Abstract: An apparatus for injecting gas into a metallurgical vessel is disclosed. The apparatus includes a gas flow duct, an elongate central tubular structure extending within the gas flow duct, a plurality of flow directing swirl vanes disposed about the central tubular structure, and cooling water passages within the central tubular structure. The forward end of the central structure has a nose portion that includes a domed outer shell, an inner component disposed within the outer shell and formed with an internal nozzle to receive water from the cooling water passages and to direct that water in a jet against the inner surface of the outer shell to produce an outwardly and backwardly fanning flow of water around the inner surface of the outer shell.

Abstract: An apparatus for injecting particulate and/or gaseous material into a metallurgical vessel for performing a metallurgical process is disclosed. The apparatus comprises a duct and an annular duct tip at a forward end of the duct. The apparatus also comprises inner and outer cooling water flow passages configured such that out flowing water passing from the duct tip to a rear end of the duct must travel through a longer flow path than inflowing water passing from the rear end of the duct to the duct tip.

Abstract: A method for making molten iron includes the steps of feeding a raw material mixture containing an iron oxide material and a carbonaceous reductant into a heating reduction furnace to reduce iron oxide in the raw material mixture with the carbonaceous reductant into solid reduced iron; transporting the solid reduced iron to a melting furnace; and combustion of a carbonaceous material supplied as fuel to melt the solid reduced iron in the melting furnace for producing molten iron. After the metallization of the solid reduced iron is enhanced to at least 60%, the solid reduced iron is transported to the melting furnace. The amounts of oxygen and the carbonaceous material supplied to the melting furnace are controlled so that the secondary combustion ratio of CO gas in the melting furnace is reduced to 40% or less. The heat transfer efficiency of the secondary combustion heat to the molten iron is preferably increased to at least 60%.

Abstract: A molten-bath based direct smelting process and apparatus for producing metals from a ferrous material is disclosed. The process includes injecting feed materials being solid material and carrier gas into a molten bath at a velocity of at least 40 m/s through at least one downwardly extending solids injection lance having a delivery tube of internal diameter of 40–200 mm that is located so that a central axis of an outlet end of the lance is at an angle of 20 to 90 degrees to a horizontal axis. The feed materials injection generates a superficial gas flow of at least 0.04 Nm3/s/m2 within the molten bath at least in part by reactions of injected material in the bath. The gas now causes molten material to be projected upwardly as splashes, droplets and streams and form an expanded molten bath zone, with the gas flow and the upwardly projected molten material causing substantial movement of material within the molten bath and strong mixing of the molten bath.

Abstract: A molten bath-based direct smelting process for producing ferrous metal from a ferrous feed material is disclosed. The process is characterised by injecting pro-heated air downwardly into metallurgical vessel at an angle of 20 to 90° C. relative to a horizontal axis and at a temperature of 800-1400 ° C. and at a velocity of 200-600 m/s via at least one lance (27) . This step forces molten material in the region of a lower end of the lance away from the lance and forming a “free”space around the lower end of the lance that has a concentration of molten material that is lower than the molten material concentration in the raised bath. The process is further characterised in that the lance is located so that: (i) the lance extends into the vessel a distance that is at least the outer diameter of he lover end of the lance; and (ii) the lower end of the lance is at least 3 times the outer diameter of the lower end of the lance above a quiescent surface of the molt bath.

Abstract: A molten-bath based direct smelting process and apparatus for producing metals from a ferrous material is disclosed. The process includes injecting feed materials being solid material and carrier gas into a molten bath at a velocity of at least 40 m/s through at least one downwardly extending solids injection lance having a delivery tube of internal diameter of 40-200 mm that is located so that a central axis of an outlet end of the lance is at an angle of 20 to 90 degrees to a horizontal axis. The feed materials injection generates a superficial gas flow of at least 0.04 Nm3/s/m2 within the molten bath at least in part by reactions of injected material in the bath. The gas now causes molten material to be projected upwardly as splashes, droplets and streams and form an expanded molten bath zone, with the gas flow and the upwardly projected molten material causing substantial movement of material within the molten bath and strong mixing of the molten bath.

