Abstract: A method for producing direct reduced iron having increased carbon content, comprises delivering each of the herein-described mixed carburizing gas streams, which are of different composition, to a transition zone of a direct reduction furnace, and exposing partially or completely reduced iron oxide to the mixed carburizing gas streams to increase the carbon content of resulting direct reduced iron to greater than 4.5 wt. %.

Abstract: A method of heating direct reduced iron between a direct reduced iron source and processing equipment for the direct reduced iron, comprises providing a conduit heater assembly between the direct reduced iron source and the processing equipment, wherein the conduit heater assembly receives a flow of the direct reduced iron from the direct reduced iron source and heats the direct reduced iron as the direct reduced iron flows through the conduit heater assembly and to the processing equipment.

Abstract: A method of heating direct reduced iron between a direct reduced iron source and processing equipment for the direct reduced iron, comprises providing a conduit heater assembly between the direct reduced iron source and the processing equipment, wherein the conduit heater assembly receives a flow of the direct reduced iron from the direct reduced iron source and heats the direct reduced iron as the direct reduced iron flows through the conduit heater assembly and to the processing equipment.

Abstract: A direct reduction process comprises providing a shaft furnace of a direct reduction plant to reduce iron oxide with reducing gas; providing a direct reduced iron melting furnace; and coupling a discharge chute between a discharge exit of the direct reduced shaft furnace and an inlet of the direct reduced iron melting furnace; wherein direct reduced iron and the reducing gas from the shaft furnace flow through the discharge chute and the reducing gas controls the melting furnace atmosphere to reducing environment.

Abstract: A process for the production of direct reduced iron (DRI), with or without carbon, using hydrogen, where the hydrogen is produced utilizing water generated internally from the process. The process is characterized by containing either one or two gas loops, one for affecting the reduction of the oxide and another for affecting the carburization of the DRI. The primary loop responsible for reduction recirculates used gas from the shaft furnace in a loop including a dry dedusting step, an oxygen removal step to generate the hydrogen, and a connection to the shaft furnace for reduction. In the absence of a second loop, this loop, in conjunction with natural gas addition, can be used to deposit carbon. A secondary carburizing loop installed downstream of the shaft furnace can more finely control carbon addition. This loop includes a reactor vessel, a dedusting step, and a gas separation unit.

Abstract: A process for the production of direct reduced iron (DRI), with or without carbon, using hydrogen, where the hydrogen is produced utilizing water generated internally from the process. The process is characterized by containing either one or two gas loops, one for affecting the reduction of the oxide and another for affecting the carburization of the DRI. The primary loop responsible for reduction recirculates used gas from the shaft furnace in a loop including a dry dedusting step, an oxygen removal step to generate the hydrogen, and a connection to the shaft furnace for reduction. In the absence of a second loop, this loop, in conjunction with natural gas addition, can be used to deposit carbon. A secondary carburizing loop installed downstream of the shaft furnace can more finely control carbon addition. This loop includes a reactor vessel, a dedusting step, and a gas separation unit.

Abstract: A direct reduction process comprises providing a shaft furnace of a direct reduction plant to reduce iron oxide with reducing gas; providing a direct reduced iron melting furnace; and coupling a discharge chute between a discharge exit of the direct reduced shaft furnace and an inlet of the direct reduced iron melting furnace; wherein direct reduced iron and the reducing gas from the shaft furnace flow through the discharge chute and the reducing gas controls the melting furnace atmosphere to reducing environment.

Abstract: A method of heating direct reduced iron between a direct reduced iron source and processing equipment for the direct reduced iron, comprises providing a conduit heater assembly between the direct reduced iron source and the processing equipment, wherein the conduit heater assembly receives a flow of the direct reduced iron from the direct reduced iron source and heats the direct reduced iron as the direct reduced iron flows through the conduit heater assembly and to the processing equipment.

Abstract: A method for producing direct reduced iron having increased carbon content, comprises: providing a carbon monoxide-rich gas stream, and separating the carbon monoxide-rich gas stream into at least two separate carbon monoxide-rich gas streams; providing a hydrocarbon-rich gas stream and separating the hydrocarbon-rich gas stream into at least two separate hydrocarbon-rich gas streams; blending one of the carbon monoxide-rich gas streams with one of the hydrocarbon-rich gas streams to form a mixed carburizing gas stream; blending another carbon monoxide-rich gas stream of the at least two separate carbon monoxide-rich gas streams with another hydrocarbon-rich gas stream of the at least two separate hydrocarbon-rich gas streams to form a distinct mixed carburizing gas stream; delivering each of the mixed carburizing gas streams, which are of different composition, to a transition zone of a direct reduction furnace, and exposing partially or completely reduced iron oxide to the mixed carburizing gas streams to i

Abstract: A process for the production of direct reduced iron (DRI), with or without carbon, using hydrogen, where the hydrogen is produced utilizing water generated internally from the process. The process is characterized by containing either one or two gas loops, one for affecting the reduction of the oxide and another for affecting the carburization of the DRI. The primary loop responsible for reduction recirculates used gas from the shaft furnace in a loop including a dry dedusting step, an oxygen removal step to generate the hydrogen, and a connection to the shaft furnace for reduction. In the absence of a second loop, this loop, in conjunction with natural gas addition, can be used to deposit carbon. A secondary carburizing loop installed downstream of the shaft furnace can more finely control carbon addition. This loop includes a reactor vessel, a dedusting step, and a gas separation unit.