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 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 method and an integrated steel plant wherein, instead of using coke oven gases, converter gases and blast furnace top gases available as fuel for power generation or other heating purposes, these gases are more efficiently utilized as chemical agents for direct reduction of iron ores producing DRI.

Abstract: A process for conversion of iron oxide to iron carbide, including the steps of: providing a fluidized bed reactor having a metallizing zone and a carburizing zone; feeding iron oxide to the reactor; feeding a reducing gas to the reactor so as to provide reduced iron in the metallizing zone; and feeding a carburizing gas to the carburizing zone so as to provide a final iron carbide product in the carburizing zone having between about 2.2% wt. and about 6.5 wt. % carbon and at least about 80% wt. iron.

Abstract: Method and apparatus for smelting iron ore in which iron ore is preheated and partly reduced within a first reaction zone and then further reduced in a second reaction zone. The first reaction zone can be a shaft reduction furnace and the second reaction zone can be a melter gasifier. An auxiliary third reaction zone partially oxidizes a carbonaceous material to produce char for the third reaction zone. A reducing gas produced by partial oxidation of the char is used to effect the partial reduction conducted within the first reaction zone. Volatile substances contained within a heating gas produced by the partial oxidation within the auxiliary third reaction zone is further oxidized and used to preheat the iron ore within the first reaction zone.

Abstract: Process of producing power comprising:providing a turbine adapted to generate shaft work, said turbine having a combustor; and a rocket engine having a nozzle and a compressor means;feeding fuel and oxidant to the rocket engine and the rocket engine compressor means;feeding carbonaceous matter and steam into the rocket engine nozzle;processing the output of the rocket engine nozzle into fuel for the turbine;introducing said fuel and oxidant for the turbine to the turbine combustor; andrecycling a substantial portion of the hot exhaust from the turbine to the rocket engine compressor means; andcontrolling the inlet temperature to the turbine.Apparatus for producing power comprising a rocket engine and a turbine adapted to generate shaft work is also disclosed.

Abstract: The present invention relates to a method for production of metals and/or ferro alloys by prereduction of particulate metal oxide co-current with a reducing gas. Reducing gas having a temperature between 650.degree. and 1100.degree. C. and metal oxide particles are supplied at the lower end of a substantially vertical prereduction column which comprises at least two chamber having a substantially circular cross-section, said chambers in their upper and lower ends having a decreasing cross-section and where a ringshaped member for decreasing the cross-section is arranged in the intermediate zone between the chambers. The mixture of reducing gas and prereduced metal oxide particles is collected at the top of the prereduction column, whereafter the prereduced metal oxide particles are transported to a smelting furnace for smelting and final reduction to metallic state by addition of a reduction material.The present invention also relates to a column for treatment of particulate solid materials with a gas.