Converting process with slag separation and recycle to the converter. The process includes introducing converter feed into the pot holding a molten alloy pool, oxygen injection into the pool, tapping the slag, and tapping the PGM-enriched alloy. The collector alloy contains no less than 0.5 wt % PGM, 40 wt % iron, and 0.5 wt % nickel, and no more than 3 wt % sulfur and 3 wt % copper, and the recovered slag is separated into recycle and non-recycle portions. The recycle slag portion preferably contains more PGM than the non-recycle portion. The process can also include low- or no-flux converting; using a refractory protectant in the converter; magnetic separation of slag; partial pre-oxidation of the converter feed; smelting catalyst material in a primary furnace to produce the collector alloy; and/or smelting the converter slag in a secondary furnace with slag from the primary furnace.

Converting process with partial pre-oxidation of PGM collector alloy. The process includes partially pre-oxidizing a raw alloy, introducing an initial charge of the partially pre-oxidized alloy into a converter pot, melting the initial charge, introducing converter feed to the pool, oxygen injection into the pool, tapping the slag, and tapping the PGM-enriched alloy. The collector alloy contains no less than 0.5 wt % PGM, 40 wt % iron, and 0.5 wt % nickel, and no more than 3 wt % sulfur and 3 wt % copper. The process can also include low- or no-flux converting; using a refractory protectant in the converter; magnetic separation of slag; recycling part of the slag to the converter; smelting catalyst material in a primary furnace to produce the collector alloy; and/or smelting the converter slag in a secondary furnace with slag from the primary furnace.

A converter bottom blowing system comprises a first gas source connected in parallel with a lime powder silo, a lime powder blowing tank and a first injector, where a first cut-off valve is arranged between the lime powder blowing tank and the first injector; a second gas source connected in parallel with the biochar powder silo, the biochar powder blowing tank and the second injector, where a second cut-off valve is arranged between the biochar powder blowing tank and the second injector; a converter, where a plurality of bottom blowing lances are arrayed at a bottom of a converter, the bottom blowing lances are connected with the first injector and the second injector through a three-way valve, a third cut-off valve is arranged between the first injector and the three-way valve, and a fourth cut-off valve is arranged between the second injector and the three-way valve.

A material supply apparatus and process for co-injecting heated solid metalliferous material and solid carbonaceous material via a solids injection lance into a direct smelting vessel are disclosed.

A material supply apparatus and process for co-injecting heated solid metalliferous material and solid carbonaceous material via a solids injection lance into a direct smelting vessel are disclosed.

PGM converting process and jacketed rotary converter. The process can include low- or no-flux converting; partial pre-oxidation of PGM collector alloy; using a refractory protectant in the converter; magnetic separation of slag; recycling part of the slag to the converter; smelting catalyst material in a primary furnace to produce the collector alloy; and/or smelting the converter slag in a secondary furnace with slag from the primary furnace. The converter can include an inclined converter pot mounted for rotation; a refractory lining; an opening in a top of the pot to introduce converter feed; a lance for injecting oxygen-containing gas into the alloy pool; a heat transfer jacket adjacent the refractory lining; and a coolant system to circulate a heat transfer medium through the jacket to remove heat from the alloy pool in thermal communication with the refractory lining.