Abstract: A direct smelting process for producing iron and/or ferroalloys is provided, which involves injecting feed materials into a molten bath of molten metal in a metallurgical vessel to form an expanded molten bath zone, and injecting oxygen containing gas, wherein the selection of the number of, and position of, the solids injection and oxygen gas injection lances is such that the expanded molten bath zone includes a raised region around the oxygen gas injection region, and such that splashes, droplets and streams of molten material project upwardly from the raised region, and such that a free space forms around a lower end of the oxygen gas injection lance.

Abstract: A continuous process and apparatus for transforming, by chemico-physical reactions inside molten slag, materials to be gasified, thermally destroyed, inertized, or from which elements of commercial value are to be recovered, yielding controlled composition products, in an apparatus made of a single reaction chamber, called reactor, having a substantially cylindrical symmetry, including two portions, a top and a bottom one, said process being characterised in that it comprises the steps of: introducing into the bottom portion of the reactor, sideways through a second injection level and/or vertically from the top thereof, the material to be transformed, the fuel, the comburent and possibly slag inoculants and additives and material-carrying gases; and tapping from the bottom portion of the reactor the transformed material, of controlled composition, and the inert slag.

Abstract: A direct smelting process for producing iron and/or ferroalloys is provided, which involves forming a molten bath in a metallurgical vessel, supplying feed materials, injecting oxygen containing gas, generating upward movement of the molten material from the molten bath, wherein the oxygen-containing gas is injected by three or more lances, and entraining into the jets of oxygen containing gas a volume of top space gas that is 2-6 times the volume of the injected gas.

Abstract: A direct smelting process for producing iron and/or ferroalloys is provided, which involves forming a molten bath in a metallurgical vessel, supplying feed materials, injecting oxygen containing gas, generating upward movement of the molten material from the molten bath, wherein the oxygen-containing gas is injected by three or more lances, and entraining into the jets of oxygen containing gas a volume of top space gas that is 2-6 times the volume of the injected gas.

Abstract: A direct smelting process for producing metal from a metalliferous feed material is disclosed. The direct smelting process is a molten bath-based process in which smelting occurs predominantly in the metal layer, carrier gas/metalliferous feed material/solid carbonaceous material are injected into the metal layer via lances/tuyeres, and oxygen-containing gas is injected into the top space above the molten bath and post-combusts reaction gases released from the bath. The injection of metalliferous feed material and solid carbonaceous material causes molten material to be projected from the molten bath as splashes, droplets and streams and to form a transition zone. The process is characterized by forming a pipe of a solid material on an outlet end of at least one lance/tuyere while injecting the metalliferous feed material and the carbonaceous material through the lances/tuyeres and thereby extending the effective length of the lance/tuyere or the lances/tuyeres.

Abstract: A process and an apparatus for producing metals from a metalliferous feed material are disclosed. The process includes the steps of partially reducing and at least partially melting a metalliferous feed material in a pre-reduction/melting means and completely reducing the partially reduced feed material in a reduction means. The pre-reduction/melting means is positioned directly above the reduction means and communicates with the reduction means so that at least partially molten, partially reduced feed material flows downwardly into a central region of the reduction means. The reduction means includes a vessel that contains a molten bath having a metal layer and a slag layer on the metal layer. The process includes injecting oxygen-containing gas into the reduction means and post-combusting reaction gas generated in the molten bath and injecting oxygen-containing gas into the pre-reduction/melting means and post-combusting reaction gas discharged from the reduction means.

Abstract: A direct smelting process for producing metals from a metalliferous feed material is disclosed. The process includes forming a molten bath having a metal layer (15) and a slag layer (16) on the metal layer in a metallurgical vessel, injecting metalliferous feed material and solid carbonaceous material into the metal layer via a plurality of lances/tuyeres (11), and smelting metalliferous material to metal in the metal layer. The process also includes causing molten material to be projected as splashes, droplets, and streams into a top space above a nominal quiescent surface of the molten bath to form a transition zone (23).

