Abstract: Process for producing Iron carbide wherein, in a first stage, Iron ore is reduced to sponge iron using a reducing gas containing at least 90% hydrogen, on a nitrogen-free basis, to produce a sponge iron having a carbon content of less than 1% wt.; then in a second stage the sponge iron is fluidized at a temperature of 500 to 800° C. with a methane-containing fluidizing gas in a fluidized bed reactor wherein the water content of the gas in the reactor is not more than 1.5% wt., to produce a product wherein at least 85% of the iron content is in the form of Fe3C.

Abstract: The direct reduced iron (DRI) which for at least 80 wt-% has a grain size of not more than 3 mm is melted in an electric arc furnace. The furnace contains a bath of liquid iron. During the operation of the furnace a foamy slag layer is formed on the bath and the DRI falls by gravity through at least one movable lance into the foamy slag layer on the iron bath. Preferably, the distance of the aperture of the lance to the iron bath is kept practically constant.

Abstract: Iron carbide (Fe 3 C) is produced from granulated j sponge iron which has a maximum carbon content of 2 wt. % and is supplied from an iron ore reducing plant. The sponge iron is swirled with a gas containing carbon and a maximum 1.5 vol. % water in a fluidized bed reactor at temperatures ranging, from 500 to 800° C. A product is extracted from the reactor. The total iron content of said product is fixed at a minimum of 80 wt. % Fe 3 C. Preferably, methane or a gas containing methane is fed into the fluidized bed reactor as a gas containing carbon. A waste gas can be extracted from the top area of the fluidized bed reactor and hydrogen can be separated therefrom and at least partially directed into the reducing plant.