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 method of processing red mud comprising: heating red mud to a predetermined temperature; grinding the red mud to a predetermined particle size; and physically extracting iron components from the red mud; physically extracting aluminum components from the red mud, said physically extracting of aluminum components being separate from the physically extracting of iron components, wherein the steps of physically extracting iron components and physically extracting aluminum components are performed without requiring addition of chemical additives to the red mud.

A method of processing red mud comprising: heating red mud to a predetermined temperature; grinding the red mud to a predetermined particle size; and physically extracting iron components from the red mud; physically extracting aluminum components from the red mud, said physically extracting of aluminum components being separate from the physically extracting of iron components, wherein the steps of physically extracting iron components and physically extracting aluminum components are performed without requiring addition of chemical additives to the red mud.

The present invention concerns a process and a configuration for producing steel, whereby iron ore oxide material (5) is reduced with a reducing agent (H) in a direct reduction facility (7). The reducing agent (H) is produced by electrolysis of water by means of an electrolysis unit (17).

The electric energy necessary for the electrolysis comprises re-generative energy, which is derived from hydropower and/or wind power and/or photovoltaic or other re-generative energy forms (2). The intermediate product (RM) is produced independently of the current demand, if sufficient reducing agent is available.

An iron ore oxide material (5) holding thermal energy is charged into the direct reduction facility (7). The thermal energy originates from an iron ore oxide material provider device, such as an iron ore oxide material production unit (3) or a pre-heating apparatus (4).

The reducing agent (H) reacts with the iron ore oxide material (5) for reducing the iron ore oxide material (5) into the intermediate product (RM) by utilizing the thermal energy of the iron ore oxide material (5).

An arrangement and process for charging iron ore to a direct reduction shaft, as well as an arrangement and process for discharging sponge iron from a direct reduction shaft. The processes each include the steps of evacuating gas from a vessel by application of vacuum followed by refilling the vessel with a process gas from the direct reduction shaft. Also provided is a system for the production of sponge iron including such an arrangement for charging iron ore and/or discharging sponge iron. Further provided is a process for direct reduction of iron ore, wherein the process includes introducing a process gas from direct reduction to a direct reduction shaft in conjunction with charging iron ore and/or in discharging sponge iron.

Extraction of elements and/or compounds from iron-containing materials, such as iron-containing tailings, and related systems and products are generally described. The systems and methods described herein can provide, in accordance with certain embodiments, the ability to efficiently process iron-containing (e.g., iron-rich) tailings even in the presence of aluminosilicates and/or other impurities. In addition, in accordance with some embodiments, the systems and methods described herein can provide the ability to efficiently extract different minerals and/or other compounds (e.g., metal(s), salt(s), etc.) from complex tailings structures. Furthermore, reactors and methods for recovery of a reaction product with a relatively high magnetic susceptibility are generally described. Certain reactors are configured such that, during operation, the reaction products are selectively transported to the magnetic field source, relative to the reactants.

A system for processing red mud including at least one heating section controlled to heat red mud to a predetermined temperature, a crusher configured to grind the red mud to a predetermined particle size, a first separator for physically extracting iron components from the red mud, and a second separator for physically extracting one or more of aluminum components and titanium components from the red mud, wherein the first and second separators do not require addition of chemical additives to perform the separation.

A system for processing red mud including at least one heating section controlled to heat red mud to a predetermined temperature, a crusher configured to grind the red mud to a predetermined particle size, a first separator for physically extracting iron components from the red mud, and a second separator for physically extracting one or more of aluminum components and titanium components from the red mud, wherein the first and second separators do not require addition of chemical additives to perform the separation.

A method for manufacturing pig iron in an electrical smelting furnace including a vessel, the method including the following successive steps: loading DRI product in the vessel, melting the DRI product to form a pig iron layer topped by a slag layer and, tapping the pig iron into a ladle, and adding a carbon containing material directly in the pig iron in the runner of at least one of the smelting furnace tap holes. It also deals with the manufacturing of steel from the pig iron and the associated electrical smelting furnace.