Abstract: An apparatus for removing a blockage in a solids injection lance extending into a direct smelting vessel The solids injection lance has a single inlet coupled to a section of supply line that conveys gas and solids to the solids injection lance and that is upstream and co-axial with the solids injection lance. The apparatus has a tool that extends through the supply line section and the solids injection lance to remove a blockage of solid material and an assembly for advancing the tool through the solids injection lance and the supply line section to the blockage from an upstream side of the blockage.

Abstract: A smelting vessel includes a plurality of heat pipes (21) positioned in a refractory lining of at least a part of the hearth (9) for cooling at least a part of the refractory lining. At least one of the heat pipes includes (a) a liquid phase of a heat transfer fluid, typically water, in a lower section of the heat pipe and (b) a vapor phase of the heat transfer fluid, typically steam, in an upper section of the heat pipe. The heat pipe also includes a vent to allow vapour phase to escape from the heat pipe to reduce the pressure or the temperature within the heat pipe when the vapour pressure or the temperature in the heat pipe exceeds a predetermined threshold pressure or temperature.

Abstract: An apparatus for removing a blockage in a solids injection lance extending into a direct smelting vessel The solids injection lance has a single inlet coupled to a section of supply line that conveys gas and solids to the solids injection lance and that is upstream and co-axial with the solids injection lance. The apparatus has a tool that extends through the supply line section and the solids injection lance to remove a blockage of solid material and an assembly for advancing the tool through the solids injection lance and the supply line section to the blockage from an upstream side of the blockage.

Abstract: A method of removing a blockage in a solids injection lance under normal operating conditions of a direct smelting vessel is disclosed. The direct smelting vessel contains a bath of molten metal and slag and the solids injection lance extends into the direct smelting vessel and has an outlet end that is submerged in the molten slag. The solids injection lance further has a single inlet coupled to a section of supply line that conveys gas and solid feed material to the solids injection lance. The method comprises (a) advancing a blockage-removing tool through the supply line section and through the solids injection lance to an upstream side of the blockage, (b) operating the tool under elevated gas pressure conditions to remove the blockage such that solid feed material and gas are able to flow through the solids injection lance. The method further comprises (c) retracting the tool from the solids injection lance and the supply line section.

Abstract: A slag notch for a metallurgical vessel includes a steel member that defines a passageway for molten slag and a system for cooling the steel member.

Abstract: A method of sealing a slag drain in a direct smelting vessel is disclosed. Also disclosed are a method of maintaining a slag drain channel and a direct smelting vessel with a slag drain channel that extends through a sleeve of refractory material installed in the direct smelting vessel. The method for sealing the slag drain includes locating a pre-formed refractory material at an inlet end of the slag drain channel so that it is exposed to a molten bath contained within the direct smelting vessel and sealing the slag drain channel with sealing material downstream of the pre-formed refractory material.

Abstract: A method for injecting a solid feed material through a solids injection lance includes creating flow conditions in an injection passageway of the lance so that at least a part of the feed material flowing along the passageway forms a buffer zone between a wall of a tube that defines the passageway and feed material flowing along a central section of the passageway.

Abstract: A smelting apparatus that includes (a) a smelting vessel (4) that is adapted to contain a bath of molten metal and slag and (b) a smelt cyclone (2) for pre-treating a metalliferous feed material positioned above and communicating directly with the smelting vessel The apparatus also includes an oft-gas duct (9) extending from the smelt, cyclone for discharging an off-gas from the smelt cyclone. The off-gas duct has an inlet section (18) that extends upwardly from the smelt cyclone and is formed to cause off-gas to undergo a substantial change of direction as it flows through the inlet section of the off-gas duct.

Abstract: A smelting vessel (4) for producing molten metal includes a refractory lined hearth that in use is in contact with molten slag or molten metal in the smelting vessel, and the hearth includes a plurality of heat pipes (2.1) positioned in a refractory lining of at least a part of the hearth for cooling the refractory lining.

