Patents Assigned to Midrex Technologies, Inc.
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Patent number: 9534265Abstract: Methods and systems for producing direct reduced iron (DRI), comprising: generating a syngas stream in a carbon dioxide (CO2) and steam reformer; and providing the syngas stream to a direct reduction (DR) shaft furnace as a reducing gas stream. The methods and systems also comprise combining the syngas stream with a recycled off-gas stream from the DR shaft furnace to form the reducing gas stream. The methods and systems further comprise removing carbon dioxide (CO2) from the recycled off-gas stream from the DR shaft furnace prior to combining it with the syngas stream to form the reducing gas stream. The methods and systems still further comprise feeding CO2 removed from the recycled off-gas stream from the DR shaft furnace to the CO2 and steam reformer. The methods and systems still further comprise feeding recycled off-gas from the recycled off-gas stream from the DR shaft furnace to the CO2 and steam reformer.Type: GrantFiled: December 15, 2014Date of Patent: January 3, 2017Assignee: Midrex Technologies, Inc.Inventors: Gary E. Metius, Gregory D. Hughes, James M. McClelland, Jr.
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Patent number: 9534275Abstract: A method for reducing a chromium containing material, comprising: combining the chromium containing material comprising chromium oxide with a carbonaceous reductant to form a chromium containing mixture; delivering the chromium containing mixture to a moving hearth furnace and reducing the chromium containing mixture to form a reduced chromium containing mixture; delivering the reduced chromium containing mixture to a smelting furnace; and separating the reduced chromium containing mixture into chromium metal and slag. The method also comprises agglomerating the chromium containing mixture in a granulator or the like. The chromium containing mixture has an average particle size of less than about 200 mesh (about 75 ?m).Type: GrantFiled: March 6, 2014Date of Patent: January 3, 2017Assignee: Midrex Technologies, Inc.Inventors: Vincent F. Chevrier, Russell Kakaley
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Patent number: 9175910Abstract: The present invention provides a combination reforming/reducing shaft furnace for the production of direct reduced iron that utilizes one or more burden uniformity enhancers, such as one or more rotating/reciprocating mixing shafts, one or more stationary flow aids, one or more wall structures/variations, one or more agitators, or the like for ensuring that reforming and reducing in the shaft furnace take place evenly across the width of and throughout the depth of the burden in the shaft furnace.Type: GrantFiled: October 1, 2013Date of Patent: November 3, 2015Assignee: Midrex Technologies, Inc.Inventors: Travis Wright, Steve Montague
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Patent number: 9127326Abstract: In various exemplary embodiments, the present invention provides systems and methods that can convert clean or raw natural gas, clean or dirty coke oven gas, or the like to reducing gas/syngas suitable for direct reduction with minimal processing or cleaning. Hydrocarbons and the like are converted to H2 and CO. S does not affect the conversion to reducing gas/syngas, but is removed or otherwise cleaned up by the iron bed in the direct reduction shaft furnace. Top gas may be continuously recycled or a once-through approach may be employed.Type: GrantFiled: November 1, 2013Date of Patent: September 8, 2015Assignee: Midrex Technologies, Inc.Inventors: Gary E. Metius, James M. McClelland, Jr., David C. Meissner, Stephen C. Montague
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Patent number: 9039794Abstract: The present invention provides a reformer tube apparatus, including: an axially aligned tubular structure including a flange section, a top section, a middle section, and a bottom section; wherein the top section of the axially aligned tubular structure includes a first portion having a first wall thickness; wherein the top section of the axially aligned tubular structure includes a second portion having a second wall thickness; and wherein the top section of the axially aligned tubular structure includes a third portion having a transitioning wall thickness that joins the first portion to the second portion. The flange section includes a concentric flange disposed about a top portion thereof. The bottom section of the tubular structure includes a plurality of concentric wedge structures disposed about the interior thereof. The bottom section of the tubular structure also includes a recess disposed about the exterior thereof.Type: GrantFiled: November 5, 2010Date of Patent: May 26, 2015Assignees: Midrex Technologies, Inc., MetalTek International, Inc.Inventors: Philip Crouch, Gerald Gapinski, Robert Smickley, Brian W. Voelker, Gilbert Y. Whitten
