Patents by Inventor John C. Scarlett
John C. Scarlett has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 4985068Abstract: Energy for melting iron oxide or wustite is supplied by pre-heated natural gas which is combusted with oxygen in gaseous form and the oxygen contained in the preheated feed materials. Such combustion produces carbon monoxide and hydrogen gas, thus the combustion products are carbonizing to molten iron. The carbon monoxide and hydrogen evolved at the surface of the molten metal is post-combusted above the bath to form a mixture of carbon monoxide, carbon dioxide, hydrogen, steam and nitrogen. The heat generated by this post-combustion is sufficient to supply the energy for all chemical reaction requirements as well as to melt the wustite charge or smelt the preheated iron oxide charge.Type: GrantFiled: November 27, 1989Date of Patent: January 15, 1991Assignee: Midrex International BV, Rotterdam, Zurich BranchInventors: Glenn E. Hoffmann, John C. Scarlett
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Patent number: 4685964Abstract: A highly efficient method and apparatus for production of molten iron using coal by coal gasification in a molten iron gasifier-melter. The gasifier-melter is coupled to a direct reduction shaft furnace and utilizes both the gaseous and solid output of the shaft furnace. The process is especially efficient when using non-metallurgical coals.Type: GrantFiled: October 3, 1985Date of Patent: August 11, 1987Assignee: Midrex International B.V. RotterdamInventors: Frank V. Summers, John C. Scarlett, David C. Meissner, Glenn E. Hoffman
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Patent number: 4470581Abstract: Ores which include in combination iron oxide, cobalt oxide and nickel oxide are treated in a continuous shaft reduction furnace to selectively reduce nickel and cobalt to metallized form while leaving the iron oxide in the oxide form. Reacted top gas is recycled and mixed with partially combusted gasified fossil fuel in a combustion chamber to achieve the required concentration of reductants in the reducing gas. The cooling zone operates with a similar concentration of reductants in the cooling gas. Apparatus is also disclosed for carrying out the process.Type: GrantFiled: January 20, 1983Date of Patent: September 11, 1984Assignee: Midrex CorporationInventors: William A. Ahrendt, David C. Meissner, Charles W. Sanzenbacher, John C. Scarlett
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Patent number: 4381939Abstract: Ores which include in combination iron oxide, cobalt oxide and nickel oxide are treated in a continuous shaft reduction furnace to selectively reduce nickel and cobalt to metallized form while leaving the iron oxide in the oxide form. Reacted top gas is recycled and mixed with partially combusted gasified fossil fuel in a combustion chamber to achieve the required concentration of reductants in the reducing gas. The cooling zone operates with a similar concentration of reductants in the cooling gas. Apparatus is also disclosed for carrying out the process.Type: GrantFiled: January 29, 1981Date of Patent: May 3, 1983Assignee: Midrex CorporationInventors: William A. Ahrendt, David C. Meissner, Charles W. Sanzenbacher, John C. Scarlett
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Patent number: 4365789Abstract: A method and apparatus for the direct reduction of iron in a shaft furnace using gas from the gasification of solid fossil fuel, such as coal, in which the fuel gas is desulfurized and upgraded in the shaft furnace and direct reduction of iron oxide is carried out in the same furnace. Clean export fuel can be produced by this method along with direct reduced iron. The apparatus includes means for controlling the temperature of the process gas entering the furnace.Type: GrantFiled: October 5, 1981Date of Patent: December 28, 1982Assignee: Midrex CorporationInventors: John C. Scarlett, Charles W. Sanzenbacher
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Patent number: 4331470Abstract: A method and apparatus for the direct reduction of iron in a shaft furnace using gas from the gasification of solid fossil fuel, such as coal, in which the fuel gas is desulfurized and upgraded in the shaft furnace and direct reduction of iron oxide is carried out in the same furnace. Clean export fuel can be produced by this method along with direct reduced iron. The apparatus includes means for controlling the temperature of the process gas entering the furnace.Type: GrantFiled: September 15, 1980Date of Patent: May 25, 1982Assignee: Midrex CorporationInventors: John C. Scarlett, Charles W. Sanzenbacher
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Patent number: 4316739Abstract: A method and apparatus for producing molten iron in which pulverized coal is gasified with oxygen in an iron melting chamber, iron pellets on an upstanding hearth in the melting chamber are exposed to the gasification heat and melted. Molten iron trickles down from the hearth to a surrounding liquid bath. Off-gases from the chamber are utilized for direct reduction of iron oxide pellets to produce hot reduced iron pellets which are melted in the chamber.Type: GrantFiled: August 25, 1980Date of Patent: February 23, 1982Assignee: Midrex CorporationInventors: Donald Beggs, John C. Scarlett
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Patent number: 4286775Abstract: A method and apparatus for reducing particulate iron oxide and producing molten iron in which coal and oxygen are impinged onto a molten iron bath in a closed vessel to melt the iron and gasify the coal. The hot off gas from the vessel is removed and used as the reductant in a counterflow shaft furnace to reduce iron oxide pellets and/or iron ore in a continuous manner. The hot reduced product from the shaft is discharged directly into the molten iron bath and melted.Type: GrantFiled: September 19, 1980Date of Patent: September 1, 1981Assignee: Midrex CorporationInventors: John C. Scarlett, Charles W. Sanzenbacher
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Patent number: 4270740Abstract: Apparatus for reducing particulate iron oxide and producing molten iron in which coal and oxygen are injected into a molten iron bath to melt the iron, gasify the coal and produce a hot off-gas which is then used as the reductant in a counterflow shaft furnace to reduce iron oxide pellets and/or natural ore in a continuous manner. The hot reduced iron product from the shaft furnace is discharged directly into the molten iron bath from which the molten iron product is discharged.Type: GrantFiled: June 5, 1980Date of Patent: June 2, 1981Assignee: Midrex CorporationInventors: Charles W. Sanzenbacher, John C. Scarlett
