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Abstract

A method of manufacturing dust-free spheroidized magnetite beads comprising the steps of introducing raw magnetic ore particles in the presence of an inert non-oxidizing carrier gas to a carbon arc plasma flame assembly to which is fed a controlled amount of nitrogen and argon gas, melting the ore particles to form spheroidized droplets thereof, allowing the spheroidized droplets to fall by gravity in a chamber having a controlled atmosphere while at the same time sweeping the inside chamber wall with a vertical flow of air or an inert gas and providing a horizontal curtain of air or an inert gas at a specific location within the chamber to remove dust formed in the process. The droplets are cooled forming beads of ore, which may be used as a xerographic carrier without further processing.

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First Claim