Abstract: A process for producing pig iron from iron ores involves the iron ores traveling from the top downwards through a reduction unit via a succession of oblique trays which are staggered in a cascade-like manner. A hot reduction gas containing carbon monoxide and hydrogen flows from the bottom of the reduction unit upwards. A reduction product is drawn off at the bottom end of the reduction unit and is fed to a unit for further treatment thereof. A reduction gas is generated in a gas generator by partial oxidation of carbon carriers or by cracking of natural gas or petroleum. Iron ores having at least a high proportion of dust-like and/or fine granular iron ores are sorted into fractions according to grain size and introduced into the reduction unit in such a way that the course fraction of the iron ore is introduced into the top section of the system and the fine fraction of the iron ore is introduced into the middle zone or into the middle and bottom zones of the system.

Abstract: A process for cooling and cleaning hot gas containing ultrafine particles exhausted from a coal gasification plant, a blast furnace, or the like. The process utilizes a vertical saturation stage to enrich the gas stream with water vapor and thereby saturate the ultrafine particles contained in the gas stream. The resulting mixture of particles, exhaust gas, water vapor, and water is then directed through a packing prewasher and then an annular clearance washer for removal of the particles through the rapid condensation of the water vapor. The water and particles are separated from the gas stream in several stages throughout the process resulting in a final gas exhaust stream with a significantly lower ultrafine particle content.

Abstract: A process for the direct production of sponge iron particles and liquid pig iron from lump iron ore is described, in which the iron ore is reduced as a loose bed in a direct reduction unit by means of hot reducing gases to sponge iron and is subsequently melted in a melting gasifier by means of the introduced carbon and blown in oxygen-containing gas, accompanied by the production of reducing gas. At least part of the reducing gas, after cooling to the temperature necessary for reduction, is introduced into the reduction zone of the direct reduction unit. A considerable part of the carbon and reducing gas is provided by a mixture of hydrocarbon-containing plastic and petroleum coke and/or coke (fines). The reducing gases are primarily at least partly obtained by cracking from the plastic and by thermal gasification from the coke.

Abstract: There is disclosed a method of starting a plant for the production of pig iron or steel pre-material including a direct-reduction shaft furnace and a meltdown gasifier.At first the still empty meltdown gasifier is heated up by aid of a combustible gas and the smoke gases forming are introduced into the still empty direct-reduction shaft furnace.Coke or a degassed coal product is charged into the direct-reduction shaft furnace and the smoke gases introduced into the direct-reduction shaft furnace are passed through the coke or the degassed coal product by releasing their sensible heat.The coke or the degassed coal product thereby is heated to ignition temperature and is charged into the meltdown gasifier in the hot state, catching fire upon the injection of an oxygen-containing gas or of oxygen.A further coal or coke bed serving for gasification is charged on the ignited bed of coke or degassed coal product and the charging substances are charged into the direct-reduction shaft furnace.

Abstract: The invention relates to a process for the treatment of wash water from the gas washing system of an iron ore reduction plant, the wash water being brought into direct contact with dust-laden gas in a gas washer, is removed from the latter and after solids separation is again supplied in cooled form to the gas washer.

Abstract: An apparatus for charging a melting gasifier (2) with gasification media and with sponge iron discharged from a direct reduction shaft furnace (1) arranged above the melting gasifier is described. This comprises inlets and outlets in the lower part of the shaft furnace, connecting lines (4) in the form of downcomers between the shaft furnace and the gasifier in the upper region of the latter, symmetrically to the longitudinal axis of the shaft furnace and/or the gasifier and discharge means (7) for the sponge iron, such as screw conveyors or the like aligned radially to said longitudinal axis. The connecting lines at least approximately vertically issue into the lowermost, substantially horizontal base region of the shaft furnace. The discharge means are arranged at the melting gasifier inlets (9) in the discharge direction behind the connecting lines and the gasification medium inlet (3) is located in the longitudinal axis of the melting gasifier immediately adjacent to the sponge iron inlets.

