A DIRECT REDUCTION FACILITY FOR REDUCTION OF A METAL OXIDE MATERIAL

Abstract

The present invention concerns a metal material production configuration (1) and a method of direct reduction of a metal oxide material (5) holding a first thermal energy into a direct reduced metal material (16) by means of a metal material production configuration (1).

The method comprises charging the metal oxide material (5), holding the first thermal energy, into a direct reduction facility (7); introducing a hydrogen, holding a second thermal energy, into the direct reduction facility (7).

The invention involves reducing the metal oxide material (5) by using the first thermal energy of the metal oxide material (5) to heat or further heat the introduced hydrogen containing reducing agent (8) toward a required reaction temperature for providing a chemical reaction. A high-temperature exit gas (12) is removed from the direct reduction facility and fed to a high-temperature electrolysis unit (21) configured to produce the hydrogen.

Claims

1-18. (canceled)

19. A method of direct reduction of a metal oxide material comprising iron ore oxide material holding a first thermal energy into a direct reduced metal material by a metal material production configuration, the method comprising: providing the metal oxide material comprising iron ore oxide material, holding the first thermal energy, by a metal oxide material provider unit; charging the metal oxide material comprising iron ore oxide material, holding the first thermal energy, into a direct reduction facility; introducing a hydrogen containing reducing agent, holding a second thermal energy, into the direct reduction facility; reducing the metal oxide material comprising iron ore oxide material by using the first thermal energy of the metal oxide material comprising iron ore oxide material to heat or further heat the introduced hydrogen containing reducing agent toward a required reaction temperature for providing a chemical reaction between the hydrogen containing reducing agent and the metal oxide material comprising iron ore oxide material; removing a high-temperature exit gas from the direct reduction facility; feeding a high-temperature water steam of the high-temperature exit gas to a high-temperature electrolysis unit configured to produce a hydrogen; and introducing the hydrogen into the direct reduction facility.

20. The method according to claim 19, wherein the method further comprises: pre-heating the hydrogen and/or the hydrogen containing reducing agent to be introduced into the direct reduction facility for reaching the required reaction temperature.

21. The method according to claim 19, wherein the method further comprises: forming the hydrogen containing reducing agent, to be introduced into the direct reduction facility, by adding the hydrogen to a primary reducing agent.

22. The method according to claim 19, wherein the method further comprises: removing the high-temperature water steam contained in the high-temperature exit gas, which high-temperature water steam is generated by the chemical reaction between the metal oxide material and the hydrogen containing reducing agent.

23. The method according to claim 19, wherein the method further comprises: adjusting the second thermal energy of the hydrogen containing reducing agent to be introduced into the direct reduction facility for reaching the required reaction temperature.

24. The method according to claim 19, wherein the method further comprises: feeding the high-temperature exit gas to the high-temperature electrolysis unit via a filter device configured for removing impurities from the high-temperature water steam.

25. The method according to claim 19, wherein the method further comprises a step of: recovering a third thermal energy from the high-temperature water steam by a heat exchange device.

26. The method according to claim 19, wherein the method further comprises a step of: operating the high-temperature electrolysis unit by an electrical energy produced by a re-generative energy source; and producing the hydrogen by the high-temperature electrolysis unit making use of the high-temperature water steam.

27. A metal material production configuration adapted for direct reduction of a metal oxide material comprising iron ore oxide material holding a first thermal energy into a reduced metal material, the metal material production configuration comprising: a high-temperature electrolysis unit configured to produce a hydrogen; a metal oxide material provider unit configured to provide the metal oxide material comprising iron ore oxide material holding the first thermal energy; a direct reduction facility comprising: a metal oxide material charging inlet device; a reducing agent inlet device configured to introduce a hydrogen containing reducing agent holding a second thermal energy; and a control circuitry configured to control the direct reduction of the metal oxide material comprising iron ore oxide material; wherein: the metal material production configuration is adapted to reduce the metal oxide material comprising iron ore oxide material by using the first thermal energy of the metal oxide material comprising iron ore oxide material to heat or further heat the introduced hydrogen containing reducing agent toward a required reaction temperature for providing a chemical reaction between the hydrogen containing reducing agent and the metal oxide material comprising iron ore oxide material; the direct reduction facility comprises a gas outlet device configured for removing a high-temperature exit gas from the direct reduction facility; the metal material production configuration comprises: a first fluid line arrangement configured for fluid communication and adapted to feed a high-temperature water steam of the high-temperature exit gas to the high-temperature electrolysis unit; a second fluid line arrangement configured for fluid communication and adapted to feed the hydrogen from the high-temperature electrolysis unit to the direct reduction facility.

