Abstract: A method and apparatus for producing direct reduced iron from dry compacts composed of iron oxide and carbonaceous material by feeding compacts no more than two layers deep onto a hearth and removing all the volatiles and metallizing the compacts by exposing said compacts to a radiant heat source at a temperature of from about 2400.degree. to about 2600.degree. F. (1316.degree.-1427.degree. C.) for a total time period of about four to ten minutes and partially cooling the compacts while discharging them from the hearth.

Abstract: A method and apparatus for producing direct reduced iron from dry compacts composed of iron oxide and carbonaceous material by feeding compacts no more than two layers deep onto a hearth and removing all the volatiles and metallizing the compacts by exposing said compacts to a radiant heat source at a temperature of from about 2400.degree. to about 2600.degree. F (1316.degree.-1427.degree. C.) for a total time period of about four to ten minutes and partially cooling the compacts while discharging them from the hearth.

Abstract: A method and apparatus for producing direct reduced iron from iron oxide fines. The iron oxide raw material are passed through a pre-heater having a spouted port then to a primary spouted bed circulating fluidizing bed reactor and then to a bubbling fluidizing bed reactor. The reaction of the strong reducing gas mixture, through this series of beds allows intimate contact between the fines and small particles with the reducing gas to facilitate the direct reduction of the iron oxide fines to metallized iron.

Abstract: A method of producing direct reduced iron from pellets, lumps and fines of iron oxide. A mixture of iron oxide raw material is introduced to an apparatus which separates the lumps and pellets from the fines. The lumps and pellets are then introduced to a shaft furnace for direct reduction to iron. Fines are conveyed to a series of fluidizable beds which allows intimate contact with reducing gas to facilitate the direct reduction of the iron oxide fines to metallized iron.

Abstract: Apparatus for the production of iron carbide in a shaft furnace, by reacting a carbon containing reducing gas as the process gas with particulate metal oxide material for an extended residence time at low temperature, including residence time and operating temperature controls. The resulting iron carbide product is also disclosed.

Abstract: A method and apparatus for producing direct reduced iron from iron oxide fines. The iron oxide raw material is conducted through a series of circulating fluidizable beds in which the fluidizing gas is a strong reducing gas mixture, which allows intimate contact between the fines and the reducing gas to facilitate the direct reduction of the iron oxide fines to metallized iron.

Abstract: A method and apparatus for the production of iron carbide in a shaft furnace, by reacting a carbon containing reducing gas as the process gas with particulate metal oxide material for an extended residence time at low temperature.

Abstract: A method of producing direct reduced iron from pellets, lumps and fines of iron oxide. A mixture of iron oxide raw material is introduced to an apparatus which separates the lumps and pellets from the fines. The lumps and pellets are then introduced to a shaft furnace for direct reduction to iron. Fines are conveyed to a series of circulating fluidizable beds which allows intimate contact with reducing gas to facilitate the direct reduction of the iron oxide fines to metallized iron.

Abstract: A method and apparatus for producing direct reduced iron from iron oxide fines. The iron oxide raw material is conducted through a series of circulating fluidizable beds in which the fluidizing gas is a strong reducing gas mixture, which allows intimate contact between the fines and the reducing gas to facilitate the direct reduction of the iron oxide fines to metallized iron.

Abstract: A method of producing iron from finely divided iron oxide comprising the steps of: mixing iron oxide or iron ore fines with finely divided coal and a binder to form a mixture, agglomerating the mixture by compacting, pelletizing, or briquetting the mixture to form agglomerates or pellets, introducing the pellets to a rotary hearth furnace to prereduce the iron in the pellets, introducing the prereduced pellets into a smelting reduction vessel as the metallic charge constituent, introducing particulate carbonaceous fuel and oxygen to the smelting reduction vessel through the bottom of the vessel to react with the melt or bath within the vessel, reduce the iron to elemental iron and form an off gas containing CO and H.sub.2 introducing the off-gas into the rotary hearth furnace as process gas to prereduce the pellets therein, and drawing off the hot metal from the smelting reduction vessel.The prereduced compacts are preferably discharged from the rotary hearth furnace at a temperature of at least 1000.degree.

