Abstract: A method and apparatus for increasing hydrocarbons to a direct reduction shaft furnace while controlling the temperature uniformity of the center portion of the iron burden wherein the hydrocarbon gases used in direct reduction may be preheated, which increases the temperature of the hydrocarbon gases, and therefore increases the resultant temperature of the upflowing gases as it rises from the lower section of the furnace into the center of the burden. Alternatively, a portion of the upflowing gas may be removed before it enters the reduction zone of the furnace. The removed upflowing gas, known as hot bleed gas, may be ducted to the top gas scrubber of the furnace or may be mixed with the main reducing gas stream of the furnace for reintroduction to the furnace. Alternatively, hot reducing gas may be directly injected into the center portion of the burden, offsetting the cooling effect of the upflowing gas.

Abstract: An improved method and apparatus for increasing the productivity of a direct reduction process in which iron oxide is reduced to metallized iron by contact with hot reducing gas; comprising the steps of: a) providing a first hot reducing gas consisting essentially of CO and H2; b) providing additional reducing gas by reaction of a gaseous or liquid hydrocarbon fuel with oxygen; c) mixing the first hot reducing gas with the additional reducing gas to form a reducing gas mixture; d) enriching the reducing gas mixture by the addition of a gaseous or liquid hydrocarbon; e) injecting oxygen or oxygen-enriched air into the enriched mixture; and f) introducing the enriched mixture into an associated direct reduction furnace as reducing gas.

Abstract: An improved method and apparatus for increasing the productivity of a direct reduction process in which iron oxide is reduced to metallized iron by contact with hot reducing gas; comprising the steps of: a) providing a first hot reducing gas consisting essentially of CO and H2; b) providing additional reducing gas by reaction of a gaseous or liquid hydrocarbon fuel with oxygen; c) mixing the first hot reducing gas with the additional reducing gas to form a reducing gas mixture; d) enriching the reducing gas mixture by the addition of a gaseous or liquid hydrocarbon; e) injecting oxygen or oxygen-enriched air into the enriched mixture; and f) introducing the enriched mixture into an associated direct reduction furnace as reducing gas.

Abstract: A method and apparatus for discharging cold product or a combination of cold and hot products from a continuous supply of hot direct reduced iron (“DRI”) comprising a product cooler connected to a shaft furnace, with downward movement of the hot DRI and upward concurrent flow of cooling gas through the product cooler. The method and apparatus provides for diverting of hot DRI from an upper portion of the cooler for gravitational transfer to an adjacent storage unit located at a lower elevation than the furnace. The product cooler is situated at a lower height in relation to the furnace, for gravity transfer of a continuous supply of hot DRI through an entry point into the cooler. Cooler provides for cooling gas injection into the lower portion of the cooler, with gas flow upward and counter-current to the hot DRI that descends through the cooler. Recovered cooling gas is scrubbed, cooled, and recycled back for injection into the bottom portion of the cooler.