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 of starting a molten bath-based process for smelting a metalliferous material is disclosed. The method includes using the heat flux of water-cooled elements in lower parts of a smelting vessel to provide an indication of molten bath temperature during at least an early part of the start-up method and adjusting injection rates of oxygen-containing gas and/or carbonaceous material into the smelting vessel to control the molten bath temperature during start-up without exceeding critical heat flux levels and tripping the start-up method.

Abstract: A material supply apparatus and process for co-injecting heated solid metalliferous material and solid carbonaceous material via a solids injection lance into a direct smelting vessel are disclosed.

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 material supply apparatus and process for co-injecting heated solid metalliferous material and solid carbonaceous material via a solids injection lance into a direct smelting vessel are disclosed.

Abstract: A method of starting a molten-bath based melting process includes commencing supplying cold oxygen-containing gas and cold carbonaceous material into a main chamber of a smelting vessel within at most 3 hours after completing a hot metal charge into the vessel and igniting the carbonaceous material and heating the main chamber and molten metal in the main chamber.

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 method of starting a molten-bath based melting process includes establishing a sufficiently large and stable “hot zone” for ignition of oxygen and coal in a main chamber of a smelting vessel by independent means, i.e. independently of and before supplying cold oxygen and coal into the main chamber.

Abstract: A molten bath-based process for direct smelting metalliferous material and producing molten metal in a direct smelting vessel that contains a molten bath that has a metal layer that is at least 900 mm deep. The process includes selecting operating parameters of the process so that feed material (solid material and carrier gas) is injected from above the metal layer into the metal layer via at least one solids injection lance with sufficient momentum to penetrate to a depth of at least 100 mm below a nominal quiescent surface of the metal layer to cause upward movement of molten material and gas from the metal layer.

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 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 method of starting a smelting process in a smelting vessel includes heating frozen slag and forming molten slag and draining molten slag from a forehearth connection via a forehearth and establishing a clear flow path through the forehearth connection and thereafter hot starting the smelting process.

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 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 feed 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 method of starting a molten bath-based process for smelting a metalliferous material is disclosed. The method includes using the heat flux of water-cooled elements in lower parts of a smelting vessel to provide an indication of molten bath temperature during at least an early part of the start-up method and adjusting injection rates of oxygen-containing gas and/or carbonaceous material into the smelting vessel to control the molten bath temperature during start-up without exceeding critical heat flux levels and tripping the start-up method.

Abstract: A molten bath-based direct smilting 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 method of starting a smelting process in a smelting vessel includes heating frozen slag and forming molten slag and draining molten slag from a forehearth connection via a forehearth and establishing a clear flow path through the forehearth connection and thereafter hot starting the smelting process.

Abstract: A method of starting a molten-bath based melting process includes establishing a sufficiently large and stable “hot zone” for ignition of oxygen and coal in a main chamber of a smelting vessel by independent means, i.e. independently of and before supplying cold oxygen and coal into the main chamber.

Abstract: A method of starting a molten-bath based melting process includes commencing supplying cold oxygen-containing gas and cold carbonaceous material into a main chamber of a smelting vessel within at most 3 hours after completing a hot metal charge into the vessel and igniting the carbonaceous material and heating the main chamber and molten metal in the main chamber.

Abstract: A material supply apparatus and process for co-injecting heated solid metalliferous material and solid carbonaceous material via a solids injection lance into a direct smelting vessel are disclosed.