Patent ID: 6989042

Claim:
A direct smelting process for producing metals which term includes metal alloys from a ferrous material which includes the steps of: (a) forming a bath of molten metal and molten slag in a metallurgical vessel; (b) injecting feed materials being solid material and carrier gas into the molten bath at a velocity of at least 40 m/s through a downwardly extending solids injection lance having a delivery tube of internal diameter of 40–200 mm that is located so that a central axis of an outlet end of the lance is at an angle of 20 to 90 degrees to a horizontal axis and generating a superficial gas flow of at least 0.04 Nm 3 /s/m 2 within the molten bath (where m 2 relates to the area of a horizontal crosssection through the molten bath) at least in part by reactions of injected material in the bath which causes molten material to be projected upwardly as splashes, droplets and streams and form an expanded molten bath zone, the gas flow and the upwardly projected molten material causing substantial movement of material within the molten bath and strong mixing of the molten bath, the feed materials being selected so that, in an overall sense, the reactions of the feed materials in the molten bath are endothermic; and (c) injecting an oxygen-containing gas into an upper region of the vessel via at least one oxygen gas injection lance and post-combusting combustible gases released from the molten bath, whereby ascending and thereafter descending molten material in the expanded molten bath zone facilitate heat transfer to the molten bath.