Abstract: A method for off-gas composition control, wherein the off-gas results from a smelting apparatus for smelting a metalliferous feed material, wherein the smelting apparatus includes a smelting vessel, a smelt cyclone mounted on the smelting vessel and in connection with the inside of the smelting vessel and an off-gas duct connected to the smelt cyclone, wherein the method provides that an oxygen containing gas containing 95% oxygen or more is injected into the smelt cyclone and that the feed material is injected into the smelt cyclone with a carrier gas other than nitrogen gas.

Abstract: A classified reduction gasification iron smelting process of iron ore powder and coal powder in a Y-type entrained flow bed. The process comprises the following steps: uniformly mixing the pre-reduced hot iron ore powder with the coal powder, and introducing the mixture, a gasification agent and water vapor into a Y-type entrained flow bed for performing combustion, gasification and reduction reaction to obtain crude syngas and molten iron; the crude syngas is used for sucking iron ore powder to enter a riser to perform preheating and partial reduction.

Abstract: A molten bath-based direct smelting process comprises controlling the process conditions in a direct smelting vessel so that molten slag in a molten bath of metal and slag in the vessel has a viscosity in a range of 0.5-5 poise when the slag temperature is in a range of 1400-1550° C. in the molten bath in the vessel.

Abstract: A molten bath-based direct smelting process includes controlling the process conditions in a direct smelting vessel so that molten slag in a molten bath of metal and slag in the vessel has a viscosity in a range of 0.5-5 poise in an operating temperature range for the process.

Abstract: In a method for gas treatment of coal wherein coal (1, 2) is loaded on a moving mesh conveyor (111, 112) having a quadrilateral mesh and heated gas (11, 12) is circulated from above and below so as to bring the heated gas (11, 12) into contact with the coal (1, 2) via the mesh of the mesh conveyor (111, 112), two layers of coal for lower level stacking (1A, 2A) having a diameter (Dl) that is greater than twice the length (Lss) of the short side of the mesh of the mesh conveyor (111, 112) are loaded on the mesh of the mesh conveyor (111, 112) and coal for upper level stacking (1B, 2B) having a diameter (Du) that is twice said length (Lss) or less is loaded on the coal for lower level stacking (1A, 2A).

Abstract: An apparatus for manufacturing molten iron includes i) at least one fluidized-bed reduction reactor that converts iron ore into reduced materials by reducing and plasticizing the iron ore, ii) a melter-gasifier into which the reduced materials are charged and oxygen is injected such that the melter-gasifier manufactures molten iron, and iii) a reducing gas supply line that supplies a reducing gas discharged from the melter-gasifier into the fluidized-bed reduction reactor. The fluidized-bed reduction reactor includes a gas injector that injects a gas into the fluidized-bed reduction reactor to remove stagnating layers.

Abstract: An apparatus for manufacturing molten iron includes i) at least one fluidized-bed reduction reactor that reduces and plasticizes iron ore and converts the iron ore into reduced materials, ii) a melter-gasifier into which the reduced ore is charged and oxygen is injected, the melter-gasifier manufacturing molten iron, and iii) a reducing gas supply line that supplies a reducing gas discharged from the melter-gasifier to the fluidized-bed reduction reactor. The fluidized-bed reduction reactor includes a cyclone that is installed in the fluidized-bed reduction reactor to collect fine iron ore. A gas injector, which prevents the fine ore from adhering by injecting gas containing carbon, is connected to the cyclone.

Abstract: A direct reduction process for a solid metalliferous material having a particle size distribution that at least in part contains micron sized particles includes supplying the metalliferous material, a solid carbonaceous material, an oxygen-containing gas, and a fluidizing gas into a fluidized bed in a vessel and maintaining the fluidized bed in the vessel, at least partially reducing metalliferous material in the vessel, and discharging a product stream that comprises the partially reduced metalliferous material from the vessel. The process includes (a) establishing and maintaining a carbon-rich zone within the fluidized bed; (b) passing metalliferous material, including metallized material (which term includes partially metallized material), through the carbon-rich zone; and (c) injecting the oxygen-containing gas into the carbon-rich zone and oxidizing metallized material, solid carbonaceous material and other oxidizable solids and gases and causing controlled agglomeration of particles.

