Abstract: A method for introducing fine particulate material (4) of ferruginous particles into a fluidized bed reduction unit (1) having a fluidized bed (24), wherein the temperature in the fluidized bed (24) is more than 300° C., and wherein the fine particulate material (4) is introduced directly into the fluidized bed (24) and/or into a free space (25) above the fluidized bed (24) by means of a burner (2). The method may be used for producing liquid pig iron (17) or liquid steel precursor products (18) by a smelting reduction process in a smelting reduction unit (22).

Abstract: Apparatus for production of metal sponge or pig iron from metal oxide containing material in piece form using a reduction gas. A reduction reactor shaft (1); reduction gas inlet lines into the interior of the reduction reactor shaft (1); a reduction gas channel body (11) passes through the interior of the reduction reactor shaft (1) for distributing reduction gas; a reduction gas supply line for reduction gas and located below the reduction gas channel body (11) at at least one inner-wall end of the reduction gas channel body (11). The reduction gas channel body (11) has a carrier tube through which a cooling medium can flow. A first portion of the reduction gas is introduced into the bed by reduction gas inlet lines which end in the interior of the reduction reactor shaft. A second portion of the reduction gas is distributed into the bed by the reduction gas channel body.

Abstract: A low-temperature process of producing high-purity iron powder by feeding hematite and a reducing agent into a rotary reactor under pressure to form a mechanical fluid bed. The fluid bed is rotated at a particular speed within a rotary reactor. The fluid bed is simultaneously heated to a reaction temperature, and the pressure is then reduced within the rotary reactor to a pressure in a range of 0.01 bars to 2.0 bars, as a result reducing the reaction temperature to a temperature in a range of 600° C. to 850° C. Maintaining the pressure and the rotation results in the formation of a high-purity iron oxide without the requirement for post-grinding process steps because sintering is prevented by using a combination of pressure reduction and a rotary set at an optimum rotation speed, resulting in useful additives produced by a more environmentally-friendly process.

Abstract: A process for reducing iron oxide to metallic iron using coke oven gas (COG), including: a direct reduction shaft furnace for providing off gas; a COG source for injecting COG into a reducing gas stream including at least a portion of the off gas; and the direct reduction shaft furnace reducing iron oxide to metallic iron using the reducing gas stream and injected COG. The COG has a temperature of about 1,200 degrees C. or greater upon injection. The COG has a CH4 content of between about 2% and about 13%. Preferably, the COG is reformed COG. Optionally, the COG is fresh hot COG. The COG source includes a partial oxidation system. Optionally, the COG source includes a hot oxygen burner.

Abstract: A direct reduction process for a metalliferous material includes supplying the metalliferous material, a solid carbonaceous material, an oxygen-containing gas, and a fluidizing gas into a fluidized bed in a vessel and maintaining the fluidized bed in the vessel, at least partially reducing metalliferous material in the vessel, and discharging a product stream that includes the partially reduced metalliferous material from the vessel. The process comprises (a) reducing the metalliferous material in a solid state in a metal-rich zone in the vessel; (b) injecting the oxygen-containing gas into a carbon-rich zone in the vessel with a downward flow in a range of ±40° to the vertical and generating heat by reactions between oxygen and the metalliferous material (including metallized material), the solid carbonaceous material and other oxidizable solids and gases in the fluidized bed, and (c) transferring heat from the carbon-rich zone to the metal-rich zone by movement of solids within the vessel.

Abstract: A direct smelting process for producing molten metal from a metalliferous feed material in a direct smelting vessel is disclosed. The process includes using a stream of off-gas from the vessel as a fuel gas in (i) stoves for generating a hot blast of air or oxygen-enriched air for the process and (ii) a waste heat recovery apparatus for generating steam for the process. The process also includes controlling pressure in the vessel by controlling pressure in the off-gas stream while the process is producing molten metal.

Abstract: The present invention relates to a method for the conveyance of fine-grained solids in a fluidized bed reactor and also to a corresponding plant. It is proposed to introduce a first gas or gas mixture from below through a central tube (3) into a mixing chamber (7) of the reactor (1), the central tube (3) being at least partly surrounded by a stationary annular fluidized bed (10) which is fluidized by supplying fluidizing gas. The gas velocities of the first gas or gas mixture as well as of the fluidizing gas for the annular fluidized bed (10) are adjusted such that the particle Froude numbers in the central tube (3) are between 1 and 100, in the annular fluidizied bed (10) between 0.02 and 2 in the mixing chamber (7) between 0.3 and 30.

