Abstract: A hearth furnace 10 for producing metallic iron material has a furnace housing 11 with a drying/preheat zone 12 capable of providing a drying/preheat atmosphere for reducible material, a conversion zone 13 capable of providing a reducing atmosphere for reducible material, a fusion zone 14 capable of providing an atmosphere to at least partially reduced metallic iron material, and optionally a cooling zone 15 capable of providing a cooling atmosphere for reduced material containing metallic iron material. A hearth 20 is movable within the furnace housing 11 in a direction through the drying/preheat zone 12, then the conversion zone 13, then the fusion zone 14, and then the cooling zone 15.

Abstract: A multiple moving hearth furnace (10) having a furnace housing (11) with at least two moving hearths (20) positioned laterally within the furnace housing, the hearths moving in opposite directions and each moving hearth (20) capable of being charged with at least one layer of iron oxide and carbon bearing material at one end, and being capable of discharging reduced material at the other end. A heat insulating partition (92) is positioned between adjacent moving hearths of at least portions of the conversion zones (13), and is capable of communicating gases between the atmospheres of the conversion zones of adjacent moving hearths. A drying/preheat zone (12), a conversion zone (13), and optionally a cooling zone (15) are sequentially positioned along each moving hearth (30) in the furnace housing (11).

Abstract: Method and system for producing metallic nuggets includes providing reducible mixture (e.g., reducible micro-agglomerates; reducing material and reducible iron bearing material; reducible mixture including additives such as a fluxing agent; compacts, etc.) on at least a portion of a hearth material layer. In one embodiment, a plurality of channel openings extend at least partially through a layer of the reducible mixture to define a plurality of nugget forming reducible material regions. Such channel openings may be at least partially filled with nugget separation fill material (e.g., carbonaceous material). Thermally treating the layer of reducible mixture results in formation of one or more metallic iron nuggets. In other embodiments, various compositions of the reducible mixture and the formation of the reducible mixture provide one or more beneficial characteristics.

Abstract: Method and system for producing metallic nuggets includes providing reducible mixture (e.g., reducible micro-agglomerates; reducing material and reducible iron bearing material; reducible mixture including additives such as a fluxing agent; compacts, etc.) on at least a portion of a hearth material layer. In one embodiment, a plurality of channel openings extend at least partially through a layer of the reducible mixture to define a plurality of nugget forming reducible material regions. Such channel openings may be at least partially filled with nugget separation fill material (e.g., carbonaceous material). Thermally treating the layer of reducible mixture results in formation of one or more metallic iron nuggets. In other embodiments, various compositions of the reducible mixture and the formation of the reducible mixture provide one or more beneficial characteristics.

Abstract: A hearth furnace 10 for producing metallic iron material has a furnace housing 11 having a drying/preheat zone 12, a conversion zone 13, a fusion zone 14, and optionally a cooling zone 15, the conversion zone 13 is between the drying/preheat zone 12 and the fusion zone 14. A moving hearth 20 is positioned within the furnace housing 11. A hood or separation barrier 30 within at least a portion of the conversion zone 13, fusion zone 14 or both separates the fusion zone 14 into an upper region and a lower region with the lower region adjacent the hearth 20 and the upper region adjacent the lower region and spaced from the hearth 20. An injector introduces a gaseous reductant into the lower region adjacent the hearth 20. A combustion region may be formed above the hood or separation barrier.

Abstract: Method and system for producing metallic nuggets includes providing reducible mixture of reducing material (such as carbonaceous material) and reducible iron bearing material (such as iron oxide) that may be arranged in discrete portions, such as mounds or briquettes, on at least a portion of a hearth material layer (such as carbonaceous material). A coarse overlayer of carbonaceous material may be provided over at least some of the discrete portions. Heating the reducible mixture to 1425° C. or 1400° C. or 1375° C. results in formation of an intermediate product of one or more metallic iron nuggets, which may have a sulfur content of less than 0.03%, and slag, which may have less than 5% mass MgO, which may have a ratio of percent by weight sulfur in the slag over percent by weight sulfur in the metallic nuggets of at least about 12 or at least about 15.

Abstract: A battery of stationary hearth furnaces, and method for using, for producing metallic iron nodules having a furnace having a stationary hearth, an inlet and an outlet; a heating chamber beneath the stationary hearth having heated fluids circulated thereto and heating reducible material on the stationary hearth; passageways circulating fluids, through ports from the furnace housing above the reducible material to the heating chamber beneath; burners and air inlets in the furnace and optionally in at least one passageway and a heating chamber for drying and heating the reducible material, driving off and burning volatile material, and forming metallic iron nodules; a loading device for loading reducible material and optionally hearth material onto the stationary hearth through the inlet; and a discharging device capable of discharging metallic iron nodules and optionally related material from the stationary hearth through the outlet.

Abstract: Systems and methods for use in processing raw material (e.g., iron bearing material) include a linear furnace apparatus extending along a longitudinal axis between a charging end and a discharging end (e.g., the linear furnace apparatus includes at least a furnace zone positioned along the longitudinal axis). Raw material is provided into one or more separate or separable containers (e.g., trays) at the charging end of the linear furnace apparatus. The separate or separable containers are moved through at least the furnace zone and to the discharging end where the processed material is discharged resulting in one or more empty containers. One or more of the empty containers are returned to the charging end of the linear furnace apparatus to receive further raw material.

Abstract: Systems and methods for use in processing raw material (e.g., iron bearing material) include a linear furnace apparatus extending along a longitudinal axis between a charging end and a discharging end (e.g., the linear furnace apparatus includes at least a furnace zone positioned along the longitudinal axis). Raw material is provided into one or more separate or separable containers (e.g., trays) at the charging end of the linear furnace apparatus. The separate or separable containers are moved through at least the furnace zone and to the discharging end where the processed material is discharged resulting in one or more empty containers. One or more of the empty containers are returned to the charging end of the linear furnace apparatus to receive further raw material.