Abstract: A steelmaking process is disclosed. The process includes producing molten steel and molten steelmaking slag in a steelmaking process, the steelmaking slag including iron units and flux units, and thereafter producing molten iron in a molten bath based direct smelting process using a substantial portion of the steelmaking slag as part of the feed material requirements for the direct smelting process. A direct smelting process is also disclosed. The process includes pre-treating ferrous material including steelmaking slag and thereafter direct smelting molten iron using the pretreated ferrous material as part of the feed material for the process.

Abstract: A solids feed means for a direct smelting plant is disclosed. The solids feed means includes 2 or more pairs of lances for injecting solid feed materials for a direct smelting process into a direct smelting vessel. The solids feed means also includes a main supply line and a pair of branch lines for supplying solid feed material to the lances of each pair of lances with the branch lines interconnecting the main supply line and the lances of the pair of lances. The lances are arranged around the vessel in pairs of diametrically opposed lances. At least one pair of lances is provided for injecting metalliferous feed material (such as iron-containing materials, particularly iron ore fines) and at least one of the other pairs of lances is provided for injecting solid carbonaceous material (such as coal) and optionally fluxes. The pairs of lances are arranged around the vessel so that adjacent lances are lances that are provided to inject different materials.

Abstract: The present invention relates to an apparatus for injecting gas into a vessel. The apparatus may include a gas flow duct and a central body within a forward end region of the duct. The central body and the gas flow duct form an annular nozzle for the discharge of gas from the duct. A plurality of flow directing vanes are disposed about the central body to impart swirl to a gas flow through the nozzle. The flow directing vanes have substantially straight leading end portions radiating outwardly from the central body and extending along the duct. The vanes also have substantially helical trailing end portions extending helically about the central body toward the front end of the duct and transition portions joining the leading end portions to the trailing end portions. The transition portions are shaped so as to merge smoothly with both the leading end portions and the trailing end portions and to smoothly and progressively change shape between them.