Abstract: The present invention relates to a method for the heat treatment of fine-grained solids, in particular gypsum, in which the solids are heated to a temperature of 50 to 1000° C. in a fluidized bed reactor (1), and to a corresponding plant. To improve the energy utilization, it is proposed to introduce a first gas or gas mixture from below through a preferably central gas supply tube (3) into a mixing chamber (21) of the reactor (1), the gas supply tube (3) being at least partly surrounded by a stationary annular fluidized bed (2) which is fluidized by supplying fluidizing gas, and to adjust the gas velocities of the first gas or gas mixture as well as of the fluidizing gas for the annular fluidized bed (2) such that the particle Froude numbers in the gas supply tube (3) are between 1 and 100, in the annular fluidized bed (2) between 0.02 and 2 and in the mixing chamber (21) between 0.3 and 30.

Abstract: A process for treating a finely particulate, in particular metal-containing, charge material: The charge material and a treatment gas, in particular a reduction gas, are introduced into a fluidized bed chamber of a fluidized bed reactor to form a fluidized bed. After at least partial reaction in the fluidized bed, the treatment gas is discharged from the fluidized bed and, outside the fluidized bed, is at least partially reprocessed, preferably oxidized, by an exothermic, chemical reaction with a reactant, preferably with a gaseous and/or liquid oxidizing agent. The thermal energy of this reaction is at least partially introduced into the fluidized bed chamber, in particular into the fluidized bed, or being discharged therefrom to affect the temperature of the particulate material above the bed. Also an apparatus for operating such a fluidized bed includes the chamber, lines into and out of the chamber for gas and material and a cyclone at the chamber for the material.

Abstract: An apparatus for reducing a metalliferous material in a fluidized bed includes a vessel for containing the fluidized bed, a mechanism for supplying the metalliferous material, a solid carbonaceous material, an oxygen-containing gas, and a fluidizing gas into the vessel for forming the fluidized bed in the vessel. The oxygen-containing gas supply mechanism includes one or more than one oxygen-containing gas injection lance having a lance tip with an outlet that is positioned for injecting the oxygen-containing gas in a downward flow into the vessel within a range of plus or minus 40° to the vertical.

Abstract: This invention discloses a method of making an oxygen scavenging particle comprised of an activating component and an oxidizable component wherein one component is deposited upon the other component from a vapor phase and is particularly useful when the activating component is a protic solvent hydrolysable halogen compound and the oxygen scavenging particle is a reduced metal.

Abstract: The present invention relates to a method and a plant for the heat treatment of solids containing titanium and possibly further metal oxides, in which fine-grained solids are heated to a temperature of 700 to 950° C. in a fluidized bed reactor (1). To improve the energy utilization, it is proposed to introduce a first gas or gas mixture from below through a gas supply tube (3) into a mixing chamber (7) of the reactor (1), the gas supply tube (3) being at least partly surrounded by a stationary annular fluidized bed (10) which is fluidized by supplying fluidizing gas. The gas velocities of the first gas or gas mixture as well as of the fluidizing gas for the annular fluidized bed (10) are adjusted such that the particle Froude numbers in the gas supply tube (3) are between 1 and 100, in the annular fluidized bed (10) between 0.02 and 2 and in the mixing chamber (7) between 0.3 and 30.

Abstract: A method for the heat treatment of solids containing iron oxide, in which fine-grained solids are heated to a temperature of about 630° C. in a fluidized-bed reactor (1). To improve the utilization of energy, it is proposed to introduce a first gas or gas mixture from below through a supply tube (3) into a mixing chamber (7) of the reactor (1), the gas supply tube (3) being at least partly surrounded by a stationary annular fluidized bed (10) which is fluidized by supplying fluidizing gas. The gas velocities of the first gas or gas mixture and of the fluidizing gas for the annular fluidized bet (10) are adjusted such that the Particle-Froude-Numbers in the gas supply tube (3) are between 1 and 100, in the annular fluidized bed (10) between 0.02 and 2, and in the mixing chamber (7) between 0.3 and 30.

