Abstract: This invention relates to a burner and a method of combustion for producing a flame jet sheet or sheets for various applications in industrial furnaces. The burner has at least one linear or curvilinear flame nozzle having a ratio of width to height of greater than unity in order to produce high velocity and high temperature flame jet sheet or sheets with a well defined geometry. The burner is capable of being scaled to various sizes for various industrial furnace applications due to its geometry.

Abstract: Method and apparatus for smelting iron ore in which iron ore is preheated and partly reduced within a first reaction zone and then further reduced in a second reaction zone. The first reaction zone can be a shaft reduction furnace and the second reaction zone can be a melter gasifier. An auxiliary third reaction zone partially oxidizes a carbonaceous material to produce char for the third reaction zone. A reducing gas produced by partial oxidation of the char is used to effect the partial reduction conducted within the first reaction zone. Volatile substances contained within a heating gas produced by the partial oxidation within the auxiliary third reaction zone is further oxidized and used to preheat the iron ore within the first reaction zone.

Abstract: A method of smelting iron ore in which iron oxide and hot char are introduced into a primary reactor to reduce the iron oxide and thereby form a molten pool of elemental iron and iron oxide slag. A carbon containing substance, comprising fixed carbon and a hydrocarbon containing volatile matter, is introduced into a secondary reactor. The hydrocarbon containing volatile matter is partially oxidized within the secondary reactor to produce the hot char and a fuel gas comprising hydrocarbons, carbon monoxide, carbon dioxide, steam, and hydrogen with a CO2:CO molar ratio greater than about 0.25. The fuel gas is burned within the primary reactor so that a projected flame is produced and the projected flame is directed into the iron oxide slag of the molten pool.

Abstract: Method and apparatus for smelting iron ore in which iron ore is preheated and partly reduced within a first reaction zone and then further reduced in a second reaction zone. The first reaction zone can be a shaft reduction furnace and the second reaction zone can be a melter gasifier. An auxiliary third reaction zone partially oxidizes a carbonaceous material to produce char for the third reaction zone. A reducing gas produced by partial oxidation of the char is used to effect the partial reduction conducted within the first reaction zone. Volatile substances contained within a heating gas produced by the partial oxidation within the auxiliary third reaction zone is further oxidized and used to preheat the iron ore within the first reaction zone.

Abstract: An iron ore refining method in which a secondary reactor is employed for partly reducing iron ore and partly oxidizing a carbon containing substance to form partly reduced secondary iron ore, the coal char and a calorific containing carbon dioxide and carbon monoxide in a ratio of no less than about 0.25. The calorific gas is separated from the partly reduced secondary iron ore and the coal char and the resulting heated solids are introduced into the primary reactor without substantial cooling. All or part of the iron product is formed from the partly reduced iron ore produced in the primary reactor. Since the secondary reactor operates at a lower temperature than the primary reactor, part of the iron product is processed at a lower temperature to reduce oxygen requirements for the refining and to increase thermal efficiency.

Abstract: A heat exchanger for use within a sump to condense an vapor and to vaporize the liquid. The heat exchanger includes a core having alternating passages to vaporize the liquid and to condense the vapor. Liquid is distributed into passages through a liquid distributor and the passages involved in vaporizing the liquid are provided with a down flow, stage and one or more thermosiphon stages situated below the down flow stage. In such manner, part of the liquid is vaporized within the down flow stage and the remainder is vaporized within the thermosiphon stage or stages.

Abstract: A heat exchanger is provided which is suitable for use as a condenser/reboiler in a double distillation column. The heat exchanger has alternating first and second passages and a reservoir located above the first and second passages for receiving a first fluid and for containing a froth. A series of orifices can be provided by a distributor tray to provide flow communication between the reservoir and the first passages to allow at least a liquid phase of the froth to weep into the first passages and to be partly vaporized through indirect heat exchange with a second fluid flowing through the second passages. The partial vaporization produces a vapor phase of the froth which can at least in part escape from the orifices and interact with the first fluid to thereby form the froth. A remaining part of the liquid phase, not vaporized through the indirect heat exchange, is discharged from the bottom of the first passages into a sump.