METAL ORE REDUCTION REACTOR WITH SELF-GENERATING REDUCTANT

Abstract

A system and method for generating reductants during direct reduction of metal ore is provided. The system has a reduction portion configured to accept the metal ore and to heat the metal ore to form a gas and particle mixture, a quench section in communication with the reduction portion and configured to receive the mixture having a catalyst located in an interior of the quench section, and a heat exchanger located in an interior of the quench section, having at least one channel configured to contact the mixture and form a hot reactant stream from the gas and particle mixture, wherein the heat exchanger utilizes a heat energy from the reduction portion, and a reactant inlet configured to provide reactants to the interior of the quench section, and wherein the reactants react using heat from the stream to generate a reductant.

Claims

1. A system for generating reductants during direct reduction of metal ore, the system comprising: a reduction portion configured to accept the metal ore and to heat the metal ore to form a gas and particle mixture; a quench section in communication with the reduction portion, wherein the quench section is configured to receive the mixture, and wherein the quench section comprises: a catalyst located in an interior of the quench section; a heat exchanger located in the interior of the quench section, wherein the heat exchanger comprises at least one channel configured to contact the mixture and form a hot reactant stream from the gas and particle mixture, wherein the heat exchanger utilizes a heat energy from the reduction portion; a reactant inlet in communication with the interior of the quench section, wherein the reactant inlet is configured to provide reactants to the interior of the quench section, and wherein the reactants react using heat from the mixture to generate a reductant; a first product outlet in communication with the interior of the quench section, wherein the first product outlet is configured to dispel the reductant; an exit portion coupled to the quench section, wherein the exit portion is configured to release direct reduced metal ore and gas.

2. The system of claim 1, wherein a temperature of the gas and particle mixture is greater than a temperature of the stream at an outlet of portion of the quench section.

3. The system of claim 1, wherein the heat exchanger comprises: a lower catalyst containment wall, wherein the lower catalyst containment wall comprises lower pores configured to allow the reactant flow in the interior of the quench section; an upper catalyst containment wall, wherein the upper catalyst containment wall comprise upper pores configured to allow the reactant flow in the interior of the quench section.

4. The system of claim 1, wherein the reactant inlet is configured to receive a reactant stream, wherein the reactant stream is a cold reactant stream compared to the hot reactant stream, wherein the reactants comprise reforming or shifting species, and wherein the reforming or shifting species comprise hydrocarbons, carbon monoxide, carbon dioxide, water vapor, or a combination thereof.

5. The system of claim 1, wherein the stream comprises at least one of ore particles, reduced metal particles, gaseous reductants, gaseous ore reduction products, r gaseous combustion products unreacted reactants, unreacted reactants, or a combination thereof.

6. The system of claim 1, wherein the reductants comprise hydrogen, carbon monoxide, syngas, methane or a combination thereof.

7. The system of claim 1, further comprising a second outlet in communication with the heat exchanger and located in an interior of the quench section, wherein the at least one channel is located at a bottom of the quench section, wherein the at least one channel is configured to contact the mixture, wherein the mixture has passed through the heat exchanger and retains heat for transfer to continue to heat the hot reactant stream from a gas mixture which originated as the gas and particle mixture, wherein the gas mixture exits the second outlet.

8. A method for generating reductants during direct reduction of metal ores, the method comprising: receiving a metal ore at a reduction portion of a reactor; receiving a reductant at a reduction portion of a reactor; heating the metal ore and the reductant to form a gas and particle mixture; receiving the mixture at a quench section of the reactor, wherein the quench section comprises a heat exchanger having at least one channel configured to accept the mixture and form a hot reaction stream; introducing a catalyst located in the quench section; utilizing a heat energy from the reduction portion of the reactor to heat the catalyst and form the hot reaction stream; providing a reactant stream to the heat exchanger positioned in the quench section such that the reactant stream receives heat from channel of the heat exchanger, wherein the reactants become the hot reaction stream and react to generate a reductant; dispelling the reductant from a first product outlet, wherein the first product outlet is in communication with the interior of the quench section; and releasing direct reduced metal ore from an exit portion.

9. The method of claim 8, wherein a temperature of the gas and particle mixture is greater than a temperature at an outlet of portion of the quench section.

10. The method of claim 8, further comprising: containing the catalyst in the heat exchanger using lower containment walls, and allowing the reactant to flow in the interior of the quench section using lower pores; containing the catalyst in the heat exchanger using upper containment walls, and allowing the reactant and reductant to flow out of the interior of the quench section using upper pores.

11. The method of claim 8, where providing a reactant stream comprises providing a cold reactant stream compared to the hot reactant stream, wherein the reactants comprise reforming or shifting species, wherein reforming or shifting species comprise hydrocarbons, carbon monoxide, carbon dioxide, water vapor, or a combination thereof.

12. The method of claim 8, wherein the stream comprises at least one of ore particles, reduced metal particles, metal particles, gaseous reductants, gaseous ore reduction products, gaseous combustion products or unreacted reactants.

13. The method of claim 8, wherein the reductants comprise hydrogen, carbon monoxide, syngas, methane or a combination thereof.

14. The method of claim 8, further comprising porting a portion of the gas component of the mixture which has emanated from at least one channel emanating from the bottom of the quench section, comprising a second heat exchanger, wherein additional heat from the gas component of the mixture forms the hot reactant stream and exits the port providing a mechanism to acquire more heat from the gas mixture for reductant generation without adding height to the quench section.

15. A quench device for a reactor for generating reductants during direct reduction of metal ores, the quench device comprising: an inlet configured to receive a mixture of hot metal ore, gas and particles; a catalyst located in an interior portion of the quench device; a heat exchanger located in an interior of the quench device, wherein the heat exchanger comprises at least one channel configured to contact the mixture and form a hot reactant stream, wherein the heat exchanger utilizes a heat energy from the reduction portion; a reactant inlet in communication with the interior of the quench device, wherein the reactant inlet is configured to provide reactants to the interior of the quench device, wherein the reactants react with the streams to generate a reductant; a first product outlet in communication with the interior of the quench device, wherein the first product outlet is configured to dispel the reductant.

16. The device of claim 15, wherein the heat exchanger comprises: a lower catalyst containment wall, wherein the lower catalyst containment wall comprises lower pores configured to allow reactant flow in the interior of the quench device; an upper catalyst containment wall, wherein the upper catalyst containment wall comprise upper pores configured to allow reactant and reductant flow out of the interior of the quench device.

17. The device of claim 16, wherein the reactant inlet is configured to receive a reactant stream, wherein the reactant stream is a cold reactant stream compared to the hot reactant stream, wherein the reactants comprise reforming or shifting species, wherein reforming or shifting species comprise hydrocarbons, carbon monoxide, carbon dioxide, water vapor, or a combination thereof.