28. The metal material production configuration according to claim 27, wherein the metal material production configuration comprises a reducing agent supply configured to add the hydrogen to a primary reducing agent for providing the hydrogen containing reducing agent.

29. The metal material production configuration according to claim 27, wherein the reducing agent supply is coupled to the direct reduction facility via a third fluid line arrangement configured for fluid communication and adapted to feed the hydrogen containing reducing agent to the direct reduction facility from the reducing agent supply.

30. The metal material production configuration according to claim 27, wherein a heat exchange device is configured to recover a third thermal energy from the high-temperature water steam, which heat exchange device is coupled to the direct reduction facility via a fourth fluid line arrangement adapted for feeding the hydrogen pre-heated by the heat exchange device.

31. The metal material production configuration according to claim 27, wherein the control circuitry is electrically coupled to a reducing agent pre-heating device for adjusting the second thermal energy of the hydrogen containing reducing agent to be introduced into the direct reduction facility for reaching the required reaction temperature.

32. The metal material production configuration according to claim 30, wherein the control circuitry is electrically coupled to the heat exchange device of the first fluid line arrangement, which heat exchange device is configured to transfer heat energy from the high-temperature water steam to the hydrogen produced by the high-temperature electrolysis unit.

33. A data program comprising a program code readable on a computer of the control circuitry, which data program is programmed for causing the metal material production configuration according to claim 27 to execute the method steps of: providing the metal oxide material comprising iron ore oxide material, holding the first thermal energy, by the metal oxide material provider unit; charging the metal oxide material comprising iron ore oxide material, holding the first thermal energy, into a direct reduction facility; introducing a hydrogen containing reducing agent, holding a second thermal energy, into the direct reduction facility; wherein reducing the metal oxide material comprising iron ore oxide material by using the first thermal energy of the metal oxide material to heat or further heat the introduced hydrogen containing reducing agent toward a required reaction temperature for providing a chemical reaction between the hydrogen containing reducing agent and the metal oxide material comprising iron ore oxide material; removing a high-temperature exit gas from the direct reduction facility; feeding a high-temperature water steam to of the high-temperature exit gas a high-temperature electrolysis unit configured to produce a hydrogen; and introducing the hydrogen into the direct reduction facility.

34. The data program according to claim 33, wherein the data program further is programmed for causing the metal material production configuration to execute the method steps of claim 20.

35. A data medium, configured for storing the data program according to claim 33, wherein the data medium comprises the program code being readable on the computer for performing the method according to claim 19.

36. A direct reduction facility comprising a metal oxide material charging inlet device, a reducing agent inlet device configured to introduce a hydrogen containing reducing agent holding a second thermal energy; wherein the direct reduction facility comprises the metal material production configuration according to claim 27.

Description

BRIEF DESCRIPTION OF THE DRAWING

[0344] Hereinafter, the invention will be described with reference to examples and accompanying schematic drawings, wherein for the sake of clarity and understanding of the invention some details of no importance may be deleted from the drawings.

[0345] FIG. 1 illustrates a metal material production configuration adapted for reduction of a metal oxide material according to a first example;

[0346] FIG. 2 illustrates a metal material production configuration adapted for reduction of a metal oxide material according to a second example;

[0347] FIG. 3 illustrates a metal material production configuration adapted for reduction of a metal oxide material according to a third example;

[0348] FIG. 4 illustrates a flow diagram of a metal material production configuration adapted for reduction of a metal oxide material according to a fourth example;

[0349] FIG. 5 illustrates a phase diagram of iron phase domains as a function of oxidizing power of hydrogen and temperature;

[0350] FIGS. 6-7 illustrate flowcharts showing exemplary methods of direct reduction of a metal oxide material into a reduced metal material;

[0351] FIG. 8 illustrates a control circuitry of an exemplary metal material production configuration; and

[0352] FIG. 9 illustrates an iron material production configuration adapted for direct reduction of an iron ore oxide material 5 according to a further example.

