Abstract: A process for the gaseous reduction of iron ore to sponge iron in a vertical shaft, moving bed reactor wherein a hot gaseous mixture of hydrogen and a carbon monoxide is used to reduce the ore. It has been found unnecessary to use the external catalytic reformer of prior art processes to reform the methane and other hydrocarbon constituents of the natural gas commonly used as a source of gaseous reductants. By establishing a reducing gas recycle loop to which make-up natural gas and steam are fed in the proper proportions, the product sponge iron in the reactor can be used to catalyze hydrocarbon reformation, provided that the carbon content of the recycled gas is maintained low by removing carbon dioxide therefrom. Where pure methane is employed, steam/methane molar ratios within the preferred range of 1.4:1 to 2.2:1 are used.

Abstract: A discharge flow regulating device for regulating the discharge of sponge metal from the bottom of a vertical, moving bed reduction reactor. A frustoconical baffle near the bottom of the reactor directs the flow of particles toward a horizontal plate spaced from the baffle and having a diameter sufficient to block the passage of the particles. Gas under pressure is supplied to the center of the plate and directed radially outward to blow particles over the rim of the plate. The supply of pressurized gas is regulated to regulate the rate at which particles are forced to and over the perimeter of the plate. The gas also serves to cool the sponge metal in the lower portion of the reactor.