Abstract: An energy efficient, coal-based method and apparatus that are environmentally friendly which produce under pressure metallized/carbon product and molten metal directly from abundant coal or other carbonaceous material, and low cost fines (or ore concentrate) wherein the metal is devoid of gangue material and possesses the inherent advantage of retaining the heat for subsequent processing. This method and apparatus which are modular and highly integrated significantly reduce capital and operating costs; they also provide the capability selective placement of the reductant for the delivery of high levels of thermal energy input which leads to ease of desulflurization and high productivity. The technology herein disclosed is entirely closed and is applicable to various ores including ferrous and non-ferrous.

Abstract: A process for direct smelting a metalliferous feed material is disclosed. Char and fuel gas are produced by pre-treating coal with an oxygen-containing gas. The fuel gas is used to heat an oxygen-containing gas and/or to produce an oxygen-containing gas in an oxygen plant. Metalliferous feed material, char, and the oxygen-containing gas are injected into a direct smelting vessel, and the metalliferous feed material is smelted to molten metal in the direct smelting vessel using the char as a source of energy and as a reductant.

Abstract: A procedure for holding production of molten metal in a direct smelting process is disclosed. In situations where it is necessary to hold metal production and there is a continuing available supply of oxygen-containing gas and solid carbonaceous material, the hold procedure includes the steps of stopping supply of metalliferous feed material, continuing to inject oxygen-containing gas and solid carbonaceous material into the vessel and generating heat within the vessel to maintain the temperature of the molten bath above a temperature at which the bath freezes. In situations where it is necessary to hold production and there is a continuing supply of oxygen-containing gas but no available solid carbonaceous material, the hold procedure includes the steps of stopping supply of metalliferous feed material and injecting oxygen-containing gas and gaseous or liquid combustible material into the vessel and generating heat within the vessel to maintain the bath temperature.

Abstract: A vessel which produces metal from a feed material by direct smelting is disclosed. The vessel contains a molten bath having a metal layer (15) and a slag layer (16) on the metal layer and a gas continuous space (31) above the slag layer. The vessel includes one or more lances/tuyeres (13) extending downwardly into the vessel and injecting an oxygen-containing gas into the vessel and injecting an oxygen-containing bas into the vessel above the metal and slag layer. The vessel includes a plurality of pairs of lances/tuyeres (11) extending downwardly and inwardly into the vessel and injecting feed material with a carrier gas into the molten bath so as to penetrate the metal layer and generate a bath-derived gas flow which carries molten material upwardly. The pairs of lances/tuyeres are spaced around the circumference of the vessel with one lance/tuyere of each pair injecting metalliferous feed material, at a temperature of at least 200° C.

Abstract: A process for direct smelting metalliferous feed material is disclosed. Iron oxides are partially reduced in a solid state in a pre-reduction vessel. The partially reduced iron oxides are smelted to molten iron in a direct smelting vessel which contains a molten bath of iron and slag and is supplied with a solid carbonaceous material as a source of reductant and energy and with an oxygen-containing gas for post-combusting carbon monoxide and hydrogen generated in the vessel. The direct smelting step generates an off-gas that contains sulphur and the off-gas is released from the direct smelting vessel. Part only of the off-gas released from the direct smelting vessel is used in the pre-reduction step to pre-reduce iron oxides in the pre-reduction vessel. Part only of the off-gas is used in the pre-reduction step in order to control the amount of sulphur that is returned with the partially reduced iron oxides to the direct smelting vessel.

Abstract: A direct smelting process for producing metals from metalliferous feed material is disclosed. The process includes forming a molten bath having a metal layer and a slag layer on the metal layer and smelting injected metalliferous feed material in the metal layer. The process also includes generating an upward gas flow from the metal layer which entrains molten material that is in the metal layer and carries the molten material into the slay layer and forms a region of turbulence at least at the interface of the slag layer and the metal layer. The process also includes injecting a gas into the slag layer via a plurality of lances/tuyeres and generating turbulence in an upper region of the slag layer and projecting splashes, droplets and streams of molten material from the slag layer into a top space of the vessel that is above the slag layer.