18. The device of claim 15, wherein the stream comprises at least one of ore particles, reduced metal particles, metal particles, gaseous reductants, gaseous ore reduction products, gaseous combustion products or unreacted reactants.

19. The device of claim 15, wherein the reductants comprise hydrogen, carbon monoxide, syngas, methane or a combination thereof.

20. The device of claim 15, further comprising a second outlet in communication with the heat exchanger located in an interior of the quench device, wherein the heat exchanger comprises at least one channel emanating from the bottom of the quench device configured to contact the mixture, which has passed through the heat exchanger and may still retain heat for transfer, to continue to heat a hot reactant stream from the gas mixture which originated as the gas and particle mixture, wherein gas exits the second outlet.

Description

BRIEF DESCRIPTION OF FIGURES

[0022] Aspects of the present disclosure are illustrated by way of example and are not limited by the accompanying figures for which like references indicate like elements.

[0023] FIG. 1 is a vertical sectional view of an exemplary integrated reactor system showing a single pass quench section accordance with embodiments of the present disclosure;

[0024] FIG. 2a is a top view of an exemplary heat exchanger for use in the middle quench section integrated reactor in in accordance with an embodiment of the present disclosure;

[0025] FIG. 2b is a top view of an exemplary top for use in the upper quench section integrated reactor in in accordance with an embodiments of the present disclosure;

[0026] FIG. 3 is a vertical lengthwise external side-view of an exemplary integrated reactor system in accordance with embodiments of the present disclosure;

[0027] FIG. 4 is another vertical lengthwise, external side-view of an exemplary integrated reactor system and a selected top view cross section in accordance with embodiments of the present disclosure;

[0028] FIG. 5 shows top views of exemplary tops for quench section in accordance with embodiments of the present disclosure;

[0029] FIG. 6 is another vertical lengthwise, external side-view of a double-pass quench section 1, in accordance with embodiments of the present disclosure;

[0030] FIG. 7 is a series of exemplary top view cross sections of the reduction portion in accordance with embodiments of the present disclosure;

[0031] FIG. 8 is a series of exemplary top view cross sections of the quench section in accordance with embodiments of the present disclosure;

[0032] FIG. 9 is a vertical sectional view of an exemplary integrated reactor system having a double pass quench section in accordance with embodiments of the present disclosure;

[0033] FIG. 10 is a top view of an exemplary double pass heat exchanger for use in the integrated reactor in accordance with embodiments of the present disclosure;

[0034] FIG. 11 is a step-wise flow chart for a method to generate hydrogen, carbon monoxide (CO) syngas, or a combination thereof during metal ore reduction;

[0035] FIG. 12 is a is a vertical sectional view of an exemplary integrated reactor system and a metal ore input in accordance with embodiments of the present disclosure;

[0036] FIG. 13 is schematic block diagram to generate hydrogen, carbon monoxide (CO) syngas, or a combination thereof during metal ore reduction.

DETAILED DESCRIPTION

[0037] Exemplary embodiments are discussed below with reference to the Figures.

[0038] In the descriptions above and in the claims, phrases such as at least one of or one or more of may occur followed by a conjunctive list of elements or features. The term and/or may also occur in a list of two or more elements or features. Unless otherwise implicitly or explicitly contradicted by the context in which it used, such a phrase is intended to mean any of the listed elements or features individually or any of the recited elements or features in combination with any of the other recited elements or features. For example, the phrases at least one of A and B; one or more of A and B; and A and/or B are each intended to mean A alone, B alone, or A and B together. A similar interpretation is also intended for lists including three or more items. For example, the phrases at least one of A, B, and C; one or more of A, B, and C; and A, B, and/or C are each intended to mean A alone, B alone, C alone, A and B together, A and C together, B and C together, or A and B and C together. Use of the term based on, above and in the claims is intended to mean, based at least in part on, such that an unrecited feature or element is also permissible.

[0039] The subject matter described herein can be embodied in systems, apparatus, methods, and/or articles depending on the desired configuration. The implementations set forth in the foregoing description do not represent all implementations consistent with the subject matter described herein. Instead, they are merely some examples consistent with aspects related to the described subject matter. Although a few variations have been described in detail above, other modifications or additions are possible. In particular, further features and/or variations can be provided in addition to those set forth herein. For example, the implementations described above can be directed to various combinations and sub combinations of the disclosed features and/or combinations and sub combinations of several further features disclosed above. In addition, the logic flows depicted in the accompanying figures and/or described herein do not necessarily require the particular order shown, or sequential order, to achieve desirable results. Other implementations may be within the scope of the following claims.

[0040] The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.

[0041] Exemplary Materials For Reduction

[0042] Various metal ores types may be reduced in the exemplary reactor systems described herein. Metal ores may include, but are not limited to, carbides, oxides and sulfides of Al, W, Ti, Fe, Cu, Cr, Co, Zn, Mn, Sn, Ni, Sm, Mg, Li, Sc, Y, U, Th and lanthanides. Exemplary systems described herein may be particularly suited for iron oxide ores. In some instances, metal ores provided to reactor systems may comprise Fe2O3 and/or Fe3O4.

[0043] Exemplary metal ores provided to the reactor systems may be in powder form. Particle size provided to reactors may have a nominal length or diameter ranging between preferably 5-250 microns in embodiments, more preferably 10-150 microns, and more preferably approximately 150 microns. Exemplary reduced metal ore or partially reduced metal ore, also referred to as metallized ore may be a powder with nominal length or diameter ranging from 3-240 microns in embodiments, more preferably approximately 245 microns.

[0044] Various gases, such as reductants, may be provided to the reactor system, exemplary gaseous species include but are not limited to hydrogen (H2), carbon monoxide (CO) and methane (CH4).

[0045] In operation, outlet streams provided by the reactor system described herein may comprise solids and gaseous streams, which themselves may comprise reduction products, unreacted reductants, unreacted solids, combustion products, or any combination thereof. Exemplary unreacted reductant species may comprise hydrogen (H2), carbon monoxide (CO) and methane (CH4). Exemplary reduction products may comprise iron (Fe), FeO, CO2, H2O, or any combinations thereof. Exemplary unreacted solids may comprise Fe2O3 and/or Fe3O4. Exemplary combustion products may comprise CO2, H2O, nitrogen (N2), NOx, or any combinations thereof.

