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.

A system and method for the fluidized direct reduction of iron ore concentrate powder. A two-phase fluidized bed is used for the direct reduction of iron ore concentrate powder. Each phase of the fluidized bed is formed by a bubbling bed and a circulating bed. Use of serial-connection processing involving gas and of high-gas-velocity processing of the circulating bed increase the gas utilization rate and the reduction efficiency of single-phase reduction. Once reduced gases are subjected to preheating, each gas is sent into an initial reduction phase and a final reduction phase so as to implement reduction of minerals. Use of mixed-connection processing involving gas appropriately reduces processing pressure. Hot flue gas produced by combustion in a gas heater is sent to a mineral pre-heating system that is used for pre-heating iron ore concentrate powder.

Method, apparatus and system for improved energy efficiency in a direct reduction iron production process which uses a direct reduction shaft furnace and syngas as the reduction gas. The method and system of the invention use a part of the top gas emanating from the shaft furnace as transport gas for the gasifier, and control the volume of the top gas used as recycled top gas or fuel for the gas heater. The present invention achieves high energy efficiency, and reduces the need to use additional CH.sub.4 source for the reduction gas.

A suspension roasting system includes a feeding bin, a Venturi dryer, a first cyclone preheater, a second cyclone preheater, a pre-oxidation suspension roasting furnace, a thermal separation cyclone cylinder, a suspension and reduction roasting furnace, a collecting bin, a grinding machine, a magnetic ore separator and a draught fan. A suspension roasting method includes: crushing iron and manganese ores; conveying the ores to the Venturi dryer; starting the draught fan and enabling combustion gas in the Venturi dryer to be mixed with dust ores to remove water; enabling obtained solid materials to enter the pre-oxidation suspension roasting furnace after being preheated by the first and second cyclone preheaters; enabling obtained gas to enter the suspension and reduction roasting furnace through the thermal separation cyclone cylinder; performing suspension and reduction roasting; enabling obtained reducing slag powder to enter the collecting bin through cooling cyclone cylinders; and performing grinding and magnetic separation.

An externally heated vertical reactor for reduction of iron ore, the reactor including: (a) a reactor tube positioned vertically adjacent to a furnace; (b) an external furnace positioned vertically adjacent at least one wall of the reactor tube to provide heat to be conducted through the at least one wall; (c) an input port at a base of the reactor tube, wherein the reducing gases are heated and injected into the input port such that the reducing gases rise upward through the reactor tube; (d) a gas exhaust positioned adjacent a top surface of the reactor; (e) a gas filter positioned adjacent an entrance to the gas exhaust; and (f) a bed positioned at the base of the reactor tube, wherein the reduced iron powder product is collected in the bed at the base of the reactor tube.

A device for manufacturing molten iron is provided. The device for manufacturing the molten iron includes a multi-stage fluidized reduction furnace for reducing a powdered iron ore including hematite and limonite, a melting gas furnace connected to the fluidized reduction furnace through an ore conduit and a gas conduit, a fluidized bed oxidation furnace for oxidizing magnetite to be converted into hematite through steam provided from the fluidized reduction furnace, and a hydrogen processing unit for processing hydrogen generated by the oxidation reaction of magnetite in the fluidized bed oxidation furnace.

A direct steelmaking device for iron containing powder in a reducing atmosphere and a method for its use are provided. The device comprises a steelmaking pool, a gas making tower, a fast reduction area, an ore feeding area, and a control system. The steelmaking pool arranged at the bottom comprises a slag flux pile, the bottom of the steelmaking pool is provided with a molten steel layer, and a liquid slag layer is provided on the molten steel layer. The fast reduction area is provided above the steelmaking pool. A gas making tower is provided on one side of a lower part of the fast reduction area, and the ore feeding area is provided above the fast reduction area.

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.

There is provided a method and system for recycling by-products containing large amounts of useful components and discharged in the form of dust and sludge from a coal-based molten iron making process to reuse the by-products in a reduced iron agglomeration process. The system includes: a fluidized reduction furnace reducing fine iron ore; a reduced iron tank connected to the fluidized reduction furnace through a reduced iron discharge pipe for storing the reduced iron and supplying the reduced iron in an agglomeration system; an agglomeration system agglomerating the reduced iron transferred from the reduced iron tank; and a transfer unit transferring compactions of by-products discharged from a molten iron making process through a by-product supply pipe. The compactions of the by-products are supplied to at least one selected from the group consisting of the fluidized reduction furnace, the reduced iron supply pipe, and the reduced iron tank.

A method of recovering enriched iron fines from bauxite waste includes calcining particles of bauxite waste to form oxygen carrier particles, subjecting the oxygen carrier particles to chemical looping combustion at a temperature of about 950 C.-1,050 C. for energy production and to produce the enriched iron fines as a by-product from the oxygen carrier particles via natural attrition and collecting the enriched iron fines.