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Patent number: 9028585Abstract: Novel systems and methods are described for reducing iron oxide to metallic iron in an integrated steel mill or the like that has a coke oven and/or an oxygen steelmaking furnace. More specifically, the present invention relates to novel systems and methods for reducing iron oxide to metallic iron using coke oven gas (COG) or COG and basic oxygen furnace gas (BOFG).Type: GrantFiled: July 31, 2013Date of Patent: May 12, 2015Assignee: Midrex Technologies, Inc.Inventors: Gary E. Metius, James M. McClelland, Jr., David C. Meissner, Stephen C. Montague
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Patent number: 8999033Abstract: The present invention provides a method for producing direct reduced iron and/or hot metal using high-moisture content carbonaceous material, including: agglomerating carbonaceous material from the high-moisture content carbonaceous material with a metal oxide-bearing material to form an agglomerate suitable for use in a direct reduction and/or hot metal producing process. The method also includes distilling the high-moisture content carbonaceous material. The method further includes dry quenching the carbonaceous material obtained from the distilling step. The method still further includes drying the high-moisture content carbonaceous material with energy from a hot off gas from a furnace for producing direct reduced iron and/or hot metal prior to the distilling step.Type: GrantFiled: December 14, 2011Date of Patent: April 7, 2015Assignee: Midrex Technologies, Inc.Inventors: Masahiko Tetsumoto, Todd Astoria
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Patent number: 8871000Abstract: The present invention relates generally to a smelting operation or the like, by which molten metal is produced from a metal oxide after metal oxide agglomerates are directly reduced and melted with a carbonaceous material in an electric heating and melting furnace. More specifically, the present invention relates to an electric furnace for producing molten metal that has material recycling capability, especially in-process material recycling capability.Type: GrantFiled: November 29, 2011Date of Patent: October 28, 2014Assignee: Midrex Technologies, Inc.Inventor: Masahiko Tetsumoto
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Patent number: 8771638Abstract: A method and apparatus for sequestering carbon dioxide from a waste gas and reusing it as a recycled gas without emissions concerns, including: given a gas source divided into a process gas and a waste gas: mixing the process gas with a hydrocarbon and feeding a resulting feed gas into a reformer for reforming the feed gas and forming a reducing gas; and feeding at least a portion of the waste gas into a carbon dioxide scrubber for removing at least some carbon dioxide from the waste gas and forming a carbon dioxide lean gas that is mixed with the reducing gas. Optionally, the method also includes feeding at least a portion of the waste gas into the carbon dioxide scrubber for removing at least some carbon dioxide from the waste gas and forming a fuel gas after the addition of a hydrocarbon that is fed into the reformer.Type: GrantFiled: February 15, 2013Date of Patent: July 8, 2014Assignee: Midrex Technologies, Inc.Inventors: Gary E. Metius, James M. McClelland
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Patent number: 8709131Abstract: Methods and systems for the production of direct reduced iron, including: removing a top gas from a direct reduction furnace; carbon monoxide shifting the top gas using a carbon monoxide shift reactor to form a carbon monoxide shifted top gas having a reduced carbon monoxide content; adding one of a coal gas, a synthesis gas, and an export gas to at least a portion of the carbon monoxide shifted top gas to form a combined gas; removing carbon dioxide from the combined gas using a carbon dioxide removal unit to form a carbon dioxide lean combined gas; and providing the carbon dioxide lean combined gas to the direct reduction furnace as a reducing gas for producing direct reduced iron after heating to reduction temperature. Optionally, the method includes removing carbon dioxide from the top gas using a carbon dioxide removal unit prior to carbon monoxide shifting the top gas.Type: GrantFiled: February 15, 2012Date of Patent: April 29, 2014Assignee: Midrex Technologies, Inc.Inventors: David C. Meissner, Gary E. Metius, Gregory D. Hughes
