Abstract: A direct smelting vessel and a hearth cooler element are disclosed. The vessel includes a refractory lined hearth. An inner surface of an upper part of the hearth extends upwardly and outwardly to side walls of the vessel. The upper part of the hearth incorporates a hearth cooler disposed outwardly behind the refractory lining of that part of the hearth and below the cooling panels on the side walls of the vessel. The hearth cooler comprises a plurality of cooler elements. Each cooler element has a hollow open-backed shell structure having base, top and side walls formed integrally in a cast structure and incorporating coolant flow passages.

Abstract: Efficient coordination of processing (by desulphurising) and moving hot metal from a direct smelter, producing hot metal on a continuous basis, to an electric arc furnace DIRECT or furnaces, operating on a batch basis, is disclosed. The invention includes the use of hot metal storage devices, such as ladles, that are large enough to supply hot metal for a small number, preferably two or three, of electric arc furnace batch operations.

Abstract: A gravity gradiometer is disclosed which has a sensor in the form of bars (41 and 42) which are supported on a mounting (5) which has a first mount section (10) and a second mount section (20). A first flexure web (33) pivotally couples the first and second mount sections about a first axis. The second mount has a first part (25), a second part (26) and a third part (27). The parts (25 and 26) are connected by a second flexure web (37) and the parts (26 and 27) are connected by a third flexure web (35). The bars (41 and 42) are located in housings (45 and 47) and form a monolithic structure with the housings (45 and 47) respectively. The housings (45 and 47) are connected to opposite sides of the second mount section 20. The bars (41 and 42) are connected to their respective housings by flexure webs (59). Transducers (71) are located in proximity to the bars for detecting movement of the bars to in turn enable the gravitational gradient tensor to be measured.

Abstract: An apparatus for injecting gas into a vessel includes a gas flow duct which receives hot gas through a gas inlet structure at a rear end of the duct. The forward end of the duct has an annular duct with an internal cooling water passage. Cooling water supply and return passages are formed within the wall of the duct such that water flows to and from a tip through the supply and return passages. The tip includes a hollow shell and a partitioning structure that has a ring and a plurality of circumferential flanges that project outwardly from the ring to the shell to form a series of water flow galleries, each extending circumferentially around the tip and interconnected for flow of cooling water sequentially through the galleries from the water supply passages to the water return passage. The circumferential flanges also serve as buttress supports for the shell.

Abstract: A direct smelting plant for producing molten metal from a metalliferous feed material using a molten bath based direct smelting process is disclosed. The plant includes an offgas duct assembly to facilitate flow of offgas from the vessel, the offgas duct assembly including two offgas ducts of matching diameter extending outwardly from the vessel.

Abstract: A floating water surface cover module, comprising a rim (1), and a shallow dome-shaped cover (2 )extending from the top of the rim (1 )and formed with a vent (3), the rim and cover being formed with shaped air-filled air-tight cavities (5 )spaced around the rim (1 )to provide buoyancy, the rim (1 )and the cover (2 )being configured so that one module will nest within another to form a stable stack.

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: A metallurgical vessel (11) has circumferentially spaced tubular mountings (25) through which to extend solids injection lances (31) into the vessel. Lance extraction apparatus (33) comprises an elongate track support structure (41) supporting a twin rail track (40) inclined upwardly and outwardly from the vessel above the direction of inclination of a respective lance (31). Interconnected upper and lower carriages (42, 44) are moveable along track (40) by operation of a hoist (47). Extraction apparatus (33) is operable sequentially to remove solids delivery line sections (36) and (37) and the lance (31) by connection to the carriages (42, 44) and upward movement of those carriages along track (40). Upper carriage (42) carries a pivot arm (51) for connection to upper parts of components to be removed such that those components can be pivoted downwardly to positions in which they can be hung from an overhead crane for removal to a remote location.

Abstract: A direct smelting plant that includes an effective and reliable solids feed means for injecting solid feed materials, particularly carbonaceous material, into a direct smelting vessel of the plant is disclosed. The solid feed means is characterised by independent supply of carbonaceous material to injection lances. The independent supply of carbonaceous material minimises the possible adverse impact of a breakdown of one or more than one lance or a breakdown of the carbonaceous material injection means for that lance or lances.

Abstract: Apparatus for injecting gas into a vessel including a gas flow duct 31 which receives hot gas through a gas inlet structure 32 at a rear end of the duct. An elongate central structure 33 extends throughout the length of duct 31 and carries a series of vanes 34 for imparting swirl to the gas flow exiting the forward end of the duct. The forward end of the duct 31 has an internally water cooled tip 36 and water flows to and from tip 36 through annular passages 43, 44 in the wall of duct 31. Vanes 34 are mounted on central structure 33 so as to extend to forward ends disposed within the duct tip 36 and are dimensioned such that during operation of the apparatus their forward ends are engaged and supported by the internally water cooled duct tip 36.

Abstract: A hot gas injection lance (26) for injecting hot gas into a vessel (11) is made of three modules (26A, 26B and 26C) which all fabricated separately and brought together in successive steps and connected together by releasable fastenings. Lance module (26A) is a main duct module providing an elongate duct (31) through which to direct hot gas into an upper region of the vessel. Lance module (26B) is a gas inlet module through which to direct hot gas into duct (31) of module (26A). Lance module (26C) is a central module which includes an elongate central tubular structure (33) that extends within the gas flow duct (31) and carries at its lower end a series of swirl imparting tubular structure (33) that extends within the gas flow duct (31) and carries at its lower end a series of swirl imparting vanes (34) for imparting swirl to the gas flow exiting the duct.

