Abstract: Processes that generate syngas or reformed gas that have the desired H2/CO ratio, such that they can be used directly for producing higher value liquids, such as using a FT GTL process. The systems and methods of the present invention are simpler and more cost effective than conventional systems and methods. The systems and methods of the present invention generate the required CO2 in a reforming furnace by combusting natural gas with a mixture of O2 from an external source and CO2 that is recirculated from a reforming furnace. A second application of the natural gas combustion with external O2 mixed with recirculated CO2 in the reformer burners can be utilized in a DR process. The reformed gas or syngas containing H2 and CO is used to reduce iron oxide to metallic iron in a shaft furnace, for example.

Abstract: The present disclosure provides a Fischer-Tropsch tail gas recycling system, including: a Fischer-Tropsch reactor providing a source of tail gas; a first preheater for preheating the tail gas to between about 200 and 300 degrees C.; a hydrogenator for hydrogenating the tail gas; an expansion device for reducing the pressure of the tail gas to between about 2.5 and 5 bar; a second preheater for preheating a feed gas comprising the tail gas and steam to between about 500 and 600 degrees C.; and a catalytic reformer for reforming the feed gas in the presence of a catalyst, wherein the catalytic reformer operates at about 2 bar and about 1000 degrees C., for example. Optionally, CO2 and/or natural gas are also added to the tail gas and/or steam to form the feed gas.

Abstract: In various exemplary embodiments, the present invention provides systems and methods that can convert clean or raw natural gas, clean or dirty coke oven gas, or the like to reducing gas/syngas suitable for direct reduction with minimal processing or cleaning. Hydrocarbons and the like are converted to H2 and CO. S does not affect the conversion to reducing gas/syngas, but is removed or otherwise cleaned up by the iron bed in the direct reduction shaft furnace. Top gas may be continuously recycled or a once-through approach may be employed.

Abstract: Novel systems and methods are described for reducing iron oxide to metallic iron in an integrated steel mill or the like that has a coke oven and/or an oxygen steelmaking furnace. More specifically, the present invention relates to novel systems and methods for reducing iron oxide to metallic iron using coke oven gas (COG) or COG and basic oxygen furnace gas (BOFG).

Abstract: Processes that generate syngas or reformed gas that have the desired H2/CO ratio, such that they can be used directly for producing higher value liquids, such as using a FT GTL process. The systems and methods of the present invention are simpler and more cost effective than conventional systems and methods. The systems and methods of the present invention generate the required CO2 in a reforming furnace by combusting natural gas with a mixture of O2 from an external source and CO2 that is recirculated from a reforming furnace. A second application of the natural gas combustion with external O2 mixed with recirculated CO2 in the reformer burners can be utilized in a DR process. The reformed gas or syngas containing H2 and CO is used to reduce iron oxide to metallic iron in a shaft furnace, for example.

Abstract: Methods and systems for the production of direct reduced iron, including: removing a top gas from a direct reduction furnace; carbon monoxide shifting the top gas using a carbon monoxide shift reactor to form a carbon monoxide shifted top gas having a reduced carbon monoxide content; adding one of a coal gas, a synthesis gas, and an export gas to at least a portion of the carbon monoxide shifted top gas to form a combined gas; removing carbon dioxide from the combined gas using a carbon dioxide removal unit to form a carbon dioxide lean combined gas; and providing the carbon dioxide lean combined gas to the direct reduction furnace as a reducing gas for producing direct reduced iron after heating to reduction temperature. Optionally, the method includes removing carbon dioxide from the top gas using a carbon dioxide removal unit prior to carbon monoxide shifting the top gas.

Abstract: A process for reducing iron oxide to metallic iron using coke oven gas (COG), including: a direct reduction shaft furnace for providing off gas; a COG source for injecting COG into a reducing gas stream including at least a portion of the off gas; and the direct reduction shaft furnace reducing iron oxide to metallic iron using the reducing gas stream and injected COG. The COG has a temperature of about 1,200 degrees C. or greater upon injection. The COG has a CH4 content of between about 2% and about 13%. Preferably, the COG is reformed COG. Optionally, the COG is fresh hot COG. The COG source includes a partial oxidation system. Optionally, the COG source includes a hot oxygen burner.