Abstract: The present invention is directed to additives for coal-fired furnaces, particularly furnaces using a layer of slag to capture coal particles for combustion. The additive(s) include iron, mineralizer(s), handling aid(s), flow aid(s), and/or abrasive material(s). The iron and mineralizers can lower the melting temperature of ash in low-iron, high alkali coals, leading to improved furnace performance.

Abstract: In a method for producing liquid pig iron (9) or steel pre-products from fine-particulate iron-containing material (4) in a melter gasifier (1), the iron-containing material (4) is melted in a bed of solid carbon carriers (2) under supply of carbon-containing material (2) and oxygen-containing gas, at the simultaneous formation of a reducing gas, wherein the fine-particulate reduced material (4) and oxygen are introduced into the bed (20, 21) from the side.

Abstract: A process and an apparatus for producing metals from a metalliferous feed material are disclosed. The process includes the steps of partially reducing and at least partially melting a metalliferous feed material in a pre-reduction/melting means and completely reducing the partially reduced feed material in a reduction means. The pre-reduction/melting means is positioned directly above the reduction means and communicates with the reduction means so that at least partially molten, partially reduced feed material flows downwardly into a central region of the reduction means. The reduction means includes a vessel that contains a molten bath having a metal layer and a slag layer on the metal layer. The process includes injecting oxygen-containing gas into the reduction means and post-combusting reaction gas generated in the molten bath and injecting oxygen-containing gas into the pre-reduction/melting means and post-combusting reaction gas discharged from the reduction means.

Abstract: The invention relates to a method for processing steel slags and iron carriers such as, e.g., electric furnace slags, converter slags, fine ores, dusts from the production of steel and millscale, for recovering pig iron and environmentally safe slags. A molten slag bath and a molten iron bath are used at a volume ratio of between 0.5:1 and 1.5:1 and carbon carriers are introduced into the bath and hot air is top-blown. From the starting slags and iron carriers, a mixed slag having a basicity CaO/SiO2 of between 1.2 and 2.

Abstract: A process is described for direct production of cast iron starting from iron bearing ore in an apparatus having two communicating chambers in which to carry out the process, comprising the following operations: pre-reduction and pre-heating to founding point of the iron bearing ore in a first substantially cylindrical chamber; final reduction, carburization and founding of the resulting iron in a second chamber arranged below said first chamber, in which coal and oxygen, injected into said second chamber, provide the reducing gas both in said second and in said first chamber, characterized by the fact that: said iron bearing ore and oxygen are introduced into said first chamber through the side walls thereof, simultaneously but separately, the oxygen being introduced at a speed lower or equal to the speed of introduction of said iron bearing ore; and said oxygen, coal and flux are introduced into said second chamber simultaneously but separately through the side walls thereof and in a manner inclined downward

Abstract: In a process for working up steel slags and iron carriers such as, e.g., electric furnace slags, converter slags, fine ores, dusts from steel production, mill scales for obtaining pig iron and environmentally safe slags, the volume ratio of molten slag to iron bath is chosen to be larger than 0.5 to 1 and, preferably, 0.8:1 to 1.5:1 and the slags are supplemented with SiO2 carriers such as, e.g., foundry sands, metallurgical sands and/or fine ores so as to adjust a slag basicity (CaO/SiO2) of between 1.0 and 1.8 and, preferably, 1.2 and 1.8 at an Al2O3 content of between 10 and 25% by weight, based on the slag. In doing so, hot blast is top-blown and coal, optionally along with an inert gas and, in particular, nitrogen and, furthermore, optionally oxygen or hot air is blown through the iron bath.

Abstract: A method of reducing the iron content of starting material containing calcium, silicon and oxygen, and iron in the form of a ferrite and/or oxide, for example a steel slag, includes the steps of heating the starting material to a temperature of at least 800° C. and preferably between 900° C. and 1150° C. inclusive, in the presence of a reductant such as carbon monoxide and in the presence of a siliceous material with which non-ferrous oxides released during the reduction form high melting point compounds, to produce a magnetic form of iron, and removing at least some of the magnetic form of iron to produce a product, which may be used as a raw material in the cement industry.