Abstract: A process is described for direct production of cast iron starting from iron bearing ore in an apparatus having two communicating chambers in which to carry out the process, comprising the following operations: pre-reduction and pre-heating to founding point of the iron bearing ore in a first substantially cylindrical chamber; final reduction, carburization and founding of the resulting iron in a second chamber arranged below said first chamber, in which coal and oxygen, injected into said second chamber, provide the reducing gas both in said second and in said first chamber, characterized by the fact that: said iron bearing ore and oxygen are introduced into said first chamber through the side walls thereof, simultaneously but separately, the oxygen being introduced at a speed lower or equal to the speed of introduction of said iron bearing ore; and said oxygen, coal and flux are introduced into said second chamber simultaneously but separately through the side walls thereof and in a manner inclined downward

Abstract: In a process for working up steel slags and iron carriers such as, e.g., electric furnace slags, converter slags, fine ores, dusts from steel production, mill scales for obtaining pig iron and environmentally safe slags, the volume ratio of molten slag to iron bath is chosen to be larger than 0.5 to 1 and, preferably, 0.8:1 to 1.5:1 and the slags are supplemented with SiO2 carriers such as, e.g., foundry sands, metallurgical sands and/or fine ores so as to adjust a slag basicity (CaO/SiO2) of between 1.0 and 1.8 and, preferably, 1.2 and 1.8 at an Al2O3 content of between 10 and 25% by weight, based on the slag. In doing so, hot blast is top-blown and coal, optionally along with an inert gas and, in particular, nitrogen and, furthermore, optionally oxygen or hot air is blown through the iron bath.

Abstract: In a method of charging metal carriers which contain a portion of fines and are at least partially reduced and carbon carriers to a melter gasifier (10) in which a melt-down gasifying zone (11) is maintained, the metal carriers and the carbon carriers are fed into the melter gasifier (10) above the level of the melt-down gasifying zone (11) and descend to the melt-down gasifying zone (11) and travel through the same forming a metal melt and producing a reducing gas by coal gasification. In order to prevent a partial discharge of the metal carriers from the melter gasifier (10) during the charging of the same and to be able to achieve uniform distribution of the carbon carriers and the metal carriers, both the carbon carriers and the metal carriers are introduced into the melter gasifier centrally above the melt-down gasifying zone (11), preferably gravitationally, with a central strand (32) of metal carriers being formed which is peripherally surrounded by a jacket strand (37) formed by the carbon carriers.

Abstract: A method and an apparatus for producing metals and metal alloys from metal oxides in a metallurgical vessel containing a molten bath having a metal layer and a slag layer is disclosed. The method is characterized by injecting a carrier gas and a solid carbonaceous material and/or metal oxides into the molten bath from a side of the vessel that is in contact with the molten bath or from above the molten bath so that the solids penetrate the molten bath and cause molten metal to be projected into the gas space above the molten bath to form a transition zone. The method is also characterized by injecting an oxygen-containing gas into the gas space to post-combust reaction gases released from the molten bath into the transition zone.

Abstract: In a method of charging metal carriers which contain a portion of fines and are at least partially reduced to a melter gasifier in which a melt-down gasifying zone formed by a bed is maintained, the metal carriers and carbon carriers are fed into the melter gasifier above the level of the melt-down gasifying zone. The metal carriers descend to the melt-down gasifying zone and travel through the same forming a metal melt and producing a reducing gas by coal gasification.

Abstract: This invention relates to making steel directly from ore concentrate and non-coking coal to which flux material is added. The method eliminates numerous steps by reducing the ore with the coal in a sealed chamber and under pressure termed “carbotreating” to make a fluxed iron/carbon product which after crushing, is injected while hot into a melting furnace. The hot product is melted with oxygen under reducing conditions using excess carbon from the coal to make a carburized molten iron and a slag low in FeO termed “oxymelting”. After the tapping of the slag, the carburized molten iron to which flux material is added, is blown with oxygen to make steel, CO, and a slag high in FeO termed “decarburizing”. The steel is tapped while the slag is retained in the furnace. All of the above steps are carried out in an efficient and environmentally sound manner which render the art of steelmaking significantly more economical than conventionally practiced.