Abstract: A highly efficient method and apparatus for production of molten iron using coal by coal gasification in a molten iron gasifier-melter. The gasifier-melter is coupled to a direct reduction shaft furnace and utilizes both the gaseous and solid output of the shaft furnace. The process is especially efficient when using non-metallurgical coals.

Abstract: A method for forming a reducing gas in a molten metal bath gasifier and simultaneously directly reducing iron oxide in a shaft furnace with the gas thus produced, wherein the bath coolant is preferably provided by cleaned recycle gas from the direct reduction shaft furnace.

Abstract: Apparatus for generating a reducing gas in a molten iron bath gasifier while simultaneously producing direct reduced iron oxide in an associated shaft furnace with the gas from the gasifier. The apparatus includes means for controlling the temperature of the reducing gas to the shaft furnace, means for cleaning, upgrading, and introducing spent top gas from the direct reduction furnace to the molten bath gasifier as a gaseous coolant to cool the reaction with the bath and reduce refractory wear within the gasifier.

Abstract: Ores which include in combination iron oxide, cobalt oxide and nickel oxide are treated in a continuous shaft reduction furnace to selectively reduce nickel and cobalt to metallized form while leaving the iron oxide in the oxide form. Reacted top gas is recycled and mixed with partially combusted gasified fossil fuel in a combustion chamber to achieve the required concentration of reductants in the reducing gas. The cooling zone operates with a similar concentration of reductants in the cooling gas. Apparatus is also disclosed for carrying out the process.

Abstract: Ores which include in combination iron oxide, cobalt oxide and nickel oxide are treated in a continuous shaft reduction furnace to selectively reduce nickel and cobalt to metallized form while leaving the iron oxide in the oxide form. Reacted top gas is recycled and mixed with partially combusted gasified fossil fuel in a combustion chamber to achieve the required concentration of reductants in the reducing gas. The cooling zone operates with a similar concentration of reductants in the cooling gas. Apparatus is also disclosed for carrying out the process.

Abstract: A method and apparatus for the dry collection of metallized fines from a direct reduction furnace cooling zone in which cooling gas removed from the cooling zone passes through a dust collector and the removed dust is cooled in a fluidized bed, the fluidizing gas being recirculated through an indirect cooler. The process is continuous and the fines are collected at a sufficiently low temperature for easy handling. The apparatus includes a hot gas cyclone in the cooling gas withdrawal line connected to a fluidized bed cooler, a conduit for withdrawing fluidizing gas from the fluidized bed cooler passes through a second cyclone dust collector then through an indirect cooler and returns to the fluidized bed cooler. Cool fines are withdrawn from the fluidized bed cooler into a collector.

Abstract: A method and 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 counterflow relationship thereby heating and reducing the burden. The heat for reduction is generated by passing electric current through the burden. A portion of the heat for melting of reduced iron and a supplemental source of hot reducing gas is provided by oxy-fuel burners located in the shaft furnace above the molten iron pool.

Abstract: A method of producing direct reduced iron with fluid bed coal gasification in which a portion of cooled, recycled gas is used as coolant in the gasification chamber and a second portion of the cleaned recycled gas is heated and mixed with the hot, dust-free gasification gas to form reducing gas for the direct reduction process. Limestone is preferably mixed with the pulverized coal feed to the gasification chamber to desulfurize the gas.

Abstract: A method and 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 counterflow relationship thereby heating and reducing the burden. The heat for reduction is generated by passing electric current through the burden. A portion of the heat for melting of reduced iron and a supplemental source of hot reducing gas is provided by oxy-fuel burners located in the shaft furnace above the molten iron pool.

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.