Abstract: The present invention relates to a method and a plant for the heat treatment of solids containing iron oxide, in which fine-grained solids are heated to a temperature of 700 to 1150° C. in a fluidized bed reactor (8). To improve the utilization of energy, it is proposed to introduce a first gas or gas mixture from below through at least one gas supply tube (9) into a mixing chamber region (15) of the reactor (8), the gas supply tube (9) being at least partly surrounded by a stationary annular fluidized bed (12) which is fluidized by supplying fluidizing gas. The gas velocities of the first gas or gas mixture and of the fluidizing gas for the annular fluidized bed (12) are adjusted such that the Particle-Froude-Numbers in the gas supply tube (9) are between 1 and 100, in the annular fluidized bed (12) between 0.02 and 2, and in the mixing chamber (15) between 0.3 and 30.

Abstract: This invention discloses a method of making an oxygen scavenging particle comprised of an activating component and an oxidizable component wherein one component is deposited upon the other component from a vapour phase and is particularly useful when the activating component is a protic solvent hydrolysable halogen compound and the oxygen scavenging particle is a reduced metal.

Abstract: An apparatus for reducing a metalliferous material in a fluidized bed includes a vessel for containing the fluidized bed, a mechanism for supplying the metalliferous material, a solid carbonaceous material, an oxygen-containing gas, and a fluidizing gas into the vessel for forming the fluidized bed in the vessel. The oxygen-containing gas supply mechanism includes one or more than one oxygen-containing gas injection lance having a lance tip with an outlet that is positioned for injecting the oxygen-containing gas in a downward flow into the vessel within a range of plus or minus 40° to the vertical.

Abstract: A direct reduction process for a metalliferous material includes supplying the metalliferous material, a solid carbonaceous material, an oxygen-containing gas, and a fluidizing gas into a fluidized bed in a vessel and maintaining the fluidized bed in the vessel, at least partially reducing metalliferous material in the vessel, and discharging a product stream that includes the partially reduced metalliferous material from the vessel. The process comprises (a) reducing the metalliferous material in a solid state in a metal-rich zone in the vessel; (b) injecting the oxygen-containing gas into a carbon-rich zone in the vessel with a downward flow in a range of ±40° to the vertical and generating heat by reactions between oxygen and the metalliferous material (including metallized material), the solid carbonaceous material and other oxidizable solids and gases in the fluidized bed, and (c) transferring heat from the carbon-rich zone to the metal-rich zone by movement of solids within the vessel.

Abstract: Method for removing tar-forming hydrocarbons from an effluent gas mixtures from Chemical Vapor Deposition or Chemical Vapor Infiltration processes. Method includes passing at elevated temperature effluent gas mixture containing hydrogen, methane, and high molecular weight hydrocarbons through a bed that contains iron pellets, thereby decomposing tar-forming high molecular weight hydrocarbons in the effluent gas mixture. Apparatus including a de-tarring vessel (5) having a packed bed (7, 8, 9) of iron or iron oxide pellets (1) resting over a perforated distributor plate (2) and having an exhaust port (12), said de-tarring vessel being operatively linked via an exhaust port (6) to a CVI or CVD reactor vessel.

Abstract: The present invention relates to method, which helps to reduce and remove the build-up forming on the grate of a fluidized-bed furnace in the roasting of fine-grained material such as concentrate. The concentrate is fed into the roaster from the wall of the furnace, and oxygen-containing gas is fed via gas nozzles under the grate in the bottom of the furnace in order to fluidize the concentrate and oxidize it during fluidization. Below the concentrate feed point, or feed grate, the oxygen content of the gas to be fed is raised compared with the oxygen content of the gas fed elsewhere.

Abstract: The invention relates to the reduction of fine ores, whereby in a multi-stage gas suspension preheater the fine ores are preheated, calcined and then reduced in at least one lowest heat exchanger stage with the addition of a reducing agent in a delivered hot gas stream. The principal part of the reducing heat treatment of the fine ores is carried out in a reactor loop constructed in the lowest heat exchanger stage of the gas suspension preheater. The reactor loop has an uptake conduit section and a curved section adjoining the uptake conduit section and with which the reactor loop opens into at least one precipitating cyclone which is disposed downstream and for this purpose a hot reducing gas is introduced into the rising hot gas stream.

