A direct reduction shaft furnace having at least one probe disposed vertically within the reduction zone thereof. The probe preferably extends from the top to the bottom of the reduction zone. The probe allows for gas sampling along the length thereof and transmittal of the gas to at least one type of gas analysis device. The probe may also allow for the measurement of the temperature and pressure of the gas sample as it is taken.

A direct reduction shaft furnace having at least one probe disposed vertically within the reduction zone thereof. The probe preferably extends from the top to the bottom of the reduction zone. The probe allows for gas sampling along the length thereof and transmittal of the gas to at least one type of gas analysis device. The probe may also allow for the measurement of the temperature and pressure of the gas sample as it is taken.

A method and apparatus for producing direct reduced iron using a pre-treated make-up gas as a reducing agent in a direct reduced iron reactor are provided. The method involves pre-treating a stream of make-up gas containing heavy hydrocarbons by subjecting the stream to low temperature adiabatic reforming at a temperature between 300° C. and 600° C., prior to using the stream of make-up gas as a reducing agent for producing direct reduced iron. The method also involves adjusting the humidity content of the stream of make-up gas after the low temperature adiabatic reforming by bypassing the stream to selectively split it into a first part of the stream of make-up gas and a second part of the stream of make-up gas, subjecting the first part to water separation, and then mixing the first part with the second part to obtain a reducing stream to be sent to direct reduced iron production.

A raw material for direct reduction which is reduced in a shaft furnace includes a raw material, and a coating layer which coats the raw material and has a porosity of 20 volume % or more.

A raw material for direct reduction which is reduced in a shaft furnace includes a raw material, and a coating layer which coats the raw material and has a porosity of 20 volume % or more.

A modular direct reduction system for producing direct reduced iron (DRI) includes a reformer system which receives a flow of feed gas and which discharges a flow of reducing gas, the reformer system including a plurality of separate reformer modules connected together and wherein each reformer module includes a reformer vessel including an internal chamber, a reactor tube extending through the internal chamber of the reformer vessel and containing a catalyst configured to react with the feed gas received by the reactor tube to form the reducing gas, and a burner to burn a fuel gas to heat the reactor tube, and a furnace system connected to the reformer system and including a furnace having a first inlet which receives an iron ore, a second inlet which receives the reducing gas from the reformer system to form the DRI, and an outlet which discharges the DRI.

A modular direct reduction system for producing direct reduced iron (DRI) includes a reformer system which receives a flow of feed gas and which discharges a flow of reducing gas, the reformer system including a plurality of separate reformer modules connected together and wherein each reformer module includes a reformer vessel including an internal chamber, a reactor tube extending through the internal chamber of the reformer vessel and containing a catalyst configured to react with the feed gas received by the reactor tube to form the reducing gas, and a burner to burn a fuel gas to heat the reactor tube, and a furnace system connected to the reformer system and including a furnace having a first inlet which receives an iron ore, a second inlet which receives the reducing gas from the reformer system to form the DRI, and an outlet which discharges the DRI.

A direct reduction process comprises providing a shaft furnace of a direct reduction plant to reduce iron oxide with reducing gas; providing a direct reduced iron melting furnace; and coupling a discharge chute between a discharge exit of the direct reduced shaft furnace and an inlet of the direct reduced iron melting furnace; wherein direct reduced iron and the reducing gas from the shaft furnace flow through the discharge chute and the reducing gas controls the melting furnace atmosphere to reducing environment.

A method of heating direct reduced iron between a direct reduced iron source and processing equipment for the direct reduced iron, comprises providing a conduit heater assembly between the direct reduced iron source and the processing equipment, wherein the conduit heater assembly receives a flow of the direct reduced iron from the direct reduced iron source and heats the direct reduced iron as the direct reduced iron flows through the conduit heater assembly and to the processing equipment.

A method for the direct reduction of feedstock, containing metal-oxide, to form metallic material, by contact with hot reduction gas in a reduction assembly (1): the product of the direct reduction process is discharged from the reduction assembly by a product discharge apparatus, which is flushed with seal gas, drawn off from the vent gas and subsequently dedusted. At least one portion of the dedusted vent gas is used as a combustion energy source during the production of the reduction gas, and/or as a component of a furnace fuel gas during a combustion process for heating the reduction gas, and/or as a component of the reduction gas. Apparatus for carrying out the method is disclosed.