Abstract:
Direct smelting plant for Producing molten metal from a metalliferous feed material induces a smelting vessel  11  to hold a molten metal and slag bath beneath a hot gas space. Solids injection lances  27  extend downwardly and inwardly through side walls of the vessel and hot oxidising gas is directed downwardly into the gas space by a central vertical gas injection lance  26 . The plant layout is divided into four functional zones spaced circumferentially around vessel  11  and radiating outwardly from the vessel. Zone  1  contains an overhead hot gas delivery duct  31  supplying gas to lance  26  and an offgas duct  32 ; Zone  2  contains a forehearth  19  and forehearth tapping launder  34 ; Zone  3  contains slag notches  45  and slag launders  46 ; and Zone  4  contains a primary slag drain taphole and launder  48 . This layout minimises the potential for interference between the transport of the hot gases, the metaliferous feed material, and the molten metal and slag.

Description:
TECHNICAL FIELD  
         [0001]    The present invention relates to direct smelting plant for producing molten metal in pure or alloy form from a metalliferous feed material such as ores, partly reduced ores and metal-containing waste streams.  
           [0002]    A known direct smelting process, which relies principally on a molten metal layer as a reaction medium, and is generally referred to as the HIsmelt process, is described in International Application PCT/AU96/00197 (WO 96/31627) in the name of the applicant.  
           [0003]    The HIsmelt process as described in the International application comprises:  
           [0004]    (a) forming a bath of molten iron and slag in a vessel;  
           [0005]    (b) injecting into the bath:  
           [0006]    (i) a metalliferous feed material, typically metal oxides; and  
           [0007]    (ii) a solid carbonaceous material, typically coal, which acts as a reductant of the metal oxides and a source of energy; and  
           [0008]    (c) smelting metalliferous feed material to metal in the metal layer.  
           [0009]    The term “smelting” is herein understood to mean thermal processing wherein chemical reactions that reduce metal oxides take place to produce liquid metal.  
           [0010]    The HIsmelt process also comprises post-combusting reaction gases, such as CO and H 2  released from the bath in the space above the bath with oxygen-containing gas and transferring the heat generated by the post-combustion to the bath to contribute to the thermal energy required to smelt the metalliferous feed materials.  
           [0011]    The HIsmelt process also comprises forming a transition zone above the nominal quiescent surface of the bath in which there is a favourable mass of ascending and thereafter descending droplets or splashes or streams of molten metal and/or slag which provide an effective medium to transfer to the bath the thermal energy generated by post-combusting reaction gases above the bath.  
           [0012]    In the HIsmelt process the metalliferous feed material and solid carbonaceous material is injected into the metal layer through a number of lances/tuyeres which are inclined to the vertical so as to extend downwardly and inwardly through the side wall of the smelting vessel and into the lower region of the vessel so as to deliver the solids material into the metal layer in the bottom of the vessel. To promote the post combustion of reaction gases in the upper part of the vessel, a blast of hot air, which may be oxygen enriched, is injected into the upper region of the vessel through the downwardly extending hot air injection lance. Offgases resulting from the post-combustion of reaction gases in the vessel are taken away from the upper part of the vessel through an offgas duct.  
           [0013]    The HIsmelt process enables large quantities of molten metal to be produced by direct smelting in a single compact vessel. However, in order to achieve this it is necessary to transport hot gases to and from the vessel, to transport the metalliferous feed material to the vessel and to transport the molten metal product and slag away from the vessel all within a relatively confined area. These functions must continue throughout a smelting operation which can be extended over a long period. It is also necessary to provide access and handling facilities to enable access to the vessel and lifting of equipment between smelting operations. The present invention enables a very effective arrangement of plant by which facilities for various functions are separated into distinct zones disposed about the vessel so as to minimise the potential for interference between the various functions and to maximise safety of the smelting operations.  