Abstract: Granular ore or ore concentrate is charged into a furnace for calcining the ore at temperatures of 400 to 1050° C., the ore forming a stationary fluidized bed in the furnace. The ore is thrown onto the fluidized bed through an opening in the furnace housing disposed above the fluidized bed, the ore being accelerated by blades of a rotating impeller. The impeller is disposed outside the furnace in the vicinity of the opening of the housing. Preferably, the rotational speed of the impeller is variable, and the impeller is movable and/or pivotable with respect to the furnace.

Abstract: Apparatus (1) and process for treating particulate material or powder (33) of a size capable of being fluidized in a retort (31) mounted for rotation on a pair of end axles (18, 41). Retort (31) is mounted on a tilt frame (5) for tilting movement in a vertical plane. Gas conduits (18A, 18B) are mounted within an axle (18) for the supply and exhaust of gas for retort (31). A conduit (55) mounted within the other axle (41) permits particulate material to be passed into or out of the retort (31) as shown in FIG. 1B. A removable injection assembly (90, FIG. 10) is utilized for the injection of additional particulate material. A removable sampling assembly (95, FIG. 11) is utilized for removing a sample of the particulate material from the retort (31). As the retort (31) is rotated, particles of the particulate material are constantly intermingled with each other and the walls of the retort (31). Microwave energy as shown in FIGS. 13-14 may be utilized to heat or dry materials within the retort (31).

Abstract: Granular ore or ore concentrate is charged into a furnace for calcining the ore at temperatures of 400 to 1050° C., the ore forming a stationary fluidized bed in the furnace. The ore is thrown onto the fluidized bed through an opening in the furnace housing disposed above the fluidized bed, the ore being accelerated by blades of a rotating impeller. The impeller is disposed outside the furnace in the vicinity of the opening of the housing. Preferably, the rotational speed of the impeller is variable, and the impeller is movable and/or pivotable with respect to the furnace.

Abstract: This invention relates to a method for stabilizing a fluidized bed used in roasting by adjusting the oxygen content of the roasting gas in the bed. The fine-grained material for roasting is fed into the furnace above the fluidized bed and the roasting gas, which causes the fluidizing, is fed into the bottom of the furnace through a grate. In this method, the total amount of oxygen in the roasting gas to be fed and the average total oxygen requirement of the material to be roasted are calculated and the ratio between them regulated so that the oxygen coefficient in the bed is over 1.

Abstract: The invention relates to a method for rendering inert dust residue containing silicon metal, left over from trichlorosilane synthesis. The inventive method produces valuable materials containing silicon which can be used in metallurgical processes. According to said method, the process of rendering the residue inert is carried out in several steps. In a first step, 10 to 50 wt. % water, in relation to the quantity of residue, and an at least equimolar quantity of an alkaline compound, in relation to the chloride content of the residue, are added to the residue. Subsequently or simultaneously, the residue is heated to a temperature of 50 to 200° C. In a further step, at least twice the quantity of water is added to this mixture, which is extensively liberated from dissolved salts by filtration and subsequent washing with water.

Abstract: An end product containing iron carbide (Fe3C) is produced from an intermediate product consisting of granular, directly reduced iron. Said intermediate product is supplied by an iron ore reduction plant and is fed to a carburization reactor. Liquid hydrocarbons are conveyed to the carburization reactor at temperatures of 500 to 900° C., at least part of the granular, directly reduced iron being subjected to a swirling movement. The end product removed from the carburization reactor consists of 5 to 90 wt. % Fe3C. A fluidization gas containing methane and hydrogen can be added to the carburization reactor in addition to the hydrocarbons.

Abstract: A smelting reduction apparatus which separates exhaust gas, which is exhausted from a melter-gasifier or a fluidized bed reactor, into dusts and reducing gas to supply them to each fluidized bed reactor respectively is disclosed, in which the smelting reduction apparatus includes a three-stage type fluidized bed reactor, a melter-gasifier for manufacturing molten pig iron by finally reducing the fine iron ores of which reaction is finished in a final fluidized bed reactor, and a dust separating device, which performs separation of exhausted gas from the melter-gasifier into dusts and reducing gas, so as to supply the separated reducing gas to a lower part of the final fluidized bed reactor, dusts having a larger particle sizes in the separated dusts to the melter-gasifier again, and fine dusts having a smaller particle sizes in the separated dusts to an upper part of a gas distributor of the final fluidized bed reactor.

