Process and an apparatus for producing metals and metal alloys

A process for producing iron-containing metals from a metalliferous feed material which includes the steps of partially reducing and at least partially melting the metalliferous feed material in a pre-reduction/melting means and completely reducing the partially reduced feed material in a reduction means, which pre-reduction/melting means is positioned directly above the reduction means and communicates with the reduction means so that at least partially molten, partially reduced feed material flows downwardly into a central region of the reduction means, which reduction means includes a vessel that contains a molten bath having a metal layer and a slag layer on the metal layer, and which process further comprises:

• (a) injecting solid carbonaceous material and carrier gas into a metal rich region of the molten bath via one or more than one lance/tuyere that extend downwardly towards the metal layer, the injection of carbonaceous material and carrier gas causing upward movement of splashes, droplets, and streams of material from the metal layer which:
• (i) promotes mixing of material from the metal layer in the slag layer and mixing of material from the slag layer in the metal layer;
• and
• (ii) extends into a space above the molten bath to form a transition zone;
• (b) injecting an oxygen-containing gas into the vessel and post-combusting part of a reaction gas generated in the molten bath via one or more than one lance/tuyere extending downwardly and inwardly into the vessel and being positioned so as to minimise contact with at least partially molten and partially reduced feed material flowing downwardly from the pre-reduction/melting means;
• (c) allowing at least part of the reaction gas generated in the molten bath to flow upwardly from the reduction means into the pre-reduction/melting means and partially reduce the metalliferous feed material in the pre-reduction/melting means;
• and
• (d) injecting an oxygen-containing gas into the pre-reduction/melting means and post-combusting a part of the reaction gas and thereby generating heat which at least partially melts and partially reduces metalliferous feed material and generates the at least partially molten, partially reduced feed material that flows downwardly into the reduction means;
• and
• whereby steps (b) and (d) post-combust the reaction gas generated in the molten bath to a post-combustion level of at least 70%.