         DISCLOSURE OF THE INVENTION  
         [0014]    According to the invention, there is provided direct smelting plant for producing molten metal from a metalliferous feed material including:  
           [0015]    a fixed smelting vessel to hold a molten bath having a metal layer and a slag layer on the metal layer and a gas space above the slag;  
           [0016]    a solids feed means to supply metalliferous feed material and carbonaceous material into the vessel;  
           [0017]    gas injection means extending downwardly into the vessel to inject oxidising gas into the gas space and/or the slag layer in the vessel;  
           [0018]    gas delivery duct means extending from a gas supply location away from the vessel to a delivery location above the vessel for delivery of oxidising gas into the gas injection means;  
           [0019]    offgas duct means for flow of offgas from an upper part of the vessel away from the vessel;  
           [0020]    a metal tapping means for flow of molten metal from the bath during a smelting operation out of a lower part of the vessel;  
           [0021]    a metal tapping launder to receive molten metal from the metal tapping means and to transport that molten metal away from the vessel;  
           [0022]    slag tapping means in a side wall of the vessel for tapping slag from the bath during a smelting operation; and  
           [0023]    slag tapping launder means to receive slag from the slag tapping means and to transport that slag away from the vessel;  
           [0024]    wherein the oxidising gas delivery duct means and the offgas duct means extend in a first of three discrete zones spaced circumferentially about the vessel and extending outwardly from the vessel;  
           [0025]    the metal tapping means and metal tapping launder are disposed in a second of said three zones; and  
           [0026]    the slag tapping means and slag tapping launder means are located in the third of said zones.  
           [0027]    Preferably, the second and third zones are disposed to mutually opposite sides of the smelting vessel and the first zone is disposed between the second and third zones circumferentially of the vessel.  
           [0028]    Preferably too, the plant further comprises slag draining means for draining slag from the lower part of the vessel at the end of a smelting operation, the means being lower than the slag tapping means, and slag drain launder means to receive slag from the slag draining means and to transport it away from the vessel.  
           [0029]    Preferably further, the slag draining means and the slag drain launder are located in a fourth discrete zone extending outwardly of the vessel between the second and third zones.  
           [0030]    Preferably further, the fourth zone is disposed generally opposite to the first zone relative to the vessel.  
           [0031]    The metal tapping means may comprise a metal flow forehearth projecting outwardly from the lower part of the vessel.  
           [0032]    The plant may further include a metal holding means disposed away from the vessel and the metal tapping launder may extend to the holding means to deliver molten metal into the holding means.  
           [0033]    Preferably the plant further includes gas heating means at the gas supply location to supply hot gas to the gas delivery duct means for injection into the vessel.  
           [0034]    The gas delivery duct means may comprise a single gas duct extending from the gas supply location to the delivery location.  
           [0035]    The solids feed means may comprise one or more solids injection lances.  
           [0036]    More particularly, there may be a plurality of solids injection lances spaced circumferentially of the vessel. Each of the lances may extend downwardly and inwardly into the vessel through a side wall of the vessel.  
           [0037]    The slag tapping means may comprise a pair of slag tapping notches in the side wall of the vessel.  
           [0038]    The vessel may be disposed about a central upright axis and said zones may radiate outwardly of the central axis outside the vessel. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0039]    In order that the invention may be more fully explained, one particular embodiment will be described in detail with reference to the accompanying drawings in which:  
         [0040]    [0040]FIG. 1 is a vertical cross-section through a direct smelting vessel incorporated in a smelting plant layed out in accordance with the present invention;  
         [0041]    [0041]FIG. 2 is a diagrammatic plan of the vessel showing four separate operational zones spaced circumferentially about the vessel and radiating outwardly from it;  
         [0042]    [0042]FIG. 3 is a diagrammatic plan of the smelting vessel and the molten metal and slag handling facilities in the installation;  
         [0043]    [0043]FIG. 4 is a diagrammatic plan similar to FIG. 3 but showing slightly modified slag handling facilities in regard to slag draining;  
         [0044]    [0044]FIG. 5 is a diagrammatic plan of slightly modified metal handling facilities;  
         [0045]    [0045]FIG. 6 illustrates a forehearth eruption containment hood;  
         [0046]    [0046]FIG. 7 is a diagrammatic plan of a forehearth tap-hole and launder;  
         [0047]    [0047]FIG. 8 is a schematic section through the vessel and the metal and slag handling facilities;  
         [0048]    [0048]FIG. 9 is a schematic layout of slag drain tap-hole facilities;  
         [0049]    [0049]FIG. 10 is a diagrammatic plan of slag notch and launder facilities of the installation; and  
         [0050]    [0050]FIG. 11 is a schematic cross-section of break out containment facilities of the installation. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0051]    [0051]FIG. 1 illustrates a direct smelting vessel suitable for operation by the HIsmelt process as described in International Patent Application PCT/AU96/00197. The metallurgical vessel is denoted generally as  11  and has a hearth that incudes a base  12  and sides  13  formed from refractory bricks; side walls  14  which form a generally cylindrical barrel extending upwardly from the sides  13  of the hearth and which incudes an upper barrel section and a lower barrel section; a roof  17 ; an outlet  18  for offgases; a forehearth  19  for discharging molten metal continuously; and a tap-hole  21  for discharging molten slag.  