Abstract: Iron ore is reduced to molten iron by introducing the ore into a reactor while combusting coal with pure oxygen in the reactor. The molten iron phase, which forms at the bottom of the reactor, is stirred by injecting carbon monoxide into the molten iron. In a preferred embodiment, finely pulverized iron ore is injected with pure oxygen tangentially into a cyclone section of the furnace situated on top of a converter section, thereby causing melting and preliminary reduction of the ore to take place in the cyclone section. Primary reduction of the iron oxide occurs in the converter section of the furnace.

Abstract: A method of liquid iron production using high sulfur fuels is provided in which the level of sulfur in the iron is maintained below 0.1%. The low sulfur content is achieved even in the presence of high sulfur concentrations in the reducing gases and without the introduction of lime or limestone. According to one aspect, liquid iron in the fusion zone of a smelting system is saturated with carbon, thereby desulfurizing the liquid iron. The carbon saturation level is at least 4.5% carbon by weight and preferably, at least 5.0% carbon by weight. According to another aspect, the desulfurization of the liquid iron is enhanced by elevating the tapping temperatures to temperatures in excess of 1465° C., and preferably of about 1490° C. According to another aspect, the desulfurization process is supplemented by the presence of significant levels of silicon and/or manganese, both of which are highly soluble in the liquid iron.

Abstract: A method of smelting iron ore in which iron oxide and hot char are introduced into a primary reactor to reduce the iron oxide and thereby form a molten pool of elemental iron and iron oxide slag. A carbon containing substance, comprising fixed carbon and a hydrocarbon containing volatile matter, is introduced into a secondary reactor. The hydrocarbon containing volatile matter is partially oxidized within the secondary reactor to produce the hot char and a fuel gas comprising hydrocarbons, carbon monoxide, carbon dioxide, steam, and hydrogen with a CO2:CO molar ratio greater than about 0.25. The fuel gas is burned within the primary reactor so that a projected flame is produced and the projected flame is directed into the iron oxide slag of the molten pool.

Abstract: A process of producing molten iron involves: a) introducing iron oxide, flux, oxygen, nitrogen, carbon, and hydrogen to a smelter reactor; b) maintaining conditions to cause (i) the iron oxide to be reduced, (ii) molten iron to be created and stirred in the bottom of the reactor, surmounted by a layer of foaming, FeO-containing slag, and (iii) carbon monoxide gas to rise through the slag; c) causing at least some of the carbon monoxide to react with the oxygen; d) releasing an offgas containing CO, CO2, H2, and H2O; and e) removing at least some of the molten iron and slag from the reactor. Good process stability is achieved by: f) repeatedly measuring, during the process, the conditions of the slag height, the temperature of the molten iron, the levels of CO, CO2, H2, and H2O in the offgas, the carbon level in the molten iron, and the FeO level in the slag, and g) subsequently adjusting one or more process variables (e.g.

Abstract: A molten bath-based direct smelting process for producing metals from metal oxides (including partially reduced metal oxides) is disclosed. The process includes causing upward movement of splashes, droplets, and streams of molten material from a metal layer (15) of the molten bath which:(i) promotes strong mixing of metal in a slag layer (16) of the molten bath so that the slag layer (16) is maintained in a strongly reducing condition leading to FeO levels below 8 wt % based on the total weight of the slag in the slag layer (16); and(ii) extends into a space above a nominal quiescent surface of the molten bath to form a transition zone (23).

Abstract: A method and an apparatus for producing metals and metal alloys from metal oxides in a metallurgical vessel containing a molten bath having a metal layer and a slag layer is disclosed. The method is characterized by injecting a carrier gas and a solid carbonaceous material and/or metal oxides into the molten bath from a side of the vessel that is in contact with the molten bath or from above the molten bath so that the solids penetrate the molten bath and cause molten metal to be projected into the gas space above the molten bath to form a transition zone. The method is also characterized by injecting an oxygen-containing gas into the gas space to post-combust reaction gases released from the molten bath into the transition zone.