DETAILED DESCRIPTION

[0353] FIG. 1 illustrates a metal material production configuration 1 according to a first example provided for direct reduction of a metal oxide material 5 into a reduced metal material 16. The metal material production configuration 1 is adapted for direct reduction of the metal oxide material 5 holding a first thermal energy. The metal material production configuration 1 comprises a metal oxide material provider unit 3, such as a metal oxide pelletizing plant (not shown) or metal oxide material pre-heating plant (not shown), configured for causing the first thermal energy, e.g. heat energy containing a temperature of about 900 C. to about 1500 C., preferably about 1000 C. to about 1400 C.

[0354] The metal oxide material 5 holding the first thermal energy is fed to and is charged, via a metal oxide material charging inlet device a, into an upper interior portion UP of a direct reduction facility 7 of the material production configuration 1, wherein the first thermal energy of the charged metal oxide material 5 to great extent corresponds with that generated by the metal oxide material provider unit 3. The direct reduction facility 7 is adapted for direct reduction of the metal oxide material 5 holding the first thermal energy, wherein the metal oxide material 5 is direct reduced into the reduced metal material 16.

[0355] The direct reduction facility 7 comprises a reducing agent inlet device b configured to introduce a hydrogen containing reducing agent 8 holding a second thermal energy, which second thermal energy is generated by means of a reducing agent pre-heating device 18 and/or a heat exchange device (not shown).

[0356] The hydrogen containing reducing agent 8 comprises a hydrogen H produced by means of a high-temperature electrolysis unit 21 and is introduced into the direct reduction facility 7 via the reducing agent inlet device b.

[0357] The high-temperature electrolysis unit 21 of the metal material production configuration 1 is configured to produce the hydrogen H, forming the hydrogen containing reducing agent 8. The high-temperature electrolysis unit 21 operates by means of a high-temperature water steam 14 of a high-temperature exit gas 12 removed from the direct reduction facility 7 via a gas outlet device c of the upper interior portion UP of the direct reduction facility 7, and is fed to the high-temperature electrolysis unit 21. The high-temperature electrolysis unit 21 operates to separate an oxygen gas (not shown and is alternatively fed to the metal oxide pelletizing plant for oxidization of metal ore material) and the hydrogen H from the water of the high-temperature water steam 14 by running an electrical current through the water. The electrical current may be provided by re-generative energy produced by a renewable energy source (not shown).

[0358] A control circuitry 50 of the metal material production configuration 1 is provided to control the direct reduction of the metal oxide material 5 and the chemical reaction. The control circuitry 50 is electrically coupled to the reducing agent pre-heating device 18 and is adapted to control the heat energy of the second thermal energy adapted for the direct reduction of the metal oxide material 5, wherein the first thermal energy of the metal oxide material 5 heats or further heats the introduced hydrogen containing reducing agent 8 toward a required reaction temperature for providing a chemical reaction between the hydrogen containing reducing agent 8 and the metal oxide material 5.

[0359] The metal material production configuration 1 comprises a first fluid line arrangement FL configured for fluid communication and adapted to feed the high-temperature water steam 14 to the high-temperature electrolysis unit 21.

[0360] The first fluid line arrangement FL may comprise a filter device (not shown) configured to separate the high-temperature water stem 14 from the high-temperature exit gas 12 and cooling down the high-temperature water stem 14 by means of the heat exchange device and/or by adding water to the high-temperature water stem 14 before introducing it into the high-temperature electrolysis unit 21.

[0361] The metal material production configuration 1 further comprises a second fluid line arrangement FL configured for fluid communication and adapted to feed the hydrogen H from the high-temperature electrolysis unit 21 into the direct reduction facility 7.

[0362] The reduced metal material is discharged via an outlet d of a lower interior portion LP of the direct reduction facility 7. The lower interior portion LP may be cone-shaped and narrows toward the outlet d.