         [0052]    In use, the vessel contains a molten bath of iron and slag which includes a layer  22  of molten metal and a layer  23  of molten slag on the metal layer  22 . The arrow marked by the numeral  24  indicates the position of the nominal quiescent surface of the metal layer  22  and the arrow marked by the numeral  25  indicates the position of the nominal quiescent surface of the slag layer  23 . The term “quiescent surface” is understood to mean the surface when there is no injection of gas and solids into the vessel.  
         [0053]    The vessel may be fitted with a downwardly extending gas injection lance  26  for delivering a hot air blast into an upper region of the vessel and eight solids injection lances  27  extending downwardly and inwardly through the side walls  14  and into the slag layer  23  for injecting iron ore, solid carbonaceous material, and fluxes entrained in an oxygen-deficient carrier gas into the metal layer  22 . The position of the lances  27  is selected so that their outlet ends  28  are above the surface of the metal layer  22  during operation of the process. This position of the lances reduces the risk of damage through contact with molten metal and also makes it possible to cool the lances by forced internal water cooling without significant risk of water coming into contact with the molten metal in the vessel.  
         [0054]    Gas injection lance  26  receives an oxygen enriched hot air flow through a hot gas delivery duct  31  which extends from a hot gas supply station located some distance away from the reduction vessel  11 . The hot gas supply station may incorporate a series of hot gas stoves and an oxygen plant to enable an oxygen enriched air stream to be passed through the hot gas stoves and into the hot gas delivery duct  31  which extends to a connection with the gas injection lance  26  at a location above the reduction vessel  11 . Alternatively the oxygen may be added to the air stream after the air stream has been heated by the stoves.  
         [0055]    The offgas outlet  18  is connected to an offgas duct  32  which transports the offgas away from the reduction vessel  11  to a treatment station where it may be cleaned and passed through heat exchangers for preheating the materials fed to the reduction vessel  11 .  
         [0056]    The hot gas delivery duct  31  and offgas duct  32  must extend away from the upper part of the vessel to remote locations and they may therefore interfere with the operation of overhead cranes or mobile handling equipment required for maintenance of the vessel and for transporting hot metal and hot slag away from the vessel during smelting operations. Hot metal from the vessel is delivered through the forehearth  19  and must be taken away through a hot metal launder system that preferably includes a surge launder and a forehearth drain tap launder. There must also be a slag tapping system comprising one or more slag notches and launders and also a slag draining system to drain slag from the lower part of the vessel at the end of a smelting operation. The present invention enables installation and operation of all this equipment around the compact reduction vessel  11  in a way which separates the various operational functions into separate zones spaced circumferentially around the vessel, so minimising interference between the various operations and operation of handling equipment and accordingly, maximising operational safety.  
         [0057]    [0057]FIGS. 2 and 3 illustrate the manner in which the layout of the installation is divided into four functional zones spaced circumferentially around the vessel  11  and radiating outwardly of the central upright axis of the vessel. These zones are as follows:  
         [0058]    Zone  1 : General Access and Services  
         [0059]    This zone contains:  
         [0060]    the “footprints” of the overhead hot gas delivery duct  31  and offgas duct  32 ;  
         [0061]    the direct access route to a side entry door  33  in the reduction vessel  11 .  
         [0062]    Zone  2 : Metal Tapping  
         [0063]    This zone contains:  
         [0064]    Forehearth  19  and a forehearth tapping launder  34 .  
         [0065]    A holding furnace  35  and a tapping spout  36 .  
         [0066]    An end-taphole  63 , drill and launder  38 .  
