Abstract: In view of the foregoing embodiments of the disclosure provide a high value steel/carbon product from a low value iron-containing waste material and process for producing the steel/carbon product. The high value steel/carbon product is derived from a mixture of metallurgical coal and an oxidized iron waste material under a reducing atmosphere. The steel/carbon product has a porosity of greater than about 60% and a density of greater than about 900 kg/m3 and the steel component of the steel/carbon product has a percent of metalization of greater than about 85 wt. %.

Abstract: An alternative ironmaking process for simultaneously producing a highly metalized iron/steel product, coke from coal, an iron/steel product from an iron rich feedstock, and, optionally, energy using heat recovery. The simultaneous process is performed in the environment of a non-recovery or heat recovery coke oven. The iron rich feedstock is layered on top of a coal bed. The iron rich feedstock and coal bed are heated in the presence of a reducing gas to reduce the iron oxides of the iron rich feedstock into the iron/steel product and to devolatilize the coal into coke. After quenching the iron/steel product and coke, the iron/steel product is separated from the coke.

Abstract: An alternative ironmaking process for simultaneously producing a highly metalized iron/steel product, coke from coal, an iron/steel product from an iron rich feedstock, and, optionally, energy using heat recovery. The simultaneous process is performed in the environment of a non-recovery or heat recovery coke oven. The iron rich feedstock is layered on top of a coal bed. The iron rich feedstock and coal bed are heated in the presence of a reducing gas to reduce the iron oxides of the iron rich feedstock into the iron/steel product and to devolatilize the coal into coke. After quenching the iron/steel product and coke, the iron/steel product is separated from the coke.