Abstract: A process for producing metals in the reduced state from their oxides using a simple and less expensive facility with lower running cost. A metal oxide in the form of particles is supplied into a high temperature flame from an oxygen burner in a reactor furnace to heat and melt the metal oxide. A reducing agent is also supplied into the flame to cause a reducing reaction of the molten metal oxide with the reducing agent. The resulting metal is recovered.

Abstract: A method for injecting fine iron ore in a smelting reducing process is disclosed, in which the carrier gas for the iron ore is the discharge gas from a melter gasifier without the need of separate carrier gas. It includes the steps of pre-reducing iron ore in a pre-reduction furnace, melting and reducing it in the melter gasifier, supplying the discharge gas from the melter gasifier through an ascending tube to a cyclone and to said pre-reduction furnace, directing the cooled and cleaned fine iron ore through a recycling system and a melting burner into the melter gasifier. A part of the discharge gas is supplied through a venturi scrubber, a first compressor and a circulating tube into an ascending tube. A part of the compressed gas circulating through the tube is recompressed by means of a second compressor and fine iron ore from a stored source is injected into ascending the tube by the recompressed gas by means of a pneumatic fine iron ore conveying system.

Abstract: In order to lower the sulfuric content of the offgas from a smelter reactor in which iron oxide is reduced to molten iron, in the presence of sulfur contaminants, a sufficient amount of a source of zinc is included in the charge to the reactor that the combined weight of the zinc source and the iron oxide source contains at least about 0.6% Zn (calculated as elemental zinc), on a dry weight basis. The temperature of the offgas is maintained at or above approximately 700.degree. C. Vaporized zinc, present in the offgas, binds with sulfur in the offgas to precipitate solid ZnS. After removal of the ZnS, the offgas may have a sulfuric content below 50 ppm by volume of H.sub.2 S equivalent. Suitable sources of zinc include blast furnace dust, electric arc dust, basic oxygen furnace dust, zinc calcine, and zinc sinter.

Abstract: The invention relates to a method for increasing the effectiveness of the smelting reduction of oxidic metal carriers, particularly iron ore, and improving the heat efficiency of the charged fuels in the smelting reduction process which takes place in a reaction vessel containing a molten bath with a layer of slag and wherein the reaction gases escaping from the molten bath are afterburned with oxidizing gases, the resulting heat is transferred to the molten bath and the reacting agents, ore and carbon, are fed to the smelt at least partly from the top through the gas space of the reaction vessel, wherein these reacting agents, ore and carbon, are added in a compact form to the molten bath as a composite material with or without further escort substances.

Abstract: A process of smelting iron that comprises the steps of:a) introducing a source of iron oxide, oxygen, nitrogen, and a source of carbonaceous fuel to a smelting reactor, at least some of said oxygen being continuously introduced through an overhead lance;b) maintaining conditions in said reactor to cause (i) at least some of the iron oxide to be chemically reduced, (ii) a bath of molten iron to be created and stirred in the bottom of the reactor, surmounted by a layer of slag, and (iii) carbon monoxide gas to rise through the slag;c) causing at least some of said carbon monoxide to react in the reactor with the incoming oxygen, thereby generating heat for reactions taking place in the reactor; andd) releasing from the reactor an offgas effluent,is run in a way that keeps iron losses in the offgas relatively low. After start-up of the process is complete, steps (a) and (b) are controlled so as to:e) keep the temperature of the molten iron at or below about 1550.degree. C.

Abstract: A self-cleaning lance includes a lance body elongated along a longitudinal axis and having an upper end portion and a lower end portion, the lower end portion being spaced apart from the upper end portion along the longitudinal axis. One or more main nozzles are located proximal to the lower end portion and are adapted to release an oxygen-containing gas. One or more deskulling nozzles are spaced upwardly from the lower end portion and are adapted to release a deskulling gas. The lance body has a first portion that extends axially from the deskulling nozzles to the main nozzles and a second portion above the deskulling nozzles. The first portion has a smaller outer perimeter than the outer perimeter of the second portion. Each of the deskulling nozzles extends by an angle of not greater than 25 degrees with respect to the longitudinal axis.

