It is a direct smelting process for making liquid iron straight from the iron ore. The process has been developed to treat iron ore fines with minimum pretreatment, making the process more flexible in terms of the quality of iron ore it can treat. The process allows the use of non coking coal and iron ore fines with significant impurities. The core of the HIsmelt process is the smelt reduction vessel SRV which has a refractory lined hearth and water cooled upper shell. The process is carried out in this vessel. The refractory hearth contains the molten iron bath and liquid slag.

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In CRA now Rio Tinto recognised the potential of the Klckner steelmaking converter technologies to be adapted to smelt iron ore instead of gasifying coal and melting scrap. CRA formed a joint venture with Klckner Werke to pursue the steelmaking and smelting reduction technologies.

Trials were conducted in a 60 tonne OBM converter to demonstrate the fundamentals of the smelt reduction process. With a capacity of , tpa, the design was based on a horizontal, rotating Smelt Reduction Vessel SRV that used bottom tuyeres for injection of coal, oxygen, fluxes and iron ore. The SSPP operated from to and this phase of the project proved the viability of the technology.

However, scaling up the process still remained a question. During this period, several restructuring events occurred. Klckner withdrew from the project in , and two years later CRA formed a Joint Venture with Midrex Corporation to continue the development of the technology. The pilot plant operation was deemed a success and it was decided that further testing at a larger scale was required. The principle objective of the HRDF was to demonstrate the process and engineering scale-up of the core plant and to provide operating data for commercial evaluation.

The original smelting vessel configuration for Kwinana was a direct scale-up of the SSPP smelt reduction vessel, i. Whilst scale-up of the process was successfully demonstrated, the complexity of engineering a horizontal vessel limited its commercial viability.

To overcome the deficiencies of the horizontal vessel a design was developed for a water-cooled vertical vessel. Design and engineering for the vertical SRV was completed in The main improvements incorporated into the design included a stationary vertical vessel, top injection of solids, a simplified hot air blast lance, a forehearth for continuous tapping of metal and water-cooled panels to overcome refractory wear problems.

The vertical vessel demonstrated major improvements over the horizontal vessel in terms of refractory wear, reliability, availability, productivity and simplicity in design. The HRDF vertical vessel addressed all the key requirements for a successful direct smelting iron making technology combining a high level of technical achievement with simple engineering concepts and plant technology. The vertical vessel operation confirmed the process was ready to be scaled up to a commercial plant.

Located in Kwinana, Western Australia, the merchant pig iron facility was designed and engineered with a 6-metre hearth diameter Smelt Reduction Vessel. Starting from November , the HIsmelt Kwinana plant is scheduled to take 3 years to ramp up to its name-plate hot metal production rate of tonnes per hour, or , tonnes per year, with a coal consumption rate of kg per tonne of hot metal. Achievements so far include: - A production rate of 65 tonnes of hot metal per hour with a coal rate of kg per tonne of hot metal.

HIsmelt Corporation continues to develop the technology to deliver cleaner, more flexible and lower cost iron-making to the world steel industry. All Rights Related Interests.


HIsmelt Technology Sets New Production Record in China

HIsmelt Technology Sets New Production Record in China Posted on October 25, Comments Off on HIsmelt Technology Sets New Production Record in China The Shouguang Shandong plant has reached the milestone of days of continuous operation producing, on average, more than 55, tonne hot metal per month HIsmelt is a breakthrough iron making technology that has attained full-scale commercial viability and is taking rapid strides in China where clampdown on traditional BF facilities have been ramped up of late, due mainly to ever-growing environmental concerns, and the thrust is definitely on non-BF iron and steelmaking research. China commissions first commercial HIsmelt plant in Shandong province, which can produce steel using low-grade Iron ore fines and non-coking coal. Remarkable Record While production statistics of the Shouguang Shandong HIsmelt plant in China were floating in the public domain since the plant achieved three months of continuous production in — after the first charge in August — news has recently trickled in that the plant has completed days of continuous operation, thereby setting a new running record, with average hot metal production of more than 55, tonne per month. It will soon resume operations after a few days of maintenance.


HIsmelt - The Technology

Tapping slag at the HIsarna pilot plant The HIsarna process is a smelting reduction process with two directly coupled process stages in which the production of liquid pig iron takes place. The HIsarna plant is shaped like a wine bottle: a "bottle" at the bottom and a thin "neck" at the top. The geometry of this furnace causes a cyclone to form in the neck when the crushed iron ore is injected into this cyclone together with oxygen so oxygen is injected at the top rather than at the bottom. The heat of the cyclone causes the initial partial reduction reaction to take place that reduces iron ore to iron. Here the droplets fall from the wall into the molten slag, which sits on top of the liquid iron bath in the bottom of the furnace. Between the cyclone and the slag layer, oxygen is injected through water cooled lances to generate heat by partly combusting the gasses being released from the final reduction reaction step that takes place in the slag. Powder coal is injected into the slag layer, again through water cooled lances.

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