A groundbreaking new iron-making technology developed by Chinese researchers is poised to revolutionize the global steel industry. This innovative method, perfected after more than a decade of intensive research, promises to significantly enhance efficiency, reduce environmental impact, and reshape the landscape of steel production.

The flash iron-making process, detailed in a recent research publication in the journal Nonferrous Metals, drastically accelerates the traditional iron-making process. While conventional blast furnaces take five to six hours to produce iron, this revolutionary technique achieves the same result in a mere three to six seconds. This represents a staggering 3,600-fold increase in speed.

The core of this technology involves injecting finely ground iron ore powder into a superheated furnace, triggering a rapid and intense chemical reaction. This reaction results in the formation of high-purity liquid iron, which accumulates at the furnace's base, ready for direct casting or further processing into steel.

China, a global steel powerhouse, heavily relies on high-grade iron ore imports from Australia, Brazil, and Africa. The new flash iron-making process offers a significant advantage by enabling the efficient utilization of low- and medium-grade ores, which are abundant within the country.

Beyond efficiency gains, this technology holds the potential to revolutionize the environmental impact of steel production. By eliminating the need for coal-based coke, a primary source of greenhouse gas emissions in traditional ironmaking, the new process paves the way for a more sustainable steel industry. Chinese researchers estimate that this innovation could reduce energy consumption by over one-third and significantly lower carbon dioxide emissions.

One of the key challenges in developing flash iron-making technology lies in the design of the ore-spraying lance. This critical component must effectively disperse iron ore particles within the high-temperature furnace to initiate the desired chemical reaction.

Zhang Wenhai's team has successfully addressed this challenge by developing a vortex lance capable of injecting a substantial 450 tonnes of iron ore particles per hour. A reactor equipped with three such lances can produce a substantial 7.11 million tonnes of iron annually. Importantly, this innovative lance technology has already entered commercial production.

While the concept of flash ironmaking originated in the United States, it was the Chinese research team that pioneered the development of a technology capable of directly producing liquid iron. After securing a patent in 2013, the team dedicated the subsequent decade to refining the process. Rigorous laboratory and pilot tests have confirmed the feasibility of this revolutionary approach.

Given China's track record of successfully commercializing pilot-tested technologies, the global steel industry eagerly anticipates the widespread adoption of flash ironmaking. This breakthrough innovation has the potential to reshape the future of steel production, driving efficiency, sustainability, and global economic growth.