Abstract: A process and apparatus for the production of reformed gases. Natural gas and/or liquid hydrocarbons and oxygen are combusted in a first stage to produce carbon dioxide and water. The products of combustion are conveyed to a second stage. Reforming gas or atomized liquid hydrocarbons and oxygen are injected into the second stage and mixed with the products of combustion to react with the carbon dioxide and water to produce carbon monoxide and hydrogen. The process and apparatus are particularly adapted for use in supplementing the reform gases produced in a Direct Reduced Iron plant wherein iron ore is reduced to iron inside a shaft furnace. The process and apparatus may also be used to provide heated enrichment natural gas or liquid hydrocarbons for use as a source of carbon in the shaft furnace to provide for carburization of the iron. Additionally, the process and apparatus may be used as a process control device for controlling the temperature of the reformed gases flowing to the shaft furnace.

Abstract: An improved method and apparatus for increasing the productivity of a direct reduction process in which iron oxide is reduced to metallized iron by contact with hot reducing gas; comprising the steps of: a) providing a first hot reducing gas consisting essentially of CO and H2; b) providing additional reducing gas by reaction of a gaseous or liquid hydrocarbon fuel with oxygen; c) mixing the first hot reducing gas with the additional reducing gas to form a reducing gas mixture; d) enriching the reducing gas mixture by the addition of a gaseous or liquid hydrocarbon; e) injecting oxygen or oxygen-enriched air into the enriched mixture; and f) introducing the enriched mixture into an associated direct reduction furnace as reducing gas.

Abstract: A process and apparatus for the production of reformed gases. Natural gas and/or liquid hydrocarbons and oxygen are combusted in a first stage to produce carbon dioxide and water. The products of combustion are conveyed to a second stage. Reforming gas or atomized liquid hydrocarbons and oxygen are injected into the second stage and mixed with the products of combustion to react with the carbon dioxide and water to produce carbon monoxide and hydrogen. The process and apparatus are particularly adapted for use in supplementing the reform gases produced in a Direct Reduced Iron plant wherein iron ore is reduced to iron inside a shaft furnace. The process and apparatus may also be used to provide heated enrichment natural gas or liquid hydrocarbons for use as a source of carbon in the shaft furnace to provide for carburization of the iron. Additionally, the process and apparatus may be used as a process control device for controlling the temperature of the reformed gases flowing to the shaft furnace.

Abstract: An improved method and apparatus for increasing the productivity of a direct reduction process in which iron oxide is reduced to metallized iron by contact with hot reducing gas; comprising the steps of: a) providing a first hot reducing gas consisting essentially of CO and H2; b) providing additional reducing gas by reaction of a gaseous or liquid hydrocarbon fuel with oxygen; c) mixing the first hot reducing gas with the additional reducing gas to form a reducing gas mixture; d) enriching the reducing gas mixture by the addition of a gaseous or liquid hydrocarbon; e) injecting oxygen or oxygen-enriched air into the enriched mixture; and f) introducing the enriched mixture into an associated direct reduction furnace as reducing gas.

Abstract: A method of producing a hot, carburized metallized iron product in a generally vertical shaft furnace having an upper reducing zone in which iron oxide reacts with a gaseous reductant, and a lower carbon control and product discharge zone, including: establishing a gravitationally descending iron oxide burden in the furnace; reacting hot gaseous gaseous reductant with the descending burden to form a metallized iron product and a reacted top gas; and injecting a hydrocarbon gas mixture consisting of hot reformed reducing gas and cool natural gas to the product discharge section of the shaft furnace; whereby the carbon content of the metallized iron pellet product is controlled by mixing the reformed gas and natural gas in the proper ratio to balance the endothermic and exothermic reactions within the discharge zone of the furnace.