Abstract: The application describes pellets comprising particulate iron ore and between 0.05 and 1.0% by weight of an organic binder. The use of such pellets in electric arc furnaces to produce steel is also described.

Abstract: There is provided a method and system for recycling by-products containing large amounts of useful components and discharged in the form of dust and sludge from a coal-based molten iron making process to reuse the by-products in a reduced iron agglomeration process. The system includes: a fluidized reduction furnace reducing fine iron ore; a reduced iron tank connected to the fluidized reduction furnace through a reduced iron discharge pipe for storing the reduced iron and supplying the reduced iron in an agglomeration system; an agglomeration system agglomerating the reduced iron transferred from the reduced iron tank; and a transfer unit transferring compactions of by-products discharged from a molten iron making process through a by-product supply pipe. The compactions of the by-products are supplied to at least one selected from the group consisting of the fluidized reduction furnace, the reduced iron supply pipe, and the reduced iron tank.

Abstract: The present invention relates to a process for the recycling of steel industry iron bearing by-products into a shape suitable for feeding into a direct reduction furnace, comprising the steps of mixing and grinding 50 to 99 wt % of ore and pellet fines and 1 to 50 wt % of slurry, mill scale and/or bag house dust, pelletizing the mixture and indurating the pellets so obtained by heating for 5-60 minutes at a temperature in the range of 1100-1350° C.; and a pellet produced from Iron bearing waste material and having compression strength of at least 2.8 kN and/or a drop number of at least 3.

Abstract: Provided is a method for producing hot briquette iron by hot-forming high-temperature reduced iron reduced in a reducing furnace, involving cooling the high-temperature reduced iron and controlling the temperature of the reduced iron to an appropriate hot-forming temperature of over 600° C. and 750° C. or less, producing hot briquette iron by hot-forming the high-temperature reduced iron at an appropriate hot-forming temperature with a briquetting machine.

Abstract: The present invention relates generally to a method and system for the supply of a continuous stream of hot direct reduced iron (HDRI) from a direct reduction (DR) shaft furnace or direct reduced iron (DRI) reheating furnace to a point outside of the DR shaft furnace or DRI reheating furnace where the HDRI stream is split into at least two HDRI streams. The first HDRI stream is sent continuously to a hot briquetting plant by gravity in a closed duct system. The second HDRI stream is sent continuously to an adjacent melting furnace also by gravity in a closed duct system, with a surge bin and feeders, or by a combination of gravity in a closed duct system, also with a surge bin and feeders, and a generally horizontal charge conveyor. Optionally, a third HDRI stream is employed to continuously feed multiple hot transport vessels.

Abstract: A producing method of direct reduced iron includes the steps of: drying an oxidized iron raw material selected from a group including iron ore and iron-making dust generated in an iron-making process to have a predetermined moisture content; mixing the oxidized iron raw material subjected to the drying step and a reducing material having a predetermined moisture content to obtain a mixture; pulverizing the mixture obtained in the mixing step for 80% minus-sieve to have a particle diameter of 70 ?m to 500 ?m; kneading the mixture after the moisture content of the mixture subjected to the pulverizing step is adjusted; agglomerating the mixture subjected to the kneading step to be agglomerate; and reducing the agglomerate obtained in the agglomerating step by a rotary hearth furnace to generate direct reduced iron.

Abstract: A method for producing metallic iron nodules by assembling a shielding entry system to introduce coarse carbonaceous material greater than 6 mesh in to the furnace atmosphere at location(s) where the temperature of the furnace atmosphere adjacent at least partially reduced reducible iron bearing material is between about 2200 and 2650° F. (1200 and 1450° C., the shielding entry system adapted to inhibit emission of infrared radiation from the furnace atmosphere and seal the furnace atmosphere from exterior atmosphere while introducing coarse carbonaceous material greater than 6 mesh into the furnace to be distributed over the at least partially reduced reducible iron bearing material, and heating the covered at least partially reduced reducible iron bearing material in a fusion atmosphere to assist in fusion and inhibit reoxidation of the reduced material during fusion to assist in fusion and inhibit reoxidation of the reduced material in forming metallic iron nodules.

