Chinese scientists develop groundbreaking method for rapid iron production

Chinese researchers have introduced an innovative method for producing iron in mere seconds, potentially revolutionizing the steel industry. According to media reports, including the South China Morning Post, this new technique leverages a process known as "flash smelting," historically used primarily in copper production, to achieve remarkable efficiency gains.

The flash smelting process involves introducing finely ground iron ore powder into an extremely hot furnace. A chemical reaction resembling an explosion generates liquid iron droplets, which collect at the base of the furnace and can be immediately utilized for steel production. The entire process takes just 3 to 6 seconds, a dramatic reduction from the traditional production time of 5 to 6 hours.

At the core of this breakthrough is a newly designed spray lance, which precisely injects the ore into the furnace, ensuring an even distribution of the powder and enhancing efficiency. Remarkably, a single blast furnace equipped with just three spray lances could produce over 7 million tons of iron annually. For context, China produced a total of 871 million tons of pig iron in 2023.

One of the most striking aspects of this method is its elimination of coal from the production process. This not only reduces resource consumption but also represents a significant step toward carbon-free steel production. Researchers estimate that this innovation could improve the energy efficiency of China’s steel industry by up to one-third.

The development stems from the work of Zhang Wenhai and his team at the Chinese Academy of Engineering. Research into this technology began in 2002, with a patent filed in 2013. The spray lance technology is reportedly already being used commercially.

While similar approaches have been explored in the United States, Chinese researchers have advanced the method to the point where it can produce liquid iron, a pivotal achievement that could transform global steel production.

Source: Chinese Morning Post, Photo: Fotolia