[0363] Alternatively, the reduction facility 7 is configured for permitting the reduced metal material 16 and the metal oxide material 5 subject to direct reduction to descend downward from the upper interior portion UP toward the lower interior portion LP, whereas the second thermal energy of the introduced hydrogen containing reducing agent 8 decreases the cooling rate of the metal oxide material 8.

[0364] Alternatively, the heat energy of the first thermal energy is higher than the heat energy of the second thermal energy.

[0365] Alternatively, the heat energy of the second thermal energy is higher than the heat energy of the first thermal energy.

[0366] In such way is achieved that the introduced hydrogen containing reducing agent, disregarding the energy level of the heat energy of the second thermal energy, will decrease the cooling rate of the metal oxide material 5 descending in the reduction facility 7.

[0367] Alternatively, the major part of the heat energy required for the chemical reaction in the upper interior portion of the direct reduction facility 7 is provided by the first thermal energy, whereas the major part of the heat energy required for the chemical reaction further down in the direct reduction facility 7 is provided by the second thermal energy and/or the first thermal energy.

[0368] FIG. 2 illustrates, according to a second example, a metal material production configuration 1 adapted for direct reduction of a metal oxide material 5 holding a first thermal energy into a reduced metal material 16 to be discharged from a direct reduction facility 7. A metal oxide material provider unit 3, such as a metal oxide pelletizing plant (not shown) or metal oxide material pre-heating plant (not shown), is configured for providing the first thermal energy.

[0369] The metal oxide material 5 is charged via a metal oxide material charging inlet device a into an upper interior portion UP of a direct reduction facility 7.

[0370] The direct reduction facility 7 further comprises a reducing agent inlet device b configured to introduce a hydrogen containing reducing agent 8 holding a second thermal energy, which second thermal energy is generated by means of a reducing agent pre-heating device 18 and/or a heat exchange device 24.

[0371] A high-temperature exit gas 12 is removed from the direct reduction facility 7 via a gas outlet device c of the upper interior portion UP. The high-temperature exit gas 12 is fed from the gas outlet device c to a filter device 22. The filter device 22 is configured to separate dust particles or other substances, from the high-temperature exit gas 12.

[0372] Preferably, a high-temperature water steam 14 is separated from the high-temperature exit gas 12 by means of a separation unit (not shown) and is fed to the heat exchange device 24. Preferably, the high-temperature water steam 14 may be cooled down to a temperature being optimal for efficient high-temperature electrolysis.

[0373] The heat exchange device 24 comprises a process gas line system (not shown) configured to recover a third thermal energy TH3 from the high-temperature water steam 14. The third thermal energy of the process gas is transferred to the reducing agent pre-heating device 18 configured to pre-heat the hydrogen containing reducing agent 8 to be introduced into the direct reduction facility 7.

[0374] Alternatively, the gas outlet device c is coupled via a top gas fluid line arrangement to the filter device 22.

[0375] The metal material production configuration 1 comprises a first fluid line arrangement FL configured for fluid communication and adapted to feed the high-temperature water steam 14 to a high-temperature electrolysis unit 21.

[0376] Alternatively, the filter device 22 is coupled to the heat exchange device 24 via a water steam fluid line arrangement of the first fluid line arrangement FL.

[0377] Alternatively, the heat exchange device 24 is coupled to a high-temperature electrolysis unit 21 via fluid line arrangement.

[0378] The high-temperature water steam 14 that has been cooled down is fed to the high-temperature electrolysis unit 21 for production of hydrogen and oxygen gas. The high-temperature electrolysis unit 21 is configured to decompose the high-temperature water steam into the hydrogen and the oxygen gas by means electricity produced by a re-generative and/or fossil free energy source.

[0379] Alternatively, the high-temperature electrolysis unit 21 operates at temperature at about 100 C. to about 850 C., preferably at about 300 C. to about 650 C., or at about 300 C. to about 1050 C., preferably at about 500 C. to about 850 C.

[0380] Alternatively, the high-temperature electrolysis unit is configured to dissociate the high-temperature water steam into hydrogen and oxygen at temperatures between about 500 C. and 1100 C., preferably at about 600 C. to about 1000 C.