Abstract: A process for producing molten pig iron uses direct reduction of iron ore in a pre-reduction stage followed by a final reduction stage.In the pre-reduction stage iron ore is pre-reduced in a melting cyclone by means of a reducing process gas originating from the final reduction stage. A post-combustion occurs in the reducing process gas in the melting cyclone so that said iron ore in said melting cyclone is at least partly melted. The partly melted iron ore passes downwardly into a metallurgical vessel situated beneath the cyclone in which the final reduction takes place by supply of coal and oxygen, thereby forming a reducing process gas. A partial post-combustion occurs in the reducing process gas in the metallurgical vessel by means of said oxygen supplied thereto. The post-combustion ratio of the gas on exiting the metallurgical vessel is not more than 0.55.

Abstract: A process and a smelt reduction vessel (1) for producing metals and metal alloys, in particular iron and iron alloys, from metal oxides and ores in a smelt reduction vessel. The process and the vessel are characterized in that loss of liquid and solids with waste gases (11) from the vessel are minimized by causing the waste gases, oxidizing gases (5) and entrained liquid and solids in the space in the vessel that is above the molten metal to rotate about a vertical axis of the vessel thereby forcing liquid and solids outwardly toward the wall of the vessel. This rotational motion may be caused by injecting some or all the oxidizing gases through tuyeres (4) positioned above the bath surface obliquely to a vertical plane through a vertical axis of the vessel. The vessel may have a substantially rotationally symmetrical shape at least in the space above the molten metal (2A).

Abstract: Copper and or nickel sulfide ore concentrates of high intrinsic value are oxygen smelted by introducing such concentrates via feeds (32) into a closed loop extraction circuit in which a molten sulphide carrier composition is forcibly circulated by an R-H unit (14) through lower hearth (10) at which feed of the concentrates takes place, and upper hearth (12) at which controlled oxidation with technically pure oxygen through top lances (4) takes place to oxidize copper sulphide and iron sulphide in the concentrate to iron oxide. Copper is removed via line (42). Slag containing iron oxide is discharged via weir (22) into a secondary circuit in hearths (24 and 28). Carbonaceous reductant added to the slag in (28) reduces the iron oxide in the slag to hot iron product.

Abstract: A process for the production of iron from ferrous raw materials, the process comprising conducting a production phase and a tapping phase, the production phase including feeding fuel to an iron bath contained in a converter, continuously feeding ferrous raw materials to the iron bath through a gas space above the iron bath, continuously blowing oxygenous gases onto the surface of the iron bath, reducing the ferrous raw materials with the fuel to produce reduced iron, afterburning reaction gases comprising CO and H.sub.2 emerging from the iron bath with oxidizing gases in the gas space to produce heat, and transferring the heat to the iron bath; and the tapping phase including removing 40% to 90% of the iron bath to produce a final bath which can then be used as an initial bath in a subsequent production phase.

Abstract: A process and a smelt reduction vessel (1) for producing metals and metal alloys, in particular iron and iron alloys, from metal oxides and ores in a smelt reduction vessel. The process and the vessel are characterized in that loss of liquid and solids with waste gases (11) from the vessel are minimized by causing the waste gases, oxidizing gases (5) and entrained liquid and solids in the space in the vessel that is above the molten metal to rotate about a vertical axis of the vessel thereby forcing liquid and solids outwardly toward the wall of the vessel. This rotational motion may be caused by injecting some or all of the oxidizing gases through tuyeres (4) positioned above the bath surface obliquely to a vertical plane through a vertical axis of the vessel. The vessel may have a substantially rotationally symmetrical shape at least in the space above the molten metal (2A).

Abstract: A process and apparatus for smelting reduction of ores or pre-reduced metal carriers in the form of an emulsion composed of slag, liquid metal and floating coke particles which pass from a smelting reduction reactor to a separate settling tank through a connection conduit. At least one lance is provided for blowing a "hard" stream of oxygen into the settling tank while a second lance is provided for blowing a relatively "soft" stream of oxygen into the settling tank. The relatively softly blown stream of oxygen sufficiently increases the volume of gas in the settling tank beyond that resulting from the hard oxygen stream alone so as to drive back coke particles floating on the emulsion from the settling tank to the smelting reduction reactor through the connection conduit.

