This invention provides processes and systems for converting biomass into high-carbon biogenic reagents that are suitable for a variety of commercial applications. Some embodiments employ pyrolysis in the presence of an inert gas to generate hot pyrolyzed solids, condensable vapors, and non-condensable gases, followed by separation of vapors and gases, and cooling of the hot pyrolyzed solids in the presence of the inert gas. Additives may be introduced during processing or combined with the reagent, or both. The biogenic reagent may include at least 70 wt %, 80 wt %, 90 wt %, 95 wt %, or more total carbon on a dry basis. The biogenic reagent may have an energy content of at least 12,000 Btu/lb, 13,000 Btu/lb, 14,000 Btu/lb, or 14,500 Btu/lb on a dry basis. The biogenic reagent may be formed into fine powders, or structural objects. The structural objects may have a structure and/or strength that derive from the feedstock, heat rate, and additives.

This invention provides processes and systems for converting biomass into high carbon biogenic reagents that are suitable for a variety of commercial applications. Some embodiments employ pyrolysis in the presence of an inert gas to generate hot pyrolyzed solids, condensable vapors, and non-condensable gases, followed by separation of vapors and gases, and cooling of the hot pyrolyzed solids in the presence of the inert gas. Additives may be introduced during processing or combined with the reagent, or both. The biogenic reagent may include at least 70 wt %, 80 wt %, 90 wt %, 95 wt %, or more total carbon on a dry basis. The biogenic reagent may have an energy content of at least 12,000 Btu/lb, 13,000 Btu/lb, 14,000 Btu/lb, or 14,500 Btu/lb on a dry basis. The biogenic reagent may be formed into fine powders, or structural objects. The structural objects may have a structure and/or strength that derive from the feedstock, heat rate, and additives.

Producing direct reduced iron (DRI) having chemically-combined carbon includes providing DRI at a temperature above 400 C., providing a first gas stream including hydrogen and carbon monoxide, passing the first gas stream through a methane forming process to yield a second gas stream containing a higher concentration of methane than the first gas stream; and contacting the second gas stream with the DRI. A system for producing the DRI includes a vessel for containing DRI at a temperature above 400 C., a methane forming reactor containing a catalyst bed for producing methane from a first gas stream containing hydrogen and carbon monoxide, a first conduit to feed a gas stream including hydrogen and carbon monoxide to the methane forming reactor, and a second conduit to feed the second gas stream to the vessel containing the DRI.

Stabilized volatile briquettes and processes and apparatuses for making and using the same are provided. The stabilized volatile briquette includes a volatile material and a thermoplastic binder material such that the thermoplastic binder material binds the volatile material together to define a briquette that is stable. The process includes mixing a volatile waste material and a thermoplastic binder material to form a briquette mixture, shearing the briquette mixture, extruding the briquette mixture to form a thermoplastic briquette extrusion, and hardening the thermoplastic briquette extrusion to form a stabilized volatile briquette. The apparatus includes an extruder, a heating portion operably connected to the extruder, and a heated die operably connected to the heating portion such that the extruder, the heating portion, and the heated die are configured to gradually heat a thermoplastic binder material such that the thermoplastic binder material binds a provided volatile material together.

Particles with suitable properties may be generated using systems and methods provided herein. The particles may include carbon particles. In some examples, carbon particles for metallurgy applications are provided.

This invention provides processes and systems for converting biomass into highcarbon biogenic reagents that are suitable for a variety of commercial applications. Some embodiments employ pyrolysis in the presence of an inert gas to generate hot pyrolyzed solids, condensable vapors, and non-condensable gases, followed by separation of vapors and gases, and cooling of the hot pyrolyzed solids in the presence of the inert gas. Additives may be introduced during processing or combined with the reagent, or both. The biogenic reagent may include at least 70 wt %, 80 wt %, 90 wt %, 95 wt %, or more total carbon on a dry basis. The biogenic reagent may have an energy content of at least 12,000 Btu/lb, 13,000 Btu/lb, 14,000 Btu/lb, or 14,500 Btu/lb on a dry basis. The biogenic reagent may be formed into fine powders, or structural objects.

A flash ironmaking system and a flash ironmaking method are provided. The flash ironmaking system includes a pulverized coal gasifier; a drying pre-reduction kiln; and a flash furnace having a horizontal bottom in which a molten iron layer region, a slag layer region and a carburizing bed layer region are sequentially formed, a reduction tower, a concentrate nozzle, and a flue.

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.

Processes and systems for converting biomass into high-carbon biogenic reagents that are suitable for a variety of commercial applications. Pyrolysis in the presence of an inert gas is employed to generate hot pyrolyzed solids, condensable vapors, and non-condensable gases, followed by separation of vapors and gases, and cooling of the hot pyrolyzed solids in the presence of the inert gas. Additives may be introduced during processing or combined with the reagent, or both. The biogenic reagent may include at least 70 wt %, 80 wt %, 90 wt %, 95 wt %, or more total carbon on a dry basis. The biogenic reagent may have an energy content of at least 12,000 Btu/lb, 13,000 Btu/lb, 14,000 Btu/lb, or 14,500 Btu/lb on a dry basis. The biogenic reagent may be formed into fine powders, or structural objects. The structural objects may have a structure and/or strength that derive from the feedstock, heat rate, and additives.

The reduced iron manufacturing method of the present invention includes preparing an agglomerate by agglomerating a mixture containing an iron oxide-containing substance and a carbonaceous reducing agent, and preparing reduced iron by heating the agglomerate to reduce iron oxide in the agglomerate, characterized in that Expression (I) as follows is satisfied:
C.sub.fixX.sub.under105/O.sub.FeO51(I)
where O.sub.FeO is the mass percentage of oxygen contained in the iron oxide in the agglomerate, C.sub.fix is the mass percentage of total fixed carbon contained in the agglomerate, and X.sub.under105 is the mass percentage of particles having a particle diameter of 105 m or less with respect to the total mass of particles configuring the carbonaceous reducing agent.