Patents by Inventor James M. McClelland
James M. McClelland has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 9534265Abstract: Methods and systems for producing direct reduced iron (DRI), comprising: generating a syngas stream in a carbon dioxide (CO2) and steam reformer; and providing the syngas stream to a direct reduction (DR) shaft furnace as a reducing gas stream. The methods and systems also comprise combining the syngas stream with a recycled off-gas stream from the DR shaft furnace to form the reducing gas stream. The methods and systems further comprise removing carbon dioxide (CO2) from the recycled off-gas stream from the DR shaft furnace prior to combining it with the syngas stream to form the reducing gas stream. The methods and systems still further comprise feeding CO2 removed from the recycled off-gas stream from the DR shaft furnace to the CO2 and steam reformer. The methods and systems still further comprise feeding recycled off-gas from the recycled off-gas stream from the DR shaft furnace to the CO2 and steam reformer.Type: GrantFiled: December 15, 2014Date of Patent: January 3, 2017Assignee: Midrex Technologies, Inc.Inventors: Gary E. Metius, Gregory D. Hughes, James M. McClelland, Jr.
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Publication number: 20160168653Abstract: Methods and systems for producing direct reduced iron (DRI), comprising: generating a syngas stream in a carbon dioxide (CO2) and steam reformer; and providing the syngas stream to a direct reduction (DR) shaft furnace as a reducing gas stream. The methods and systems also comprise combining the syngas stream with a recycled off-gas stream from the DR shaft furnace to form the reducing gas stream. The methods and systems further comprise removing carbon dioxide (CO2) from the recycled off-gas stream from the DR shaft furnace prior to combining it with the syngas stream to form the reducing gas stream. The methods and systems still further comprise feeding CO2 removed from the recycled off-gas stream from the DR shaft furnace to the CO2 and steam reformer. The methods and systems still further comprise feeding recycled off-gas from the recycled off-gas stream from the DR shaft furnace to the CO2 and steam reformer.Type: ApplicationFiled: December 15, 2014Publication date: June 16, 2016Applicant: MIDREX TECHNOLOGIES, INC.Inventors: Gary E. METIUS, Gregory D. HUGHES, James M. MCCLELLAND, JR.
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Patent number: 9127326Abstract: In various exemplary embodiments, the present invention provides systems and methods that can convert clean or raw natural gas, clean or dirty coke oven gas, or the like to reducing gas/syngas suitable for direct reduction with minimal processing or cleaning. Hydrocarbons and the like are converted to H2 and CO. S does not affect the conversion to reducing gas/syngas, but is removed or otherwise cleaned up by the iron bed in the direct reduction shaft furnace. Top gas may be continuously recycled or a once-through approach may be employed.Type: GrantFiled: November 1, 2013Date of Patent: September 8, 2015Assignee: Midrex Technologies, Inc.Inventors: Gary E. Metius, James M. McClelland, Jr., David C. Meissner, Stephen C. Montague
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Patent number: 9028585Abstract: Novel systems and methods are described for reducing iron oxide to metallic iron in an integrated steel mill or the like that has a coke oven and/or an oxygen steelmaking furnace. More specifically, the present invention relates to novel systems and methods for reducing iron oxide to metallic iron using coke oven gas (COG) or COG and basic oxygen furnace gas (BOFG).Type: GrantFiled: July 31, 2013Date of Patent: May 12, 2015Assignee: Midrex Technologies, Inc.Inventors: Gary E. Metius, James M. McClelland, Jr., David C. Meissner, Stephen C. Montague
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Patent number: 8771638Abstract: A method and apparatus for sequestering carbon dioxide from a waste gas and reusing it as a recycled gas without emissions concerns, including: given a gas source divided into a process gas and a waste gas: mixing the process gas with a hydrocarbon and feeding a resulting feed gas into a reformer for reforming the feed gas and forming a reducing gas; and feeding at least a portion of the waste gas into a carbon dioxide scrubber for removing at least some carbon dioxide from the waste gas and forming a carbon dioxide lean gas that is mixed with the reducing gas. Optionally, the method also includes feeding at least a portion of the waste gas into the carbon dioxide scrubber for removing at least some carbon dioxide from the waste gas and forming a fuel gas after the addition of a hydrocarbon that is fed into the reformer.Type: GrantFiled: February 15, 2013Date of Patent: July 8, 2014Assignee: Midrex Technologies, Inc.Inventors: Gary E. Metius, James M. McClelland