Abstract: In various exemplary embodiments, the present invention provides systems and methods that can convert clean or raw natural gas, clean or dirty coke oven gas, or the like to reducing gas/syngas suitable for direct reduction with minimal processing or cleaning. Hydrocarbons and the like are converted to H2 and CO. S does not affect the conversion to reducing gas/syngas, but is removed or otherwise cleaned up by the iron bed in the direct reduction shaft furnace. Top gas may be continuously recycled or a once-through approach may be employed.

Abstract: Novel systems and methods are described for reducing iron oxide to metallic iron in an integrated steel mill or the like that has a coke oven and/or an oxygen steelmaking furnace. More specifically, the present invention relates to novel systems and methods for reducing iron oxide to metallic iron using coke oven gas (COG) or COG and basic oxygen furnace gas (BOFG).

Abstract: Methods and systems for the production of direct reduced iron, including: removing a top gas from a direct reduction furnace; carbon monoxide shifting the top gas using a carbon monoxide shift reactor to form a carbon monoxide shifted top gas having a reduced carbon monoxide content; adding one of a coal gas, a synthesis gas, and an export gas to at least a portion of the carbon monoxide shifted top gas to form a combined gas; removing carbon dioxide from the combined gas using a carbon dioxide removal unit to form a carbon dioxide lean combined gas; and providing the carbon dioxide lean combined gas to the direct reduction furnace as a reducing gas for producing direct reduced iron after heating to reduction temperature. Optionally, the method includes removing carbon dioxide from the top gas using a carbon dioxide removal unit prior to carbon monoxide shifting the top gas.

Abstract: A process for the direct reduction of iron ore when the external source of reductants is one or both of coke oven gas (COG) and basic oxygen furnace gas (BOFG). Carbon dioxide (CO2) is removed from a mixture of shaft furnace off gas, obtained from a conventional direct reduction shaft furnace, and BOFG. This CO2 lean gas is mixed with clean COG, humidified, and heated in an indirect heater. Oxygen (O2) is injected into the heated reducing gas. This hot reducing gas flows to the direct reduction shaft furnace for use. The spent hot reducing gas exits the direct reduction shaft furnace as shaft furnace off gas, produces steam in a waste heat boiler, is cleaned in a cooler scrubber, and is compressed and recycled to join fresh BOFG. A portion of the shaft furnace off gas is sent to the heater burners. The BOFG and COG are also employed for a variety of other purposes in the process.

Abstract: A process for reducing iron oxide to metallic iron using coke oven gas (COG), including: a direct reduction shaft furnace for providing off gas; a COG source for injecting COG into a reducing gas stream including at least a portion of the off gas; and the direct reduction shaft furnace reducing iron oxide to metallic iron using the reducing gas stream and injected COG. The COG has a temperature of about 1,200 degrees C. or greater upon injection. The COG has a CH4 content of between about 2% and about 13%. Preferably, the COG is reformed COG. Optionally, the COG is fresh hot COG. The COG source includes a partial oxidation system. Optionally, the COG source includes a hot oxygen burner.

Abstract: A process for the direct reduction of iron ore when the external source of reductants is one or both of coke oven gas (COG) and basic oxygen furnace gas (BOFG). Carbon dioxide (CO2) is removed from a mixture of shaft furnace off gas, obtained from a conventional direct reduction shaft furnace, and BOFG. This CO2 lean gas is mixed with clean COG, humidified, and heated in an indirect heater. Oxygen (O2) is injected into the heated reducing gas. This hot reducing gas flows to the direct reduction shaft furnace for use. The spent hot reducing gas exits the direct reduction shaft furnace as shaft furnace off gas, produces steam in a waste heat boiler, is cleaned in a cooler scrubber, and is compressed and recycled to join fresh BOFG. A portion of the shaft furnace off gas is sent to the heater burners. The BOFG and COG are also employed for a variety of other purposes in the process.

Abstract: The invention is a method for producing a cast ceramic anode for metal oxide electrolytic reduction by feeding metallic iron and metallic nickel in solid form to an oxidizing reactor; melting and oxidizing the iron and nickel and forming molten nickel ferrite; mixing the molten nickel ferrite with dopant in a holding vessel such as ladle or tundish to increase electrical conductivity of the mixture, and casting the mixture into a mold to form a near net shape of the desired anode. Apparatus for carrying out the method, and the resulting product are also disclosed.

