The HIsmelt Process is a direct smelting process involving a coal-injected smelting reactor with the off-gas passing through a circulating fluidised bed in which fine iron ore is pre-reduced and pre-heated. Control of the pre-reduction system would benefit from an on-line measurement of the degree of pre-reduction (PRD). However, the on-line measurements need to be made on hot ore in circumstances where access to representative sample streams is very difficult. An on-line gauge based on the measurement of neutron inelastic scatter gamma-rays has been installed and calibrated at the HIsmelt plant in Kwinana, Western Australia. The gauge uses an 241Am-Be neutron source and a BGO detector inside a water-cooled tube surrounded by hot iron ore. THe gauge monitors the iron, oxygen, carbon and silica contents of the ore based neutron inelastic scatter gamma-rays at 0.85, 6.13, 4.43 and 1.78 MeV respectively. In plant trials at HIsmelt the gauge determined iron, oxygen, carbon, silica and PRD to within 2.2 wt. percent, 0.6 wt. percent, 0.5 wt. percent, 1.0 wt. percent and 0.4 percent respectively. Potential application so this technology in other direct reduction and smelting processes will also be discussed.
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