs (cylinders) and discs.

A larger product may have a major size of at least 10 cm.

A larger product may have a major size of at least 15 cm.

A larger product may have a mass of at least 1 kg. A larger product may have a mass of at least 2 kg. A larger product may have a mass of at least 3 kg. A larger product may have a mass of less than 10 kg.

In specific cases, factors affecting the shape and size of the product may include the following.

The product must have sufficient strength and stiffness so that it can be fed into a high-temperature furnace at a high-temperature processing enterprise, such as a metallurgical furnace, without significant destruction of the product with the formation of fine particles outside and / or inside the furnace.

The product must be large enough and have the required mechanical properties, such as strength, to withstand high-temperature and reaction conditions in a high-temperature furnace in a high-temperature processing plant, such as a metallurgical furnace, and to facilitate the controlled dissolution of the product in the furnace over the required period of time. Depending on the high temperature process, this period of time may be a relatively short period of time or a longer period of time. The required dissolution rate may vary depending on the chemical reaction conditions of the high-temperature process and the total process time. For example, for some processes it may be important that the combustion of combustible components in the product takes place as soon as possible. In other situations, it may be important to have a relatively slow dissolution of the product so that the product is consumed during the entire process.

The present invention also provides a method for producing a composite product comprising a metal-containing material and a polymeric material acting as a binder for the metal-containing material.

The product described in the previous paragraph may include other materials, such as materials that are a carbon source, other than a polymeric binder.

The present invention also provides a method for producing a composite product comprising a carbon-containing material and a polymeric material acting as a binder for the carbon-containing material.

The product described in the previous paragraph may include other materials, such as metal-containing material.

The product may include a continuous network of polymer material and a uniform dispersion of metal-containing material or carbon-containing material.

The product may be a porous product.

The product may be a non-porous product and, therefore, will be at least substantially waterproof. This is advantageous in situations where any one or more of the components of the product is sensitive to moisture absorption during storage or transportation. For example, this is especially the case for products that include biomass as the carbon-containing material of the product.

The product may include an outer coating of a polymeric material.

Coating can make the product non-porous.

In addition or alternatively, the coating can encapsulate the fine particles in the product and minimize the release of fine particles during processing and transportation of materials.

In any particular case, the relative amounts of polymer binder, metal-containing material (if present), carbon-containing material (if present) will depend on factors such as binder requirements for composite products, requirements for metal-containing materials for a specific product purpose, and energy requirements for a particular purpose products.

The polymer binder may comprise more than 10% by weight of the product.

The polymer binder may comprise more than 15% by weight of the product.

The polymer binder may comprise less than 50% by weight of the product.

The polymer binder may comprise less than 45% by weight of the product.

The polymer binder may have an evaporation temperature lower than the temperature of the melting bath in a metallurgical furnace.

The polymer binder may be a regenerated polymer material.

The polymer binder may be regenerated polyethylene, such as low density polyethylene or high density polyethylene, or regenerated polypropylene.

The metal-containing material may be in the form of iron-containing particles.

Iron-containing particles can be in the form of finely divided particles.

The iron-containing particles may be in the form of particles of iron oxide.

The iron-containing particles may be in the form of finely divided particles of secondary scale and / or dust from a dust collector or other by-products of a steel mill.

The carbonaceous material may be in the form of particles of biomass, fly ash, rubber, paper, coke breeze, coal fines, used toner for printers and photocopiers, and any other suitable organic materials. The carbonaceous material may be a regenerated material. The carbonaceous material may be fresh material.

The product can be completely prepared from regenerated materials, while the polymer binder, and the metal-containing material (if present), and the carbon-containing material (if present) are regenerated materials.

Reclaimed materials may be obtained from any suitable source.

For example, the metal-containing components may be in the form of finely divided particles of secondary scale, the polymer binder in the form of regenerated polyethylene, and the carbon-containing components may be in the form of coke breeze or regenerated rubber.

The product may be of any suitable size and shape. The shape and size of the product may be as described above.

The product may be suitable for use in a high temperature process.

The product may be suitable for use as an energy source as a substitute for fossil fuels in power plants and kilns, such as kilns for cement production, and in other applications that require the production of heat using fossil fuels. When used as an energy source, the product can be described as artificial fuel.

The product may be suitable for use as building materials or as protective materials for building materials (for example, to impart wear resistance or corrosion resistance) or as protective materials for consumables and parts for the mining industry (for example, to impart wear resistance to consumables and parts used in the mining industry for the processing of minerals or in equipment for the extraction of minerals), such as al ternativ products from timber and steel products.

The present invention also provides a high temperature process comprising supplying the above-described composite product containing metal-containing components and carbon-containing components and a polymer binder as a raw material for the process.