[0046] Various catalysts may be used in the reactor system, specifically in the heat exchanger and reductant generator, and exemplary catalysts may be particularly suited for steam-methane reforming, carbon dioxide-methane reforming, other reforming methods, or combinations thereof. Exemplary catalysts may comprise Ni, Fe, Cu, Cr, Co, Pt, Pd, Rh, Re, Os, La, a single element or combination of elements, reduced or oxide. In some instances, the catalyst may be bulk material, mixed with or dispersed upon alumina, silica, titania or zirconia.

[0047] Exemplary Reactor Systems

[0048] With reference now to FIG. 1, a vertical sectional view of an exemplary integrated reactor system showing a single pass quench section with internal heat exchangers in accordance with embodiments of the present disclosure is shown generally at 100. Initially, it is noted that various reforming methods can be applied to the system, such as steam-methane reforming or carbon dioxide-methane reforming. Other hydrocarbons or alcohols can also be reformed. Water-gas shifting may also generate reductants in embodiments. Furthermore, the term quench is used to represent a section in which significant or rapid temperature reduction of cooling of a stream of occurs.

[0049] Various materials used in sections of the reactor system 100 may include metallics or ceramics with properties that ensure heat containment and material compatibility at operating temperatures and pressures. Furthermore, various dimensions of exemplary reactor systems are contemplated. In embodiments, an outside diameter of the reactor system 100 may range between 5-20 feet. In some embodiments, a length of the quench section may be between 5-20 feet. These dimensions are for a single reactor system which allows it to fit in various mills. In embodiments, the system 100 may provide production rate capability for fully reduced hematite or magnetite v from 2,500 to 150,000 tonnes/yr. Other ore types may result in higher or lower production rates. In embodiments, the reduction portion may be generally cylindrical and have an inner diameter that is generally constant along the flow direction of the particles (i.e., the length of the reduction portion).

[0050] The integrated reactor system 100 comprises a reduction portion (also referred to as reduction reactor) 102, a quench section (also referred to reductant generating section) 104 and an exit portion 106. Quench section 104 comprises multiple heat exchanger and reductant generator 108 positioned therein. The heat exchanger and reductant generator 108 are positioned internally in the quench section 104, and spaced apart at predetermined distances depending upon the maxima, optimal or desired reductant generation rate from the quench section 104 for the production rate for metallized ore. The heat exchanger and reductant generator 108 are interconnected in the quench section 104. The heat exchanger is a conduit extending from the cold inlet to the hot outlet and passing through the quench section comprising catalyst particles 124.

[0051] In operation, solids such as various metal ores, and gases such as H2, CO, CO2, H2O and CH4 re provided to reduction portion 102 as a gas and particle mixture in flow direction 114, pass through quench section 104 making contact with the heat exchanger and reductant generator 108 and continue through outer channels 110a, inner channels 110b, and central channel 110c., and exit the reactor system at exit 106 via multiple streams due to the channels 110.

[0052] Reduction portion 102 receives solids, which may be particles, powders, and the like, as well as gaseous species. Exemplary sizes for solids are provided in greater detail above. As discussed above, exemplary solids species may comprise Fe2O3 and Fe3O4. Exemplary gaseous species may comprise reductants such as H2, CO and CH4.

[0053] In embodiments, exemplary solids and gaseous species may be provided to the reduction portion 102 at a temperature between 500 C. and 1000 C., but in some embodiments, can be provided at low room temperature. In some embodiments, exemplary solids and gaseous species may be provided to the reduction portion 102 at a pressure between 15 psia and 120 psia.

[0054] Heat is provided in the reduction portion 102, typically by combustion, to provide energy required for ore reduction. As a result, solid species may react with gaseous species while traveling through reduction portion 102. The result is a mix of solids and gases at stream 114 which exits the heated reduction section 102. Exemplary species may comprise unreacted reductants such as H2, CO, CH4, reduction products such as Fe, FeO, CO2 and H2O, unreacted solids such as Fe2O3 and Fe3O4 and combustion products such as CO2 and H2O. Combustion might also include nitrogen if air is used, NOx if nitrogen is present and oxygen, which is often provided in excess for combustion.

[0055] In embodiments, exemplary solids and gaseous species may reach 1450 C. within stream 114. In some embodiments, exemplary solids and gaseous species may be at a pressure between 15 psia and 120 psia, more preferrable 15 psia to 30 psia within stream 114.

[0056] After passing through reduction portion 102, solids and gaseous species enter quench portion 104, with the stream 114 being a hot stream input that provides heat to the heat exchanger and reductant generator 108 in the quench section 104.

[0057] The reactors system 100 further comprises reactant inlet 109 positioned toward a bottom or lower section of the quench section 104. The reactant inlet 109 is in fluid communication with the heat exchanger and reductant generator 108 such that heat exchanger and reductant generator 108a receives a reactant species such as CH4 at reactant inlet 109, receives heat in the quench section with the stream 114 as shown by multiple streams 116a-116e, and discharges product species at first product outlet 136 as shown by arrow 138.

[0058] The reductants generator 108 comprise lower catalyst containment wall 120, which itself contains lower pores 122 to allow for gas flow in the generator. A stream input to the heat exchanger and reductant generator 108 comprises travels into the interior of reductant generator 108a, reacts with catalyst 124a, then travels out of upper catalyst containment wall 130 via upper pores 132 of the reactants provided at reactant inlet 109. The reactants can move into each of the reductant generator 108 as shown by each arrow, all along the way producing H2, CO, and transporting unreacted CH4 and water vapor for the outlet stream 138. Arrow 150 represents the heat transfer across the walls (i.e., all walls of the reductant generator) of the reductant generator 108 into the channels as follows: central channel 116c for hot reduction reactor gas/particles flow (heat exchange being shown by arrows 150), outer channels 110a and 110a, for hot reduction reactor gas/particles flow and inner channels 110b and 110b for hot reduction reactor gas/particles flow. Further, each reductant generator may comprise angled caps 140 to mitigate particle build-up.

[0059] In this way, reduction of solids particles can continue in quench portion 104, particularly while the solids and gaseous components are above a predetermined reduction temperature. As the solids and gaseous components pass from reduction portion 102 to exit 106 a temperature of those components is reduced. That is, a temperature of solids and gaseous components is greater at the entrance of quench section 104 than leaving quench section 104. In embodiments, reduction portion 102, quench section 104, and exit portion 106, are all an integral unit.

[0060] Referring still to FIG. 1, combustion reactants (shown in FIG. 13) are combusted to provide heat for ore reduction. Exemplary relative radial concentrations of these solids and gaseous species within reduction portion 102 stream 114 may be consistent or homogenous or, in embodiments, they may be inhomogeneous. This is a function of the fluid dynamics environment and the relative introduction locations for ore, reductant and combustion at the top of reduction portion 102.

