Abstract: Method of constructing and installing a direct smelting unit comprising a smelting vessel (11). The vessel is prefabricated off site in three modules (11A, 11B, 11C) which are then transported to the installation site where they are hoisted by a crane and deposited sequentially on top of one another and joined together by welding to form a unitary vessel. The vessel modules are prefabricated so as to be internally lined with water cooling panels connected to water inlet and outlet connectors (62) on the exterior of the circumferential wall sections of those modules. A vessel access tower is formed in modules brought together to envelop the tower and carrying water supply and return piping which is connected to the water inlet and outlet connectors (62) of the cooling panels.

Abstract: Metallurgical processing installation comprising a metallurgical vessel lined internally with water cooled panels. A vessel access tower (61) fits around vessel (11) and supports a coolant flow system (62) to provide for flow of cooling water to and from the cooling panels within the vessel through water inlet and outlet connections (42,43) distributed around the exterior of the vessel. Coolant flow system (62) includes large diameter water supply and return pipes (66,67) mounted on an upper part of the tower (61) to extend around the upper end of vessel (11), a first series of vertical dropper pipes (68) of relatively small diameter connected to the main water supply pipe 66 and extending downwardly to connections with the water inlet connectors for respecting cooling panels of the vessel and a second series of smaller diameter vertical pipes (69) connected at their upper ends to the main return pipe (67) and at their lower ends to undivided outlet connectors for the cooling panels in the vessel.

Abstract: Method of building a direct smelting plant comprising a metal smelting vessel (11) and ancillary plant components such as the components of a hot air supply station (24), an offgas treatment station (32), a solids feed station (41), a hot metal desulphurization station (47) and hot metal and slag launders extending from the smelting vessel (11). The ring track (53) of a ringer crane (51) is installed in front of location at which vessel (11) is to be installed. Crane boom (54) is laid out along elongate stretch of the building site which becomes a corridor (60) between major ancillary components when plant is fully erected. Boom (54) is connected to crane carriage (52) and hoisted to provide high lift capacity over a ground area embracing proposed site of vessel (11) and ancillary components. Prefabricated components are then lifted by crane (51) into appropriate position for final installation.

Abstract: A process for producing desulphurised iron in a solid form. The process includes (a) direct smelting an iron-containing metalliferous feed material and producing molten iron; (b) desulphurising molten iron produced in the direct smelting (a); and (c) casting desulphurised molten iron from the desulphurisation (b) into a solid form, such as pigs.

Abstract: Method of constructing and installing a direct smelting unit comprising a smelting vessel (11). The vessel is prefabricated off site in three modules (11A, 11B, 11C) which are then transported to the installation site where they are hoisted by a crane and deposited sequentially on top of one another and joined together by welding to form a unitary vessel. The vessel modules are prefabricated so as to be internally lined with water cooling panels connected to water inlet and outlet connectors (62) on the exterior of the circumferential wall sections of those modules. A vessel access tower is formed in modules brought together to envelop the tower and carrying water supply and return piping which is connected to the water inlet and outlet connectors (62) of the cooling panels.

Abstract: A direct smelting plant for producing molten metal from a metalliferous feed material is disclosed. The plant includes a fixed smelting vessel to hold a molten bath of metal and slag and a gas space above the bath. The plant also includes means for supplying solids and gas feed materials to the vessel and for tapping molten material from the vessel. The plant also includes at least two platforms for supporting plant operators at different heights of the vessel. The metal tapping means and the slag tapping means are located so as to be accessible by plant operators on a cast house platform and the end metal tapping means and the end slag tapping means are located to be accessible by plant operators on an end tap platform that is at a lower height than the cast house platform.

Abstract: A direct smelting plant for producing molten metal from a metalliferous feed material is disclosed. The plant includes a fixed smelting vessel to hold a molten bath of metal and slag and a gas space above the bath. The plant also includes means for supplying solids and gas feed materials to the vessel and for tapping molten material from the vessel. The plant also includes at least two platforms for supporting plant operators at different heights of the vessel. The metal tapping means and the slag tapping means are located so as to be accessible by plant operators on a cast house platform and the end metal tapping means and the end slag tapping means are located to be accessible by plant operators on an end tap platform that is at a lower height than the cast house platform.