Abstract: The present invention relates to a method and apparatus for separating undesired toxic metals, such as Zn, Pb and Cd, from iron-containing materials by: sintering a mixture of such materials (typically including EAF dust and mill scale) with carbonaceous particles to form sturdy sinter lumps; preheating such lumps in a non-reducing atmosphere, if needed, to achieve an elevated temperature generally above the vaporization temperature of the undesired metals, but below the sticking temperature of iron-containing lumps (which is typically below the vaporization temperatures of such undesired metals in their oxide form), feeding the lumps at such elevated temperature into a reduction reactor; flowing hot reducing gas through lumps to volatilize undesired reduced metals and carry the volatilized metals out of reduction reactor leaving the iron-containing lumps largely stripped of the undesired metals and ready for discharge and safe and/or useful disposal or re-use, and finally cooling the off gas from the reactor

Abstract: The wet granulated iron ore is initially conducted through a drying zone. The ore leaves the drying zone at a temperature of 120-400° C. The ore is then heated in direct contact with hot gas to temperatures of 700-1,100° C. before being delivered to a reduction zone. The ore coming out of the drying zone is fully or partially guided through a separating device so as to separate the ore into fine and coarse grain fractions. The fine-grained ore fraction is conveyed to a granulating device so as to produce an iron ore granulate which is conducted to the drying zone. The coarse-grained ore fraction is heated to temperatures of 700-1,100° C. before it is guide into the reduction zone.

Abstract: The present invention is a process for the conversion of iron-containing material into iron carbide. The process includes a first step in which the iron-containing material is contacted with a reducing gas that contains no more than a small amount of reactive carbon to produce metallic iron and a second step in which the metallic iron is contacted with a reducing and carburizing gas to produce iron carbide. The reducing and carburizing gas includes reactive carbon, hydrogen, and methane. The iron carbide product is of high purity.

Abstract: In a method for treating particulate material in the fluidized bed method, the particulate material is maintained in a fluidized bed by a treating gas flowing from bottom to top and thereby is treated. To minimize the consumption of treating gas and to reduce entrainment of fine particles by the treating gas, a particulate material having a wide grain distribution and a relatively high portion of fines is used for treatment and the treating gas in the fluidized bed is maintained at a superficial velocity less than the velocity required for fluidizing the largest particles of said particulate material.

Abstract: A two step twin-single fluidized bed type reduction apparatus for fine iron ore, and a method therefor, are disclosed. The fluidizing of the fine iron ore is stabilized so as to improve the reduction degree and the gas utilization rate, and so as to minimize the elutriation loss of the iron ore. The apparatus includes a first fluidized bed furnace for carrying out a first pre-reduction on only coarse/intermediate iron ore particles among fine iron ores of a wide particle size distribution by a bubbling/turbulent fluidization after their charge from a charging hopper, while making fine iron ore particles fly away. A second fluidized bed furnace carries out a first pre-reduction on the fine iron ore particles flown from the first fluidized bed furnace by a bubbling fluidization, and a third fluidized bed furnace carries out a second pre-reduction on the iron ores discharged from the first and second fluidized bed furnaces after their first pre-reduction.

Abstract: Methods and apparatus for the reduction into metallic iron of iron-oxides-containing particles having a broad range of sizes. Particles, typically within a broad range of sizes of about 0.1 mm to about 50 mm, are reduced by contact with a hot reducing gas, preferably from a horizontal gas distributor which defines the bottom of the reduction zone by supplying a uniform upflow of gas mainly composed of hydrogen (and/or carbon monoxide) within a temperature range of 650° C. to 1050° C. and at a velocity of about 0.5-0.7 m/s to fluidize at least some of the particles of a size of about 1.0 mm or less (when present).

Abstract: In a process for producing sponge iron by direct reduction of iron-oxide-containing material, synthesis gas is mixed with top gas forming in the direct reduction of the iron-oxide-containing material and is utilized as a CO- and H.sub.2 -containing reducing gas for direct reduction and for heating the iron-oxide-containing material to a reduction temperature. To be able to save energy in an economically efficient manner when producing steel, especially in the refining process, direct reduction is carried out as follows: (1) in addition to the reducing gas, a carbon-containing gas, such as natural gas, or a gas having higher hydrocarbons is utilized for reduction; (2) the iron-oxide-containing material for a predetermined period of time exceeding the period necessary for complete reduction is exposed to the reducing gas and to the additionally supplied carbon-containing gas, and (3) a CO/CO.sub.2 ratio ranging between 2 and 5, preferably a ratio in excess of 2.5, is adjusted in the reducing gas.