[0061] The heat is introduced at the top of or vertically throughout, or both, the reduction reactor by combustion and/or electrical methods for transfer into ore/reductant to ensure elevated temperature and endothermic reaction sufficient for high reduction or metallization of ore. Residual heat is retained in the exit or product stream which can be transferred across the wall of the device as this stream passes through channels.

[0062] Exemplary inhomogeneous concentrations of solids and gaseous components may occur just above quench section 104, as stream 114, because their flow rates may be commensurate with laminar conditions as opposed to turbulent conditions where there is less cross-mixing of species. This can also occur because the relative locations of the upstream introduced unreduced ore particles, reductants and combustion reactants were originally far apart and there is insufficient residence time at fluid dynamic conditions for cross-mixing to occur in a manner that still does not generate a homogeneous concentration. In exemplary embodiments, combustion can occur within the outer one-third of the inner radius of reduction portion 102 while ore and reductant are introduced within the inner two-thirds of the inner radius of reduction portion 102, both in laminar flow. In this example, combustion products and exhaust in stream 114 will, in embodiments, pass through the outer volume of quench section 104 while ore particles, reduced metal particles, gaseous reductants and gaseous ore reduction products in stream 114 (moving as shown by stream 114 in interior of the reduction portion 102) will, in embodiments, pass through the inner volume (i.e., channels of 110) of quench section 104. For example, the stream 114 can be inhomogeneous when it enters the device, with more combustion products on the outside and more ore/dry powder on the inside, and the cross-section with the large central channel minimizes wall contract with and erosion by the powder. Exemplary streams from reduction section 102 may be at various temperatures and pressures. For instance, the stream 114, prior to entering quench section 104, through channels and central tube or portion may be at a temperature between 400 and 1400 C. preferably between 800 and 1400. in other embodiments, the temperature, pressure, flow rate and composition type of the incoming reactants for generating reductant and/or the type and form of catalyst.

[0063] As shown, the boundary between the reduction portion 102 and quench section 104 may be metallic, ceramic, or insulated. A wall from the reduction portion 102 is shown as extending through quench section 104 and may be comprised of metal, ceramic or insulation. A top of the quench section 104 is shown which prevents reactants provided to reactant inlet 109 from entering reduction portion 102, due in some instances to pressure differential.

[0064] Solids from reduction portion 102 pass through quench section 104 via central flow portion and channels (shown in relation to FIG. 2). As shown, an inner diameter (D2) of central flow portion is less than the inner diameter (D1) of reduction portion 102. The top may be sloped or otherwise configured to transition the interior of reduction portion 102 to quench section 104. In this way, central flow portion, as it passes through quench section 104, defines a volume between the outer diameter of central flow portion and an inner diameter of a continuation of reduction portion 102. In embodiments, heat exchanger 108 is disposed annularly about the central flow portion although is appears as separate pieces in the drawings to show channels.

[0065] With references still to FIG. 1, the plurality of heat exchanger and reductant generator 108 that pass through a volume between the central flow portion (shown in FIG. 2) and the continuation of reduction portion 102. Heat may be transferred across the walls of reductant generator 108 as represented by arrows 150 into a catalyst 124 housed in the reductant generator 108. In some embodiments, entrances to reductant generator 108 may be shaped, chamfered, or comprised of dimensions that minimize the quantity and force of particle/powder impacts with reductant generator 108. Various quantities of channels may be used. For example, quench section 104 may comprise between 4 and 25 channels 110, preferably between 5 and 25, ore preferably between 10 and 25, though other numbers of reductant generator 108 may be used.

[0066] In operation, central portion (shown in FIG. 2) may receive solids and gaseous species from reduction portion 102. Heat may be transferred across the wall of central portion (FIG. 2, 204) into a catalyst 124 interior of the heat exchanger and reductant generator 108, due to the transport and impact of gaseous, vaporous and solid species passing through channels 116a-116c. In some embodiments, the entrance to central portion (shown in FIG. 2) may be shaped or chamfered or comprised of dimensions that minimize the quantity and force of particle/powder impacts with wall surfaces, but various dimensions of central portion (shown in FIG. 2) may be used.

[0067] The heat exchanger and reductant generator 108 may be disposed annularly about the central flow portion (shown in FIG. 2). The heat exchanger and reductant generator 108 may have various input and output configurations such that flow within the heat exchanger and reductant generator 108 is countercurrent to or concurrent with the flow through the reductant generating section 102.

[0068] In embodiments, the heat exchanger and reductant generator 108 may comprise catalyst 124 packed within the volume 124 of heat exchanger and reductant generator 108. In embodiments catalyst 124 heat exchanger and reductant generator 108 the catalyst 124 may be in the form of a powder, coated on tube or vessel walls, in the form of a pellet, bead, or on foams, fins or foils upon which the catalyst 124 is coated or dispersed in the interior 126 of the reductant generator 108.

[0069] In embodiments, catalysts 124 may be used in the heat exchanger and reductant generator 108, and exemplary catalysts 124 may be particularly suited for steam-methane reforming, carbon dioxide-methane reforming, other reforming methods, or combinations thereof. Exemplary catalysts 124 may comprise Ni, Fe, Cu, Cr, Co, Pt, Pd, Rh, Re, Os, La, a single element or combination of elements, reduced or oxide. In some embodiments, the catalyst 124 may be bulk material, mixed with or dispersed upon alumina, silica, titania or zirconia.

[0070] Referring still to FIG. 1, the heat exchanger and reductant generator 108 can receive reactants at reactant inlet 109. In embodiments, reactants comprise reforming species. As an example, reactants provided at reactant inlet 109 may comprise CH4, other hydrocarbons, carbon dioxide (CO2), CO, and/or water vapor (steam).

[0071] The heat exchanger and reductant generator 108 discharge one or more products at product outlet 136. In embodiments, the one or more products comprise various reforming products. In various embodiments, a product stream exiting product outlet 136 may comprise CH4, other hydrocarbons, carbon monoxide (CO), carbon dioxide (CO2), hydrogen and water vapor (steam).

[0072] With reference now to FIG. 2a, a top view of an exemplary heat exchanger 108 for use in the integrated reactor is shown at generally 200a. The heat exchanger 108 comprises outer wall 202, central channel 116c, outer channel 116a for hot reduction, reactor, gas and particle flow, inner channel 116b for hot reduction reactor gas and particle flow. The interior 126 may comprise catalyst 124 as described above.

[0073] With reference to FIG. 2b, a top view of an exemplary heat exchanger 108 for use in the integrated reactor is shown at generally 200. In some embodiments, outer wall 202 comprises a second intermediate wall 204 (or thick outer wall 202). Also, in this embodiment, the interior does not comprise catalyst and only the central channel or inner flow portion 116c and outer channels 116a exist.