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Patent number: 8685136Abstract: A process for reducing iron oxide to metallic iron using coke oven gas (COG), including: a direct reduction shaft furnace for providing off gas; a COG source for injecting COG into a reducing gas stream including at least a portion of the off gas; and the direct reduction shaft furnace reducing iron oxide to metallic iron using the reducing gas stream and injected COG. The COG has a temperature of about 1,200 degrees C. or greater upon injection. The COG has a CH4 content of between about 2% and about 13%. Preferably, the COG is reformed COG. Optionally, the COG is fresh hot COG. The COG source includes a partial oxidation system. Optionally, the COG source includes a hot oxygen burner.Type: GrantFiled: January 31, 2012Date of Patent: April 1, 2014Assignee: Midrex Technologies, Inc.Inventors: Gary E. Metius, James M. McClelland, Jr., David C. Meissner
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Patent number: 8496730Abstract: A process for the direct reduction of iron ore when the external source of reductants is one or both of coke oven gas (COG) and basic oxygen furnace gas (BOFG). Carbon dioxide (CO2) is removed from a mixture of shaft furnace off gas, obtained from a conventional direct reduction shaft furnace, and BOFG. This CO2 lean gas is mixed with clean COG, humidified, and heated in an indirect heater. Oxygen (O2) is injected into the heated reducing gas. This hot reducing gas flows to the direct reduction shaft furnace for use. The spent hot reducing gas exits the direct reduction shaft furnace as shaft furnace off gas, produces steam in a waste heat boiler, is cleaned in a cooler scrubber, and is compressed and recycled to join fresh BOFG. A portion of the shaft furnace off gas is sent to the heater burners. The BOFG and COG are also employed for a variety of other purposes in the process.Type: GrantFiled: May 13, 2011Date of Patent: July 30, 2013Assignee: Midrex Technologies, Inc.Inventors: Gary E. Metius, James M. McClelland, Jr., David C. Meissner
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Publication number: 20130171049Abstract: A method and apparatus for sequestering carbon dioxide from a waste gas and reusing it as a recycled gas without emissions concerns, including: given a gas source divided into a process gas and a waste gas: mixing the process gas with a hydrocarbon and feeding a resulting feed gas into a reformer for reforming the feed gas and forming a reducing gas; and feeding at least a portion of the waste gas into a carbon dioxide scrubber for removing at least some carbon dioxide from the waste gas and forming a carbon dioxide lean gas that is mixed with the reducing gas. Optionally, the method also includes feeding at least a portion of the waste gas into the carbon dioxide scrubber for removing at least some carbon dioxide from the waste gas and forming a fuel gas after the addition of a hydrocarbon that is fed into the reformer.Type: ApplicationFiled: February 15, 2013Publication date: July 4, 2013Applicant: Midrex Technologies, Inc.Inventors: Gary E. Metius, James M. McClelland, JR.
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Patent number: 8377417Abstract: A method and apparatus for sequestering carbon dioxide from a waste gas and reusing it as a recycled gas without emissions concerns, including: given a gas source divided into a process gas and a waste gas: mixing the process gas with a hydrocarbon and feeding a resulting feed gas into a reformer for reforming the feed gas and forming a reducing gas; and feeding at least a portion of the waste gas into a carbon dioxide scrubber for removing at least some carbon dioxide from the waste gas and forming a carbon dioxide lean gas that is mixed with the reducing gas. Optionally, the method also includes feeding at least a portion of the waste gas into the carbon dioxide scrubber for removing at least some carbon dioxide from the waste gas and forming a fuel gas after the addition of a hydrocarbon that is fed into the reformer.Type: GrantFiled: April 19, 2010Date of Patent: February 19, 2013Assignee: Midrex Technologies, Inc.Inventors: Gary E. Metius, James M. McClelland, Jr.
