Direct smelting processes

Second, development efforts ia direct reduction and direct smelting processes have also iacreased. Whereas these developmeats require significant commitment of finances and labor to achieve commercialization, the rewards promised by avoiding cokemaking and hy utilizing smaller scale units which have relatively low capital costs make the commitment worthwhile. 

Processes operating ia the range of 1300—1530°C produce molten iron, called hot metal or pig iron. These processes are classified as direct smelting processes. Processes operating above 1530°C produce molten steel (qv) and are called direct steehnakiag processes. 

Direct Smelting. Direct smelting processes use coal directly instead of coke. Several processes are under development which effectively divide the functions of the blast furnace into two separate but connected unit operations. First, the iron ore is prereduced in a shaft furnace or a fluidized bed, depending on the process and the type of ore used. Second, the prereduced ore is charged into a molten bath into which coal and oxygen or air are also introduced. The gases leaving the smelter are used to perform the reduction in the prereduction vessel. 

Long-term development work is focusing on direct smelting technologies. Multimillion dollar development programs are underway in the United States (AISI Direct Ironmaking process), Australia (HIsmelt process), and Japan (DIOS process). A direct smelting process, called the COREX process, already is in commercial operation in South Africa. 

NICKEL, COBALT AND COPPER RECOVERY FROM SEA NODULES BY DIRECT SMELTING PROCESS... 

---