A method for processing iron ore to obtain steel by feeding the DRI into a smelting furnace so as to obtain an intermediate iron product, which is then subsequently introduced into a conversion unit for obtaining steel form the intermediate iron product. Moreover, carbon is introduced into the process. As a consequence, a suitable carbon content may be achieved for the intermediate iron product such that impurities of the intermediate iron product may be reduced along with carbon contents thereof in a steel conversion process without sacrificing iron contents of the intermediate iron product. Simultaneously, suitable fluxes are fed into the smelting furnace together with the DRI, such that high-quality slag suitable as raw material for further processing is obtained therefrom. An associated smelting furnace arrangement is also disclosed.

A method and system for recovering a high yield of low carbon ferroalloy, e.g., low carbon ferrochrome, from chromite and low carbon ferrochrome produced by the method. A stoichiometric mixture of feed materials including scrap aluminum granules, lime, silica sand, and chromite ore are provided into a plasma arc furnace. The scrap aluminum granules are produced from used aluminum beverage containers. The feed materials are heated, whereupon the aluminum in the aluminum granules produces an exothermic reaction reducing the chromium oxide and iron oxide in the chromite to produce molten low carbon ferrochrome with molten slag floating thereon. The molten low carbon ferrochrome is extracted, solidified and granulated into granules of low carbon ferrochrome. The molten slag is extracted, solidified and granulated into granules of slag.

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.

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.

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.

A method and apparatus for producing direct reduced iron (DRI), including: generating a reducing gas in a coal gasifier using coal, oxygen, steam, and a first coke oven gas (COG) stream as inputs to the coal gasifier; and delivering the reducing gas to a shaft furnace and exposing iron ore agglomerates to the reducing gas to form metallic iron agglomerates. The method further includes delivering a second COG stream directly to the shaft furnace.

A process for the manufacturing of hot briquetted iron (HBI) from direct reduced iron (DRI) wherein iron ore is direct reduced in a reactor by a reducing gas consisting of natural gas and/or hydrogen and/or carbon monoxide under elevated temperatures and discharging the direct reduced iron to at least one briquetting device where briquettes are pressed from the direct reduced iron characterized in that the direct reduced iron after leaving the reactor and before briquetting is heated to a target briquetting temperature.

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.

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.

An apparatus for producing hot briquetted iron and a method for producing hot briquetted iron using such an apparatus. The apparatus includes a briquetting press and a force feeder arrangement. The apparatus further includes a powder injection arrangement, the powder injection arrangement including a powder dosing unit and at least one injection line. The powder dosing unit is arranged to be able to dose powder at a predetermined rate to the at least one injection line. Each injection line extends from a line inlet to a line outlet. Each line inlet is arranged to be connectible to a source of pressurized carrier gas and each line outlet is arranged to be able to inject powder into a material supply tank of the force feeder arrangement.