Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: Apparatus for separating a strip of briquets issuing from a briquetting machine into individual briquets by bending the briquet strip both longitudinally and transversely to break the connections between adjacent briquets. The apparatus includes a carrying conveyor having arcuate, waveform or sawtooth conveyor slats and a conforming conveyor having conveyor slats with a cross section which mates with that of the carrying conveyor. The conforming conveyor forces the briquet strip to conform to the slat configuration of the first conveyor and to pass around a pivot means which breaks or separates the strip into individual briquets.

Abstract: Apparatus for reducing particulate iron oxide to molten iron utilizing solid carbonaceous fuel as reductant in a shaft type reducing furnace, in which a furnace burden is formed of a mixture of iron oxide lumps or pellets and particulate solid fuel. Reacted top gas is upgraded and recirculated through the burden in counter-flow relationship thereby heating, reducing and melting the burden. The heat for reduction and melting is generated by passing electric current through the burden.

Abstract: A method and apparatus for the continuous direct reduction of metal oxides, ores, etc. to a hot metallized product in solid form. A gas unique seal is employed to prevent the leakage of reduction gas from the bottom of the closed shaft furnace when the product is being discharged which does not affect the discharge temperature of the product.

Abstract: A method for reducing particulate iron oxide to molten iron utilizing solid carbonaceous fuel as reductant in a shaft type reducing furnace, in which a furnace burden is formed of a mixture of iron oxide lumps or pellets and particulate solid fuel. Reacted top gas is upgraded and recirculated through the burden in counter-flow relationship thereby heating, reducing and melting the burden. The heat for reduction and melting is generated by passing electric current through the burden.

Abstract: Apparatus for monitoring the feeding of particulate materials into a packed bed furnace such as a shaft furnace by locating thermowells each containing a thermocouple at the wall of the furnace, preferaby recessed therein, beneath the normal stockline of the furnace. The thermocouple determines the presence of feed material and in the absence of such material a signal is generated which may be an alarm.

Abstract: A method for direct reduction of iron in a shaft reduction furnace. Spent gas from the furnace is upgraded in reductant by removal of CO.sub.2 and water to form an upgraded gas. A fossil fuel is gasified to produce a hot gas which is tempered with a first stream of upgraded gas. The mixture is desulfurized by reaction with lime to produce hot desulfurized gas. A second stream of upgraded gas is heated and mixed with the hot desulfurized gas to produce hot reducing gas.

Abstract: Apparatus for contacting a packed bed of particulate material with a treating gas includes a downwardly converging bin, hot gas distributors and a cooling gas distributor. The method whereby the apparatus is used as a reactor dryer to treat particulate sponge iron is also disclosed.

Abstract: Apparatus for separating a sheet of briquets issuing from a briquetting machine into individual briquets by bending the briquet sheet both longitudinally and transversely to break the connections between adjacent briquets. The apparatus includes a carrying conveyor having arcuate, waveform or sawtooth conveyor slats and a conforming conveyor having conveyor slats with a cross section which mates with that of the carrying conveyor. The conforming conveyor forces the briquet sheet to conform to the slat configuration of the first conveyor and to pass around a pivot means which breaks or separates the sheet into individual briquets.

Abstract: A method and apparatus for reducing particulate iron oxide to metallic iron utilizing solid carbonaceous fuel as reductant in a shaft type reducing furnace, in which a furnace burden is formed of a mixture of iron oxide lumps or pellets and particulate solid fuel. Reacted top gas is upgraded and recirculated through the burden in counter-flow relationship thereby heating and partially reducing the burden. The heat for final reduction is generated by passing electric current through the burden.

Abstract: The method of making a briquet from directly reduced finely divided metallized material is disclosed whereby 85 to 95% of metallized material is mixed with 5 to 15% of a binder to form a free flowing briquet feed, then densifying the feed material and forming it into briquets.

Abstract: A briquet consisting of agglomerated directly reduced metallized particles, or mineral ore particles or a mixture thereof and a binder consisting of hydrated lime, sodium silicate and water. The method of making the briquet is also disclosed.

Abstract: A compacted, passivated metallized iron product useful as a feed material for a steelmaking process, the product generally being formed by the compaction of hot metallized iron material, thus forming a product with a very dense face and a less dense center. The total iron present in the product is at least 75% in the metallic state and generally from 90% to 96% in the metallic state.

Abstract: A method for direct reduction of iron ore containing sulfur in a shaft type reduction furnace wherein two separate streams of spent reducing gas are withdrawn from the reduction furnace. One stream, being substantially free of sulfur, is recycled through a catalytic reformer to produce fresh reducing gas, the other stream, containing sulfur, is utilized in the process where sulfur is not of consequence.

Abstract: A method and apparatus for reducing particulate iron oxide to metallic iron utilizing solid carbonaceous fuel as reductant in a shaft type reducing furnace, in which a furnace burden is formed of a mixtue of iron oxide lumps or pellets and particulate solid fuel. Reacted top gas is upgraded and recirculated through the burden in counter-flow relationship thereby heating and partially reducing the burden. The heat for final reduction is generated by passing electric current through the burden.

Abstract: A method for continuous passivation of hot sponge iron material, by feeding hot sponge iron material to a compactor, compacting the material to a high density elongated strip-like mass, cutting the mass longitudinally into a plurality of strips while simultaneously compacting the freshly cut longitudinal edges, cutting the strips transversely of their longitudinal dimensions while simultaneously compacting these freshly cut transverse edges.