Abstract: A method of reducing metal oxides in a vessel containing a molten bath, the bath comprising a metal layer and a slag layer, wherein metal oxides and carbonaceous material are introduced into the bath, gas is injected into the slag layer to case the eruption of molten slag parts, droplets and/or streams into the gas space above the bath and oxygen-containing gas is injected into the gas space to case post-combustion.

Abstract: The invention describes a process for the manufacture of steel with a carbon content of <0.8 wt.-% by reducing iron ore and refining the hot metal. Iron ore and fuel are introduced into the reduction zone of a reactor that contains an iron melt in the reduction zone. This melt is covered by a liquid slag layer from which liquid slag is withdrawn. Further, oxygen-containing gas together with fuel is blown into the iron melt contained in the reduction zone. The iron melt extends into the refining zone of the reactor, the slag layer flows from the refining zone into the reduction zone and in the refining zone liquid steel is withdrawn. Oxygen-containing gas is supplied to the iron melt contained in the refining zone and liquid iron is withdrawn therefrom.

Abstract: A process for continuously smelting iron ore by use of coal to yield molten iron or semi-steel is disclosed. The process comprises the steps of establishing a melt covered by slag; inducing the slag and the molten iron to flow countercurrently to one another, toward opposite ends of the smelter; maintaining iron oxide-reducing conditions in that zone of the smelter towards which the slag flows; maintaining carbon-oxidizing conditions in that zone of the smelter towards which the molten iron flows; continuously or semicontinuously tapping the slag from the reducing zone end of the smelter; continuously or semicontinuously tapping the molten iron from the oxidizing zone end of the smelter; and adding to both zones iron ore, coal, oxygen, and flux at addition rates sufficient to keep the molten iron in the reducing zone substantially saturated with carbon, maintain in the slag being tapped an FeO content of about 5 weight percent or less, and maintain in the molten iron being tapped a carbon content of about 0.

Abstract: The specification discloses a process for producing a ferroalloy in a smelting vessel. A material containing an alloying metal is injected into a molten bath contained in the vessel. A flux, a carbonaceous material and an oxygen-containing gas are also injected into the vessel. A gas which may be the oxygen-containing gas is injected into the molten bath in order to stir it. The rates of injection of the various components are controlled to achieve control of the oxidizing and reducing environment within the vessel consistent with a rapid rate of injection. The material containing the alloying metal is either reduced and incorporated into the metal phase or oxidized and incorporated into the slag. Combustion gases above the molten bath are oxidized to provide further heat to the process. Alloyed metal or slag containing the alloying metal are recovered as product. The process is applicable to the production of ferroalloys such as ferrochromium, ferromanganese, ferronickel and ferrovanadium.

Abstract: This invention provides a method and apparatus whereby steel of various compositions may be produced from iron ore and coal through a series of stages without the intermediate production of liquid iron. A reforming reactor receives top gases from the steel making reactors, and converts them to high reduction potential gases which are returned to the steel making reactors. The iron ore and reductants, such as coal, are charged to a controlled atmosphere reactor which may be an inclined rotary cylindrical shaft. From the controlled atmosphere reactor the charge is moved to a potential shift reactor which is inclined or vertical and encounters increasing heat and rising gases for converting the carbonized sponge into a semi-molten state. The charge then passes to a high temperature reactor where it encounters the reducing gases from the reforming reactor and preheated oxygen to create temperature in which steel is made.

Abstract: A method of in-bath smelting reduction comprises the step of selectively supplying powder materials into a gas upflow region or a gas downflow region within a furnace during the time that oxygen-containing gas is concurrently being blown into the furnace from a top lance. Also disclosed is an in-bath smelting reduction furnace for carrying out the method.

Abstract: Process and apparatus for post combustion of reaction gases generated in a molten iron bath above the bath by means of at least one jet of oxidizing gases, whereby energy thereby produced is transferred to the bath and whereby the or each jet of oxidizing gases is injected with a swirl through one or more tuyeres towards the surface of the bath or the or each jet of oxidizing gases is injected in the form of a hollow jet through one or more tuyeres towards the surface of the bath.