Abstract: A method for inhibiting rusting of sponge iron or any form of directly reduced iron when contacted by air, water, or other oxidant, by treating the sponge iron with a water soluble alkali metal silicate solution. The resulting product, a sodium silicate treated, rust-resistant metallized iron pellet, is also disclosed.

Abstract: This invention relates to a method for controlling the carbon content of metallized iron pellets produced by the continuous direct reduction of iron oxide in a vertical shaft furnace with a reducing gas having a high hydrogen and carbon monoxide content. According to the method, in addition to the standard reducing gases introduced to the reducing zone, methane or methane-containing gas is introduced to the shaft furnace at specified locations beneath the reducing zone and, by controlling the conditions in the furnace, a proportion of the injected gas is reformed in the furnace to reducing gases.

Abstract: A method for preparing iron powder for powder metallurgy and other applications from particulate iron oxide by reducing the particle size of at least part of the particulate feed material chemically reducing the feed material to increase the percentage of metallization by contact with a gaseous reductant in a shaft furnace at high temperatures, and removing the reduced iron powder product from the furnace. Preferably the product is screened and oversized material is returned to the furnace for additional reduction. An alternative method contemplates additional steps of grinding, and further decrepitation to reduce the particle size of the larger particle fractions.

Abstract: A method of extending the useful life of a catalyst employed in the endothermic catalytic reforming of gaseous hydrocarbons in which a substantial portion of the sulfur contained in such gaseous hydrocarbons is removed by contacting them with an aqueous solution of a water soluble metallic salt having a free metallic ion which forms an insoluble precipitate with sulfur. A preferred salt is zinc chromate.

Abstract: A method of producing metallic iron pellets in a generally vertical furnace in which a gravitational flow of particulate material is reduced in a reducing zone by a countercurrent flow of a reducing gas containing a reductant, the spent reducing gas is removed and cooled and a portion is introduced as cooling gas in a cooling zone near the bottom of the furnace, and a portion of the cooling gas is upgraded in reducing potential and introduced to the reducing zone as reducing gas.

Abstract: A method of producing iron particles in a generally vertical furnace in which a gravitational flow of particulate material is reduced in a reducing zone by a countercurrent flow of a reducing gas containing a reductant, the spent reducing gas is removed and cooled and a portion is introduced as cooling gas in a cooling zone near the bottom of the furnace, and a portion of the cooling gas is upgraded in reducing potential and introduced to the reducing zone as reducing gas. Apparatus is also provided for carrying out the method.

Abstract: A method of producing metallic iron pellets in a generally vertical furnace in which a gravitational flow of particulate material is reduced in a reducing zone by a countercurrent flow of a reducing gas containing a reductant, the spent reducing gas is removed and cooled and a portion is introduced as a cooling gas in a cooling zone near the bottom of the furnace while a second portion is employed as a fuel to heat a catalyst through which a gaseous hydrocarbon and steam are passed to form a reducing gas mixture for introduction into the furnace, and a portion of the cooling gas is upgraded in reducing potential and introduced to the reducing zone as reducing gas. Apparatus is also provided for carrying out the method.

Abstract: Apparatus for continuous passivation of hot sponge iron material consists of a feeder, a roll compactor for forming a high density continuous elongated mass, and longitudinal and transverse shearing devices, along with the requisite control and transporting mechanisms.

Abstract: Apparatus for direct reduction of iron ore containing sulfur comprises a shaft type reduction furnace with means for withdrawing two separate streams of spent reducing gas. One stream, being substantially free of sulfur is recycled through a catalytic reformer to produce fresh reducing gas. The other stream containing sulfur, is connected to process equipment such as a burner where sulfur is not of consequence.

Abstract: A binder composition for agglomerating directly reduced metallized particles and mineral ore particles comprises pitch, hydrated lime, sodium silicate and water. An agglomerated product is also disclosed.

Abstract: Apparatus for treating particulate material with hot gases wherein preheated gases are introduced to the particulate material to heat and treat such material and a second cooler gas is introduced to the heated material to impart some cooling to the material and to heat the second gas to treatment temperature followed by movement of the heated second gas through the bed of material in which it acts in the same manner as the hot treating gas.