Abstract: The present invention relates to a process for the recycling of steel industry iron bearing by-products into a shape suitable for feeding into a direct reduction furnace, comprising the steps of mixing and grinding 50 to 99 wt % of ore and pellet fines and 1 to 50 wt % of slurry, mill scale and/or bag house dust, pelletizing the mixture and indurating the pellets so obtained by heating for 5-60 minutes at a temperature in the range of 1100-1350° C.; and a pellet produced from Iron bearing waste material and having compression strength of at least 2.8 kN and/or a drop number of at least 3.

Abstract: Systems and methods for use in processing raw material (e.g., iron bearing material) include a linear furnace apparatus extending along a longitudinal axis between a charging end and a discharging end (e.g., the linear furnace apparatus includes at least a furnace zone positioned along the longitudinal axis). Raw material is provided into one or more separate or separable containers (e.g., trays) at the charging end of the linear furnace apparatus. The separate or separable containers are moved through at least the furnace zone and to the discharging end where the processed material is discharged resulting in one or more empty containers. One or more of the empty containers are returned to the charging end of the linear furnace apparatus to receive further raw material.

Abstract: The present invention relates to an apparatus for manufacturing molten irons by injecting fine carbonaceous materials into a melter-gasifier and a method for manufacturing molten irons using the same.

Abstract: A method for manufacturing sponge iron includes heating iron oxide together with a solid reducing agent to reduce the iron oxide into sponge iron, wherein the iron oxide includes a mixture of powdered hematite and powdered iron ore or a mixture of powdered hematite and powdered mill scale, the powdered hematite has a specific surface area of 2.0 m2/g or more, and the content of the powdered hematite is 5-45% by mass with respect to the total quantity of iron oxide.

Abstract: A method of upgrading relatively rich, fine-grained earthy hematite iron ores is provided. The iron ore, after suitable preparation, is reduced using a solid state reduction technique. As a result of the reduction process, the iron grains undergo size enhancement while the nonmetallic oxides are unreduced and remain as refractory oxide gangue. After completion of the reduction process, the enlarged malleable metallic iron grains are crushed in such a way as to cause the iron grains to fuse together, forming large, flat iron flakes. In order to achieve maximum flake size, the crushing system applies a relatively gradual pressing force rather than a rapid, impact type of force. As the large flakes are formed, the iron grains are liberated from the refractory oxide grains resulting in an increase in density. The crushing system causes non-iron oxide bonds to be broken, resulting in the formation of residual refractory particles generally with a grain size of less than 0.05 millimeters.

Abstract: A method of separating and recycling shards and fines that occur in a briquetting operation using an non-reactive carrier gas to separate and entrain the hot shards and fines, and conduct them to a material inlet of the briquetting machine, while separating and recycling the carrier gas. Apparatus for carrying out the method is also disclosed.

Abstract: A process and apparatus for separating briquettes and fragments in a product stream resulting from briquetting direct reduced iron. Separating and cooling of the briquettes and fragments are carried out simultaneously in an initial step with use of separating means submerged in a cooling bath. The process enables use of less rugged apparatus following the initial step and the apparatus is not subjected to handling the product stream at the elevated temperatures at which briquetting is carried out. Capital expenditure and equipment maintenance is thus reduced.

Abstract: The present invention concerns additives for non-ferrous, liquid metals. The additives consist of compacted bodies of essentially pure iron particles.

Abstract: A method of separating and recycling shards and fines that occur in a briquetting operation using an non-reactive carrier gas to separate and entrain the hot shards and fines, and conduct them to a material inlet of the briquetting machine, while separating and recycling the carrier gas. Apparatus for carrying out the method is also disclosed.

Abstract: The present invention concerns additives for non-ferrous, liquid metals. The additives consist of compacted bodies of essentially pure iron particles.

Abstract: In a plant for the production of pig iron and/or sponge iron, comprising at least one fluidized bed reactor adapted to receive fine ore, a reducing-gas feed duct leading to said fluidized bed reactor, an off gas discharge duct departing from the fluidized bed reactor and a discharge means, preferably a briquetting means, provided for the reduction product formed in the fluidized bed reactor, the off gas discharge duct of the fluidized bed reactor runs into a purification means, such as a scrubber, subsequently into a heating means and finally into the reducing gas feed duct of the fluidized bed reactor. To produce a product having a high quality standard at a minimum energy input, the heating means is constructed such that it comprises two stages including a heat exchanger as the heating means for the reducing gas and, connected serially therewith, a partial combustion means for the reducing gas with an oxygen feeding means.