[0381] Alternatively, the high-temperature electrolysis unit is configured to dissociate the high-temperature water steam into hydrogen and oxygen at temperatures higher than 1000 C. making use of the fact that the electrolysis efficiency increases with increasing operating temperatures.

[0382] By making use of the high-temperature water steam produced by the direct reduction facility there is achieved a more energy efficient electrolysis than that of the conventional electrolysis achieved at room temperature.

[0383] The hydrogen containing reducing agent 8 comprises a hydrogen H produced by means of a high-temperature electrolysis unit 21 and is introduced into the direct reduction facility 7 via the reducing agent inlet device b.

[0384] The produced hydrogen H is mixed with a primary reducing agent BS for providing the hydrogen containing reducing agent 8, which is pre-heated by the reducing agent pre-heating device 18.

[0385] Alternatively, a primary reducing agent provider S is configured to provide the primary reducing agent BS.

[0386] Alternatively, the produced hydrogen H is fed directly into the direct reduction facility 7 after being pre-heated.

[0387] A control circuitry 50 of the metal material production configuration 1 is electrically coupled to the reducing agent pre-heating device 18 for adjusting the second thermal energy. The educing agent pre-heating device 18 may comprise an electric pre-heater (not shown) configured to pre-heat the hydrogen containing reducing agent 8.

[0388] The control circuitry 50 is adapted to control the required reaction temperature by adjusting the second thermal energy by means of the reducing agent pre-heating device 18.

[0389] The metal material production configuration 1 further comprises a second fluid line arrangement FL configured for fluid communication and adapted to feed the hydrogen H from the high-temperature electrolysis unit 21 into the direct reduction facility 7.

[0390] The reduced metal material 16 is discharged via an outlet d of a lower interior portion LP of the direct reduction facility 7.

[0391] FIG. 3 illustrates a metal material production configuration 1 adapted for direct reduction of a metal oxide material 5 according to a third example. The metal material production configuration 1 is provided for direct reduction of the metal oxide material 5 holding a first thermal energy, wherein the metal oxide material 5 is reduced into a reduced metal material 16.

[0392] A direct reduction facility 7 of the metal material production configuration 1 is provided for direct reducing the metal oxide material 5 by using the first thermal energy of the metal oxide material 5 to heat or further heat the introduced hydrogen containing reducing agent 8 toward a required reaction temperature for providing a chemical reaction between the hydrogen containing reducing agent 8 and the metal oxide material 5.

[0393] A metal oxide material provider unit 3, such as a metal oxide pelletizing plant (not shown) or a metal oxide material pre-heating plant (not shown), is configured for providing the first thermal energy of the metal oxide material to be charged into the direct reduction facility 7. The first thermal energy may be generated by a pelletization process provided by the metal oxide pelletizing plant, wherein the first thermal energy of the metal oxide material 5 may generated by means of an induration facility (not shown) of the metal oxide pelletizing plant.

[0394] The metal oxide material 5 holding the first thermal energy is charged into an upper interior portion UP of a direct reduction facility 7 via a metal oxide material charging inlet device a.

[0395] The direct reduction facility 7 further comprises a reducing agent inlet device b configured to introduce a hydrogen containing reducing agent 8 holding a second thermal energy, which second thermal energy is generated by means of a reducing agent pre-heating device 18 and/or a heat exchange device 24.

[0396] A high-temperature exit gas 12 is removed from the direct reduction facility 7 via a gas outlet device c of the upper interior portion UP. The high-temperature exit gas 12 is fed from the gas outlet device c to a filter device 22.

[0397] Alternatively, the filter device 22 is configured to remove dust particles from the high-temperature exit gas 12.

[0398] Alternatively, a separation unit (not shown) is configured to separate a high-temperature water steam 14 from the high-temperature exit gas 12, which high-temperature water steam 14 is configured for production of a hydrogen H.

[0399] Alternatively, the high-temperature water steam 14 is fed to a high-temperature electrolysis unit 21 via the heat exchange device 24.

[0400] In such way is achieved that not oxidized hydrogen and dust particles or other substances are separated from the high-temperature exit gas 12.

[0401] The high-temperature water steam 14 is fed to the heat exchange device 24 and/or is injected with water, wherein the high-temperature water steam 14 being cooled down to a desired temperature for efficient high-temperature electrolysis provided by the high-temperature electrolysis unit 21 for production of the hydrogen H.

