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A Novel Flash Ironmaking Process
The novel, high-intensity flash ironmaking process is a viable alternative that uses iron ore concentrates that are plentiful in the United States. The process would use inexpensive, abundant natural gas (or hydrogen) to both heat the ore in the furnace and to remove oxygen, converting the ore to iron metal. Although similar to Direct Reduced Iron, this advance would process fine powder ore, eliminating the briquetting process. The product could be added to Electric Arc Furnaces or Basic Oxygen Furnaces for cleaner steelmaking.
A major advantage of flash ironmaking over powder-based processes that use shaft or fluidized-bed furnaces is the elimination of sticking and particle fusion at high temperatures. The ability to use ore fines provides a cost advantage over processes that require ore to be agglomerated into pellets for ironmaking. The fine particles also cut the furnace’s processing time to seconds. This translates to a smaller system for the same output, reducing both capital costs and operating costs. Other potential benefits include improved refractory life, and ease of feeding raw materials into the vessel.