Abstract: A method is disclosed for the gaseous reduction of iron ore to sponge iron at a given degree of carburization and yet at a temperature suitable for hot briquetting or for direct feed to a melter or to a refining furnace. The desired percentage of carburization and the preferred elevated temperature are achieved by using a hot blend of recycled reducing gas and essentially uncracked natural gas or methane to carburize and to decrease the temperature of the sponge iron in the modifying zone of the reactor.

Abstract: A method is disclosed for the gaseous reduction of iron ore to sponge iron at a given degree of carburization and yet at a temperature suitable for hot briquetting or for direct feed to a melter or to a refining furnace. The desired percentage of carburization and the preferred elevated temperature are achieved by using a hot blend of recycled reducing gas and essentially uncracked natural gas or methane to carburize and to decrease the temperature of the sponge iron in the cooling zone of the reactor.

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.