The present document describes a smelting apparatus for smelting metallic ore. The smelting apparatus comprises a furnace having a continuous curved wall and end walls defining a longitudinal volume having a longitudinal axis in a horizontal direction. The continuous curved wall has a lowermost area. The longitudinal volume is divided in at least three longitudinal layers comprising a top layer within which gasified fuel is combusted for creating a hot gas composition at a temperature sufficient to release, from the metallic ore, at least molten metal and slag, a lowermost layer at the lowermost area for holding molten metal, and a mid-layer above the lowermost layer in which the slag accumulates. The present document also describes processes using the smelting apparatus for producing ferrous and non-ferrous minerals from a metallic ore.

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 CO.sub.2 emissions are reduced by 60-95%, depending on whether natural gas or hydrogen is used.

A smelting apparatus that includes (a) a smelting vessel (4) that is adapted to contain a bath of molten metal and slag and (b) a smelt cyclone (2) for pre-treating a metalliferous feed material positioned above and communicating directly with the smelting vessel The apparatus also includes an oft-gas duct (9) extending from the smelt, cyclone for discharging an off-gas from the smelt cyclone. The off-gas duct has an inlet section (18) that extends upwardly from the smelt cyclone and is formed to cause off-gas to undergo a substantial change of direction as it flows through the inlet section of the off-gas duct.

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 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.

Method and apparatus for producing direct reduced iron (DRI) powder or molten iron from iron ore fines by mixing said iron ore fines with hydrogen and oxygen and igniting the mixture in a flame reactor with flame temperatures controlled to produce solid iron powder or molten iron.

An apparatus for manufacturing molten iron includes: an iron ore-mixing/pre-reducing furnace receiving and mixing natural iron ore and oxidized iron ore to form a mixture, and heating or pre-reducing the mixture using a reaction gas to form a pre-heated or pre-reduced iron ore; an iron ore reduction furnace receiving the pre-heated or pre-reduced iron ore iron ore and reducing the pre-heated or pre-reduced iron ore using a reduction gas to form a reduced iron ore and produce the reaction gas; a molten gasification furnace receiving coal and the reduced iron ore and producing molten iron and the reduction gas; and an iron ore oxidizing-burning furnace receiving part of the reduced iron ore discharged from the iron ore reduction furnace and oxidizing the received reduced iron ore to produce the oxidized iron ore. The oxidized iron ore is supplied to the iron ore-mixing/pre-reducing furnace.

Method for producing direct reduced metal material (106) in a continuous process, wherein hydrogen gas and inert gas is circulated in respective closed-loop first and second gas circuits via different respective gas connection stations (130,140120-122,150-151), comprising for individual mobile furnaces (101): a) charging metal material (106) into the furnace; b) moving and connecting the furnace to an inert gas connection station; c) providing heated inert gas to the furnace; d) disconnecting the furnace; e) moving and connecting the furnace to a hydrogen gas connection station; f) providing heated hydrogen gas to the furnace; g) disconnecting the furnace; h) moving and connecting the furnace to an inert gas connection station; i) providing cooled inert gas to the furnace; j) disconnecting the furnace; and k) discharging the metal material. The invention also relates to a system.

A process for direct reduction of iron ore in a solid state is disclosed. The process operates under anoxic conditions with biomass as a reductant and with electromagnetic energy as a source of heat.

A method for mitigating the buildup of direct reduced iron (DRI) clusters on the walls of a direct reduction (DR) furnace, including: injecting one or more of lime, dolomite, and another anti-sticking agent into a charge disposed within a reduction zone of the DR furnace by: (1) injecting the one or more of lime, dolomite, and another anti-sticking agent into a bustle gas stream upstream of or in a bustle of the DR furnace; (2) injecting the one or more of lime, dolomite, and another anti-sticking agent into the bustle gas stream through a pipe collocated with a bustle gas port through which the bustle gas stream is introduced into the DR furnace; and (3) injecting the one or more of lime, dolomite, and another anti-sticking agent directly into the reduction zone of the DR furnace separate from the bustle gas stream.