Abstract: A method for producing an improved charging stock for use in further metallurgical processes including the steps of providing a source of molten metal of known composition, providing a source of solid particulate material of a known composition which is compatible with the molten metal, combining the molten metal source with the solid particulate material source to produce a combined stream and forming the combined stream into a plurality of uniformly sized metal billets for use in further metallurgical processes.

Abstract: A method for producing an improved charging stock for use in further metallurgical processes including the steps of providing a source of molten metal of known composition, providing a source of solid particulate material of a known composition which is compatible with the molten metal, combining the molten metal source with the solid particulate material source to produce a combined stream and forming the combined stream into a plurality of uniformly sized metal billets for use in further metallurgical processes.

Abstract: A separator for use in a direct reduction reactor comprises an elongated tubular housing having a cooling chamber for receiving a cooling medium for cooling the internal wall surface of the separator contacted by metallized iron fines.

Abstract: A method for making iron-alloy briquettes, includes the steps of: providing hot metallized iron particles having a temperature of at least about 650.degree. C. and an initial degree of metallization of at least about 90% (wt.); providing an additive selected from the group consisting of ferroalloy powder, metal-containing ash and mixtures thereof, wherein the additive contains an alloying metal; mixing the iron particles and the additive to provide a mixture of the particles and the additive; and forming the mixture into briquettes containing the alloying metal.

Abstract: A method for reforming reducing gas in a fluidized bed process for reduction of ore in a series of ore reducing reactors, including the steps of: passing ore through a plurality of reducing reactors including a final reactor and at least one upstream reactor; flowing a reducing gas through the final reactor so as to reduce ore in the final reactor whereby a flow of partially spent reducing gas including methane and metallized iron dust exits the final reactor; mixing an oxygen source with the partially spent reducing gas so as to combust a portion of the methane with the oxygen source in the presence of the metallized iron dust and provide a reformed reducing gas; and flowing the reformed reducing gas to the upstream reactor.

Abstract: A method for direct reduction of oxides includes the steps of: providing a reduction zone for direct reduction of oxides and a gas reforming zone communicating with the reduction zone; feeding metal oxides to the reduction zone; feeding a gas mixture comprising methane and an oxygen source to the gas performing zone to provide a reformed gas comprising hydrogen and carbon monoxide; contacting the oxides and the reformed gas in the reduction zone to provide a reduced metal and a top gas; and treating the top gas so as to provide the gas mixture.

Abstract: A shaft furnace for reduction of oxides includes a shaft member having an oxide inlet and defining a pre-heating and pre-reducing zone downstream of the oxide inlet, a reducing zone downstream of the pre-heating and pre-reducing zone a transition zone downstream of the reducing zone, and a discharge zone downstream of the transition zone; and a gas reforming zone associated with the shaft member for reforming a methane-containing gas into a reformed gas and for introducing the reformed gas into the reducing zone whereby oxides in the reducing zone are reduced by the reformed gas.

Abstract: A method for modifying existing direct reduction processes and retrofitting existing direct reduction facilities so as to increase the capacity of the facilities without the need for increasing the capacity of external reformers associated with the existing facilities comprises mixing preheated air with the reformed reducing gas produced in the external reformers and containing said mixture with excess natural gas in a reduction-reaction zone of the direct reduction reactor.

Abstract: A process for converting iron oxide to iron carbide at low pressure includes providing a reforming-reduction-carburizing reactor wherein a feed gas is reformed by contact with the iron oxide materials, the iron oxide material is reduced and thereafter contacted with a carburizing agent so as to carry out the conversion of iron oxide to iron carbide in the reactor.

Abstract: A process for the direct reduction of metal oxides containing iron to obtain a DRI metallized iron product comprises feeding heavy hydrocarbon oil under controlled conditions to a cracking zone upstream of the reduction reactor so as to form a cracked product rich in CH.sub.4 and thereafter feeding said cracked product directly to the reaction zone wherein a reformed reducing gas rich in H.sub.2 and CO is formed and contacted with said iron oxide material thereby effecting reduction of said iron oxide material in the reaction zone.

Abstract: The present invention relates to a process for the production of liquid steel from iron containing metal oxides and, more particularly, a process for the direct production of iron-containing metal oxides wherein the hot discharge of direct reduced iron (DRI or sponge iron) is fed to a melting furnace with the process gases from the direct production furnace for refining the DRI to liquid steel.

Abstract: A process for the direct reduction of iron-containing metal oxides to obtain iron is disclosed in which a reformed reduction gas rich in H.sub.2 and CO and having an oxidation degree in the range of from about 0.30 to about 0.35 is formed and reduction is carried out simultaneously in a single reaction zone of a reduction reactor. The reformed reduction gas is formed using a highly endothermic reaction during which a mixture of heated natural gas, recycled top gas and air, preferably oxygen enriched air, is placed into contact with heated surfaces of DRI metallized iron in the reaction zone. The resulting reformed reducing gas consists essentially of from about 45% to about 48% hydrogen, from about 32% to about 34% carbon monoxide, from about 2% to about 4% carbon dioxide, from about 1% to about 3% methane, from about 14% to about 16% nitrogen and from about 1% to about 3% water vapor.