The high temperature method may be a method for producing molten metal (this term includes a metal alloy, including a ferroalloy) in a metallurgical furnace.

The method may be a method of producing steel.

The method for producing steel may be a method for producing steel in electric arc furnaces.

The method for producing steel may be a method for producing steel in oxygen converters.

The method may be a method for producing cast iron.

The present invention is based on the discovery by the applicant during a research project that it is possible to obtain a composite product comprising metal-containing components, in particular iron-containing components, in the form of finely divided particles of secondary scale and a polymer binder in the form of low-density regenerated polyethylene, well suited in terms of transportation of material, chemical and technological properties for use

- 4 026994 upon receipt of steel in an electric arc furnace. In particular, during the work on the project, the applicants found that the polymeric material acts as an effective binder for finely divided iron-containing particles in the composite product and provides an energy source.

The present invention is also based on the discovery by the applicant during a research project that it is possible to obtain a composite product comprising carbon-containing components in the form of finely divided coal particles and a polymer binder in the form of low-density regenerated polyethylene, well suited in terms of material transportation, chemical and technological properties for use upon receipt of steel in an electric arc furnace.

The present invention is also based on the discovery by the applicant during the project that hot forming, for example by means of heated extrusion, of mixtures of the metal-containing components and / or carbon-containing components described above and a polymer binder at temperatures at which at least part of the polymer binder it is molten, and the remaining components of the mixture remain in the solid state, is an effective way to obtain composite products with the required parameters for the transportation of the mother Al, chemical and technological properties for use in the preparation of steel in an electric arc furnace.

The present invention is also based on the discovery by the applicant during the project that a composite product based on a metal-containing component and a composite product based on a carbon-containing component according to the invention have wider end use than steel production. In particular, the applicant has found that the composite product based on the carbon-containing component according to the invention has applications such as replacing fossil fuels in power plants and kilns, such as kilns in cement production, and other applications requiring heat generation by fossil or artificial fuel.

The research project included laboratory work on a wide range of products containing 10-45 wt.% Polymer material in the form of low density polyethylene in accordance with the present invention.

Laboratory work included work on composite products, including metal-containing, in particular iron-containing, material in the form of secondary scale and polymeric material in the above ranges. In the course of laboratory work, almost 100% reduction of iron oxide in these products to molten iron was found.

Laboratory work also included work on composite products containing carbon-containing material in the form of coke breeze and polymer material in the above ranges.

According to one example, the product had a composition of 24 wt.% A binder of low density polyethylene, 1 wt.% Technological additives, 75 wt.% Coke breeze and other carbon-containing material.

The research project also included testing 1 ton of a sample of the composition of the product of the present invention when used in electric arc furnaces to produce steel.

A test product sample was successfully extruded on a standard industrial heated extruder.

A continuous strand obtained using an extruder was molded into briquettes weighing about 3 kg.

The product sample consisted of 24 wt.% Low density polyethylene, 1 wt.% Technological additives, 7 wt.% Coke and 68 wt.% Secondary scale.

Material Composition Secondary scale 68 Coke trifle 7 Regenerated Low Density Polyethylene (URE) 24 Technological Additives one Composition by elements Iron (~ 75 wt.% Re in the secondary scale) 51 Carbon (~ 85 wt.% C in low density polyethylene / ~ 85 wt.% C in coke) 26 Oxygen (~ 25 wt.% O in the secondary scale) 17 Hydrogen (~ 15 wt.% N in the polymer) 4

tons of product briquettes were loaded into the swamp of an electric arc furnace. The effect of adding product loading was monitored using cameras and standard recording of data regarding chemistry and process parameters.

- 5,026,994

The heat balance of the addition is presented below.

Product 1000 kg = 680 kg of ReO (510 kg of Re) + 240 kg of JURE + 70 kg of coke Heat arrival 240 kg Jura x 12.9 kWh / kg = 3096 kWh Heat consumption Reduction of iron oxide = 2 kWh / kg * x 680 kg = 1360 kWh Iron smelting = 510 kg x 0.44 kWh / kg = 225 kWh Balance 3096- (1360 + 225) = +1511 kWh

It should be noted that the heat balance mentioned above is based on theoretical data for standard reference materials and data obtained at the steelmaking plant in the applicant's electric arc furnaces in \ 8 \\ '(New South Wales), Australia.

The following are some of the main results of the study.

Product briquettes were a source of energy.

The briquettes of the product were magnetic - thus, the briquettes could be transported using a standard crane with an electromagnetic pickup for metal waste from the furnace — 500 kg / load.

Product briquettes were tough - without breaking regular blocks.

Product briquettes were waterproof - there was no noticeable weight gain when immersed in water for 1 week.

