Abstract: A gravity feed shaft furnace for direct reduction of iron ores having substantially cylindrical reducing and cooling zones, an inwardly tapering discharge zone of ellipsoidal cross section, an elongated substantially cylindrical member disposed axially within the furnace extending upwardly through the discharge and cooling zones to terminate in the reducing zone, a conical top secured to the elongated member and configured to cause uniform downward solids flow, and means for introducing hot reducing gas and cooling gas into the elongated member. Means are provided for distributing the hot reducing gas into the center of the reducing zone, for distributing the cooling gas into the center of the cooling zone, and for causing part of the cooling gas to cool the hot reducing gas distribution means.

Abstract: A process and apparatus for the gaseous reduction of sized iron ores wherein a steam-hydrocarbon fluid mixture, having a steam:carbon molar ratio ranging from 0.9:1 to 1.8:1, is catalytically reformed to produce a reducing gas mixture containing about 85% to 98% by volume carbon monoxide plus hydrogen, with a hydrogen:carbon monoxide volume ratio of at least 2:1. The reducing gas is transferred directly at elevated temperatures to a shaft furnace for reduction of ores therein, and the spent reducing gas is cleaned, cooled and dried, for use as fuel and/or cooling the reduced ores.