Abstract: A smelting vessel includes a plurality of heat pipes (21) positioned in a refractory lining of at least a part of the hearth (9) for cooling at least a part of the refractory lining. At least one of the heat pipes includes (a) a liquid phase of a heat transfer fluid, typically water, in a lower section of the heat pipe and (b) a vapor phase of the heat transfer fluid, typically steam, in an upper section of the heat pipe. The heat pipe also includes a vent to allow vapour phase to escape from the heat pipe to reduce the pressure or the temperature within the heat pipe when the vapour pressure or the temperature in the heat pipe exceeds a predetermined threshold pressure or temperature.

Abstract: A molten bath-based direct smelting process comprises controlling the process conditions in a direct smelting vessel so that molten slag in a molten bath of metal and slag in the vessel has a viscosity in a range of 0.5-5 poise when the slag temperature is in the range of 1400-1550° C. in the molten bath in the vessel.

Abstract: A process and apparatus for direct smelting metalliferous material is disclosed. The invention concentrates injection of solid feed materials comprising metalliferous material and carbonaceous material into a direct smelting vessel during the course of the process into a relatively small region within a metal layer in a molten bath in the vessel in order to generate a substantial upward movement of molten material and gas from the metal layer into a region in the vessel that is above the molten bath. In particular, the invention injects the solid food materials with sufficient momentum and/or velocity via an opposed pair of lances that are oriented within the vessel and arranged to form overlapping plumes of injected material in the molten bath.

Abstract: A molten bath-based direct smelting process comprises controlling the process conditions in a direct smelting vessel so that molten slag in a molten bath of metal and slag in the vessel has a viscosity in a range of 0.5-5 poise when the slag temperature is in a range of 1400-1550° C. in the molten bath in the vessel.

Abstract: A solids injection lance includes (a) a tube that defines a passageway for solid feed material to be injected through the tube and has an inlet for solid material at a rear end and an outlet for discharging solid material at a forward end of the tube and (b) a puncture detection system for detecting a puncture in the solids injection tube.

Abstract: A molten bath-based direct smelting process includes controlling the process conditions in a direct smelting vessel so that molten slag in a molten bath of metal and slag in the vessel has a viscosity in a range of 0.5-5 poise in an operating temperature range for the process.

Abstract: A slag notch for a metallurgical vessel includes a steel member defines a passageway for molten slag and a system for cooling the steel member.

Abstract: A method of removing a blockage in a solids injection lance under normal operating conditions of a direct smelting vessel is disclosed. The direct smelting vessel contains a bath of molten metal and slag and the solids injection lance extends into the direct smelting vessel and has an outlet end that is submerged in the molten slag. The solids injection lance further has a single inlet coupled to a section of supply line that conveys gas and solid feed material to the solids injection lance. The method comprises (a) advancing a blockage-removing tool through the supply line section and through the solids injection lance to an upstream side of the blockage, (b) operating the tool under elevated gas pressure conditions to remove the blockage such that solid feed material and gas are able to flow through the solids injection lance. The method further comprises (c) retracting the tool from the solids injection lance and the supply line section.

Abstract: A method of sealing a slag drain in a direct smelting vessel is disclosed. Also disclosed are a method of maintaining a slag drain channel and a direct smelting vessel with a slag drain channel that extends through a sleeve of refractory material installed in the direct smelting vessel. The method for sealing the slag drain includes locating a pre-formed refractory material at an inlet end of the slag drain channel so that it is exposed to a molten bath contained within the direct smelting vessel and sealing the slag drain channel with sealing material downstream of the pre-formed refractory material.

Abstract: A smelting vessel (4) for producing molten metal includes a refractory lined hearth that in use is in contact with molten slag or molten metal in the smelting vessel, and the hearth includes a plurality of heat pipes (2.1) positioned in a refractory lining of at least a part of the hearth for cooling the refractory lining.

Abstract: A molten bath-based direct smelting process comprises controlling the process conditions in a direct smelting vessel so that molten slag in a molten bath of metal and slag in the vessel has a viscosity in a range of 0.5-5 poise when the slag temperature is in the range of 1400-1550° C. in the molten bath in the vessel.