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Patent number: 8685136Abstract: A process for reducing iron oxide to metallic iron using coke oven gas (COG), including: a direct reduction shaft furnace for providing off gas; a COG source for injecting COG into a reducing gas stream including at least a portion of the off gas; and the direct reduction shaft furnace reducing iron oxide to metallic iron using the reducing gas stream and injected COG. The COG has a temperature of about 1,200 degrees C. or greater upon injection. The COG has a CH4 content of between about 2% and about 13%. Preferably, the COG is reformed COG. Optionally, the COG is fresh hot COG. The COG source includes a partial oxidation system. Optionally, the COG source includes a hot oxygen burner.Type: GrantFiled: January 31, 2012Date of Patent: April 1, 2014Assignee: Midrex Technologies, Inc.Inventors: Gary E. Metius, James M. McClelland, Jr., David C. Meissner
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Publication number: 20140053686Abstract: In various exemplary embodiments, the present invention provides systems and methods that can convert clean or raw natural gas, clean or dirty coke oven gas, or the like to reducing gas/syngas suitable for direct reduction with minimal processing or cleaning. Hydrocarbons and the like are converted to H2 and CO. S does not affect the conversion to reducing gas/syngas, but is removed or otherwise cleaned up by the iron bed in the direct reduction shaft furnace. Top gas may be continuously recycled or a once-through approach may be employed.Type: ApplicationFiled: November 1, 2013Publication date: February 27, 2014Applicant: MIDREX TECHNOLOGIES, INC.Inventors: Gary E. METIUS, James M. MCCLELLAND, JR., David C. MEISSNER, Stephen C. MONTAGUE
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Publication number: 20130312571Abstract: Novel systems and methods are described for reducing iron oxide to metallic iron in an integrated steel mill or the like that has a coke oven and/or an oxygen steelmaking furnace. More specifically, the present invention relates to novel systems and methods for reducing iron oxide to metallic iron using coke oven gas (COG) or COG and basic oxygen furnace gas (BOFG).Type: ApplicationFiled: July 31, 2013Publication date: November 28, 2013Applicant: MIDREX TECHNOLOGIES, INC.Inventors: Gary E. METIUS, James M. MCCLELLAND, JR., David C. MEISSNER, Stephen C. MONTAGUE
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Patent number: 8496730Abstract: A process for the direct reduction of iron ore when the external source of reductants is one or both of coke oven gas (COG) and basic oxygen furnace gas (BOFG). Carbon dioxide (CO2) is removed from a mixture of shaft furnace off gas, obtained from a conventional direct reduction shaft furnace, and BOFG. This CO2 lean gas is mixed with clean COG, humidified, and heated in an indirect heater. Oxygen (O2) is injected into the heated reducing gas. This hot reducing gas flows to the direct reduction shaft furnace for use. The spent hot reducing gas exits the direct reduction shaft furnace as shaft furnace off gas, produces steam in a waste heat boiler, is cleaned in a cooler scrubber, and is compressed and recycled to join fresh BOFG. A portion of the shaft furnace off gas is sent to the heater burners. The BOFG and COG are also employed for a variety of other purposes in the process.Type: GrantFiled: May 13, 2011Date of Patent: July 30, 2013Assignee: Midrex Technologies, Inc.Inventors: Gary E. Metius, James M. McClelland, Jr., David C. Meissner
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Publication number: 20130171049Abstract: A method and apparatus for sequestering carbon dioxide from a waste gas and reusing it as a recycled gas without emissions concerns, including: given a gas source divided into a process gas and a waste gas: mixing the process gas with a hydrocarbon and feeding a resulting feed gas into a reformer for reforming the feed gas and forming a reducing gas; and feeding at least a portion of the waste gas into a carbon dioxide scrubber for removing at least some carbon dioxide from the waste gas and forming a carbon dioxide lean gas that is mixed with the reducing gas. Optionally, the method also includes feeding at least a portion of the waste gas into the carbon dioxide scrubber for removing at least some carbon dioxide from the waste gas and forming a fuel gas after the addition of a hydrocarbon that is fed into the reformer.Type: ApplicationFiled: February 15, 2013Publication date: July 4, 2013Applicant: Midrex Technologies, Inc.Inventors: Gary E. Metius, James M. McClelland, JR.
