An improved direct smelting vessel comprising a smelt reduction vessel (SRV) and optionally a cyclone converter furnace (CCF). The SRV provides means for promoting metal mixing at a zone below a slag layer adjacent to a vessel wall of the direct smelting vessel. The means for promoting metal mixing may include a split-level refractory hearth with two refractory floor levels, a refractory hearth with one or more gas bubbling devices, and/or at least one pair of solids injection lances that provide alternating solids injection at any given time (or other means). The means for promoting the metal mixing reduces a stagnant region capable of supporting a semi-solid slag layer that restricts metal-slag heat transfer. The means for promoting the metal mixing maintains an effective temperature delta between tapped metal at a forehearth and metal at the vessel wall of no greater than 40 C.

An improved direct smelting vessel comprising a smelt reduction vessel (SRV) and optionally a cyclone converter furnace (CCF). The SRV provides means for promoting metal mixing at a zone below a slag layer adjacent to a vessel wall of the direct smelting vessel. The means for promoting metal mixing may include a split-level refractory hearth with two refractory floor levels, a refractory hearth with one or more gas bubbling devices, and/or at least one pair of solids injection lances that provide alternating solids injection at any given time (or other means). The means for promoting the metal mixing reduces a stagnant region capable of supporting a semi-solid slag layer that restricts metal-slag heat transfer. The means for promoting the metal mixing maintains an effective temperature delta between tapped metal at a forehearth and metal at the vessel wall of no greater than 40 C.