[0074] In some embodiments, the inside walls of channels 116a and 116b or central portion 116c may be made of materials having a surface hardness that mitigates potential erosion from impacting particles or powders. Channels or central portion can also be manufactured from materials whose erosion and presence can be tolerated or desired as part of the composition in the reduced metal particle product.

[0075] In some embodiments, the inside walls of channels 116a and 116b or central portion 116c may be manufactured with smooth surfaces such that particles or powders do not stick to the walls. In some embodiments, the inside walls of channels or central portion may be electrically biased to mitigate electrostatic interactions that otherwise might cause particles or powders to stick to the walls.

[0076] Referring now to FIG. 3, a vertical lengthwise external side-view of an exemplary integrated reactor system in accordance with embodiments of the present disclosure. In embodiments, reactant stream enters reactant inlet 109 at various temperatures and pressures. The stream in the quench portion 104, may be at a temperature between 0 and 400 C., preferably 150 to 250 C., and more preferably 175 to 250 C., and a pressure between 15 psia to 250 psia, preferably, 20 to 150 psia and more preferably 50 to 150 psia.

[0077] The stream exits at outlet 136 at various temperatures and pressures. For example, the stream at outlet 136, may be at a temperature between 400 and 900 C., 300 to 800 and more preferably 200 to 700 and a pressure between 15 psia to 250 psia, preferably, 20 to 150 psia, and more preferably 50 to 150 psia. Reactor product streams comprising solids and gases exit reactor system at exit portion 106. Exemplary constituents in solids and gaseous streams exiting reactor system vary depending on the input species.

[0078] Exemplary reactor product streams may be at various temperatures and pressures. For example, reactor product exit stream 308 may be at a temperature between 200 and 1000 C., preferably, 200 to 800 C., and more preferably 100 to 700 C. and a pressure between 15 psia to 120 psia, preferably, 15 to 120 psia, and more preferably 10 to 30 psia.

[0079] Referring now to FIG. 4 is another vertical lengthwise, external side-view of an exemplary integrated reactor system is shown. In this embodiment, the integrated reactor system 100 comprises a reduction portion (also referred to as reduction reactor) 102, a quench section (also referred to reductant generating section) 104 and an exit portion 106. Quench section 104 comprises heat exchanger and reductant generator 108 positioned therein. The heat exchanger and reductant generator 108 are positioned internally in the quench section 104 with channels 110a-110b spaced apart at predetermined distances depending upon the maxima, optimal or desired reductant generation rate from the quench section 104 for the production rate for metallized ore. In this embodiment, the bottom portion of the heat exchanger can be seen at 402 is provided, and is positioned at the lower end of quench section 104 to release stream 408 into exit portion 106. The bottom portion 402 cut away view is further shown which highlights the separation between solids and gaseous species. As can be seen by arrow 404, where a portion of gases and vapors passing through 110c transit upward into 108 where they eventually exit at 410 as 418.

[0080] In this embodiment, a wall from the reduction portion 102 is shown as extending through quench section 104. A top of the quench section 104 is shown which prevents reactants provided to reactant inlet 109 and products formed throughout that eventually exit at product outlet 136 from entering reduction portion 102. Embedded within the top of quench section 104 are channels 116a-116e through which the stream 114 from reduction section 102 enters quench section 104.

[0081] Exemplary solids and gaseous species stream 114 comprise ore particles, reduced metal particles, gaseous reductants, gaseous ore reduction products and gaseous combustion products (also known as exhaust). These are formed or produced from unreduced ore particles, reductants and combustion reactants upstream of, but still within reduction portion 102, and flowing in the direction of the stream as they are produced.

[0082] In this embodiment, top 414 of quench section 104 is a solid top and does not have entrances channels for heat exchangers 108. The result is a mix of solids and gaseous species in stream 114, the exit of the heated reduction section 102, which all enter quench section 104.

[0083] Stream 404 as shown in cross-section view, enters channels 110a which in this case has an entrance at the bottom of quench section 104 (as opposed to the top which is labeled 116a) and is connected to 410. In embodiments, stream 404 may be at a higher temperature than the other side of a wall in which is located the catalyst 124 section where reductant is being generated. Various quantities of channels 118 may be used. For example, quench section 104 may comprise between four and twenty-five channels, but other numbers of channels may be used.

[0084] Exemplary constituents in the solids and gaseous streams exiting quench section 104 as stream 110b and 110c vary depending on the input species to reactor system 102. As examples, a solids stream may comprise Fe, FeO, Fe2O3 and Fe3O4. A small portion of stream 404, which did not transport into quench section 104 through channels reductant generator 108 may still be present with a similar composition to that described for the gaseous stream 404 and continue to transport downward away from quench section 104 and into 106.

[0085] Exemplary streams from quench section 104, including reactor product streams, may be at various temperatures and pressures. For instance, the stream at 404, prior to entering quench section 104 through channels 116b-116d may be at a temperature between 400 and 1000 C. and a pressure between 15 psia to 120 psia. In other embodiments, reactor product stream 404 may be at a temperature between 200 and 800 C. and a pressure between 15 psia to 120 psia. In other embodiments, the reactor product stream 404 may be at a temperature between 200 and 800 C. and a pressure between 15 psia to 120 psia.

[0086] The solids and gaseous components of stream 114 become or are converted to the solids and gaseous components of stream 404 separate at the bottom or exit of quench section 104. Modification of stream 114 stream may still occur as it passes through quench section 104 because temperatures may still be sufficient for continuing ore reduction. Separation may be achieved by control of flow rate and pressure such that the pressure for stream 418 is lower than the pressure at the bottom or exit at stream 408. In some embodiments, these may be flow controllers, compressors, pumps, valves, back-pressure regulators, pressure adjustors or pressure reducers to achieve the pressure differential inside, attached to or outside the reactor system 100.

[0087] Stream 404 containing gaseous species transports upwards through channels 110a (for example) and exits at channel 418 as stream from second product outlet 410. The second outlet in communication with the heat exchanger and located in an interior of the quench section, wherein the at least one channel is located at a bottom of the quench section, wherein the at least one channel is configured to contact the mixture, wherein the mixture has passed through the heat exchanger and retains heat for transfer to continue to heat the hot reactant stream from a gas mixture which originated as the gas and particle mixture, wherein the gas mixture exits the second outlet. Also, at the exit quench section 104, the stream containing particles and powders continues to fall downwards. These particles have sizes, shapes and masses such that they do not tend to lift upward by flowing gases and instead transport downward as stream through exit portion 106. Other features such as meshes, filters, baffles, foams, conical entrances and curved or spiral tubing can also be deployed at the entrance to channel 110a to facilitate separation of gas from solid, where any upwardly transported solid is deflected out of this trajectory or rejected out of the gaseous stream 404.