Abstract: Described is a method for operating a melt-down gasifier(4) in which iron-ore-containing charge materials or iron sponge obtained from same by direct reduction are smelted due to the addition of carbon carriers and blowing an oxygen-containing gas through oxygen nozzles (6) into a fluidized bed created by same, and are (further) reduced to make liquid pig iron or steel starting material. On failure or reduction of the oxygen supply below a predetermined quantity and on failure of the water cooling system of the oxygen nozzles, the still present oxygen supply is cut-off and an inert gas is fed into the melt-down gasifier through the said oxygen nozzles instead, for protecting said oxygen nozzles. Thus, liquid fluidized bed matter is prevented from penetrating into the oxygen nozzles and to solidify in same. In the case of failure of the water cooling system of the oxygen nozzles, the inert gas serves also at the same time as cooling medium.

Abstract: An apparatus for producing cooling gas for a producer gas produced in a melt-down gasifier and surplus gas usable in an appropriate manner by cooling and cleaning at least part of the producer gas and the top gas of an iron ore reduction unit are proposed. The cooling gas is exclusively obtained by preparing producer gas. There is a cooling and a cleaning unit for the surplus gas and the cooling gas in each case. A constant gas flow is passed through the rear portion of the cooling and cleaning unit for the cooling gas with the aid of a constant volume blower. That part of the producer gas supplied to the cooling and cleaning unit for the cooling gas which exceeds this constant gas flow is passed into the cooling and cleaning unit for the surplus gas. The cooling and cleaning units can be constructed in two-stage manner, namely with in each case one packing washer (3 or 6) and a following adjustable Venturi washer (5 or 8).

Abstract: A process for producing cooling gas for a producer gas produced in a melt-down gasifier and surplus gas usable in an appropriate manner by cooling and cleaning at least part of the producer gas and the top gas of an iron ore reduction unit are proposed. The cooling gas is exclusively obtained by preparing producer gas. There is a cooling and a cleaning unit for the surplus gas and the cooling gas in each case. A constant gas flow is passed through the rear portion of the cooling and cleaning unit for the cooling gas with the aid of a constant volume blower. That part of the producer gas supplied to the cooling and cleaning unit for the cooling gas which exceeds this constant gas flow is passed into the cooling and cleaning unit for the surplus gas.

Abstract: In this process for the direct production of sponge iron particles and molten pig iron from lump iron ore, which is reduced in a direct reduction unit (2) and supplied in the hot state to a melt-down gasifier (1), the sponge iron particles discharged from the direct reduction unit are separated into a fine particle fraction and a coarse particle fraction and only the former is supplied to the melt-down gasifier. Separation takes place in an air classifier (7) connected to the discharge means of the direct reduction unit and through said classifier flows cooling gas at a predetermined velocity in countercurrent to the sponge iron particles. This cooling gas is admixed with the reducing gas produced in the melt-down gasifier for the direct reduction unit and said gas mixture, as well as the fine particle fraction of the sponge iron entrained therewith are supplied to cyclones (5 and 6). The solid separated therein, e.i.

Abstract: In a process for the direct production of sponge iron particles and liquid crude iron from iron ore in lump form, which is reduced in a direct reduction unit and fed in a hot condition to a melting gasifier, the sponge iron particles which are discharged from the direct reduction unit are separated into a fine grain fraction and a coarse grain fraction, and only the fine grain fraction is fed to the melting gasifier. That ensures economy of operation, without an excess of gas.

Abstract: In a process for the direct production of sponge iron particles and liquid crude iron from iron ore in lump form, which is reduced in a direct reduction unit and fed in a hot condition to a melting gasifier, the sponge iron particles which are discharged from the direct reduction unit are separated into a fine grain fraction and a coarse grain fraction, and only the fine grain fraction is fed to the melting gasifier. That ensures economy of operation, without an excess of gas.

Abstract: A process is described for the direct reduction of metallic oxides, primarily iron ore, to form sponge iron in a direct reduction plant by means of reduction gases containing hydrogen, at least part of the water vapor produced by the reduction process and contained in the exhaust gas being eliminated in the form of condensate. Further, there is described an apparatus for carrying out the process.