[0402] Alternatively, a control circuitry 50 (electrically coupled to the heat exchange device 24 is adapted to control the heat exchange device 24 to adjust the temperature of the cooled down high-temperature water steam 14 toward the desired temperature of the high-temperature water steam for efficient high-temperature electrolysis.

[0403] The high-temperature electrolysis unit 21 is configured to dissociate the high-temperature water steam into a hydrogen H and an oxygen gas. The oxygen gas (not shown) may be fed to the induration facility for providing oxidization of a metal ore material to produce the metal oxide material holding the first thermal energy.

[0404] By making use of the high-temperature water steam 14 produced by the direct reduction facility 7 there is achieved a more energy efficient electrolysis than that of conventional electrolysis achieved at room temperature.

[0405] The metal material production configuration 1 comprises a first fluid line arrangement FL coupled between the gas outlet device c and the high-temperature electrolysis unit 21.

[0406] Alternatively, the first fluid line arrangement FL comprises the filter device 22 and/or the separation unit and/or the heat exchange device 24.

[0407] The first fluid line arrangement FL is configured for fluid communication and is adapted to feed the high-temperature water steam 14 to the high-temperature electrolysis unit 21 from the direct reduction facility 7 via the filter device 22 and/or the heat exchange device 24.

[0408] The metal material production configuration 1 further comprises a second fluid line arrangement FL configured for fluid communication between the high-temperature electrolysis unit 21 and the direct reduction facility 7.

[0409] The second fluid line arrangement FL is adapted to feed the hydrogen H (produced by the high-temperature electrolysis unit 21) from the high-temperature electrolysis unit 21 into the direct reduction facility 7.

[0410] Alternatively, the second fluid line arrangement FL is configured to feed the hydrogen H from the high-temperature electrolysis unit 21 directly to the direct reduction facility 7 and/or via the heat exchange device 24 to the direct reduction facility 7 via a direct introduction line arrangement 33 of the second fluid line arrangement FL.

[0411] Alternatively, the second fluid line arrangement FL is configured to feed the hydrogen H from the high-temperature electrolysis unit 21 via the reducing agent pre-heating device 18 configured to pre-heat the hydrogen H.

[0412] Alternatively, the pre-heating of the hydrogen H and/or the hydrogen containing reducing agent 8 is provided by the reducing agent pre-heating device 18 electrically coupled to the control circuitry 50 for controlling the heat energy of the second thermal energy of the hydrogen H and/or the hydrogen containing reducing agent 8 for reaching the required reaction temperature.

[0413] Alternatively, the reducing agent pre-heating device 18 comprises an electric pre-heater unit and/or a heat exchange device (not shown).

[0414] Alternatively, the second fluid line arrangement FL is configured to feed the hydrogen H from the high-temperature electrolysis unit 21 to a reducing agent supply 30 for providing a hydrogen containing reducing agent 8.

[0415] The reducing agent supply 30 comprises the reducing agent pre-heating device 18.

[0416] Alternatively, the reducing agent supply 30 is configured to feed the hydrogen containing reducing agent 8 comprising a primary reducing agent BS into the direct reduction facility 7 via the reducing agent inlet device b.

[0417] The primary reducing agent BS may be fed from a primary reducing agent provider S configured to provide the primary reducing agent BS.

[0418] The reducing agent supply 30 may be configured to provide a mixture of the hydrogen H (produced by the high-temperature electrolysis unit 21) and the primary reducing agent BS for providing the hydrogen containing reducing agent 8.

[0419] The reducing agent supply 30 is coupled to the direct reduction facility 7 via a third fluid line arrangement FL configured for fluid communication between the reducing agent supply 30 and the direct reduction facility 7.

[0420] The third fluid line arrangement FL may be configured to feed the hydrogen containing reducing agent 8 into the direct reduction facility 7 from the reducing agent supply 30 via the reducing agent inlet device b.

[0421] The third fluid line arrangement FL may be coupled to the second fluid line arrangement FL for feeding the hydrogen H produced by the high-temperature electrolysis unit 21 via the direct introduction line arrangement 33 of the second fluid line arrangement FL into the direct reduction facility 7.