Abstract: A gravity gradiometer is disclosed which has a sensor in the form of bars (41 and 42) which are supported on a mounting (5) which has a first mount section (10) and a second mount section (20). A first flexure web (33) pivotally couples the first and second mount sections about a first axis. The second mount has a first part (25), a second part (26) and a third part (27). The parts (25 and 26) are connected by a second flexure web (37) and the parts (26 and 27) are connected by a third flexure web (35). The bars (41 and 42) are located in housings (45 and 47) and form a monolithic structure with the housings (45 and 47) respectively. The housings (45 and 47) are connected to opposite sides of the second mount section 20. The bars (41 and 42) are connected to their respective housings by flexure webs (59). Transducers (71) are located in proximity to the bars for detecting movement of the bars to in turn enable the gravitational gradient tensor to be measured.

Abstract: A gravity gradiometer is disclosed which has a sensor in the form of bars (41 and 42) which are supported on a mounting (5) which has a first mount section (10) and a second mount section (20). A first flexure web (33) pivotally couples the first and second mount sections about a first axis. The second mount has a first part (25), a second part (26) and a third part (27). The parts (25 and 26) are connected by a second flexure web (37) and the parts (26 and 27) are connected by a third flexure web (35). The bars (41 and 42) are located in housings (45 and 47) and form a monolithic structure with the housings (45 and 47) respectively. The housings (45 and 47) are connected to opposite sides of the second mount section 20. The bars (41 and 42) are connected to their respective housings by flexure webs (59). Transducers (71) are located in proximity to the bars for detecting movement of the bars to in turn enable the gravitational gradient tensor to be measured.

Abstract: A gravity gradiometer is disclosed which has a sensor in the form of bars (41 and 42) which are supported on a mounting (5) which has a first mount section (10) and a second mount section (20). A first flexure web (33) pivotally couples the first and second mount sections about a first axis. The second mount has a first part (25), a second part (26) and a third part (27). The parts (25 and 26) are connected by a second flexure web (37) and the parts (26 and 27) are connected by a third flexure web (35). The bars (41 and 42) are located in housings (45 and 47) and form a monolithic structure with the housings (45 and 47) respectively. The housings (45 and 47) are connected to opposite sides of the second mount section 20. The bars (41 and 42) are connected to their respective housings by flexure webs (59). Transducers (71) are located in proximity to the bars for detecting movement of the bars to in turn enable the gravitational gradient tensor to be measured.

Abstract: A gravity gradiometer is disclosed which has a sensor in the form of bars (41 and 42) which are supported on a mounting (5) which has a first mount section (10) and a second mount section (20). A first flexure web (33) pivotally couples the first and second mount sections about first axis. The second mount has first part (25), a second part (26) and a third part (27). The parts (25 and 26) are connected by second flexure web (37) and the parts (26 and 27) are connected by third flexure web (35). The bars (41 and 42) are located in housings (45 and 47) and form a monolithic structure with the housings (45 and 47) respectively. The housings (45 and 47) are connected to opposite sides of the second mount section 20. The bars (41 and 42) are connected to their respective housings by flexure webs (59).

Abstract: Smelting apparatus comprises a vessel (11) and a solids injection lance (27a) extending through an opening in the wall of vessel barrel (16) into the interior space of the vessel. Lance (27a) includes a central core tube (31) through which to pass solid particulate material into the vessel and an annular cooling jacket (32) surrounding the central core tube (31) throughout a substantial part of its length. Lance (27a) has a mounting structure (61) comprising a tubular part (60) extended about cooling jacket (32) and about twice the diameter of the cooling jacket. Tubular part (60) fits within a tubular lance mounting bracket (62) welded to the shell (16a) of vessel barrel (16) to extend outwardly from the vessel. The lance is held within mounting bracket (62) by clamping bolts acting between flanges (63,65) on tubular part (60) and tubular bracket (62).

Abstract: A gravity gradiometer is disclosed which has a sensor in the form of bars (41 and 42) which are supported on a mounting (5) which has a first mount section (10) and a second mount section (20). A first flexure web (33) pivotally couples the first and second mount sections about a first axis. The second mount has a first part (25), a second part (26) and a third part (27). The parts (25 and 26) are connected by a second flexure web (37) and the parts (26 and 27) are connected by a third flexure web (35). The bars (41 and 42) are located in housings (45 and 47) and form a monolithic structure with the housings (45 and 47) respectively. The housings (45 and 47) are connected to opposite sides of the second mount section 20. The bars (41 and 42) are connected to their respective housings by flexure webs (59). Transducers (71) are located in proximity to the bars for detecting movement of the bars to in turn enable the gravitational gradient tensor to be measured.

Abstract: A method and an apparatus for crushing material, particularly mined material, are disclosed. In one embodiment two or more pairs of crushing rolls successively crush mined material. The pairs of crushing rolls are arranged and operated so that an upstream pair of rolls produces a feed, preferably a pressurised feed, for a downstream pair of rolls. In another embodiment, at least an upstream pair of rolls is driven intermittently, for example, by means of a stepping motor to provide stepped rotational movement of the rolls.

Abstract: A gravity gradiometer is disclosed which has a sensor in the form of bars (41 and 42) which are supported on a mounting (5) which has a first mount section (10) and a second mount section (20). A first flexure web (33) pivotally couples the first and second mount sections about a first axis. The second mount has a first part (25), a second part (26) and a third part (27). The parts (25 and 26) are connected by a second flexure web (37) and the parts (26 and 27) are connected by a third flexure web (35). The bars (41 and 42) are located in housings (45 and 47) and form a monolithic structure with the housings (45 and 47) respectively. The housings (45 and 47) are connected to opposite sides of the second mount section 20. The bars (41 and 42) are connected to their respective housings by flexure webs (59). Transducers (71) are located in proximity to the bars for detecting movement of the bars to in turn enable the gravitational gradient tensor to be measured.