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Patent number: 8377417Abstract: A method and apparatus for sequestering carbon dioxide from a waste gas and reusing it as a recycled gas without emissions concerns, including: given a gas source divided into a process gas and a waste gas: mixing the process gas with a hydrocarbon and feeding a resulting feed gas into a reformer for reforming the feed gas and forming a reducing gas; and feeding at least a portion of the waste gas into a carbon dioxide scrubber for removing at least some carbon dioxide from the waste gas and forming a carbon dioxide lean gas that is mixed with the reducing gas. Optionally, the method also includes feeding at least a portion of the waste gas into the carbon dioxide scrubber for removing at least some carbon dioxide from the waste gas and forming a fuel gas after the addition of a hydrocarbon that is fed into the reformer.Type: GrantFiled: April 19, 2010Date of Patent: February 19, 2013Assignee: Midrex Technologies, Inc.Inventors: Gary E. Metius, James M. McClelland, Jr.
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Publication number: 20120125159Abstract: A process for reducing iron oxide to metallic iron using coke oven gas (COG), including: a direct reduction shaft furnace for providing off gas; a COG source for injecting COG into a reducing gas stream including at least a portion of the off gas; and the direct reduction shaft furnace reducing iron oxide to metallic iron using the reducing gas stream and injected COG. The COG has a temperature of about 1,200 degrees C. or greater upon injection. The COG has a CH4 content of between about 2% and about 13%. Preferably, the COG is reformed COG. Optionally, the COG is fresh hot COG. The COG source includes a partial oxidation system. Optionally, the COG source includes a hot oxygen burner.Type: ApplicationFiled: January 31, 2012Publication date: May 24, 2012Applicant: MIDREX TECHNOLOGIES, INC.Inventors: Gary E. METIUS, James M. MCCLELLAND, JR., David C. MEISSNER
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Publication number: 20110277591Abstract: A process for the direct reduction of iron ore when the external source of reductants is one or both of coke oven gas (COG) and basic oxygen furnace gas (BOFG). Carbon dioxide (CO2) is removed from a mixture of shaft furnace off gas, obtained from a conventional direct reduction shaft furnace, and BOFG. This CO2 lean gas is mixed with clean COG, humidified, and heated in an indirect heater. Oxygen (O2) is injected into the heated reducing gas. This hot reducing gas flows to the direct reduction shaft furnace for use. The spent hot reducing gas exits the direct reduction shaft furnace as shaft furnace off gas, produces steam in a waste heat boiler, is cleaned in a cooler scrubber, and is compressed and recycled to join fresh BOFG. A portion of the shaft furnace off gas is sent to the heater burners. The BOFG and COG are also employed for a variety of other purposes in the process.Type: ApplicationFiled: May 13, 2011Publication date: November 17, 2011Inventors: Gary E. Metius, James M. McClelland, JR., David C. Meissner
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Publication number: 20100264374Abstract: A method and apparatus for sequestering carbon dioxide from a waste gas and reusing it as a recycled gas without emissions concerns, including: given a gas source divided into a process gas and a waste gas: mixing the process gas with a hydrocarbon and feeding a resulting feed gas into a reformer for reforming the feed gas and forming a reducing gas; and feeding at least a portion of the waste gas into a carbon dioxide scrubber for removing at least some carbon dioxide from the waste gas and forming a carbon dioxide lean gas that is mixed with the reducing gas. Optionally, the method also includes feeding at least a portion of the waste gas into the carbon dioxide scrubber for removing at least some carbon dioxide from the waste gas and forming a fuel gas after the addition of a hydrocarbon that is fed into the reformer.Type: ApplicationFiled: April 19, 2010Publication date: October 21, 2010Inventors: Gary E. METIUS, James M. MCCLELLAND, JR.