Product briquettes were placed on the surface of the bath / slag and began to react inside the furnace.

Product briquettes remained intact and reacted at a controlled rate for a long period, for some samples lasting> 15 minutes.

Product briquettes generated a significant amount of heat.

Very little smoke was emitted compared to alternative plastic and rubber products.

Influence of loading - there is no noticeable change when adding 100 kg, 200 kg and 300 kg / heat to the lower bucket 1.

The test results demonstrate significant commercial opportunities for the composite product of the present invention.

In particular, the applicant based on the test found that the composite product of the present invention based on a polymeric binder bonding a carbon-containing material can be a significant energy source for which there are broader applications than the steel industry, while such applications include use as replacement of fossil fuels in power plants and kilns, such as kilns for cement production, and other applications requiring heat generation using fossil or artificial fuel.

In addition, the applicant on the basis of the test found that the composite product of the present invention allows you to enter different ratios of raw materials for steel and energy sources in the loading ladle in an electric arc furnace. Therefore, depending on the requirements, a larger or smaller amount of each of the iron-containing materials and other raw materials for producing steel and polymer material (as a binder and an energy source) may be present in the loading bucket. Therefore, the composite product of the present invention provides an opportunity for maneuverability when supplying raw materials to a method for producing steel and, in particular, an opportunity for optimizing energy use.

Another key advantage of briquettes of product samples, which is an advantage designed to facilitate the use of the composite product of the invention in electric arc furnaces and other high-temperature processes, is the adjustable and measurable reaction rate and heat generation due to the physical and chemical compositions of the briquettes of the product. The adjustable rate of fuel release leads to complete combustion and use of heat in the furnace, and not in the exhaust gases of the system. Consequently, there is less risk of a rise in temperature in the gas ducts and circuit breakers of the dust collectors, as well as the presence of unburned fuel or smoke in the exhaust gas pipelines leading to ignition. In a 1-ton test, it was noted that for briquettes of product samples (~ 3 kg each), when an oven was added to the swamp, it took more than 10 minutes to ignite. This was a key observation and a significant advantage and may allow the use of briquettes of product samples as burners under the scrap filling at a variable speed during melting instead of reacting too quickly after loading, causing smoke and flame to escape from the furnace. For comparison, when a small amount of polymer film bonded together or pieces of rubber tires were added to the oven, they reacted and ignited for several minutes. It was observed that briquettes of product samples ignited and maintained a strong flame for a long time.

Based on the test, the applicants believe that when placing the briquettes of the composite product under the scrap in an electric arc furnace, they will potentially provide pre-heating

- 6,026,994 and reduce the operating time of the furnace under current, as well as reduce energy consumption.

The slower combustion rate of the product briquettes was controlled during the test due to the complex nature of the composite product. The reaction of the polymer binder or fillers (finely divided particles of scale or coke) with oxygen was limited by the surface of the product briquettes due to the low porosity due to the binder. Thus, there was a very slight penetration of gas into the briquettes of the product. Low porosity limited the surface area for the reaction and covered the reagents inside the product. There must be a significant temperature gradient from the inside to the surface of the product, with a reaction taking place on or near the surface. In addition, there may be some effect of isolation from the gas / smoke / flame layer, formed due to smoke and ignition of the polymer at a relatively low temperature (from 250 to 400 ° C), and reaction products leaving the surface of the briquette. For example, this should isolate the product briquettes from the surrounding steel and slag having a high temperature (1500-1750 ° C) and allow the product briquettes to remain longer.

Fuel is released at a controlled speed, since only the part that is on the surface reacts.

The composite matrix structure of the product briquettes means that iron oxide protects the polymer binder and controls the reaction rate. If the filler has low flammability, then the rate of fuel supply to the surface where it will be in contact with oxygen is lower. For this reason, iron oxide products (secondary scale) will potentially last longer in liquid metal slag than briquettes containing a combustible filler such as coke or graphite. A similar protective effect can be achieved through the use of other fillers with a low burning rate (lime, dolomite, dust from the dust collector, and so on).

Composite products also slow down the reaction compared to when finely ground materials are added separately. For example, finely divided particles of both secondary scale and coke can react quickly or violently due to the reaction of carbon and oxygen when introduced into a bath with liquid steel due to the significant surface area of these materials.

From the above it follows that the reaction rate can be controlled by changing the composition of the briquettes of the product with an increase or decrease in fillers or binders. It can be used in many pyrometallurgical areas or in other high temperature applications. For example, applications include mini-furnaces, or alternative methods for producing cast iron, or methods for burning waste, or methods for generating electricity.