Abstract: Method for controlling a smelting reduction process, in particular a cyclone converter furnace process for producing pig iron, characterized in that one: measures the carbon fraction C in the off-gas in the form of CO and Co2O; measures the hydrogen fraction H2 in the off-gas in the form of H2 and H2O; determines the C/H2 ratio in the off-gas; compares the C/H2 ratio thus determined in the off-gas against the C/H2 ratio prevailing for the coal being supplied, and adjusts the coal supply based on the difference found in the C/H2 ratios in the off-gas and the coal being supplied.

Abstract: An apparatus for manufacturing molten iron by using a calcination furnace, and a manufacturing method therefor are disclosed. A high temperature reducing gas (1000 to 1100° C.) from a melter gasifier is used as a calcination heat in a calcination furnace so as to cool the high temperature reducing gas to the optimum reduction temperature (800 to 850° C.), and so as to supply the cooled reducing gas to a shaft furnace, whereby the manufacture of the molten iron can be efficiently carried out, and a high thermal efficiency is realized even without a separate gas cooling device. Therefore, a separate cooling device for cooling the hot reducing gas of the melter gasifier is not required. Further, the hot reducing gas is naturally cooled at the calcination furnace, and therefore, the thermal efficiency of the hot reducing gas of the melter gasifier is maximized. Further, a separate water-using cooler and a separate compressor are omitted, and therefore, the molten iron manufacturing facility is simplified.

Abstract: Iron ore is reduced to molten iron by introducing the ore into a reactor while combusting coal with pure oxygen in the reactor. The molten iron phase, which forms at the bottom of the reactor, is stirred by injecting carbon monoxide into the molten iron. In a preferred embodiment, finely pulverized iron ore is injected with pure oxygen tangentially into a cyclone section of the furnace situated on top of a converter section, thereby causing melting and preliminary reduction of the ore to take place in the cyclone section. Primary reduction of the iron oxide occurs in the converter section of the furnace.

Abstract: A method of smelting iron ore in which iron oxide and hot char are introduced into a primary reactor to reduce the iron oxide and thereby form a molten pool of elemental iron and iron oxide slag. A carbon containing substance, comprising fixed carbon and a hydrocarbon containing volatile matter, is introduced into a secondary reactor. The hydrocarbon containing volatile matter is partially oxidized within the secondary reactor to produce the hot char and a fuel gas comprising hydrocarbons, carbon monoxide, carbon dioxide, steam, and hydrogen with a CO2:CO molar ratio greater than about 0.25. The fuel gas is burned within the primary reactor so that a projected flame is produced and the projected flame is directed into the iron oxide slag of the molten pool.

Abstract: A process is described for direct production of cast iron starting from iron bearing ore in an apparatus having two communicating chambers in which to carry out the process, comprising the following operations: pre-reduction and pre-heating to founding point of the iron bearing ore in a first substantially cylindrical chamber; final reduction, carburization and founding of the resulting iron in a second chamber arranged below said first chamber, provide the reducing gas both in said second and in said first chamber, provide the reducing gas both in said second and in said first chamber, characterized by the fact that: said iron bearing ore and oxygen are introduced into said first chamber through the side walls thereof, simultaneously but separating, the oxygen being introduced at a speed lower or equal to the speed of introduction of said iron bearing ore; and said oxygen, coal and flux are introduced into said second chamber simultaneously but separately through the side walls thereof and in a manner inclin

Abstract: A method for injecting fine iron ore in a smelting reducing process is disclosed, in which the carrier gas for the iron ore is the discharge gas from a melter gasifier without the need of separate carrier gas. It includes the steps of pre-reducing iron ore in a pre-reduction furnace, melting and reducing it in the melter gasifier, supplying the discharge gas from the melter gasifier through an ascending tube to a cyclone and to said pre-reduction furnace, directing the cooled and cleaned fine iron ore through a recycling system and a melting burner into the melter gasifier. A part of the discharge gas is supplied through a venturi scrubber, a first compressor and a circulating tube into an ascending tube. A part of the compressed gas circulating through the tube is recompressed by means of a second compressor and fine iron ore from a stored source is injected into ascending the tube by the recompressed gas by means of a pneumatic fine iron ore conveying system.

