Abstract: Particulate iron ore is reduced to sponge iron in a vertical shaft reduction reactor by forcing the ore upwardly in a moving bed counter-current to a descending stream of hot reducing gas produced by the gasification of coal in a gasifier, for example, a melter-gasifier, containing a molten iron bath and producing a hot dust-laden gas. The product sponge iron may be used as a feed material for the molten bath in the gasifier. The reactor is equipped with a gas outlet plenum containing a renewable body of ore to minimize clogging at the gas outlet.

Abstract: A method for the batchwise reduction of iron ore to sponge iron in a multiple unit reactor system is disclosed in which (a) separate fixed beds of iron-bearing material are simultaneously treated in at least one cooling reactor and at least two reduction reactors, (b) a reducing gas composed largely of carbon monoxide and hydrogen is used to cool the iron-bearing material in said cooling reactor and thereafter to reduce the iron-bearing material in said reduction reactors, (c) a stream of said reducing gas is caused to pass through the fixed bed of iron ore in said cooling reactor and then cooled and (d) a portion of the cooled effluent reducing gas from said cooling reactor is recycled thereto, the improvement which comprises causing the remainder of the cooling reactor effluent gas to be fed to said reduction reactors and to flow in parallel through the fixed beds of metal-bearing material in said reduction reactors, and heating the reducing gas fed to said reduction reactors before it enters said reactors

Abstract: A method for the gaseous reduction of iron ore to sponge iron in a vertical moving bed reactor having a reduction zone in the upper portion thereof and a cooling zone in the lower portion thereof which comprises using a coolant gas containing up to about 30% by volume of hydrocarbon, e.g., coke oven gas, and passing a mixture of the hydrocarbon-containing gas and steam through the cooling zone to cause the sponge iron therein to catalyze the conversion of the hydrocarbon/steam mixture to carbon monoxide and hydrogen.

Abstract: A method of eliminating hot spots in a mass of sponge iron particles made by gaseous reduction of iron ore. A layer of the particulate product is moved to a separating station, near which the layer is viewed by an infra-red detector that generates a control signal when insufficiently cooled particles register therewith. The control signal is used to shift the position of a particle guide member at the separating station to cause insufficiently cooled particles to be diverted from the main particle stream. Preferably the separation is carried out in two stages. Apparatus for carrying out the method is disclosed and claimed.

Abstract: A method of using coke oven gas, and more generally gaseous mixtures containing up to about 30% by volume of methane, for the direct gaseous reduction of iron ore in a vertical shaft, moving bed reactor. In addition to the usual reduction zone and cooling zone, the reactor is provided with an intermediate reforming zone. A hot mixture of coke oven gas and steam is fed to the intermediate zone and reduced ore therein catalyzes the conversion of the methane of the coke oven gas to carbon monoxide and hydrogen. The reformed gas flows upwardly into the reduction zone of the reactor.

Abstract: A method for the gaseous reduction of particulate ores to metals in a moving bed, vertical shaft reactor using a reducing gas externally supplied from a solid or liquid fossil fuel gasification unit. The reducing gas is reformed in a reforming zone located within the reactor and treated prior to injection into the reduction zone of the reactor. A portion of the reducing gas produced in a coal gasification unit may be used to cool the metal in the cooling zone of the reactor.

Abstract: A method for inhibiting carburization of metal-bearing material in the reduction zone of a vertical shaft, moving bed reactor for the direct gaseous reduction of iron ore to sponge iron. Carburization within the reduction zone is decreased by regulating the water vapor content of the reducing gas in any of various ways, e.g., by adding water vapor in the form of steam to the reducing gas either before it enters the reduction zone, while it is within the reduction zone, or after it leaves the reduction zone or by recirculating a portion of the effluent gas from the reactor and cooling the recirculated gas to a predetermined extent.