Abstract: Ores which include in combination iron oxide, cobalt oxide and nickel oxide are treated in a continuous shaft reduction furnace to selectively reduce nickel and cobalt to metallized form while leaving the iron oxide in the oxide form. Reacted top gas is recycled and mixed with partially combusted gasified fossil fuel in a combustion chamber to achieve the required concentration of reductants in the reducing gas. The cooling zone operates with a similar concentration of reductants in the cooling gas. Apparatus is also disclosed for carrying out the process.

Abstract: Ores which include in combination iron oxide, cobalt oxide and nickel oxide are treated in a continuous shaft reduction furnace to selectively reduce nickel and cobalt to metallized form while leaving the iron oxide in the oxide form. Reacted top gas is recycled and mixed with partially combusted gasified fossil fuel in a combustion chamber to achieve the required concentration of reductants in the reducing gas. The cooling zone operates with a similar concentration of reductants in the cooling gas. Apparatus is also disclosed for carrying out the process.

Abstract: A method for the direct reduction of iron oxide utilizing sulfur-containing gas such as coke oven gas for the process gas. Sulfur-containing gas is heated and injected into a shaft furnace above the reduction zone into a prereduction and sulfur transfer zone for transferring sufficient sulfur from the process gas to the burden, that the catalyst for reforming the spent top gas will not be poisoned.

Abstract: A method and apparatus for the direct reduction of iron oxide utilizing sulfur-containing gas such as coke oven gas for the process gas. Sulfur-containing gas is heated and injected above the reduction zone to transfer the sulfur to the hot burden. The apparatus includes an upper bustle zone for prereduction and sulfur transfer and a lower bustle zone for the final reduction of the burden to metallized iron.

Abstract: A method for inhibiting rusting of sponge iron or any form of directly reduced iron when contacted by air, water, or other oxidant, by treating the sponge iron with a water soluble alkali metal silicate solution. The resulting product, a sodium silicate treated, rust-resistant metallized iron pellet, is also disclosed.