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At present in the world steel industry a certain number of processes of iron direct reduction created, including liquidphase ones, which make it possible to obtain metal iron directly from ore bypassing blast furnace. However, no one of them enables principally to obtain an iron-carbon alloy with carbon content lower 2%. A jet-emulsion metallurgical process elaborated, differing by low energy consumption, small specific volume of the facility and possibility of metal direct producing with a wide range of carbon content. Application of principles of self-organization theory and of several physical effects enabled to create a process, which has significant advantages comparing with existing metallurgical processes. High rates of physical and chemical processes are reached by creating a large reaction surface and two-phase working mixture (gas suspension or emulsion). Organization of forced motion of the working (reaction) mixture in a closed system under pressure made it possible to create considerable deviation from thermodynamic equilibrium and at the same time to solve the task of internal transportation of reaction products through all the units connected in series/ Creation of dissipative structures, considerably deviated from thermodynamic equilibrium, ensures wide possibilities to control the chemical composition of metal and slag. A technological diagram and a brief description of the jet-emulsion facility (JER). The base of the JER technological scheme make the following units: charge supply system, reactor-oscillator, connecting channel with gas-dynamic self-shutting, refining sediment box, at the same time operating as the first stage of wet gas-cleaning, as well as automated system of scull cooling. The latter enables to ensure viability of the facility, in which high-temperature gas suspension is moving with high speed. Because of high intensity of gas-dynamic processes of aggressive two-phase media taking place in the facility, the protection of all the elements of the facility is made based on circulating scull cooling.

At the large-scale test facility, manufactured at West-Siberian iron and steel plant from 1992 till 2001 40 series of experiments were accomplished, which enabled to confirm trueness of theoretical and designing solutions of jet-emulsion metallurgical process (JER) and to perfect the design of the facility. Several new low-energy intensive technologies were tested experimentally, including a technology of direct reducing of powdered ores and wastes (sludges, oiled scale) without agglomeration, a technology of obtaining manganese alloys from poor powdered ores, a technology division of titanium-magnetite concentrates into iron and conditional titaniferous slag, and a technology of metal direct reduction with simultaneous production of synthesis-gas. It was shown, that application of JER process is particularly effective for processing of poor powdered ores, as well as powdered iron-containing and coal wastes, by direct reduction in one stage without agglomeration. Possible variants of diversification of technological schemes of production considered for integrated steel plants and machine-building plants, creation of mini-mills of complete cycle (ore‒steel). An example of a layout solution for a technology based on JER process in existing building presented. The level of the development enables to design and together with a machine-building plant to construct on “turn-key” base a pilot facility of industrial scale. The advantages of the process mentioned above enable to get a quick pay-back, particularly for situation of processing of powdered wastes and ores.

The principles of creating a self-organizing jet-emulsion reactor (SER) are considered, the role of dissipative structures in solving problems of controlling the metal chemical composition is shown. The technological scheme of the unit is presented, in which it is possible to process pulverized materials with a wide range of changes in chemical composition, including sludge, scale, poor pulverized ores and tailings.

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