Abstract: Disclosed herein are methods and compositions for producing composite pellets comprising a core comprising: iron ore and a carbonaceous reducing agent; and a shell comprising: iron ore; and having a core and shell transition in a manner such that no visible boundary exists between the core and the shell in a cross-section of the pellet. The methods can be used to produce composite pellets with improved productivity and quality, and the resulting composite pellets can be used to produce direct reduced iron (DRI).

Abstract: Disclosed herein are compositions and methods of making a hard magnetic material from iron oxide fines, the hard magnetic material having a general formula MFexOy. In one aspect, the method comprises a) providing an iron oxide fine; b) providing a metal carbonate of a general formula Mx(CO3)y; c) mixing the iron oxide fine and the metal carbonate to form a mixture; d) calcining the mixture of the iron oxide fine and the metal carbonate; wherein M is a divalent metal ion.

Abstract: Iron ore pellets including a core comprising iron ore, a first coating comprising lime, and a second coating comprising cement, wherein the first coating is disposed between a surface of the core and the second coating. A process for manufacturing the iron ore pellets whereby the first coating is applied to the core to form a coated core, the surface area coverage of the first coating is measured, the second coating is applied to the coated core, and the surface area coverage of the second coating is measure. A process for manufacturing reduced iron pellets is also provided whereby the iron ore pellets are reduced with a reducing gas at temperatures up to 1100° C.

Abstract: Disclosed herein are methods and compositions for producing composite iron pellets comprising an inner core comprising iron ore and a reducing agent comprising a carbonaceous material; and an outer shell comprising unreduced iron ore. The resulting composite iron pellets can be used to produce direct reduced iron (DRI) with improved productivity while reducing gas consumption.

Abstract: Disclosed are coating compositions and methods for their use, comprising 90 wt. % electric arc furnace dust based on the total dry weight of the coating composition. The electric arc furnace dust includes at least 40 wt. % of Fe2O3 and at least 30 wt. % of CaO and CaCO3 combined, based on the total dry weight of the electric arc furnace dust.

Abstract: Iron ore pellets including a core comprising iron ore, a first coating comprising lime, and a second coating comprising cement, wherein the first coating is disposed between a surface of the core and the second coating. A process for manufacturing the iron ore pellets whereby the first coating is applied to the core to form a coated core, the surface area coverage of the first coating is measured, the second coating is applied to the coated core, and the surface area coverage of the second coating is measure. A process for manufacturing reduced iron pellets is also provided whereby the iron ore pellets are reduced with a reducing gas at temperatures up to 1100° C.

Abstract: Disclosed herein are methods and compositions for producing composite pellets comprising a core comprising: iron ore and a carbonaceous reducing agent; and a shell comprising: iron ore; and having a core and shell transition in a manner such that no visible boundary exists between the core and the shell in a cross-section of the pellet. The methods can be used to produce composite pellets with improved productivity and quality, and the resulting composite pellets can be used to produce direct reduced iron (DRI).

Abstract: Disclosed herein are compositions and methods of making a hard magnetic material from iron oxide fines, the hard magnetic material having a general formula MFexOy. In one aspect, the method comprises a) providing an iron oxide fine; b) providing a metal carbonate of a general formula Mx(CO3)y; c) mixing the iron oxide fine and the metal carbonate to form a mixture; d) calcining the mixture of the iron oxide fine and the metal carbonate; wherein M is a divalent metal ion.

Abstract: Disclosed herein are methods and compositions for producing composite iron pellets comprising an inner core comprising iron ore and a reducing agent comprising a carbonaceous material; and an outer shell comprising unreduced iron ore. The resulting composite iron pellets can be used to produce direct reduced iron (DRI) with improved productivity while reducing gas consumption.

Abstract: Disclosed herein are methods and compositions for producing coated iron oxide pellets comprising an outer coating comprising cement exhibiting a reduced sticking index while retaining a high level of metallization following reduction. The improved coated iron oxide pellets can be used to produce direct reduced iron (DRI) with improved productivity.