[0088] Stream 418 emanates from 404 and is at a lower pressure and temperature than 404. 404 emanates from 114, and in this case, specifically 116c. Stream 404 transports upward back through quench section 104, in a channel which exists for the purpose of allowing such transport with connection to outlet 410. In this way, additional heat that might still be available in streams exiting the quench section can still be transferred into the quench section and ultimately into heat exchanger and reductant generator 108 to further provide heat for generating reductant without increasing the height of quench section 104.

[0089] With reference now to FIG. 5, exemplary cross sections 502, 504 for heat exchanger are shown. Cross section 502 comprises outer wall 202, central channel 116c, outer channel 116 for hot reduction, reactor, gas and particle flow, The interior 126 may comprise catalyst 124 as described above. At 504, outer wall 202 comprises a second intermediate wall 204 (or thicker outer wall 202). Also, in this embodiment, the interior does not comprise catalyst but comprises heat transfer components to facilitate thermal decomposition or non-catalytic mechanisms for reductant generation.

[0090] In some embodiments, the inside walls of channels 116 may be made of materials having a surface hardness that mitigates potential erosion from impacting particles or powders. Channels or central portion can also be manufactured from materials whose erosion and presence can be tolerated or desired as part of the composition in the reduced metal particle product.

[0091] In some embodiments, the inside walls of channels 116 may be manufactured with smooth surfaces such that particles or powders do not stick to the walls. In some embodiments, the inside walls of channels or central portion may be electrically biased to mitigate electrostatic interactions that otherwise might cause particles or powders to stick to the walls.

[0092] Various quantities of channels 116 may be used. For example, quench section 104 may comprise between 4 and 25 channels, but other numbers of channels may be used.

[0093] Exemplary constituents in the solids and gaseous streams exiting quench system 100 as stream 116c vary depending on the input species to reactor system 100. A small portion of stream, that does not transport into quench section 104 through channels 110 may still be present with a similar composition to that described for the gaseous stream.

[0094] Exemplary streams from quench section 104, including reactor product streams, may be at various temperatures and pressures.

[0095] The solids and gaseous components of stream 116a-116e may be converted to the solids and gaseous components of streams 110a-110c and separate at the bottom or exit of section 106. Modification of stream 116 can still occur as it passes through quench section 104 because temperatures may still be sufficient for continuing ore reduction. Separation is achieved by control of flow rate and pressure such that the pressure for stream 138 or 418 at outlet 136 and 410 is lower than the pressure at the bottom or exit of section 106. In some embodiments, these may be flow controllers, compressors, pumps, valves, back-pressure regulators, pressure adjustors or pressure reducers to achieve the pressure differential inside, attached to or outside the reactor system 100. At the oulet 106 streams containing gaseous species transports upwards through channels 110 and exits at outlet 106 at stream 408. Also, at the exit is a stream comprising particles and powders continuing to fall downwards.

[0096] These particles have sizes, shapes and masses such that they do not tend to lift upward by flowing gases and instead transport downward as stream 116 through exit portion 106. Other features such as meshes, filters, baffles, foams, conical entrances and curved or spiral tubing can also be deployed at the entrance to channels 110 to facilitate separation of gas from solid, where any upwardly transported solid is deflected out of this trajectory or rejected out of the gaseous stream.

[0097] Referring now to FIG. 6, a schematic diagram showing integrated reactor system showing multiple streams 602, 604, 608 at exit 106. This embodiment shows that streams may travel in various directions at the bottom of quench section 104 and exit 106.

[0098] Referring now to FIGS. 7 and 8, a series of exemplary top view cross sections of the reduction portion (FIG. 7) and quench section (FIG. 8) is shown.

[0099] Configuration 701 comprises central section 116c is present along with channels 116a and the catalyst 124 is filed around them. As described above, solids and gaseous species enter channels 116a and central portion 116c, solids and gaseous species exit as stream 114.

[0100] Configuration 703 shows an annular design with catalyst in 702.

[0101] Configuration 705 shows the catalyst 124 inside of channels 110a.

[0102] Configuration 801 represents another embodiment that show a combination of channels 110 and no central portion. The channels are surrounded by catalyst-filled section 124.

[0103] Configuration 803 represents another embodiment which is the inversion of 703 with respect to catalyst filled sections versus. flow-through channels.

[0104] Configuration 805 represents another embodiment which is the inversion of 801 with respect to catalyst filled sections versus flow-through channels.

[0105] In operation, heat is transferred across the walls of the central portion or other pass-through channels of heat exchangers which contain gaseous reactants and catalysts for the generation of reductant species used to reduce metal ore. Reactants for generating reductant by steam-methane reforming, dry reforming, other reforming methods, water-gas shifting, thermal or thermo-catalytic decomposition are introduced at reactant inlet. Heat transferred as in arrow 150 is used to increase reactant temperature and generate reactions resulting in products and unreacted reactants exiting at product outlet.

[0106] To facilitate heat transfer across the walls of central portion and channels, fins, foams, foils, wall textures and emissive surfaces are selected to increase heat transfer into section 108, to promote desired reactions, while cooling the stream that passed through the central portion and channels.

[0107] To facilitate high surface area for catalysts in the reductant generator 108 catalysts be coated or dispersed upon foams, fins, foils, pellets or beads inside this section. Such materials also promote heat transfer from walls to catalysts reacting gases.

[0108] With reference now to FIG. 9 is a vertical sectional view of an exemplary integrated reactor system having a double pass quench section is shown generally at 900. In this embodiment, rather than having a single pass quench section, a double pass quench section is shown. Like with the embedment in FIG. 1, it is noted that various reforming methods can be applied to the system, such as steam-methane reforming or carbon dioxide-methane reforming. Other hydrocarbons or alcohols can also be reformed. Water-gas shifting may also generate reductants in embodiments.

[0109] The integrated reactor system 900 comprises a reduction portion (also referred to as reduction reactor) 102, a quench section (also referred to reductant generating section) 104 and an exit portion 106. Quench section 104 comprises double pass heat exchanger and reductant generator 908 positioned therein. The heat exchanger and reductant generator 908 are positioned internally in the quench section 104, and spaced apart at predetermined distances depending upon the maxima, optimal or desired reductant generation rate from the quench section 104 for the production rate for metallized ore.

[0110] Like in FIG. 1, in operation, solids such as various metal ores, and gases such as H2O, CO, CH4 and H2O are provided to reduction portion 102 in flow direction 114, pass through quench section 104 making contact with the heat exchanger and reductant generator 908 and continue through channels 902a-902d., and exit the reactor system at exit 106 via multiple streams due to the channels 110.

