A classified reduction gasification iron smelting process of iron ore powder and coal powder in a Y-type entrained flow bed. The process comprises the following steps: uniformly mixing the pre-reduced hot iron ore powder with the coal powder, and introducing the mixture, a gasification agent and water vapor into a Y-type entrained flow bed for performing combustion, gasification and reduction reaction to obtain crude syngas and molten iron; the crude syngas is used for sucking iron ore powder to enter a riser to perform preheating and partial reduction.

The disclosure discloses a method of operating an electric arc furnace, the method comprising capturing, from at least one facility of a steel mill, a heated metallurgical gas comprising water and carbon monoxide; conducting, by a reactor supply line, said metallurgical gas to a reactor; transforming, by a treatment of said metallurgical gas within said reactor, the carbon monoxide and water into hydrogen and carbon dioxide according to a water-gas shift reaction; and subsequently separating said hydrogen by a separation device. The method is characterized in that it further comprises providing an iron-bearing material, which comprises iron mainly in the form of iron oxide, to the electric arc furnace; at least partially melting the iron-bearing material to obtain a molten bath; conducting, by a furnace supply line, said hydrogen to the electric arc furnace, which is arranged downstream of the furnace supply line; and injecting, by a plurality of hydrogen injection devices, said hydrogen into said electric arc furnace, such that said hydrogen reacts as a reducing agent for reducing iron oxide in the molten bath during a smelting operation of the electric arc furnace.

The present disclosure relates to a method for producing steel in an integrated metallurgical plant comprising at least one direct reduction reactor for directly reducing iron ore to give sponge iron, at least one electric furnace for melting the sponge iron to give pig iron or crude steel, at least one blast furnace for smelting iron ore to give pig iron, and at least one converter for refining pig iron to give crude steel. In accordance with the invention, the process gas discharged from the direct reduction reactor is admixed at least partly to the hot blast air and/or at least partly to an optional charging material, said air and/or said material being blown into the blast furnace.

A method for recycling processing of dust generated in a converter furnace, includes: crushing and drying a cake formed by adding a binder to a slurry containing iron powder-containing dust that is generated at the time of converter blowing and wet-collected to produce a mixed slurry and subjecting the produced mixed slurry to a dehydration treatment in a filter press; accumulating the cake in an accumulation tank; and charging the cake into a converter furnace 10, the crushed product in the accumulation tank 25 is kept at a temperature of less than 90 C. by forcibly passing air into the accumulation tank 25 and charged into a converter furnace according to the converter operation.

Herein discussed is a method of producing hydrogen comprising introducing a metal smelter effluent gas or a basic oxygen furnace (BOF) effluent gas or a mixture thereof into an electrochemical (EC) reactor, wherein the EC reactor comprises a mixed-conducting membrane. In an embodiment, the method comprises introducing steam into the EC reactor on one side of the membrane, wherein the effluent gas is on the opposite side of the membrane, wherein the effluent gas and the steam are separated by the membrane and do not come in contact with each other.

The present disclosure relates to a process for producing an iron melt. The method includes; reducing iron ore to sponge iron, carburizing sponge iron with a carbonaceous gas, melting the carburized sponge iron and/or treating the melt produced from the carburized sponge iron. According to the present disclosure, the carbonaceous gas is at least a portion of the process gas obtained in the melting of the carburized sponge iron and/or treating of the melt produced from the carburized sponge iron that has been recycled.

The invention concerns a process for detecting water leaks in smelting furnaces (2; 4) or in metal or alloy treatment plants, comprising the following steps: (i) providing at least one smelting furnace (2; 4), or at least one metal or alloy treatment plant provided with a water cooling system (5) and being connected to a process fume exhaust system; (ii) mixing in the cooling water a tracer chemical which is volatile in the event of water leakage together with the exhaust gases and which is suitable to be detected by an analysis system of the exhaust gases; and (iii) detecting said tracer chemical contained in the exhaust gases by said analysis system comprised in said process fume exhaust plant, wherein said tracer chemical is deuterated water. The invention further refers to a Plant for the production of metals or alloys.

A method for reducing carbon footprint in operating a metallurgical plant for producing pig iron, including: pre-heating iron ore fines in a first electric pre-heater to obtain pre-heated iron ore fines partially reducing the pre-heated iron ore fines in one or more fluidized bed reactors in the presence of a hot reducing gas to obtain partially reduced iron; feeding the partially reduced iron to a submerged arc furnace; further reducing and melting the partially reduced iron within the submerged arc furnace in the presence of a carbonaceous material to obtain molten pig iron; where the hot reducing gas includes hydrogen, syngas, off-gas of the submerged arc furnace, other off-gases from the metallurgical plant, or mixtures of two or more thereof, where the syngas is produced from natural gas or biomethane, blast furnace gas, off-gas of the submerged arc furnace, other off-gases from the metallurgical plant, or mixtures of two or more thereof in the presence of air or oxygen enriched air, steam or carbon dioxide in one or more reforming reactors, where the hot reducing gas has a temperature above 550 C., and where the partially reduced iron has a metallization degree of 55 to 75%.

A method for recycling processing of dust generated in a converter furnace, includes: crushing and drying a cake formed by adding a binder to a slurry containing iron powder-containing dust that is generated at the time of converter blowing and wet-collected to produce a mixed slurry and subjecting the produced mixed slurry to a dehydration treatment in a filter press; accumulating the cake in an accumulation tank; and charging the cake into a converter furnace 10, the crushed product in the accumulation tank 25 is kept at a temperature of less than 90 C. by forcibly passing air into the accumulation tank 25 and charged into a converter furnace according to the converter operation.

A method for producing molten pig iron includes a first step of producing carbon-material-containing agglomerated ore from an iron-containing and carbon-containing raw materials, a second step of blowing an oxygen-containing gas into the carbon-material-containing agglomerated ore to reduce and melt it, thereby producing molten pig iron, and a third step of bringing a carbon-containing gas containing carbon monoxide and carbon dioxide produced as a by-product of the reduction into contact with a porous material, thereby recovering carbon, in which in the first step, the carbon recovered in the third step is used for a part of or an entirety of the carbon-containing raw material. The method may include, instead of the second step, a reduction step of heating the carbon-material-containing agglomerated ore to 1160 to 1450 C., and then cooling the carbon-material-containing agglomerated ore to obtain reduced iron, and a step of melting the reduced iron to produce molten pig iron.