Abstract: A method and device are provided for direct reduction of ore fines in a wide range of particle size, the reducing agent being hydrogen placed in a fluidized bed gutter with a plurality of sequentially arranged chambers. The fluidization rate in the supply base is set so that a defined class of particle size remains in the chamber concerned where it will be submitted to a reduction process and that the finest particle size fraction is discharged from the chamber, then precipitated in a hot gas cyclone to solid material (or fines) and gas. The ore fines precipitated in the cyclone then reaches the following chamber. The gas from all the hot gas cyclones is fed by a collector to the pre-heater. After reduction in the chambers, the ore fines are conveyed in pressure vessels for submission to further processes.

Abstract: The present invention describes a method and apparatus for the reduction into metallic iron of iron-oxides-containing particles having a broad range of sizes. Particles, preferably within a broad range of sizes smaller than about 3.2 mm, are reduced by contact with a hot reducing gas, preferably mainly composed of hydrogen and within a temperature range of 700 to 750.degree. C. The reducing gas flows through a descending moving bed of coarser particles and forms an ascending fluidized bed of fines, all in a single reduction reactor, where the particles charged to the reactor are fed into the lower portion of the fluidized bed and the reduced fines are withdrawn from the reactor from the upper portion of the fluidized bed.

Abstract: A method for producing iron carbide by bringing iron ore into contact with a reducing gas containing hydrogen and a carbon compound at a high reaction temperature and at a reaction pressure of the atmospheric pressure or more to reduce and carburize the iron ore with the participation of a sulfur component, the method includes measuring the reaction temperature, partial pressure P(H.sub.2) of the hydrogen and partial pressure P(H.sub.2 S) of hydrogen sulfide contained in the reducing gas, calculating sulfur activity a.sub.s in the reducing gas from Equation (1) shown below, and adjusting the partial pressure P(H.sub.2 S) of the hydrogen sulfide in the reducing gas to obtain a.sub.s =1.0 to 2.0 at reaction temperatures of 550.degree. C. and above but less than 650.degree. C., a.sub.s =0.7 to 2.0 at 650.degree. C., and a.sub.s =0.05 to 1.0 at over 650.degree. C. and up to 950.degree. C.: (1) a.sub.s =(P(H.sub.2 S)/P(H.sub.2))/(P(H.sub.2 S)/P(H.sub.2)).sub.E where (P(H.sub.2 S)/P(H.sub.

Abstract: A method for reforming reducing gas in a fluidized bed process for reduction of ore in a series of ore reducing reactors, including the steps of: passing ore through a plurality of reducing reactors including a final reactor and at least one upstream reactor; flowing a reducing gas through the final reactor so as to reduce ore in the final reactor whereby a flow of partially spent reducing gas including methane and metallized iron dust exits the final reactor; mixing an oxygen source with the partially spent reducing gas so as to combust a portion of the methane with the oxygen source in the presence of the metallized iron dust and provide a reformed reducing gas; and flowing the reformed reducing gas to the upstream reactor.

Abstract: In a process for reducing particulate oxide-containing material using the whirl bed method, the oxide-containing material, by means of reducing gas flowing from bottom to top, is maintained in the whirl layer, thus being reduced. In order to avoid or considerably reduce operational interruptions of the reduction process caused by sticking or fouling, the clear tube speed (superficial velocity) of the reducing gas, exclusively above the whirl layer, is continuously lowered along the total free height of a space above the whirl layer while the formation of further whirl formations is avoided.

Abstract: With a process for the direct reduction of particulate iron-containing material by fluidization, reformed gas, at least partially freed from CO.sub.2, is supplied to a fluidized-bed reduction zone as a reducing gas and is carried off from the same as a top gas and at least a portion of the top gas together with reformed gas is utilized for direction reduction. To economize on parts of the plant that are impinged on by reducing gas and in order to achieve savings in terms of heating costs, CH.sub.4 and N.sub.2 are, in addition to CO.sub.2, at least partially removed by adsorption, from 50 to 100% of the reformed as and 0 to 100% of the top gas, and the tail gas removed from the reformed gas and/or the top gas by adsorption is utilized as a heating gas.

