Abstract: An integrated steelmaking plant for merging continuous operation of a reduction reactor producing hot DRI with the batch operation of a DRI melting furnace(s). The reactor produces hot DRI for a DRI melting furnace or cold DRI continuously even when the DRI production exceeds the DRI consumption rate of the furnace or suffers long-term operational delays. The reduction reactor has a DRI cooling zone therein which is selectively operable for cooling DRI when the hot DRI produced in the reactor can't all be consumed by the DRI melting furnace and when the capacity of the DRI bin feeding the melting furnace is insufficient to accumulate additional hot DRI. No separate DRI cooling vessel plus its gas compressor and gas cooling-cleaning system is needed, thus decreasing capital and operational costs. This also permits a flexible and modular construction and operation of a steelmaking plant with high or low pressure reduction reactors.

Abstract: An integrated steelmaking plant design is disclosed for efficiently merging the continuous operation of a reduction reactor producing hot DRI with the batch operation of at least one DRI melting furnace. The direct reduction reactor is adapted for producing hot DRI for its consumption in a DRI melting furnace or for producing cold DRI when the continuous production of DRI will exceed the DRI consumption rate of the melting furnace or when it suffers long-term operational delays. The reduction reactor has a DRI cooling zone within the same reactor vessel which is selectively operable for cooling the DRI in the same reactor vessel when the hot DRI produced in said reactor will not be consumed by the DRI melting furnace and when the capacity of the hot DRI bin feeding the melting furnace is insufficient to accumulate the amount of hot DRI which will not be consumed.

Abstract: So as to provide a container that is inexpensive to manufacture and that promotes a uniform flow of particulate bulk materials therethrough, a vessel is suggested comprising at least two wall segments having a generally downwardly converging wall defining a vertical axis for the vessel, a first upper segment being vertically arranged above a second lower segment, each one of the wall segments having an upper edge and a lower edge, the perimeter of the upper edge of the second lower wall segment being larger than the perimeter of the lower edge of the first upper wall segment the lower edge of the first upper wall segment and the upper edge of the second lower wall segment being positioned proximate to each other and cooperating to provide an enlargement of the cross-sectional area of the volume occupied by the particulate solid material.

Abstract: So as to provide a container that is inexpensive to manufacture and that promotes a uniform flow of particulate bulk materials therethrough, a vessel (10) is suggested comprising at least two wall segments (12, 14) having a generally downwardly converging wall defining a vertical axis for said vessel, a first upper segment (12) being vertically arranged above a second lower segment (14), each one of said wall segments having an upper edge and a lower edge, the perimeter of the upper edge of said second lower wall segment (14) being larger than the perimeter of the lower edge of said first upper wall segment (12); said lower edge of said first upper wall segment (12) and said upper edge of said second lower wall segment (14) being positioned proximate to each other and cooperating to provide an enlargement (34) of the cross-sectional area of the volume occupied by said particulate solid material; and the lower edge of said first upper segment (12) defining a plane forming an angle with respect to the vertical

Abstract: Method and apparatus for pneumatically transporting solid and abrasive particulate materials at high temperature, by means of a carrier gas through a plurality of co-axial straight pipes. The pipes are maintained under constant tension by applying a force across at least one expansion joint coupling said pipes in order to maintain said pipes straight against the forces acting on said pipes which tend to cause bending and deformation thereof, as for example: thermal elongation, the weight of the solids conveyed through said pipes, the friction forces between said pipes and its supporting frame, and the pressure of the carrier gas inside said pipes. The constant tensioning force may be applied for example, by means of hydraulic cylinders in combination with a telescopic water-cooled sleeve.

Abstract: A high temperature water-cooled gas-tight lubricated steel plug valve for handling abrasive particulates (such as iron ore or sponge iron) having a water-cooled hollow double-walled housing with opposing inlet and outlet, a hollow internally-baffled axially water-cooled cylindrical plug with a transverse flow pipe defining a bore therethrough, at least one relatively thin-walled replaceable iron wear liner of generally cylindrical shape having corresponding bore passages and being positioned around said plug member and fixedly keyed within said housing whereby wear is generally limited to the relatively-moving interfacing inner surface of the wear liner and the outer surface of the plug member. The plug being machinable to restore the proper shape and tolerances when combined with replacement of the wear liner by one of compensatingly greater thickness.

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 and an apparatus for the gaseous reduction of particulate iron ores is disclosed, wherein the reduced ore, commonly called DRI (Direct Reduced Iron) or sponge iron, is treated in a vertical shaft moving bed furnace and discharged from said furnace in solid particulate form at high temperature, e.g. above 500.degree. C. The shaft furnace is of the type wherein a bed of particles descends by gravity through said furnace which has an upper section where ore pellets, lumps, or the like are reduced by reaction with a hot reducing gas, and a lower section of a downwardly tapering, preferably, in a generally conical shape, which converges to an outlet discharge orifice of smaller cross sectional area than the rest of said furnace.