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Patent number: 4260412Abstract: A method of producing direct reduced iron with fluid bed coal gasification in which a portion of cooled, recycled gas is used as coolant in the gasification chamber and a second portion of the cleaned recycled gas is heated and mixed with the hot, dust-free gasification gas to form reducing gas for the direct reduction process. Limestone is preferably mixed with the pulverized coal feed to the gasification chamber to desulfurize the gas.Type: GrantFiled: January 16, 1980Date of Patent: April 7, 1981Assignee: Midrex CorporationInventors: Frank V. Summers, David C. Meissner, John C. Scarlett
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Patent number: 4248626Abstract: A method and apparatus for reducing particulate iron oxide and producing molten iron in which coal and oxygen are impinged onto a molten iron bath in a closed vessel to melt the iron and gasify the coal. The hot off gas from the vessel is removed and used as the reductant in a counterflow shaft furnace to reduce iron oxide pellets and/or iron ore in a continuous manner. The hot reduced product from the shaft is discharged directly into the molten iron bath and melted.Type: GrantFiled: July 16, 1979Date of Patent: February 3, 1981Assignee: Midrex CorporationInventors: John C. Scarlett, Charles W. Sanzenbacher
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Patent number: 4238226Abstract: A method and apparatus for reducing particulate iron oxide and producing molten iron in which coal and oxygen are injected into a molten iron bath to melt the iron, gasify the coal and produce a hot off-gas which is then used as the reductant in a counterflow shaft furnace to reduce iron oxide pellets and/or natural ore in a continuous manner. The hot reduced iron product from the shaft furnace is discharged directly into the molten iron bath from which the molten iron product is discharged.Type: GrantFiled: July 16, 1979Date of Patent: December 9, 1980Assignee: Midrex CorporationInventors: Charles W. Sanzenbacher, John C. Scarlett
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Patent number: 4235425Abstract: A method and apparatus for producing molten iron in which pulverized coal is gasified with oxygen in an iron melting chamber, iron pellets on an upstanding hearth in the melting chamber are exposed to the gasification heat and melted. Molten iron trickles down from the hearth to a surrounding liquid bath. Off-gases from the chamber are utilized for direct reduction of iron oxide pellets to produce hot reduced iron pellets which are melted in the chamber.Type: GrantFiled: July 16, 1979Date of Patent: November 25, 1980Assignee: Midrex CorporationInventors: Donald Beggs, John C. Scarlett
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Patent number: 4234169Abstract: Apparatus for the direct reduction of iron and production of fuel gas in which a fossil fuel is gasified to produce a hot gas which is tempered with a carbon dioxide rich gas. The mixture is reacted with carbon to upgrade it in reducing potential and is desulfurized by reaction with lime in a first shaft furnace to form a hot reducing gas. The hot reducing gas is utilized as the reductant in a counterflow shaft reduction furnace, a minor portion of the spent reducing gas is recycled as tempering gas for the gas from the hot gasifier, and the major portion of spent reducing gas becomes a source of fuel gas. The apparatus includes a gasifier, counterflow shaft gas reactor, a shaft type direct reduction furnace and associated equipment.Type: GrantFiled: September 24, 1979Date of Patent: November 18, 1980Assignee: Midrex CorporationInventors: John C. Scarlett, Donald Beggs
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Patent number: 4225340Abstract: A method for the direct reduction of iron in which a fossil fuel is gasified to produce a hot gas which is tempered with a cool spent top gas from a reduction furnace, reacted with carbon to upgrade the hot gas in reducing potential, and desulfurized by reaction with lime in a first shaft furnace to form a hot reducing gas. The hot reducing gas is utilized as the reductant in a counterflow shaft reduction furnace and the spent reducing gas is recycled as tempering gas for the hot gas from the hot gasifier.Type: GrantFiled: June 12, 1979Date of Patent: September 30, 1980Assignee: Midrex CorporationInventors: Donald Beggs, John C. Scarlett
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Patent number: 4205830Abstract: A method and apparatus for the direct reduction of iron in which a fossil fuel is gasified to produce a hot gas which is tempered with a carbon dioxide lean gas. The mixture is reacted with carbon to upgrade it in reducing potential and is desulfurized by reaction with lime in a first shaft furnace to form a hot reducing gas. The hot reducing gas is utilized as the reductant in a counterflow shaft reduction furnace and the spent reducing gas is recycled as tempering gas for the gas from the hot gasifier. The apparatus includes a gasifier, counterflow shaft gas reactor, a shaft type direct reduction furnace and associated equipment.Type: GrantFiled: August 15, 1978Date of Patent: June 3, 1980Assignee: Midrex CorporationInventors: Donald Beggs, Ullrich-Horst Buskies, John C. Scarlett
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Patent number: 4201571Abstract: A method for the direct reduction of iron and production of fuel gas in which a fossil fuel is gasified to produce a hot gas which is tempered with a carbon dioxide rich gas. The mixture is reacted with carbon to upgrade it in reducing potential and is desulfurized by reaction with lime in a first shaft furnace to form a hot reducing gas. The hot reducing gas is utilized as the reductant in a counterflow shaft reduction furnace, a minor portion of the spent reducing gas is recycled as tempering gas for the gas from the hot gasifier, and the major portion of spent reducing gas becomes a source of fuel gas.Type: GrantFiled: December 7, 1978Date of Patent: May 6, 1980Assignee: Midrex CorporationInventors: John C. Scarlett, Donald Beggs