In the context of the industrial production of steel in electric arc furnaces, tests have shown that the composite product of the present invention provides opportunities for the replacement of scrap, the use of production waste and by-products from steel mills and other industries, the use of raw materials in the form of fine particles, which otherwise, they would not be applicable for use in an electric arc steel-smelting furnace, the use of regenerated materials as olimernogo binder and as an energy source, and also the possibility for selective delamination load in an electric arc furnace to optimize heat production and other reactions. These opportunities provide environmental and financial benefits.

The present invention has the following features and advantages, described largely in the context of the use of the composite product of the invention in relation to the production of steel, but also suitable for other end uses of the product.

The polymer binder allows you to get a fairly tough and in many cases waterproof product, which means less destruction of the product and a longer shelf life when transporting materials.

There are additional advantages when the product is coated with a polymer material that encapsulates finely divided particles and larger particles in the product.

Encapsulating finely divided particles and larger particles in a polymeric material can allow the product to be stored outdoors without significant moisture absorption. In addition, in a more general sense, encapsulation provides protection against moisture absorption / hydration when the product is exposed to the external environment in any storage situation. In addition, the encapsulation of finely divided particles and larger particles in the polymeric material can prevent or at least minimize the leaching of substances from the product. For example, encapsulating dust from an electric arc furnace containing heavy metals in a composite product according to the invention to prevent the washing out of heavy metals can be an advantage in processing, storage and transportation of the product.

The polymer material acts as a pure binder for transferring finely divided particles to a high temperature process. Fine particles are consumed in the furnace, and the polymer binder leaves the system in the form of gas (for example, low density polyethylene melts at a temperature of 115 ° C and evaporates at ~ 350 ° C).

The carbon and hydrogen components of the polymer binder can be used in methods

- 7,026,994 based on combustion / reduction.

The use of a polymeric material acting as a binder can be used for any suitable high-temperature process, and not just for high-temperature processes in metallurgical furnaces.

The heated extrusion method is suitable for large-scale and economically viable production of both types of products, namely, the first type of product based on a metal-containing material and the second type of product based on a carbon-containing material.

Dimensional control for a polymer binder is potentially less stringent due to melting during the extrusion process.

The use of regenerated polymeric materials as a binder can be an environmental advantage, since many polymeric materials would otherwise be sent to landfills.

Heated extrusion technology is potentially applicable to many industries, involving the extraction, transportation, and processing of fine particles, including metal and carbon particles.

The product is magnetic if it contains iron-containing components.

The use of the product in the method for producing steel in electric arc furnaces was energetically positive in every sense.

The use of the product under and around the scrap for an electric arc method of producing steel facilitates heating in direct contact with the scrap and potentially improves heat transfer and efficient use of energy.

The use of a heated extruder allows the use of raw materials with a higher moisture content due to heating in the extruder.

The invention allows the use of raw materials in the form of fine particles.

In the present invention described above, many changes can be made without departing from the spirit and scope of the present invention.

Claims (5)

CLAIM 1. A method of obtaining a composite product containing a polymer binder, which is a regenerated polymer material selected from regenerated low density polyethylene, regenerated high density polypropylene or regenerated polypropylene, and carbon-containing material, which is one or more carbon sources selected from coke breeze, charcoal fines and coal fines, and the method includes heating and mixing the components of the composite product and the subsequent molding of the heated mixture to obtain a molded final product in the form of pellets, pellets, blocks, bars, briquettes, plag or disks, while the heating step is sufficient to melt at least part of the polymer binder to facilitate the molding of the product. 2. A method of obtaining a composite product containing a polymer binder, which is a regenerated polymer material selected from regenerated low density polyethylene, regenerated high density polypropylene or regenerated polypropylene, and a metal-containing material, the method including heating and mixing the components of the composite product and the subsequent formation of the heated mixture to obtain a molded final product in the form of pellets, granules, blocks, bars, briquettes when the heating stage is sufficient to melt at least part of the polymer binder to facilitate the formation of the product, the metal-containing material is in the form of fine particles of secondary scale or dust from the dust collector or by-products of steel mills or cast iron plants . 3. The method according to claim 2, comprising mixing the metal-containing material and the polymer binder with the formation of a homogeneous dispersion of the metal-containing material. 4. A method of producing molten metal, comprising feeding a composite product with sufficient strength and rigidity, obtained by the method according to claim 1 or 2, to a high-temperature furnace at a high-temperature processing plant without substantial destruction of the product with the formation of fine particles outside and / or inside the furnace. 5. A method of producing a molten metal, comprising feeding a composite product obtained by the method according to claim 1 or 2, which has sufficiently large dimensions and possesses the required mechanical properties, such as strength, to withstand high-temperature and reaction conditions in a high-temperature furnace at a high-temperature processing plant and facilitate controlled dissolution of the product in the oven for the required period of time.