Abstract: A reduction apparatus and a method for efficient reduction of fine iron ores of wide grain range comprising serially arranged a drying/preheating furnace, a first reducing furnace for prereduction and a second reduction furnace for final reduction, each working with bubbling fluidized bed and being connected each to a cyclone for capturing iron ore dust contained in the exhaust gases, having each a tapered shape smoothly expanded outwards and thus considerably decreasing elutriation of fine particles, increasing the reduction efficiency and enhancing the utilization of the reducing gas.

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 process for converting iron oxide to iron carbide using hydrogen as a reducing gas. Water is generated by the reduction of the iron oxides using hydrogen. The amount of water present in the reactor system is controlled and the water is contacted with methane in order to internally generate carbon monoxide and/or carbon dioxide gas. The carbon monoxide and/or carbon dioxide is subsequently employed to carburize the iron to iron carbide.

Abstract: A process for producing iron carbide in a fluid bed reactor in which the pressure may be maintained in excess of the pressure at which the mole fraction of hydrogen in the process gas begins to decrease. The hydrogen concentration is increased above the equilibrium concentration for hydrogen at the temperature and pressure in the reactor. Further improvements are gained by preheating a iron ore reactor feed in which the iron oxide is primarily in the form of hematite under a reducing atmosphere, and using at least two fluid bed reactors in series.

Abstract: A method for producing iron carbide by bringing iron ore into contact with a reducing gas containing hydrogen and a carbon compound at a specified reaction temperature to reduce and carburize the iron ore with the participation of a sulfur component, the method includes measuring the reaction temperature, partial pressure P(H.sub.2) of the hydrogen and partial pressure P(H.sub.2 S) of hydrogen sulfide contained in the reducing gas, calculating sulfur activity as in the reducing gas from equation (1) shown below, and adjusting the partial pressure P(H.sub.2 S) of the hydrogen sulfide in the reducing gas to obtain as=1.0 to 2.0. at reaction temperatures of 550.degree. C. and above but less than 650.degree. C., as=0.7 to 2.0 at 650.degree. C., and as=0.05 to 1.0 at over 650.degree. C. and up to 950.degree. C.:as=(P(H.sub.2 S)/P(H.sub.2))/(P(H.sub.2 S)/P(H.sub.2))E (1)where (P(H.sub.2 S)/P(H.sub.2)) represents the ratio between the partial pressures of H.sub.2 S and H.sub.2 in the reducing gas and (P(H.sub.

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: The present invention concerns a method of and a device for directly reducing fine-particle ore in a horizontal reactor with an ore-reducing gas and a heat vehicle, also a gas, in a fluidized bed.The ore-reducing vessel itself comprises a horizontal fluidized-bed reactor (1). The ore (F) is blown into it from below. The heated ore-reducing gas (A) is blown into the reactor through oncoming-gas floors (2). The heat needed for the endothermic reaction is supplied to the reactor at different temperatures through heat exchangers (3) and transferred to the bed. Heat is supplied counter to the ore-reducing gas.Fuel (B) in the form of gas is burned with air (C) to make the heat vehicle (D). The ore-reducing gas (A') is heated in downstream heat exchangers (5.1 to 5.3) before arriving in the three sections (1a, 1b, & 1c) of the reactor through the floors.Sponge iron (6) is removed and throat gas (E) extracted from a sponge-collecting section (1d).

Abstract: A method and apparatus for preheating a reactor feed, comprised of an iron ore (10) and a process gas (21), in an iron carbide process for making steel is provided. The apparatus comprises a process gas preheater (40) having a furnace (56) and a heat exchanger (58). The process gas (21) is heated uniformly in tubes (117) of furnace (56) by burners (100). Excess heat generated by furnace (56) is captured by heat exchanger (58) and used to preheat combustion air (61) and ore (10).

Abstract: In a process for the direct reduction of particulate iron-oxide-containing material by the fluidized bed method, reformed gas is mixed with top gas forming in the direct reduction of the iron-oxide-containing material and is fed to a fluidized-bed reduction zone as a reducing gas. To lower the energy demand and utilizing the potential of the reducing gas, both the top gas and the reformed gas are subjected to CO.sub.2 scrubbing and the reducing gas formed by mixing top gas with reformed gas is adjusted to an H.sub.2 content ranging between 45 and 75%, preferably between 50 and 65%, and to a CO content ranging between 10 and 20%.

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 circulating fluidizable beds which allows intimate contact with reducing gas to facilitate the direct reduction of the iron oxide fines to metallized iron.