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Patent number: 7678176Abstract: The present invention provides a method and apparatus for charging hot direct reduced iron (HDRI) from hot transport vessels (HTVs) into a melter or finisher. In general, the apparatus includes a charging stand including a plurality of bays for receiving and supporting a plurality of HTVs. Each HTV includes at least an outlet port. This outlet port is configured to engage an inlet port of one of the plurality of bays of the charging stand via a telescoping seal that provides a substantially air-tight seal. A feed device is provided that moves the HDRI disposed within the HTVs from the outlet port/inlet port interface to a melter or finisher, such as an electric arc furnace (EAF) or the like. The charging stand also includes one or more load cells operable for weighing the HTVs and the HDRI disposed therein, such that a computer or other logic may be used to control the feed rate of the HDRI charged into the melter or finisher.Type: GrantFiled: June 29, 2007Date of Patent: March 16, 2010Assignee: Midrex Technologies, Inc.Inventors: Gilbert V. Whitten, James M. McClelland, Stephen C. Montague, Brian W. Voelker
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Publication number: 20080000327Abstract: The present invention provides a method and apparatus for charging hot direct reduced iron (HDRI) from hot transport vessels (HTVs) into a melter or finisher. In general, the apparatus includes a charging stand including a plurality of bays for receiving and supporting a plurality of HTVs. Each HTV includes at least an outlet port. This outlet port is configured to engage an inlet port of one of the plurality of bays of the charging stand via a telescoping seal that provides a substantially air-tight seal. A feed device is provided that moves the HDRI disposed within the HTVs from the outlet port/inlet port interface to a melter or finisher, such as an electric arc furnace (EAF) or the like. The charging stand also includes one or more load cells operable for weighing the HTVs and the HDRI disposed therein, such that a computer or other logic may be used to control the feed rate of the HDRI charged into the melter or finisher.Type: ApplicationFiled: June 29, 2007Publication date: January 3, 2008Inventors: Gilbert V. Whitten, James M. McClelland, Stephen C. Montague, Brian W. Voelker
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Patent number: 6802886Abstract: The invention is a method of making metallized iron agglomerates by combining iron/steel particles and a reductant material with a cellulose fiber binder material, compacting the combination to form a solid agglomerate, and reducing the iron portions of the agglomerate in a direct reduction furnace. The cellulose fiber binder material provides an agglomerate having improved strength and lower overall cost than comparable agglomerates using binders known in the art.Type: GrantFiled: May 10, 2001Date of Patent: October 12, 2004Assignee: Midrex Technologies, Inc.Inventors: Glenn E. Hoffman, James M. McClelland, Jr.
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Patent number: 6602322Abstract: An improved method and apparatus for recovering metal values from Electric Arc Furnace dust, particularly zinc and iron values, by mixing EAF dust and carbonaceous fines to form a particulate mixture; heating the mixture at a sufficient temperature and for a sufficient time to reduce and release volatile metals and alkali metals in a flue gas; collecting the released metals, and removing the metal values from the process as product.Type: GrantFiled: September 1, 2001Date of Patent: August 5, 2003Assignee: Midrex Technologies, Inc.Inventor: James M. McClelland, Jr.
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Publication number: 20030047035Abstract: An improved method and apparatus for recovering metal values from Electric Arc Furnace dust, particularly zinc and iron values, by mixing EAF dust and carbonaceous fines to form a particulate mixture; heating the mixture at a sufficient temperature and for a sufficient time to reduce and release volatile metals and alkali metals in a flue gas; collecting the released metals, and removing the metal values from the process as product.Type: ApplicationFiled: September 1, 2001Publication date: March 13, 2003Inventor: James M. McClelland
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Patent number: 6352573Abstract: A method of separating and recycling shards and fines that occur in a briquetting operation using an non-reactive carrier gas to separate and entrain the hot shards and fines, and conduct them to a material inlet of the briquetting machine, while separating and recycling the carrier gas. Apparatus for carrying out the method is also disclosed.Type: GrantFiled: March 21, 2001Date of Patent: March 5, 2002Assignee: Midrex International B.V. RotterdamInventors: James M. McClelland, Jr., Stephen C. Montague, Brian W. Voelker