         [0067]    A holding furnace bypass launder  39 .  
         [0068]    A forehearth surge launder  41  and drop chute  42 .  
         [0069]    A forehearth drain taphole  43  and launder  44 .  
         [0070]    Zone  3 : Slag Tapping  
         [0071]    This zone contains:  
         [0072]    Two slag notches  45  and launders  46 .  
         [0073]    Dedicated water-cooled plugs and prickers (illustrated in FIG. 9).  
         [0074]    Shared mechanised launder cover (also seen in FIG. 9).  
         [0075]    Zone  4 : Slag Draining  
         [0076]    This zone contains:  
         [0077]    A primary slag drain taphole  47 , mudgun, drill and launder  48 .  
         [0078]    Access route to a second side entry door  49  in the reduction vessel  11 .  
         [0079]    The reduction vessel  11  and the above described ancillary equipment including the holding vessel  35 , are installed over a drainage floor  51  leading to a break out containment pit  52 . A slag drain pit  53  is also provided to receive slag from the slag drain launder  48 .  
         [0080]    An alternative layout for the slag drain pit  53  is shown in FIG. 4. This option might be preferable where there is ground floor access restriction. It also has the advantage that it offers a more direct route for an emergency slag drain launder  54  to the slag drain pit.  
         [0081]    The illustrated plant layout in accordance with the invention enables direct overhead crane access to as much of the cast house floor and its equipment as is practical. Two or more cranes may be provided. For example, a high lifting capacity “hot metal” crane may be installed to run above the break out containment pit  52 , forehearth  19  and holding furnace  35  to enable hot metal ladle transport (for charging vessel  11 ), break out containment pit skull handling, launder change out and general maintenance activities. A separate vessel maintenance crane may be installed to service the rest of the cast house floor and the reduction vessel  11 . This crane may be used for general maintenance, consumable transport, launder and fixed launder cover change out, injection and hot gas lance handling and the moving of small mobile equipment in general lifting. Access to the vessel side entry door  33  is between the footprints of the overhead bridges for the hot air delivery duct  31  and the offgas duct  32 . This enables ready access at all times by the vessel maintenance crane. Access to the side entry door  49  in Zone  4  requires removal of the slag drain tapping launder and the installation of temporary covers over any associated holes in the cast house floor.  
         [0082]    The various functions to be carried out during smelting operations will now be described.  
       METAL TAPPING  
       [0083]    Forehearth tapping launder  34  extends directly from the back half of the forehearth  19  (nearest vessel) and over the top of the holding furnace  36 . The launder inlet is located away from the front of the forehearth where any sudden upwelling of metal associated with a pressure surge is likely to be most pronounced. The discharge end of the launder  34  has a drop hole  55  to ensure that the liquid metal will land directly in the pool in the holding furnace. This is to avoid erosion due to impingement of the falling metal stream on the refractory lining.  
         [0084]    The launder is directly accessible from above by a crane, facilitating easy change out and the holding furnace is also readily accessible by the same crane.  
         [0085]    [0085]FIGS. 3 and 4 show a holding furnace bypass launder  39  having a dedicated inlet  57  located in the front half of the forehearth  19 . This allows the entire forehearth tapping launder to be bypassed.  
         [0086]    An alternative configuration is shown in FIG. 5. During normal operation the inlet to the inlet to the bypass launder would be dammed up as shown. During bypass operation, this dam would be replaced by one immediately downstream of the dog-leg. The advantages of this alternative arrangement include:  
         [0087]    A reduction in the number of forehearth outlets.  
         [0088]    Retention of the inlet at the rear end of the forehearth.  
         [0089]    Improved forehearth accessibility.  
         [0090]    Reduced congestion between the forehearth and the holding furnace.  
         [0091]    [0091]FIGS. 3 and 4 also show a forehearth surge launder  41  and drop chute  42 . This is to divert the bulk of the metal, resulting from sever pressure surge, down to the emergency break-out containment pit  52  via the sloping ground floor  51 . A trench of sand or crushed slag could be built from the base of the drop chute to channel flow to the pit.  
         [0092]    [0092]FIGS. 3 and 4 also show a forehearth drain taphole  43  and launder  44 . These are located on one side of the forehearth to:  
         [0093]    provide maximum clear access;  
         [0094]    minimise the length of the launder; and  
         [0095]    minimise kinks and bends in the launder.  
