A process for direct reduction of iron ore in a solid state includes exposing briquettes of iron ore fragments and biomass to electromagnetic energy under anoxic conditions and generating heat within iron ore in the briquettes. The iron ore is reduced in a solid state within the briquettes, and the biomass provides a source of reductant.

This invention relates to a method and apparatus for gasifying or liquifying coal. In particular, the method comprises reacting a coal with a molten aluminum or aluminum alloy bath. The apparatus includes a reaction vessel for carrying out the reaction, as well as other equipment necessary for capturing and removing the reaction products. Further, the process can be used to cogenerate electricity using the excess heat generated by the process.

A method for the production of cast iron starting from pre-reduced iron ore (DRI) with an electric arc furnace includes the steps of preparing a charge of pre-reduced iron ore DRI having a metallization higher than 90% and containing over 2.8% by weight of carbon, wherein at least 80% of the carbon is combined with the iron to form iron carbide Fe.sub.3C; charging the charge of pre-reduced iron ore into the electric arc furnace; and melting the DRI charge to form liquid cast iron having at least 80% by weight of actual carbon content deriving from the carbon in the charge of pre-reduced iron ore, the melting step being in a reducing atmosphere and in a melting chamber of the electric arc furnace subjected to a positive internal pressure generated by the gases produced by reduction reactions that develop during melting.

The invention relates to a method for sealing a reduction assembly, wherein the reduction assembly has a product discharge device, wherein the product discharge device is supplied with sealing gas and wherein at least one compressor is provided for delivering prepared sealing gas to the product discharge device, wherein according to the invention, at least one nitrogen generator is provided for producing pure sealing gas, and wherein the sealing gas for supplying to the product discharge device is composed of pure sealing gas from the at least one nitrogen generator or composed of pure sealing gas from the at least one nitrogen generator and of prepared sealing gas from the at least one compressor. The invention also relates to a device with which the method according to the invention is carried out.

A flash ironmaking drop tube furnace includes a primary reaction section having a refractory, an induction coil around the refractory, insulation located between the refractory and the induction coil, and a susceptor located inside the refractory, the susceptor being formed of a material that is heated by induction when electrical current flows through the induction coil, and having at least one interior channel through which particles can pass. The furnace further includes a muffle, located below the primary reaction section; an outer shell surrounding the muffle; at least one heater located adjacent to the muffle; insulation located between the at least one heater and the outer shell; at least one particle feeder that feeds a predetermined volume of particles into the furnace above the primary reaction section; and an inlet port for injecting gas into the furnace, the inlet port being located so that the gas flows through the susceptor and muffle in parallel with the particles.

A method for producing a homogenous molten composition and a fluid product is disclosed. For example, the method includes producing a first molten metal composition in an enclosed volume, contacting a hydrocarbon reactant with the first molten metal composition, decomposing the hydrocarbon reactant into at least one fluid product and carbon, forming a metal alloy from a mixture of the carbon and the first molten metal composition, and separating a homogenous second molten composition from the metal alloy.

The present invention relates to a process for the smelting of a metalliferous feedstock material. The process includes the steps of: (i) feeding an agglomerate comprising of a fine metalliferous feedstock material and a fine reductant to a reactor, the agglomerate forming a packed bed within the reactor; (ii) smelting the agglomerate by passing a hot reducing gas counter current through the packed bed to form a molten material comprising a partially reduced metalliferous constituent, an intermediate slag constituent and entrained unreacted reductant constituent; and (iii) channelling the molten material to flow into a vessel to form a metal product and a slag product.

An ironmaking system and process of a two-section downdraft bed, including: a vertical melting furnace, where a basic combustor/gasifier is at the top, first and second inlets evenly along a side wall of the melting furnace below the basic combustor/gasifier, and the first inlet connected to coke powder/pulverized coal, air, and water vapor sources; a slag pool, at a bottom of the melting furnace; a vertical pre-reduction furnace, the top portion connected to the outlet of the melting furnace, third and fourth inlets on an upper portion of the pre-reduction furnace and connected respectively to a temperature-adjusting and tempering medium source and an iron mineral powder source, an outlet at a bottom of the pre-reduction furnace; and a separator, an inlet of the separator connected to the outlet of the pre-reduction furnace, and an outlet at a bottom of the separator connected to the second inlet through a pipeline.

A method for off-gas composition control, wherein the off-gas results from a smelting apparatus for smelting a metalliferous feed material, wherein the smelting apparatus includes a smelting vessel, a smelt cyclone mounted on the smelting vessel and in connection with the inside of the smelting vessel and an off-gas duct connected to the smelt cyclone, wherein the method provides that an oxygen containing gas containing 95% oxygen or more is injected into the smelt cyclone and that the feed material is injected into the smelt cyclone with a carrier gas other than nitrogen gas.

A method of direct reduction of iron (DRI) is disclosed, the method comprising generating metallic iron by removing oxygen from iron ore using a reducing gaseous mixture with excess carbon monoxide that produces an excess CO.sub.2 by-product is provided. CO.sub.2 by-product is optionally sequestered. A system for carrying out the method is also disclosed.