01
Prepare the green pellet
Iron ore fines, reductant, flux and a small binder addition are mixed and agglomerated. No separate oxidative induration plant is required.
Feedstock-flexible ironmaking
Turn non-DR-grade
iron ore into hot metal.
Flash-SR Fusion combines carbon-composite green pellets, rapid solid-state reduction and electric smelting—without depending on fired DR-grade pellets.
Green pellets
High metallization
Electric melt separation
01
The industry constraint
A reduction route should fit the ore.
Not the other way around.
Gas-based shaft furnaces perform best with strong, low-gangue DR-grade pellets. Many deposits cannot reach that specification without deep beneficiation and high-temperature pellet induration.
Flash-SR Fusion changes the sequence: prepare a low-cost carbon-composite green pellet, remove most oxygen in the solid state, then melt and separate the gangue electrically.
Higher FeHigher gangue / more complex
DR-grade concentrate
Standard 60–65% fines
Selected iron-bearing residues
One platform. Different operating recipes. Product quality is engineered through feed blending, reduction control and smelter practice.
The process
Reduction first.
Separation second.
Each stage has one clear metallurgical job.
02
Flash-SR internal reduction
Carbon sits next to iron oxide inside every pellet. A thin, continuously moving bed enables fast heat transfer, controlled post-combustion and high metallization.
03
Hot transfer
High-metallization DRI is delivered hot to the smelter, preserving sensible heat and limiting the electrical burden of final reduction.
04
Fusion Smelter
Electric smelting completes reduction, carburises the iron and separates metal from slag under a strongly reducing furnace practice.
05
Hot metal, ready for the next shop
Liquid iron can be desulfurised and hot-charged to a local steel plant, or cast when logistics require a solid merchant product.
02
Why it works
Feedstock flexibility
without accepting a low product ceiling.
Green, not fired
Composite pellets are dried and reduced directly. The route does not carry the capital and fuel burden of producing premium fired oxide pellets.
No shaft permeability constraint
The reduction bed is shallow. Feed preparation can be optimised for reaction and handling instead of surviving a tall counter-current shaft.
Oxygen removed before melting
Most reduction work is completed before the electric furnace, improving the control of final reduction, slag FeO and iron recovery.
Premium feed still pays
Higher-grade feed translates into less slag, lower smelting energy and cleaner iron. Flexibility expands the lower bound—it does not cap the upper one.
Place the work where it performs best
Three routes.
Three different constraints.
Route
Primary feed condition
Where final reduction happens
Where gangue is separated
Shaft furnace DRIGas–solid counter-current bed
Typically premium fired pellets or qualified lump
Inside the shaft
Downstream meltshop
Bath smeltingFine-feed injection
Prepared fines suitable for stable injection
Predominantly in the molten bath
Inside the smelting vessel
Flash-SR FusionInternal reduction + electric smelting
Carbon-composite green pellets from a broad range of fines
Mostly in Flash-SR; completed in the smelter
Fusion Smelter slag–metal separation
Technical note: the economic feed envelope remains project-specific. Phosphorus, copper, arsenic, tin, zinc, alkalis, gangue chemistry and power price must be assessed before route selection.
Engineered as a complete system
Not a furnace in isolation.
Feed preparation, reduction atmosphere, hot transfer, electric finishing, slag practice and heat recovery are designed as one material and energy system.
- Reduction
- Carbon–oxygen balance by ore
- Smelting
- Metallization matched to electricity price
- Product
- Chemistry matched to the downstream shop
- Energy
- Off-gas and sensible heat recovered in-process
03
Project design bases
Four engineering studies across different feedstocks.
Mineralogy, gangue content, energy prices and plant configuration all affect hot-metal chemistry and production cost. Project identities remain confidential.
Project 01
Direct-shipping hematite fines with EAF hot-metal delivery
A single-line design using 62% Fe hematite fines, imported reductant and high-temperature hot-metal transfer after KR desulfurization.
- Feed
- 62% Fe hematite fines
- Flash-SR
- 91.6% metallization
- Hot metal
- Fe 97.05% · C 2.09% · Si 0.86%
- Product route
- ≥1,450°C EAF hot charge
- Output
- 0.373 Mtpa hot metal
- Modeled full cost
- USD 264/t hot metal
Project 02
Low-cost power applied to local iron concentrate
A single-line design using local 62% Fe concentrate and low-cost electricity, with hot metal supplied to an EAF and a pig-iron standby route.
- Feed
- 62% Fe local concentrate
- Flash-SR
- ~90% metallization
- Hot metal
- Fe 97.97% · C 1.52% · Si 0.51%
- Product route
- EAF hot charge
- Output
- 0.353 Mtpa hot metal
- Modeled full cost
- USD 206/t hot metal
Project 03
Dual-line scale-up with EAF integration
Two independent reduction and smelting trains share feed preparation and heat recovery, providing a larger production base for an adjacent EAF meltshop.
- Feed
- 62% TFe magnetite concentrate
- Flash-SR
- ~90% metallization
- Hot metal
- Fe 97.66% · C 1.72% · Si 0.63%
- Product route
- ~1,500°C EAF hot charge
- Output
- 0.701 Mtpa hot metal
- Modeled full cost
- USD 285/t hot metal
Project 04
Low-grade hematite to pig iron
A single-line design based on 40% TFe hematite. The high gangue load changes the slag balance and shifts the appropriate final product from EAF hot metal to pig iron.
- Feed
- 40% TFe hematite ore
- Hot DRI
- 43.5% TFe · 90% metallization
- Hot metal
- Fe 94.18% · C 3.62% · Si 2.19%
- Product route
- Pig iron
- Output
- 0.238 Mtpa hot metal
- Modeled full cost
- USD 257/t hot metal*
Cost comparison requires normalization.
Modeled full costs are project-specific 2026 feasibility-study estimates in USD per metric tonne of hot metal. For consistent presentation, study-base CNY values are converted at CNY 7.20 = USD 1 and rounded to the nearest dollar. They reflect each study's ore, reductant, energy, labor, depreciation, finance and other assumptions; they are not quotations or performance guarantees. *Project 04 uses a base-case smelting-energy assumption that requires pilot-scale confirmation because of its high gangue load.
Start with the ore
Is Flash-SR Fusion a fit for your resource?
A preliminary assessment starts with the chemical analysis, mineralogy, particle-size distribution, local reductant, power price and intended iron product.
TFe / FeOSiO₂ + Al₂O₃P / SZn / Pb / alkalisParticle sizePower + reductant price
Request a preliminary assessment
The company
Nanjing Xingdong Environmental Technology Co., Ltd.
We develop resource-flexible ironmaking solutions around feed preparation, Flash-SR reduction, Fusion Smelter integration, heat recovery and complete project engineering.
zhaojjiie@gmail.com