         [0096]    A forehearth eruption hood  50  is shown in FIG. 6. Its purpose is to contain flying metal droplets and hot gases/flame in the event of a violent forehearth eruption. Hot gases and flame is vented out through the top of this hood. The hood is supported on locating pins  60  fixed to the side of the support structure for vessel  11  and it is readily accessible by the “hot metal” crane so that it can be simply lifted off the support pins  60  for removal.  
         [0097]    End tapping is carried out by use of an end-taphole  63 , drill  64  and launder  38  as seen in FIGS. 3, 4 and  7  which shows a slightly modified forehearth draining arrangement with a connection to the end tap launder  38 . The drill is of fixed pedestal design because it is a reliable and robust piece of equipment. A diverting launder  65  is provided to allow the vessel to be drained directly into the break-out containment pit  52  in an emergency, if the hot metal transport containers were unavailable.  
       SLAG NOTCH TAPPING  
       [0098]    The slag notch and launder configuration/locations are shown in FIGS. 3, 4,  10  and  11 . The locations  66  of slag notch plugging bots, prickers and mechanised launder cover  68  are shown in FIG. 11. The illustrated layout has the following features:  
         [0099]    The shared mechanised launder cover is placed between the launders as it does not require much operator access.  
         [0100]    It is preferred that the launder cover is mounted on a turn-table to simplify and speed up the changeover to the other slag notch.  
         [0101]    The bots and prickers (or mudguns and drills) are on the “outside” of the launders to maximise unobstructed operator access (which is more frequent than for the launder cover).  
         [0102]    The slag bots and prickers (or mudguns and drills) are of a pedestal mounted “over and under” design, located near the slag notch end of the launders. This is to minimise their combined “footprint areas” and hence maximise the clear space available for mobile equipment access (used for launder cleaning).  
         [0103]    Pedestal mounted bots and prickers (or mudguns and drills) are preferred to overhead rail mounted machines. This is because the trailing catenaries of the latter are believed to be vulnerable to damage by radiant heat and, in particular, flying slag and metal droplets. These are inevitable, particularly during slag notch plugging, because the vessel is pressurised.  
         [0104]    The launder layout allows for a “slag trajectory catchment zone”, roughly the length of the mechanised launder cover. This limits the maximum slope of the launder in this area and is to avoid erosion of the refractory lining of the cover.  
         [0105]    The “wider spread” launder layout provides more space to accommodate the possible requirement of bifurcated launders and the associated slag pots.  
       SLAG DRAIN TAPPING  
       [0106]    A primary slag drain taphole  47  and launder  48  is located in Zone  4  to minimise congestion and complexity. The location and configuration of these components are shown in FIGS. 3, 4,  8  and  9 . A remotely located second emergency slag drain taphole allows the latter to be accessed independently of the first, minimising the exposure of personnel to splash, radiant heat and fume. The primary slag drain taphole  47  is integral with one of the vessel side entry doors  49  to make effective use of available casthouse floor space.  
         [0107]    [0107]FIG. 9 shows a dedicated mudgun  71  and drill  72 . The mudgun and drill may be an “over-and-under” pedestal mounted design, allowing them to be mounted on the same side of the taphole/launder on the slag notch side of the primary slag drain taphole/launder. This is to maximise the distance between them and the forehearth, to minimise exposure risk in the event of a forehearth eruption.  
       BREAK-OUT CONTAINMENT  
       [0108]    The system for break-out containment is shown in FIGS. 3, 4 and  11 . It includes the sloping drainage floor  57  under the reduction vessel  11 , forehearth  19  and holding furnace  35 . The floor  51  is sloped down into the break-out containment pit  52 . The drainage floor  51  overlaps the footprints of the units mentioned and is bounded by a combination of bunds  73  and the slag drain pit walls  74 . The floor of the break-out facilities may be formed of compacted soil (sand) covered with a layer of crushed slag, stone, or other suitable material. This is to minimise direct contact by slag and metal run-off as the soil (sand) is likely to contain some moisture. It is also to provide a permeable barrier for water to drain through and for steam to escape, in the event a water leak in conjunction with a break-out, alternatively a concrete formulation could be installed.