Abstract: A process for producing molten pig iron uses direct reduction of iron ore in a pre-reduction stage followed by a final reduction stage.In the pre-reduction stage iron ore is pre-reduced in a melting cyclone by means of a reducing process gas originating from the final reduction stage. A post-combustion occurs in the reducing process gas in the melting cyclone so that said iron ore in said melting cyclone is at least partly melted. The partly melted iron ore passes downwardly into a metallurgical vessel situated beneath the cyclone in which the final reduction takes place by supply of coal and oxygen, thereby forming a reducing process gas. A partial post-combustion occurs in the reducing process gas in the metallurgical vessel by means of said oxygen supplied thereto. The post-combustion ratio of the gas on exiting the metallurgical vessel is not more than 0.55.

Abstract: Apparatus for producing molten pig iron by direct reduction of iron ore, comprises(i) a metallurgical vessel, in which with supply of coal and oxygen the iron ore undergoes a final reduction with production of a process gas and said process gas undergoes a partial post-combustion, and(ii) a melting cyclone in which the iron ore undergoes a pre-reduction and is melted. To improve the control of the thermal flows and to reduce maintenance, the vessel has(a) a top part, in which the partial post-combustion of said process gas takes place, in the form of a pressure-resistant hood having an interior wall comprising cooling water pipes, and(b) a bottom part for accommodating an iron bath having a slag layer in which said final reduction of said iron ore takes place, the bottom part having an internal refractory lining and means for water cooling the internal refractory lining.

Abstract: A method and apparatus for production of iron from iron compounds is provided. There is a first stage of pre-reducing the iron compounds in a first chamber having a rotationally symmetrical wall, and a second stage of further reducing the iron compounds in a second chamber below the first chamber, fuel and oxygen being supplied to the second chamber. A reducing gas passes upwardly into the first chamber to effect the pre-reduction therein. Oxygen is fed to the first chamber. The iron compounds in the first chamber at least partly melt and then flow downwardly along the wall towards said second chamber. The iron compounds are introduced into the first chamber in particle form and by means of a carrier gas which provides one or more jets. The oxygen is fed into the first chamber at least partly in the form of one or more jets having tangential components.

Abstract: A method making pig iron employs an in-bath direct reduction performed in a metallurgical vessel which has above it a melting cyclone in which iron-oxide-containing material fed thereinto is pre-reduced by hot reducing gas coming from the vessel. Molten material passes downwardly from the melting cyclone into the vessel. In order to recover zinc from a dust containing zinc and/or zinc oxide, the dust is fed into the melting cyclone. Zinc is allowed to vaporize out of the dust into the hot gas in the melting cyclone. The hot gas containing zinc is discharged from the melting cyclone, and zinc-containing material is extracted from this hot gas.

Abstract: A closed-cover hot cyclone reactor is used to melt and partially reduce particulate iron or ferro-alloy ores fed to it in a stream. Tangential streams of fuel gas or, preferably, producer gas supplied by an associated bath smelter, interact with the spiralling particles as they pass through the reactor. The molten metal travels downwardly along the reactor walls and can be discharged by gravity onto the receiving bath. The system eliminates the need for pelletizing ore and coking coal in smelting of iron products.

Abstract: A method and apparatus for producing, in a reactor, a suitable prereduced product for final reduction from material containing metal oxide. The material is preheated in a fluidized bed by means of hot gases from a subsequent prereduction stage. The hot material is smelted and prereduced in a flame chamber utilizing hot reducing gases from a subsequent final reduction stage. The prereduced material is completely reduced in the final reduction stage.

Abstract: An apparatus for smelting meltable substances, particularly ore concentrates. A transfer element joins the cyclone discharge to the furnace and is arranged between the melting cyclone and the furnace. In this way, the fitting, particularly the re-fitting of an open-hearth furnace with a melting cyclone can be significantly simplified; or, on the other hand, the melting cyclone can be very easily dismantled for the purpose of repair or can be replaced by another melting cyclone in a relatively short time, namely without a significant interruption of furnace operations.