DC Smelting Flexible, sustainable, and cost-efficient The Metso Outotec DC (Direct Current) Smelting Furnace is a cost-efficient, sustainable, and compact solution for ferroalloy processing. It can be used for direct smelting of fine ores, even those with highly variable chemical or mineralogical compositions, as well as for recycling challenging by-products like steel dust. The furnace capacity is custom-designed for your specific application, and can easily be scaled up to meet changing requirements. The flexibility of the Metso Outotec DC Furnace opens up We can provide a complete solution for a wide range of opportunities for exploiting reserves that would have been production capacity requirements, with typical furnace power considered economically unattractive using conventional ranging from 10–45 MW. Our offering includes proprietary Benefits smelting technology. Typical applications include fine technology, process design, and fabrication services, as well • Enables direct smelting of ores chromites, ilmenite, low-grade laterites, and dust generated as supervision, training, and operation and maintenance during steel production, especially stainless steel. services. with fine particle sizes • Accurate process control with Robust, safe, and easy to operate, our DC furnace solutions An experienced technology partner high metal recovery, even with are custom-designed for each individual application. The Metso Outotec has a long history of success in project optimized furnace and feed system layout makes it a highly deliveries. Our vastly experienced personnel and harmonized lower-grade ores cost-efficient solution with a low CAPEX requirement. Cost- project management processes ensure agreed project • Cost-efficient recycling method efficiency is further improved with the possibility to use budgets and schedules are adhered to. Metso Outotec has for challenging by-products cheaper, lower-grade reductants such as anthracite or coal. the test campaign capabilities as well as the supplier and partner network necessary to deliver successful projects, • Cuts operational cost with from studies to complete technology packages and EPC(M) the ability to use low-cost agreements. reductants • Optimized layout and design ensures lower CAPEX and better economies of scale for smaller plant capacities 2 Huge range of potential applications Technical overview Proprietary key equipment One of the biggest benefits of DC smelting technology • Continuous electrical direct current supplied by Because we design and manufacture all the key equipment lies in recycling applications. It can be used to process and transformer and rectifier associated with the Metso Outotec DC Smelting Furnace, we recover valuable metals from materials such as the dust • Graphite electrode forms negative cathode and bottom are also able to supply process guarantees. resulting from the production of steel and other metals. of the furnace the positive anode Traditionally these materials would have ended up in landfill, • Smelting energy supplied by open plasma arc Key equipment includes: but with Metso Outotec DC Smelting they can be processed • Raw material reduced at high temperature with carbon • Metso Outotec Furnace Feed System without any agglomeration. reductant such as anthracite or coal • Metso Outotec Furnace Water-Cooled Shell, Roof, • Alloy sinks to bottom and slag floats at top; these are and Electrode Seal Metso Outotec DC Smelting is suitable for a wide range of tapped intermittently through dedicated tap holes • Metso Outotec Graphite Electrode Equipment commodities and applications, including: • Off-gas – mainly carbon monoxide – is cleaned and • Metso Outotec High-Current Conductors and Flexibles • Ilmenites (Ti) and titaniferous magnetites (Ti, V) can be reused as combustible fuel • Metso Outotec Bottom Anode • Chromites (Cr) • Metso Outotec Venturi Scrubber • Laterites (Ni) • Metso Outotec CO Gas Filter • Steel-plant dusts (Ni, Co, Cr) • Metso Outotec Cogeneration • Slag cleaning (Co, Cu, Ni, V) • Metso Outotec Smelting Plant Control System • Blast furnace slag (Pb and Zn fuming and condensing) • Equipment for selected downstream processes – • Platinum group metal smelting (including Pt and Pd) for example, slag granulation and pig iron casting • Dolomites and magnesites (Mg) We have successfully completed smelting test campaigns with chromite, titanomagnetite, and ilmenite at our Pori Research Center in Finland. Prereduction test campaigns can be carried out in parallel with smelting test campaigns. Combining DC smelting with other Metso Outotec technologies Metso Outotec DC Smelting can be combined, for example, with the Metso Outotec Ferrochrome Process to enable efficient treatment of all side streams. Metso Outotec DC Smelting can also be combined with the Metso Outotec Rotary Kiln for energy-efficient ilmenite smelting, or Metso Outotec Circulating Fluidized Bed technology as part of the modified Metso Outotec Circonickel process for laterite smelting. 3 Metso Outotec is a frontrunner in sustainable technologies, end-to-end solutions and services for the aggregates, minerals processing and metals refining industries globally. By improving our customers’ energy and water efficiency, increasing their productivity, and reducing environmental risks with our product and process expertise, we are the partner for positive change. 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