A process for direct reduction of iron ore in a solid state includes exposing briquettes of iron ore fragments and biomass to electromagnetic energy under anoxic conditions and generating heat within iron ore in the briquettes. The iron ore is reduced in a solid state within the briquettes, and the biomass provides a source of reductant.

A method for the production of cast iron starting from pre-reduced iron ore (DRI) with an electric arc furnace includes the steps of preparing a charge of pre-reduced iron ore DRI having a metallization higher than 90% and containing over 2.8% by weight of carbon, wherein at least 80% of the carbon is combined with the iron to form iron carbide Fe.sub.3C; charging the charge of pre-reduced iron ore into the electric arc furnace; and melting the DRI charge to form liquid cast iron having at least 80% by weight of actual carbon content deriving from the carbon in the charge of pre-reduced iron ore, the melting step being in a reducing atmosphere and in a melting chamber of the electric arc furnace subjected to a positive internal pressure generated by the gases produced by reduction reactions that develop during melting.

A method for the production of cast iron starting from pre-reduced iron ore (DRI) with an electric arc furnace includes the steps of preparing a charge of pre-reduced iron ore DRI having a metallization higher than 90% and containing over 2.8% by weight of carbon, wherein at least 80% of the carbon is combined with the iron to form iron carbide Fe.sub.3C; charging the charge of pre-reduced iron ore into the electric arc furnace; and melting the DRI charge to form liquid cast iron having at least 80% by weight of actual carbon content deriving from the carbon in the charge of pre-reduced iron ore, the melting step being in a reducing atmosphere and in a melting chamber of the electric arc furnace subjected to a positive internal pressure generated by the gases produced by reduction reactions that develop during melting.

A flash ironmaking drop tube furnace includes a primary reaction section having a refractory, an induction coil around the refractory, insulation located between the refractory and the induction coil, and a susceptor located inside the refractory, the susceptor being formed of a material that is heated by induction when electrical current flows through the induction coil, and having at least one interior channel through which particles can pass. The furnace further includes a muffle, located below the primary reaction section; an outer shell surrounding the muffle; at least one heater located adjacent to the muffle; insulation located between the at least one heater and the outer shell; at least one particle feeder that feeds a predetermined volume of particles into the furnace above the primary reaction section; and an inlet port for injecting gas into the furnace, the inlet port being located so that the gas flows through the susceptor and muffle in parallel with the particles.

The present invention relates to a process for the smelting of a metalliferous feedstock material. The process includes the steps of: (i) feeding an agglomerate comprising of a fine metalliferous feedstock material and a fine reductant to a reactor, the agglomerate forming a packed bed within the reactor; (ii) smelting the agglomerate by passing a hot reducing gas counter current through the packed bed to form a molten material comprising a partially reduced metalliferous constituent, an intermediate slag constituent and entrained unreacted reductant constituent; and (iii) channelling the molten material to flow into a vessel to form a metal product and a slag product.

A metallurgical furnace including a vessel with a lower shell for containing a metal bath, the metal bath composed of molten metal and an overlying layer of slag. The lower shell is tiltingly supported and provided with a deslagging opening for evacuating the slag and a tapping opening for tapping the molten metal. The vessel includes an upper shell removably positioned on the lower shell and first and second inlet openings for feeding. The vessel includes a closing roof for the upper closing of the vessel removably positioned on the upper shell and a passage opening for the passage, through the same, of at least one electrode, at least one charge opening for feeding, through the same, charge material in the solid state. At least one of the inlet openings, passage opening, and charge opening is closed or associated with a closing element.

A metallurgical furnace including a vessel with a lower shell for containing a metal bath, the metal bath composed of molten metal and an overlying layer of slag. The lower shell is tiltingly supported and provided with a deslagging opening for evacuating the slag and a tapping opening for tapping the molten metal. The vessel includes an upper shell removably positioned on the lower shell and first and second inlet openings for feeding. The vessel includes a closing roof for the upper closing of the vessel removably positioned on the upper shell and a passage opening for the passage, through the same, of at least one electrode, at least one charge opening for feeding, through the same, charge material in the solid state. At least one of the inlet openings, passage opening, and charge opening is closed or associated with a closing element.

An electrolytic smelting system includes: an electrolytic smelting furnace including a furnace body to which a molten ore is introduced, a cathode substrate which is installed on a bottom portion in the furnace body, and an anode substrate which is positioned above the cathode substrate in the furnace body; an inert gas circulation unit including a circulation line to recover an inert gas supplied into the electrolytic smelting furnace together with oxygen and supply the inert gas to the molten ore; and an oxygen-removing unit which is installed in the circulation line and which removes oxygen from the circulation line.

An electrolytic smelting system includes: an electrolytic smelting furnace including a furnace body to which a molten ore is introduced, a cathode substrate which is installed on a bottom portion in the furnace body, and an anode substrate which is positioned above the cathode substrate in the furnace body; an inert gas circulation unit including a circulation line to recover an inert gas supplied into the electrolytic smelting furnace together with oxygen and supply the inert gas to the molten ore; and an oxygen-removing unit which is installed in the circulation line and which removes oxygen from the circulation line.

A method for the production of cast iron starting from pre-reduced iron ore (DRI) with an electric arc furnace includes the steps of preparing a charge of pre-reduced iron ore DRI having a metallization higher than 90% and containing over 2.8% by weight of carbon, wherein at least 80% of the carbon is combined with the iron to form iron carbide Fe.sub.3C; charging the charge of pre-reduced iron ore into the electric arc furnace; and melting the DRI charge to form liquid cast iron having at least 80% by weight of actual carbon content deriving from the carbon in the charge of pre-reduced iron ore, the melting step being in a reducing atmosphere and in a melting chamber of the electric arc furnace subjected to a positive internal pressure generated by the gases produced by reduction reactions that develop during melting.