Abstract: An alternative approach to producing iron from iron concentrates produced from low grade iron ore without going through pelletization and induration. Such a method may include providing iron ore concentrate in a small particle form, passing the iron ore concentrate through a moving bed conveyor reduction furnace with at least one of hydrogen or natural gas, wherein the concentrate is present in a layer that is no more than about 5 cm thick, the hydrogen gas or natural gas reducing the concentrate so as to remove oxygen therefrom, converting the iron ore concentrate to iron that has a composition similar to direct reduced iron (DRI) or sponge iron product, having about 90-95% iron, up to about 10% oxygen, with other trace impurities. Energy consumption is reduced by 30-50% and CO2 emissions are reduced by 60-95%, depending on whether natural gas or hydrogen is used.

Abstract: The present invention is directed to additives for coal-fired furnaces, particularly furnaces using a layer of slag to capture coal particles for combustion. The additive(s) include iron, mineralizer(s), handling aid(s), flow aid(s), and/or abrasive material(s). The iron and mineralizers can lower the melting temperature of ash in low-iron, high alkali coals, leading to improved furnace performance.

Abstract: Disclosed herein are methods and compositions for producing composite iron pellets comprising an inner core comprising iron ore and a reducing agent comprising a carbonaceous material; and an outer shell comprising unreduced iron ore. The resulting composite iron pellets can be used to produce direct reduced iron (DRI) with improved productivity while reducing gas consumption.

Abstract: An apparatus and method for processing iron sinter is provided. A cooling system is arranged downstream of a furnace for cooling the iron sinter. The cooling system includes a convective cooling system for forcing air into the iron sinter and an evaporative cooling system for directing fluid into the hot sinter.