[0111] After passing through reduction portion 102, solids and gaseous species enter quench portion 104, with the stream 114 being a hot stream input that provides heat to the heat exchanger and reductant generator 908 in the quench section 104.

[0112] The reactors system 100 further comprises reactant inlet 109 positioned toward a bottom or lower section of the quench section 104. The reactant inlet 109 is in fluid communication with the heat exchanger and reductant generator 108 such that heat exchanger and reductant generator 108 receives a reactant species such as CH4 and H2O at reactant inlet 109, reacts in the quench section using heat received from the stream 114 as shown by multiple streams 950a-950e, and discharges product species at product outlet 136 as shown by arrow 138 or in FIG. 9 as 952.

[0113] The reductant generator 108 comprise lower catalyst containment wall 120, which itself comprises contains lower pores 122 to allow for gas flow in the generator. As can be seen by upward arrows, a cold stream input to the heat exchanger and reductant generator 108 comprises travels into the interior of reductant generator 108, reacts with other species as promoted by catalyst 124, then travels out of upper catalyst containment wall 130 via upper pores 132 of the reactants provided at reactant inlet 109. The reactants transport into and throughout the lower portion of 908 near simultaneously due to the distribution pores 122 in 120, passing into and through the reductant generator as shown by each arrow, all along the way producing H2O, CO, and maintaining unreacted CH4 for the outlet stream 138. Arrow 150 represents the heat transfer across the walls (i.e., all walls of the reductant generator) of the reductant generator 108 (or 908) into the channels as follows: all channels are for hot reduction reactor gas/particles flow.

[0114] Reduction of solids particles can continue in quench portion 104, particularly while the solids and gaseous components are above a predetermined reduction temperature, which ranges from 400-1000 C. As the solids and gaseous components pass from reduction portion 102 to exit 106 a temperature of those components is reduced. That is, a temperature of solids and gaseous components is greater at the entrance of quench section 104 than leaving quench section 104. In embodiments, reduction portion 102, quench section 104, and exit portion 106, are all an integral unit.

[0115] The reactors system 900 further comprises reactant inlet 109 positioned toward a bottom or lower section of the quench section 104. The reactant inlet 109 is in fluid communication with the heat exchanger and reductant generator 108 such that heat exchanger and reductant generator 108a receives a reactant species such as CH4 and H2O at reactant inlet 109, reacts in the quench section using heat received from the stream 114 as shown by multiple streams 950 and discharges product species at product outlet 136 as shown by arrow 952.

[0116] The reactants generator 908 comprise lower catalyst containment wall 120, which itself comprises contains lower pores 122 to allow for gas flow in the generator, and upper catalyst containment wall 130 having pores 132 which allow further gas flow out of the generator 908 as stream 952. As can be seen by upward arrows, a cold stream input to the heat exchanger and reductant generator 908 comprises travels into the interior of reductant generator 908, reacts with catalyst 124, then travels out of upper catalyst containment wall 130 via upper pores 132 of the reactants provided at reactant inlet 109. The reactants, along with products generated in prior layers, move through reductant generator 908 as shown by the upward arrows, all along the way producing H2O, CO, and transporting unreacted CH4 for the outlet stream 138 (or 952). Arrow 150 represents the heat transfer across the walls (i.e., all walls of the reductant generator 108 (or 908) into the channels 950a-950d for hot reduction reactor gas/particles flow.

[0117] Operationally, the embodiment functions similar to FIG. 1 except that double pass reductant generator 908 is a combination of 108 with additional channels whose entrance is at the bottom of 108 for transport of gas and vapor species back up into 108 (now 908) to facilitate additional heat transfer for reductant generation. The double pass reductant generator 908 may have a manifold 930 configured to port the gas flow to outlet 1001 shown in FIG. 10. The spaces 904 in the manifolds are configured to allow transfer of gas and particles via mesh/filter inlet 960 for second pass gas flow back into the integrated device without particles as shown by arrows 961.

[0118] In embodiments, the heat exchanger and reductant generator 108 may comprise catalyst 124 packed within the volume of heat exchanger and reductant generator 108 with additional channels 902a-902c. In embodiments catalyst may be in the form of a powder, coated on tube or vessel walls, in the form of a pellet, bead, or on foams, fins or foils upon which the catalyst is coated or dispersed in the interior of the reductant generator.

[0119] In embodiments, catalysts may be particularly suited for steam-methane reforming, carbon dioxide-methane reforming, other reforming methods, or combinations thereof. Exemplary catalysts may comprise Ni, Fe, Cu, Cr, Co, Pt, Pd, Rh, Re, Os, La, a single element or combination of elements, reduced or oxide. In some embodiments, the catalyst 124 may be bulk material, mixed with or dispersed upon alumina, silica, titania or zirconia.

[0120] Referring still to FIG. 9, the heat exchanger and reductant generator 908 can receive reactants at reactant inlet 109. In embodiments, reactants comprise reforming species. As an example, reactants provided at reactant inlet 109 may comprise CH4, other hydrocarbons, carbon dioxide (CO2), and/or water vapor (steam).

[0121] The heat exchanger and reductant generator 908 discharge one or more products at product outlet 136, in this case, after multiple passes. In embodiments, the one or more products comprise various reforming products. In various embodiments, a product stream exiting product outlet 136 may comprise CH4, other hydrocarbons, carbon monoxide (CO), carbon dioxide (CO2), hydrogen and water vapor (steam).

[0122] Referring now to FIG. 10, is a top view of an exemplary double pass heat exchanger 908 for use in the integrated reactor shown at 1000. Heat exchanger 908 comprises channels 902 which are single pass channels for hot reduction reactor gas/particles flow and manifold 1008 which double pass channels hot reduction reactor gas flow 922 at double-pass channel intersection examples such as 1006 and 1010 on the underside of the manifold 1008. Outlet 1001 shown with arrow 1014 is the outlet flow for second (or double)-pass reduction reactor gas flow.

[0123] Exemplary Methods of Operation

[0124] Exemplary methods of operating the reactor may be applied to exemplary reactor configurations shown in FIGS. 1-10.

[0125] With reference now to FIG. 11, a step-wise flow chart for a method to generating hydrogen, carbon monoxide (CO) syngas, or a combination thereof during metal ore reduction.

[0126] At step 1102, solids and a gaseous stream are provided to an inlet of the reduction portion 102. At step 1104, heat is applied resulting in ore reduction to reduced metal. The reactions on-going inside reduction section 102 include ore reduction and combustion. Reduction of magnetite is shown as an ore reduction example. Combustion, for heat, may be by natural gas as complete oxidation or partial oxidation or it may be hydrogen. If air is used for combustion, nitrogen and NOx may be present on the product side of the reaction expressions.