[0422] The third fluid line arrangement FL may be coupled to the second fluid line arrangement FL for feeding the hydrogen H to the reducing agent supply 30 for providing the hydrogen containing reducing agent 8.

[0423] The heat exchange device 24 may be coupled to the direct reduction facility 7 via a fourth fluid line arrangement FL configured for fluid communication between the heat exchange device 24 and the direct reduction facility 7.

[0424] The second fluid line arrangement FL may comprise the fourth fluid line arrangement FL adapted to feed the hydrogen H produced by the high-temperature electrolysis unit 21 into the direct reduction facility 7 via the direct introduction line arrangement 33 of the second fluid line arrangement FL.

[0425] Alternatively, the produced hydrogen H is fed via the fourth fluid line arrangement FL to the reducing agent pre-heating device 18 for pre-heating the hydrogen H to be introduced into the direct reduction facility 7.

[0426] Alternatively, the produced hydrogen H is fed via the fourth fluid line arrangement FL to the third fluid line arrangement FL for adding the hydrogen H to the hydrogen containing reducing agent 8 to be introduced into the direct reduction facility 7.

[0427] Alternatively, the produced hydrogen H is fed via the heat exchange device 24 of the fourth fluid line arrangement FL for pre-heating the hydrogen H to be introduced into the direct reduction facility 7.

[0428] The high-temperature electrolysis unit 21 may be operated by means of electrical energy produced by a re-generative energy source RGE and by the introduced high-temperature water steam 14.

[0429] Alternatively, the control circuitry 50 is electrically coupled to the high-temperature electrolysis unit 21 and/or to the metal oxide material provider unit 3 and/or to the reducing agent pre-heating device 18 and/or to the reducing agent supply 30.

[0430] The pre-heating of the hydrogen H and/or the hydrogen containing reducing agent 8 to be introduced into the direct reduction facility 7 is provided for reaching the required reaction temperature.

[0431] Alternatively, an excess hydrogen H is separated from the high-temperature exit gas removed from the direct reduction facility is re-circulated and introduced into the direct reduction facility 7 via the second fluid line arrangement FL and/or the third fluid line arrangement FL.

[0432] Alternatively, a water supply WS is configured to fed fresh water to the heat exchange device 24 for generating fresh hot water steam to be fed to the high-temperature electrolysis unit 21. The high-temperature electrolysis unit 21 is configured to produce hydrogen H from the fresh hot water steam to be fed to the direct reduction facility 7.

[0433] FIG. 4 illustrates a flow diagram of a metal material production configuration adapted for reduction of a metal oxide material according to a fourth example. A metal oxide material 5 holding a first thermal energy is charged into a reduction facility 7. The reduction facility 7 may be defined to have an upper interior portion UP, an intermediate interior portion IP and a lower interior portion LP.

[0434] Alternatively, the hydrogen containing reducing agent 8 holding a second thermal energy is introduced into the intermediate interior portion IP and flows upward meeting the downward moving metal oxide material, whereby the upper interior portion UP exhibits a required reaction temperature and functions as a counter current heat exchange zone for providing the chemical reaction between the metal oxide material 5 and the hydrogen containing reducing agent 8.

[0435] Preferably, the hydrogen containing reducing agent 8 and/or the hydrogen H being pre-heated before being introduced into the direct reduction facility 7.

[0436] Alternatively, the metal oxide material 5 descends from the upper interior portion UP to the intermediate IP and/or the lower interior portion LP by means of gravity.

[0437] Alternatively, the temperature of the hydrogen containing reducing agent 8 introduced into the direct reduction facility 7 is controlled by a control circuitry (not shown) to produce a high-temperature exit gas 12 comprising more than about 60-80 % high-temperature water steam or more or substantially 100 % water steam.

[0438] In such way is achieved an excess volume of the hydrogen containing reducing agent and ensuring complete reduction of the metal oxide material.

[0439] Due to the high temperature of the charged metal oxide material 5, there is achieved an efficient direct reduction of the metal oxide material 5 in the upper interior portion UP, despite the fact that the hydrogen containing reducing agent 8 comprises a large amount of water steam.

