Abstract: The present disclosure is directed to an improved direct smelting process for improving the efficiency of energy/heat recovery from hot smelter offgas for the purpose of steam raising and power generation. In examples, the formation of alkali sulfate accretions in the temperature range 500-1000° C. are removed by introducing a mechanical sweep-cleaning system to an offgas duct of the smelter. The sweep-cleaning system comprises at least one central rotating shaft with chains, with each chain optionally having an accretion-removal member at its distal end. When rotated, the chains lift and the accretion-removal member sweeps the walls of the duct to remove the accretions.

Abstract: An improved direct smelting system and process using a smelt reduction vessel (SRV), and optionally, a cyclone converter furnace (CCF). The improved system and process utilizes a fast quench system in which hot process offgas containing molten material is quench-cooled from greater than 1400° C. (2552° F.) to no more than 600° C. (1112° F.) in a time-of-flight of no greater than 1 second. The quenching occurs using water spray injection and vaporization to cool, stress and break solid slag into slag pieces small enough to remove from the quenching system. The improved system eliminates plant availability problems associated with (i) accretion formation in the offgas train as hot process offgas cools down in a conventional (slow) manner to allow for steam-raising for power generation or other heat recovery purposes, and (ii) trigger mechanisms causing slag foaming events in the SRV that propagate up the offgas train.

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: 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 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 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 a gas delivery duct assembly extending from a gas supply location away from the vessel to deliver oxygen-containing gas to gas injection lances extending into a direct smelting vessel. The gas delivery duct assembly includes a single gas delivery main connected to the gas injection lances to supply oxygen-containing gas to the gas injection lances. The gas delivery main is located at a height above a lower half of the vessel.

Abstract: A direct smelting plant for producing molten metal from a metalliferous feed material using a molten bath based direct melting process is disclosed. The plant includes a plurality of gas injection lances to inject the oxygen-containing gas into the vessel that extend downwardly through openings in a side wall of a direct smelting vessel.

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 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: 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 forehearth (5) for containing a volume of molten material and a direct smelting vessel (3) that includes the forehearth are disclosed. The forehearth includes a forehearth connection (15) for connecting the foreheath with a smelting chamber (4) of a smelting vessel (8) so that molten material can flow from the smelting chamber into the forehearth. The forehearth connection is formed so that there is an unrestricted line of sight through the forehearth connection from a location that is external to the forehearth. This makes it possible to unblock the forehearth connection by a mechanical drill or other equipment extending into the forehearth connection and operated externally of the forehearth.

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 a gas delivery duct assembly extending from a gas supply location away from the vessel to deliver oxygen-containing gas to gas injection lances extending into a direct smelting vessel. The gas delivery duct assembly includes a single gas delivery main connected to the gas injection lances to supply oxygen-containing gas to the gas injection lances. The gas delivery main is located at a height above a lower half of the vessel.

Abstract: A direct smelting plant for producing molten metal from a metalliferous feed material using a molten bath based direct melting process is disclosed. The plant includes a plurality of gas injection lances to inject the oxygen-containing gas into the vessel that extend downwardly through openings in a side wall of a direct smelting vessel.

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 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: 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.