Abstract: The granular sponge iron is supplied to a roller press at temperatures of 600 to 850.degree. C. for molding the hot briquets. There is produced a strip structure of sponge iron containing formed hot briquets, which are arranged at a distance from each other. By smashing the strip structure, the hot briquets are separated from each other, so that fragments of the strip structure are obtained. The hot briquets and at least part of the fragments are cooled to temperatures in the range from 20 to 400.degree. C., and the cooled briquets and fragments are passed through a rotary drum. In the rotary drum, fine-grained fines of the briquets and fragments are produced. Subsequently, these fines are separated from the briquets and fragments, as they exhibit a pyrophoric behavior.

Abstract: A method of upgrading relatively rich, fine-grained earthy hematite iron ores is provided. The iron ore, after suitable preparation, is reduced using a solid state reduction technique. As a result of the reduction process, the iron grains undergo size enhancement while the nonmetallic oxides are unreduced and remain as refractory oxide gangue. After completion of the reduction process, the enlarged malleable metallic iron grains are crushed in such a way as to cause the iron grains to fuse together, forming large, flat iron flakes. In order to achieve maximum flake size, the crushing system applies a relatively gradual pressing force rather than a rapid, impact type of force. As the large flakes are formed, the iron grains are liberated from the refractory oxide grains resulting in an increase in density. The crushing system causes non-iron oxide bonds to be broken, resulting in the formation of residual refractory particles generally with a grain size of less than 0.05 millimeters.

Abstract: In order to attain as low a final temperature as possible after as short a period of time as possible in a method of cooling hot briquetted sponge iron (3) under optimum utilization of the cooling medium, the hot briquetted sponge iron (3), in a first cooling step (11), is passed exclusively by a gaseous cooling medium while being gently cooled and subsequently, in a second cooling step (14), is sprayed with a liquid cooling medium, thus being intensively cooled to the final temperature desired.

Abstract: A method for making iron-alloy briquettes, includes the steps of: providing hot metallized iron particles having a temperature of at least about 650.degree. C. and an initial degree of metallization of at least about 90% (wt.); providing an additive selected from the group consisting of ferroalloy powder, metal-containing ash and mixtures thereof, wherein the additive contains an alloying metal; mixing the iron particles and the additive to provide a mixture of the particles and the additive; and forming the mixture into briquettes containing the alloying metal.

Abstract: A plant for the production of pig iron and/or sponge iron includes a direct-reduction shaft furnace for lumpy iron ore, a melter gasifier, a feed duct for a reducing gas connecting the melter gasifier with the shaft furnace, a conveying duct for the reduction product formed in the shaft furnace connecting the shaft furnace with the melter gasifier, a top-gas discharge duct departing from the shaft furnace, feed ducts for oxygen-containing gases and carbon carriers running into the melter gasifier and a tap for pig iron and slag provided at the melting vessel.

Abstract: A process for treating iron-bearing material with a carbonaceous material to form a mixture, wherein the amount of carbonaceous material added exceeds the stoichiometric amount required to reduce the metal oxide to elemental metal. In one embodiment, the process also includes blending an organic binder with the mixture. The mixture is agglomerated using compaction to bond the mixture and form green compacts. The green compacts are loaded into a heated furnace and heated for about 5-12 minutes at a temperature of between about 2100.degree.-2500.degree. F. and at a CO/CO.sub.2 ratio of about 1.5-2.5 proximate the discharge area to reduce the iron oxide containing compacts to compacts containing elemental iron and an excess amount of carbonaceous material wherein the excess amount of carbonaceous material counteracts re-oxidation of the elemental iron. The reduced compacts are then discharged from the furnace.

Abstract: A process for recovering iron from iron-bearing materials including steel mill waste and iron-bearing ores. The process includes the steps of providing a mixture of iron-bearing materials having iron oxides therein and carbonaceous material. The mixture is agglomerated to form green compacts. The green compacts are then loaded into a preheated rotary hearth furnace void of compacts to form a layer of compacts no more than about two compacts high. The green compacts are heated for about 5 to 12 minutes at a temperature of between about 2200.degree. F. to 2500.degree. F. to reduce the compacts and evolve undesirable oxides from the compacts. The reduced compacts are then discharged from the rotary hearth furnace whereupon they are soaked to provide additional time for reaction to achieve 99% or more reduction of the iron oxides. The metallized iron compacts may then be cooled or transported hot to a steel making operation.

