Patent ID: 7691178

Claim:
A process for producing iron in a solid form that comprises: (a) direct smelting an iron-containing metalliferous feed material in a direct smelting vessel and producing a continuous stream of molten iron; (b) filling ladles with molten iron from the continuous stream at first and second docking areas of a ladle filling station adjacent to the direct smelting vessel and desulphurizing the molten iron produced in the direct smelting vessel on a batch basis in a ladle at a first desulphurization station adjacent to the direct smelting vessel and located at the first and second docking areas of the ladle filling station, transferring the ladle containing desulphurized molten iron to first or second docking areas of a second desulphurisation station spaced away from the first desulphurisation station and adjacent to a casting apparatus, and de-slagging desulphurized molten iron at the second desulphurisation station; (c) casting desulphurized molten iron into a solid form in the casting apparatus by discharging de-slagged and desulphurized molten iron from the ladle at the second desulphurisation station and forming a continuous stream of molten iron into the casting apparatus; and (d) controlling the process so that there is always at least one ladle at the second desulphurisation station discharging de-slagged and desulphurised molten iron into the casting apparatus to ensure a continuous stream of molten iron in the casting apparatus and so there is always at least one ladle at the ladle filling station receiving molten iron from the continuous stream of molten iron.