Smelter: Melting of Direct Reduced Iron

The Smelter, an electric smelting furnace for ironmaking, extends the range of direct reduced iron compatible with various steelmaking routes. As the demand for high-grade iron ore increases, the availability of low-grade ore presents both a challenge and an opportunity. Designed to process direct reduced iron (DRI) made from low-grade iron ore, the Smelter can handle larger proportions of slag with much greater ease than an electric arc furnace. The electric smelting furnace optimizes the use of these resources, significantly reducing carbon emissions through electrification and integrating seamlessly into existing production facilities.

The Smelter is engineered to revolutionize steel production by efficiently utilizing low-grade iron ore in an electric smelting furnace. This technology reduces reliance on traditional blast furnaces, which are significant contributors to CO₂ emissions. The electric smelter melts DRI in a reducing atmosphere, producing hot metal with medium carbon content that can be further processed in the LD converter. By incorporating the Smelter into existing steel plants to process DRI made from low-grade iron ore, producers can achieve a substantial reduction in environmental impact while maintaining production efficiency and high-quality hot metal. Consequently, the Smelter is a pivotal technology in the production of decarbonized green steel.

The modular design of the Smelter enables flexible integration, allowing for the support of blast-furnace-like capacities when multiple Smelters are used, making it a versatile choice for modern steelmaking operations. Its ability to adjust the carbon level of the output material ensures compatibility with various production processes, further enhancing its appeal to steel producers. Moreover, the resulting slag from the Smelter is comparable to that of the blast furnace, containing low levels of iron oxides. This slag supports the circular economy by being reused in cement production.

Benefits of the Smelter

• Reduced carbon emissions: achieves significant reductions in CO₂ emissions, supporting the transition to a low-carbon steel industry.
• Cost-effective production: utilizes low-grade iron ore, recycling of by-products, reducing raw material costs and enhancing profitability.
• Seamless integration: easily integrates with existing steel production facilities, minimizing disruption and maximizing efficiency.
• High flexibility: It adapts to various input materials and production requirements, offering a tailored solution for steel producers.
• Environmental sustainability: reduces slag waste and supports the circular economy by producing reusable slag for the cement industry.
• Scalable design: Modular configuration enables scalable production capacity, meeting the demands of growing steel markets.