[0127] For magnetite:

##STR00001##

[0128] For combustion:

##STR00002##

[0129] In some embodiments, combustion may be by other hydrocarbons, alcohols or heat may be provided electrically or by a combination. Exemplary hydrocarbons are methane, ethane, propane, butane, kerosene, diesel or gasoline. Exemplary alcohols are methanol, ethanol or propanol. Hydrocarbon or alcohol isomers and species with double or triple bonds are included.

[0130] Exemplary solids and gaseous species may be provided to the reduction portion 102 at a temperature between 400 C. and 1000 C., but can be as low as room temperature. In some embodiments, exemplary solids and gaseous species may be provided to the reduction portion 102 at a pressure between 15 psia and 120 psia.

[0131] At step 1106, a reactant stream is provided to a heat exchanging unit positioned in the quench section 104 such that the reactant stream passes in a conduit or channel through a portion of the quench section 104. Exemplary streams enter quench section 104 at various temperatures and pressures. For example, the stream at quench section 104, at the entrance may be at a temperature between 0 and 400 C. and a pressure between 15 psia to 250 psia.

[0132] In various embodiments, reactor product exit stream may be at a temperature between 200 and 1000 C. and a pressure between 10 psia to 120 psia.

[0133] In embodiments, the stream at 114, prior to entering quench section 104 through channels 116 may be at a temperature between 400 and 1000 C. and a pressure between 15 psia to 120 psia. In another instance, reactor product stream may be at a temperature between 200 and 800 C. and a pressure between 15 psia to 120 psia. In another instance, reactor product stream 408 may be at a temperature between 200 and 800 C. and a pressure between 15 psia to 120 psia. Analogous streams in FIG. 3 are at the same temperatures and pressures.

[0134] After the solids and gases pass through reduction portion 102, at step 1108, the result is the stream which may comprise unreacted reactants and products mentioned above, as well as FeO or wstite, an intermediate oxide phase. Stream 114 also carries heat and is at a temperature between 600 and 1400 C. when it enters the top of quench section 104. The components of stream 114 transport through the central portion and channels 116 of quench section 104 whereupon heat from stream 116 is transferred across the walls into 108.

[0135] At step 1110 a catalyst 124 is introduced or is already present in 108. The catalyst 124 type, quantity and distribution are selected to affect the type and rate of reforming desired. This flexibility allows the application of catalysts 124 which may operate at lower temperatures than others, effectively reducing the energy required to generate reductant. This flexibility also provides a control mechanism for the ratio of reductant species generated, hydrogen vs. carbon monoxide, since different catalysts 124 can produce different product combination results.

[0136] At step 1112, at entrance, reactant species for reforming are delivered at a desired feed rate and ratio of reactants to generate desired product or reductant combinations at product outlet. At step 1114, steam-methane or dry reforming may be applied or a combination. Steam to methane or carbon dioxide to methane ratios are required higher than shown by stoichiometry below, to ensure forward reaction, and can be adjusted, up or down, to affect the actual ratio of hydrogen to carbon monoxide shown relative to stoichiometry.

[0137] SMR (steam-methane) reforming:

##STR00003##

[0138] DR (carbon dioxide-methane reforming or dry reforming) CH4+CO2.fwdarw.2CO+2H2

[0139] Some water-gas shifting can also occur during steam-methane reforming which results in carbon dioxide being present on the product side. The result is a stream exiting product outlet comprising unreacted reactants, products and carbon dioxide. This stream can be treated, adjusted or conditioned external to reactor system 100 as needed for final delivery into reduction section to reduce iron ore.

[0140] Water-gas shifting might also be specifically applied: CO+H2O.fwdarw.CO2+H2

[0141] In some embodiments, reforming may use other hydrocarbons or alcohols. Exemplary hydrocarbons may comprise methane, ethane, propane, butane, kerosene, diesel or gasoline. Exemplary alcohols are methanol, ethanol or propanol Hydrocarbon or alcohol isomers and species with double or triple bonds are included.

[0142] At step 1116, reforming reactants and catalyst are heated by the heat transferred across channels and central portion walls from stream. The transferred heat provides sensible heat which may increase a temperature within section 108 to be at least 700 C. and up to 900 C. In this temperature range, the reforming reactions may vigorously proceed and are endothermic. The SMR heat of reaction is about 206 KJ/mol and the dry reforming heat of reaction is about 247 KJ/mol. The endothermic reactions in section 108 may continue to pull heat from streams 116a-116e. This interactive relationship results in the cooling or quenching of streams 116a-116c while providing heat to effect reforming and the generation of reductant where the reductant is eventually delivered with stream for ore reduction.

[0143] At step 1120 exit stream exits quench section 104 into exit portion 106. Exit stream enters quench section 104 with reduced temperature, potentially reduced pressure and may have a different composition. Ore reduction might continue because the stream may still have unreduced ore and unreacted reductant and be at temperatures above 500 C., where ore reduction may continue until the stream exits the quench section 104.

[0144] The solids and gaseous components of exit stream 110a-110c may be separated which occurs below exit portion 106. This may occur at a location below which additional heat is transferred for pre-heating reforming reactants.

[0145] Referring now to FIG. 12 a is a vertical sectional view of an exemplary integrated reactor system and a metal ore input is shown. The integrated reactor system comprises a reduction portion (also referred to as reduction reactor) 112, a quench section (also referred to reductant generating section) 104 and an exit portion 106 into DRI holding container 1206. The ores and fines 306 are delivered to the system via pipe 1202 and are delivered into reactor via input 1204. Once the ore is reacted, it may be moved to a next stage, such as an electric arc surface 1208 to make steel. The recycled energy, recycled gases and newly generated gases are generally shown at 1210 and will emanate from both 104 and 106.

[0146] With reference now to FIG. 13 is schematic block diagram to generating hydrogen, carbon monoxide (CO), syngas, or a combination thereof during metal ore reduction (referred to as direct reduced iron (dri) generation).

[0147] In operation, ore stock 306 is sent to the reduction portion 102 along with reducing gases (not shown) and a heat source 1302. Ore is reduced and ends up in 104, the quench section where heat from gases and solids exiting 102 are used to create reductant 1306, for use in metal ore reduction, from reactants 1304. An external reactant 1310 may also be provided to the reductant portion 102. Metal, formerly ore, now exits 106 and goes to a containment or direct transport feature 1206 for use in an electric arc furnace, 1208, as an example use of the direct reduced iron (dri).