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Patent number: 7938882Abstract: The present invention relates generally to a method and system for the supply of a continuous stream of hot direct reduced iron (HDRI) from a direct reduction (DR) shaft furnace or direct reduced iron (DRI) reheating furnace to a point outside of the DR shaft furnace or DRI reheating furnace where the HDRI stream is split into at least two HDRI streams. The first HDRI stream is sent continuously to a hot briquetting plant by gravity in a closed duct system. The second HDRI stream is sent continuously to an adjacent melting furnace also by gravity in a closed duct system, with a surge bin and feeders, or by a combination of gravity in a closed duct system, also with a surge bin and feeders, and a generally horizontal charge conveyor. Optionally, a third HDRI stream is employed to continuously feed multiple hot transport vessels.Type: GrantFiled: March 28, 2008Date of Patent: May 10, 2011Assignee: Midrex Technologies, Inc.Inventors: Gary Edward Metius, Stephen Craig Montague, Russell Kakaley
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Patent number: 7678176Abstract: The present invention provides a method and apparatus for charging hot direct reduced iron (HDRI) from hot transport vessels (HTVs) into a melter or finisher. In general, the apparatus includes a charging stand including a plurality of bays for receiving and supporting a plurality of HTVs. Each HTV includes at least an outlet port. This outlet port is configured to engage an inlet port of one of the plurality of bays of the charging stand via a telescoping seal that provides a substantially air-tight seal. A feed device is provided that moves the HDRI disposed within the HTVs from the outlet port/inlet port interface to a melter or finisher, such as an electric arc furnace (EAF) or the like. The charging stand also includes one or more load cells operable for weighing the HTVs and the HDRI disposed therein, such that a computer or other logic may be used to control the feed rate of the HDRI charged into the melter or finisher.Type: GrantFiled: June 29, 2007Date of Patent: March 16, 2010Assignee: Midrex Technologies, Inc.Inventors: Gilbert V. Whitten, James M. McClelland, Stephen C. Montague, Brian W. Voelker
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Patent number: 6802886Abstract: The invention is a method of making metallized iron agglomerates by combining iron/steel particles and a reductant material with a cellulose fiber binder material, compacting the combination to form a solid agglomerate, and reducing the iron portions of the agglomerate in a direct reduction furnace. The cellulose fiber binder material provides an agglomerate having improved strength and lower overall cost than comparable agglomerates using binders known in the art.Type: GrantFiled: May 10, 2001Date of Patent: October 12, 2004Assignee: Midrex Technologies, Inc.Inventors: Glenn E. Hoffman, James M. McClelland, Jr.
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Patent number: 6602322Abstract: An improved method and apparatus for recovering metal values from Electric Arc Furnace dust, particularly zinc and iron values, by mixing EAF dust and carbonaceous fines to form a particulate mixture; heating the mixture at a sufficient temperature and for a sufficient time to reduce and release volatile metals and alkali metals in a flue gas; collecting the released metals, and removing the metal values from the process as product.Type: GrantFiled: September 1, 2001Date of Patent: August 5, 2003Assignee: Midrex Technologies, Inc.Inventor: James M. McClelland, Jr.
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Patent number: 6524356Abstract: A process and apparatus for the production of reformed gases. Natural gas and/or liquid hydrocarbons and oxygen are combusted in a first stage to produce carbon dioxide and water. The products of combustion are conveyed to a second stage. Reforming gas or atomized liquid hydrocarbons and oxygen are injected into the second stage and mixed with the products of combustion to react with the carbon dioxide and water to produce carbon monoxide and hydrogen. The process and apparatus are particularly adapted for use in supplementing the reform gases produced in a Direct Reduced Iron plant wherein iron ore is reduced to iron inside a shaft furnace. The process and apparatus may also be used to provide heated enrichment natural gas or liquid hydrocarbons for use as a source of carbon in the shaft furnace to provide for carburization of the iron. Additionally, the process and apparatus may be used as a process control device for controlling the temperature of the reformed gases flowing to the shaft furnace.Type: GrantFiled: December 7, 1999Date of Patent: February 25, 2003Assignee: Midrex Technologies, Inc.Inventors: Donald J. Fournier, Marvin E. Tester, Gregory D. Hughes
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Patent number: 6506230Abstract: An improved method and apparatus for increasing the productivity of a direct reduction process in which iron oxide is reduced to metallized iron by contact with hot reducing gas; comprising the steps of: a) providing a first hot reducing gas consisting essentially of CO and H2; b) providing additional reducing gas by reaction of a gaseous or liquid hydrocarbon fuel with oxygen; c) mixing the first hot reducing gas with the additional reducing gas to form a reducing gas mixture; d) enriching the reducing gas mixture by the addition of a gaseous or liquid hydrocarbon; e) injecting oxygen or oxygen-enriched air into the enriched mixture; and f) introducing the enriched mixture into an associated direct reduction furnace as reducing gas.Type: GrantFiled: February 12, 2001Date of Patent: January 14, 2003Assignee: Midrex Technologies, Inc.Inventors: Stephen C. Montague, Russell Kakaley, Gregory D. Hughes, Gary E. Metius