Abstract: The process for producing the sponge iron includes the steps of preparing a sandwich of at least two layers wherein the at least two layers includes a first layer (10) of iron oxide source which content is carbon free or comprises of only self-contaminant carbon or carbonaceous and second layer (12) is a mixture of iron oxide source and carbon source and subjecting the sandwich of at least two layers to a pyrolysis process in a non-oxidative environment at temperature between 950° C. to 1900° C. for a period between 10 minutes to 36 hours. The carbon source in the second layer (12) is equal to or more than stoichiometric weight of carbon according to a predominant reaction. The non-oxidative pyrolysis occurs in a reactor. The sandwich of two layers is placed in a moving carrier (16) such as tray to accommodate the sandwich of two layers in the reactor.

Abstract: The present invention relates to a process for producing sponge iron with in-situ carbon removal. The process for producing the sponge iron includes the steps of preparing a sandwich of at least two layers wherein the at least two layers includes a first layer (10) of iron oxide source which content is carbon free or comprises of only self-contaminant carbon or carbonaceous and second layer (12) is a mixture of iron oxide source and carbon source and subjecting the sandwich of at least two layers to a pyrolysis process in a non-oxidative environment at temperature between 950° C. to 1900° C. for a period between 10 minutes to 36 hours. The carbon source in the second layer (12) is equal to or more than stoichiometric weight of carbon according to a predominant reaction. The non-oxidative pyrolysis occurs in a reactor. The sandwich of two layers is placed in a moving carrier (16) such as tray to accommodate the sandwich of two layers in the reactor.

Abstract: The current invention relates to a method of manufacturing iron oxide pigments from mill scale. The mill scale is mixed with alien iron oxide and the resultant mixture is heated to a temperature of 200° C. to 900° C. in an oxidizing atmosphere to produce iron oxide pigment which can be black, brown or red. The alien iron oxide used and the iron oxide pigment produced are predominantly Fe2O3 or Fe3O4 or a mixture of both. The iron oxide pigment produced as above or from any other sources can be turn into black by mixing it with mill scale and the resultant mixture is heated to a temperature of 200° C. to 900° C. in a non-oxidizing or reducing atmosphere to produced iron oxide black pigment. Additives can be added to produce better quality iron oxide black pigment. The additives can be chromium oxide or manganese oxide or magnesium oxide or any carbonaceous material or mixtures thereof. The iron oxide black pigment produced as above is cooled in a non-oxidizing or reducing atmosphere to ensure no re-oxidation.

Abstract: The current invention relates to a method of manufacturing iron oxide pigments from mill scale. The mill scale is mixed with alien iron oxide and the resultant mixture is heated to a temperature of 200° C. to 900° C. in an oxidizing atmosphere to produce iron oxide pigment which can be black, brown or red. The alien iron oxide used and the iron oxide pigment produced are predominantly Fe2O3 or Fe3O4 or a mixture of both. The iron oxide pigment produced as above or from any other sources can be turn into black by mixing it with mill scale and the resultant mixture is heated to a temperature of 200° C. to 900° C. in a non-oxidizing or reducing atmosphere to produced iron oxide black pigment. Additives can be added to produce better quality iron oxide black pigment. The additives can be chromium oxide or manganese oxide or magnesium oxide or any carbonaceous material or mixtures thereof. The iron oxide black pigment produced as above is cooled in a non-oxidizing or reducing atmosphere to ensure no re-oxidation.