Abstract: A method for producing a more concentrated iron product from an industrial waste materials stream comprising iron and non-iron constituents such as EAF and basic oxygen furnace dust generally comprising the steps of compacting or briquetting the waste materials stream, roasting the waste materials stream at temperatures above about 980.degree. C. to convert the iron compounds to direct reduced iron, crushing the roasted waste materials stream, separating the iron compounds contained in the waste materials stream by magnetic separation or flotation, and providing the iron compounds back to the EAF or basic oxygen furnace.

Abstract: A process for treating iron-bearing material with a carbonaceous material to form a dry mixture, wherein the amount of carbonaceous material added exceeds the stoichiometric amount required to reduce the metal oxide to elemental metal. In one embodiment, the process also includes blending an organic binder with the dry mixture. The dry mixture is agglomerated to bond the dry mixture and form green compacts. The green compacts are loaded into a heated furnace and heated for about 5-12 minutes at a temperature of between about 2100.degree.-2500.degree. F. to reduce the iron oxide containing compacts to compacts containing elemental iron and an excess amount of carbonaceous material wherein the excess amount of carbonaceous material counteracts re-oxidation of the elemental iron. The reduced compacts are then discharged from the furnace.

Abstract: A method and apparatus for producing direct reduced iron from dry compacts composed of iron oxide and carbonaceous material by feeding compacts no more than two layers deep onto a hearth and removing all the volatiles and metallizing the compacts by exposing said compacts to a radiant heat source at a temperature of from about 2400.degree. to about 2600.degree. F (1316.degree.-1427.degree. C.) for a total time period of about four to ten minutes and partially cooling the compacts while discharging them from the hearth.

Abstract: A method for agglomerating iron ore particles pre-reduced to produce hot pig iron, wherein hot iron ore particles pre-reduced in the pre-reduction furnace are simply mixed with aluminum powder or aluminum-containing metal powder before being loaded in the smelting reduction furnace so that they will be agglomerated, thereby being capable of not only simplifying the agglomeration, but also eliminating the adverse effect on the quality of ingot iron caused by impurities such as S or P. Aluminum dross, which is a waste, may be used as the aluminum-containing metal powder for agglomerating the iron ore particles. In this case, a reduced energy consumption and disposal of wastes can be achieved.

Abstract: A mechanical alloying process wherein compacting of particulate feedstock is physically separate from subsequent comminuting improves control and consistency in mechanical alloying. The preferred compaction is by squeezing between rollers or other compacting means to produce a coherent mass such as a strip. The coherent mass (preferably rolled strip) is comminuted separately from the rolling or compression. This allows for a reduced temperature in comminuting or an atmosphere different from compacting or compressing. Compacting and comminuting are repeated to produce the desired extent of alloying and homogenization.

Abstract: A method and apparatus for producing direct reduced iron using a melter-gasifier and two reduction reactors. In the first reduction reactor, iron ore is prereduced using a reducing gas from a melter-gasifier. This prereduced iron ore is fed into the melter-gasifier to produce pig iron. A secondary reducing gas comprising hydrogen and carbon monoxide is withdrawn from the first reduction reactor and is reacted with water to produce carbon dioxide which is subsequently removed to produce a tertiary reducing gas that is used in the second reduction reactor to produce direct reduced iron from iron ore.

Abstract: A process for producing pig iron from iron ores involves the iron ores traveling from the top downwards through a reduction unit via a succession of oblique trays which are staggered in a cascade-like manner. A hot reduction gas containing carbon monoxide and hydrogen flows from the bottom of the reduction unit upwards. A reduction product is drawn off at the bottom end of the reduction unit and is fed to a unit for further treatment thereof. A reduction gas is generated in a gas generator by partial oxidation of carbon carriers or by cracking of natural gas or petroleum. Iron ores having at least a high proportion of dust-like and/or fine granular iron ores are sorted into fractions according to grain size and introduced into the reduction unit in such a way that the course fraction of the iron ore is introduced into the top section of the system and the fine fraction of the iron ore is introduced into the middle zone or into the middle and bottom zones of the system.

Abstract: A method of producing direct reduced iron from pellets, lumps and fines of iron oxide. A mixture of iron oxide raw material is introduced to an apparatus which separates the lumps and pellets from the fines. The lumps and pellets are then introduced to a shaft furnace for direct reduction to iron. Fines are conveyed to a series of fluidizable beds which allows intimate contact with reducing gas to facilitate the direct reduction of the iron oxide fines to metallized iron.

