Abstract: A system for producing molten iron from iron ores, including a direct reduction shaft furnace, a melting zone in a melting furnace having a coke bed in its lower portion and a charging and preheating chamber in its upper portion, and at least one reducing gas generation zone in communication with said melting zone.

Abstract: A method and apparatus for the production of prereduced iron ore, DRI, sponge iron or the like by the gaseous reduction of iron-oxide containing particles in a reduction system which comprises a preheating device for the iron ore particles. The preheating device preserves the strength of the iron ore particles through the reduction system by preheating the particles with non-reducing (or preferably oxidizing) gas, whereby the DRI or like material produced is stronger than if it were processed in a reduction reactor without said preheating device. The invention thereby avoids sticking and fines production problems which some iron ores cause in the reduction reactor. The preheating device also produces other advantages in the reduction system as, for example, that the reducing gas reaches a higher degree of oxidation in the reduction reactor whereby the productivity of the reduction system increases as a result of the decreased amount of reducing gas as well as the decreased residence time required.

Abstract: Methods and apparatus for the reduction into metallic iron of iron-oxides-containing particles having a broad range of sizes. Particles, typically within a broad range of sizes of about 0.1 mm to about 50 mm, are reduced by contact with a hot reducing gas, preferably from a horizontal gas distributor which defines the bottom of the reduction zone by supplying a uniform upflow of gas mainly composed of hydrogen (and/or carbon monoxide) within a temperature range of 650° C. to 1050° C. and at a velocity of about 0.5-0.7 m/s to fluidize at least some of the particles of a size of about 1.0 mm or less (when present).

Abstract: The present invention describes a method and apparatus for the reduction into metallic iron of iron-oxides-containing particles having a broad range of sizes. Particles, preferably within a broad range of sizes smaller than about 3.2 mm, are reduced by contact with a hot reducing gas, preferably mainly composed of hydrogen and within a temperature range of 700 to 750.degree. C. The reducing gas flows through a descending moving bed of coarser particles and forms an ascending fluidized bed of fines, all in a single reduction reactor, where the particles charged to the reactor are fed into the lower portion of the fluidized bed and the reduced fines are withdrawn from the reactor from the upper portion of the fluidized bed.

Abstract: A method and apparatus for producing DRI, prereduced materials, or the like, utilized in the steelmaking industry, where hydrogen contained in the gas stream purged from the reduction reactor is separated (preferably by means of a PSA system) and recycled to said reduction reactor. The productivity of the reduction plant is increased by using the separated hydrogen as a chemical reductant in the reactor, instead of using it as fuel. This is particularly useful in upgrading existing DRI production plants.

Abstract: A process for the gaseous reduction of iron ore to sponge in a vertical shaft, moving bed reactor wherein a hot gaseous mixture of hydrogen and carbon monoxide generated by the internal steam reformation of gaseous hydrocarbon(s), preferably methane or natural gas, is used to reduce the ore without the need for any external catalytic reformer. A reducing gas recycle loop is established to which hydrocarbon and reclaimed waste hot water are fed in the proper proportions as the reducing gas make-up source with the sponge iron produced in the reduction reactor being used to catalyze hydrocarbon reformation, and with the carbon content of the recycled gas being maintained low by removing carbon dioxide therefrom.

Abstract: A method for the desulfurization of sour natural gas containing sulfur contaminants wherein the natural gas is first heated to a temperature in the range of 250.degree. C. to 450.degree. C. and then contacted with a bed of sponge iron to remove at least a portion of the sulfur contaminants to form a sweet natural gas.

Abstract: A method is disclosed for achieving improved reduction efficiency and economy in the reduction of particulate metal ores, e.g. iron ore, in a vertical shaft, moving bed reactor having a reduction zone in which a heated reducing gas is caused to flow through a portion of the ore bed to reduce the metal ore thereof to metal; e.g. sponge iron. The improved efficiency and economy is achieved through an integrated reduction system in which a conventional reformer is used without the need to upgrade the reformed gas prior to feeding it directly to the reduction reactor as a reducing gas.