Novel process for the smelting of a metalliferous feedstock material yielding reduced carbon emissions

A process for the smelting of a metalliferous-containing feedstock material, the process comprising the steps of:

• (i) feeding a metalliferous-containing feedstock material, reductant and fluxes into an Open Bath Furnace (OBF) by peripheral to sidewall or peripheral to electrode feeding of the metalliferous-containing feedstock material, wherein the OBF can be operated in open arc mode (short open and long open arc-controlled mode), brushed arc mode, and immersed arc mode wherein at least one pile arrangement is formed during peripheral to sidewall feeding;
• (ii) heating the metalliferous-containing feedstock material in the OBF at a temperature of between 1 400° C. to 1 800° C. to sufficiently smelt the metalliferous-containing feedstock material to form a liquid metal product, a liquid slag product and a CO-containing gas;
• (iii) carburizing the metal product by introducing a source of carbon into the OBF using pneumatic carbon injection into the metal product, wherein the pneumatic injection not only enhances carburization of the metal product but also improves the heat transfer from the slag product to the metal product;
• and
• (iv) ensuring the continuous feeding of the metalliferous-containing feedstock material, reductant and fluxes into the OBF to preserve the at least one pile arrangement formed during peripheral to sidewall feeding;
• wherein the liquid metal product has a carbon content of above 4.0% (m/m %) and a silicon content of below 1.5% (m/m %).