Abstract: An apparatus and method for the direct reduction of iron oxide utilizes a hearth furnace having a vitreous hearth layer of conditioning materials, with the vitreous hearth layer introduced onto a refractory surface of the furnace. The vitreous hearth layer may have upper layers of coating compounds including carbonaceous materials, onto which iron oxide feed material is placed with the carbonaceous materials assisting with segregating the reduced molten iron nuggets from the vitreous hearth layer. The conditioning materials may include compounds such as silicon oxide, magnesium oxide, iron oxides, and aluminum oxide. The conditioning materials are placed in solid or liquid form on the refractory surface, which allows the conditioning materials to raise the melting temperature of the vitreous hearth layer onto which the coating compounds and iron oxide materials are placed.

Abstract: A method for producing a non-carbon inert anode for metal oxide electrolytic reduction by coating a metal, cermet, or ceramic substrate with a molten metal oxide compound of a ferrite and at least one divalent metal selected from iron, nickel, manganese, magnesium, and cobalt. The coated anode is protected from attack by the liberated oxygen and the solute in the electrolysis of metals, such as aluminum, magnesium, lithium, or calcium. Apparatus for carrying out the method, and the resulting product are also disclosed.

Abstract: The invention is a method for producing a cast ceramic anode for metal oxide electrolytic reduction by feeding metallic iron and metallic nickel in solid form to an oxidizing reactor; melting and oxidizing the iron and nickel and forming molten nickel ferrite; mixing the molten nickel ferrite with dopant in a holding vessel such as ladle or tundish to increase electrical conductivity of the mixture, and casting the mixture into a mold to form a near net shape of the desired anode. Apparatus for carrying out the method, and the resulting product are also disclosed.

Abstract: The present invention is an apparatus and method for the direct reduction of iron oxide utilizing a rotary hearth furnace to form a high purity carbon-containing iron metal button. The hearth layer may be a refractory or a vitreous hearth layer of iron oxide, carbon, and silica compounds. Additionally, coating materials may be introduced onto the refractory or vitreous hearth layer before iron oxide ore and carbon materials are added, with the coating materials preventing attack of the molten iron on the hearth layer. The coating materials may include compounds of carbon, iron oxide, silicon oxide, magnesium oxide, and/or aluminum oxide. The coating materials may be placed as a solid or a slurry on the hearth layer and heated, which provides a protective layer onto which the iron oxide ores and carbon materials are placed. The iron oxide is reduced and forms molten globules of high purity iron and residual carbon, which remain separate from the hearth layer.

Abstract: The present invention is an apparatus and method for the direct reduction of iron oxide utilizing a rotary hearth furnace to form a high purity carbon-containing iron metal button. The hearth layer may be a refractory or a vitreous hearth layer of iron oxide, carbon, and silica compounds. Additionally, coating materials may be introduced onto the refractory or vitreous hearth layer before iron oxide ore and carbon materials are added, with the coating materials preventing attack of the molten iron on the hearth layer. The coating materials may include compounds of carbon, iron oxide, silicon oxide, magnesium oxide, and/or aluminum oxide. The coating materials may be placed as a solid or a slurry on the hearth layer and heated, which provides a protective layer onto which the iron oxide ores and carbon materials are placed. The iron oxide is reduced and forms molten globules of high purity iron and residual carbon, which remain separate from the hearth layer.

Abstract: A method for producing solid metal product is disclosed including the steps of providing carbon and metal bearing compounds in compacts, coating the compacts with treatment materials, encapsulating the compacts with carbonaceous containing materials to form a residual layer, and treating the residual layer before introduction of the compacts into a furnace. The compacts contain carbon containing metal bearing compounds, and are coated with mixtures of carbonaceous materials dispersed within a binder material such as a viscous liquid, molasses, alcohol, or fuel oil. The coated compacts are treated to form a hardened outer residual layer. The outer residual layer provides for a sacrificial outer coating on the compacts that reacts with any oxidizing gaseous components within the furnace, while the carbon containing metal bearing compounds within the compacts are heated and metallized inside the compounds.