Abstract: In order to effect a reduction and a carburization to form Fe.sub.3 C to the highest possible degree in a relatively short time in an economical process, a treatment in two stages is effected in fluidized beds. The first stage is effected in a circulating fluidized bed system, in which the amount of solids circulated per hour is at least five times the weight of solids contained in the fluidized bed reactor and a major part of the iron content of the charge is pre-reduced. The remaining reduction and the partial or complete conversion to Fe.sub.3 C are effected in the second stage in a conventional fluidized bed. Water is condensed from the exhaust gas from the circulating fluidized bed system and that gas is strengthened by an addition of reducing gases and is reheated to the temperature which is required for the process.

Abstract: In order to effect a reduction and a carburization to form Fe.sub.3 C to the highest possible degree in a relatively short time in an economical process, a treatment in two stages is effected in fluidized beds. The first stage is effected in a circulating fluidized bed system, in which the amount of solids circulated per hour is at least five times the weight of solids contained in the fluidized bed reactor and a major part of the iron content of the charge is pre-reduced. The remaining reduction and the partial or complete conversion to Fe.sub.3 C are effected in the second stage in a conventional fluidized bed. Water is condensed from the exhaust gas from the circulating fluidized bed system and that gas is strengthened by an addition of reducing gases and is reheated to the temperature which is required for the process.

Abstract: Installation for producing steel by melting scrap comprising an electric furnace (2') supplied with individual batches of scrap sequentially charged into the furnace after preheating in a preheating chamber (4) forming a batch container open at both ends and having a releasable bottom. The preheating chamber is mounted on a transporting device for movement between a first, preheating position, in which it is connected to a hot gas circulating circuit, and a second position in which it empties the batch of preheated scrap into the furnace. The lower portion of the side wall of the preheating chamber (4) forms a skirt (43) with a wide downwardly directed opening, and the chamber (4) is combined, in the preheating position, with a movable device (54) for sealably engaging the lower end (42) of the skirt (43) with a matching stationary base plate (3), whereby the skirt is sealed in the preheating position.

Abstract: Sponge iron particles obtained in a reduction unit are, subsequently, subjected to a hot-briquetting process and supplied to the refining vessel in a condition in which they are still hot from the hot-briquetting process. By means of this measure, the amount of energy consumed in the steel making process is reduced. The transport of the sponge iron briquettes from the hot-briquetting unit to the refining vessel can preferably be carried out in heat-insulated buckets. Possible heat losses which may perhaps still occur can be compensated for by a preheater preceding the refining vessel. For this purpose, the hot sponge iron briquettes are filled into the preheater, where they will then be heated by the hot waste gases originating from the refining vessel. In addition, this process offers a solution for the smooth transition from the continuous production of sponge iron briquettes to the discontinuous refining process.

Abstract: A fluidized bed direct process is discharged for reducing raw iron ore fines and directly producing a steel product. The disclosed process includes a process for feeding raw iron ore fines into a multi-stage reactor assembly; a process for reducing fines in fluidized beds developed by a counter-current flow of reducing gas, where the reducing gas is developed in a reformer assembly; and, a process for recycling offgas exiting said reactor assembly.

Abstract: Steel sheet is formed directly from iron ore concentrate by reducing a bed of iron ore concentrate, particularly high purity magnetized magnetic gamma hematite, to a low density hot cake of carburized metallic iron and then hot rolling the hot cake to a metallic sheet of full density (meeting market specification).

Abstract: A fluidized bed direct process for reducing raw iron ore fines and directly producing an iron product comprises a process for feeding raw iron ore fines into a multi-stage reactor assembly; a process for reducing fines in fluidized beds developed by a counter-current flow of reducing gas, where the reducing gas is developed in a process for directly producing slag and iron in a gasifier/smelter assembly; a process for producing iron by further reducing and removing impurities from a part of the reduced iron ore in a gasifier/smelter assembly; a process for compacting excess reduced iron ore; and, a process for preparing reducing gas from offgas exiting said gasifier/smelter assembly; and, a process for recycling spent reducing gas exiting said reactor assembly. The processed offgas is 100% utilizable as reducing gas by balancing the reduced iron ore between the gasifier/smelter and compacting assemblies.