[0440] Alternatively, the introduction of the hydrogen H may be provided into the intermediate interior portion IP and/or the lower interior portion LP.

[0441] The heat energy of the second thermal energy may be controlled by the control circuitry (not shown) for controlling a reducing agent supply (not shown) to adjust the heat energy of the second thermal energy of the hydrogen containing reducing agent 8 and/or the hydrogen H to be introduced into the direct reduction facility 7 for reaching a required reaction heat energy (required reaction temperature under specific pressure in the direct reduction facility 7).

[0442] FIG. 5 illustrates a phase diagram of iron phase domains as a function of oxidizing power of hydrogen and temperature, for the gas mixture H.sub.2-H.sub.2O in direct reduction of an iron ore oxide material (hematite and/or magnetite and/or wstite) into a reduced iron ore material.

[0443] The direct reduction takes place in two or three stages, depending on whether the temperature is above or below 570 C. In this case, hematite Fe.sub.2O.sub.3 is first reduced to magnetite Fe.sub.3O.sub.4, then to wstite FeO.sub.x and finally to iron Fe. The diagram discloses that increasing content of water steam in the interior of the direct reduction facility requires higher temperature to obtain reduction of the iron ore oxide material.

[0444] The pre-heated hydrogen containing reducing agent, holding the second thermal energy, being introduced into the direct reduction facility ascends upward in the direct reduction facility and contacts the descending iron ore oxide material holding the first thermal energy.

[0445] Due to the charging of the iron ore oxide material holding the first thermal energy into the direct reduction facility it is possible to achieve direct reduction of the iron ore oxide material, even if the content of water steam in the hydrogen containing reducing agent is high (see phase diagram in FIG. 5 at position Q, e.g. H2O/(H2O+H.sub.2) quota about 0,9).

[0446] Preferably, further down in the direct reduction facility there is less content of water steam in the hydrogen containing reducing agent than in the upper part of the direct reduction facility, since the hydrogen to less extent has been used for the direct reduction. For example the hydrogen content may be twice as much as the water steam content in the hydrogen containing reducing agent (see phase diagram in FIG. 5 at position R, e.g. a H2O/(H2O+H2) quota about 0,3).

[0447] Alternatively, a control circuitry (not shown) is adapted to control the direct reduction in the direct reduction facility such that the reduced metal material is not re-oxidated.

[0448] The control circuitry may by electrically coupled to a reducing agent thermal energy adjusting device (not shown) and/or to a pressurization adjusting device (not shown) and/or to a reducing agent mass flow adjusting device (not shown) and/or to a means of a residence time period adjusting device (not shown) adapted to hold the iron ore oxide material during a specific residence time period in the direct reduction facility and/or to a reducing agent introduction/pressurizing device and/or a top gas removing device, for controlling the required reaction temperature.

[0449] The required reaction temperature is thus maintained by means of the control circuitry by adjusting the temperature of the hydrogen containing reducing agent and/or by adjusting the mass flow of the pre-heated hydrogen containing reducing agent fed into the direct reduction facility.

[0450] In such way, it is achieved that the reduced iron material not being re-oxidized in the direct reduction facility.

[0451] Alternatively, the control circuitry is adapted to control the reducing agent mass flow adjusting device to feed a relatively high flow of the pre-heated hydrogen containing reducing agent into the direct reduction facility to hold down the water steam burden in the direct reduction facility for providing an efficient direct reduction and fully direct reduced iron material.

[0452] By means of the second thermal energy of the pre-heated hydrogen containing reducing agent it is thus possibly to provide the direct reduction despite the fact that the content of water is relatively high further down in the direct reduction facility (see phase diagram in FIG. 5 at position R).

[0453] Alternatively, the pre-heated hydrogen containing reducing agent introduced into the direct reduction facility may exhibit higher thermal heat the farther up the pre-heated hydrogen containing reducing agent ascends in the direct reduction facility, since the warmer iron ore oxide material heats the pre-heated hydrogen containing reducing agent for providing the required reaction temperature.

[0454] Alternatively, the pre-heated hydrogen containing reducing agent reduces the cooling rate of the iron ore oxide material descending in the direct reduction facility.

[0455] Alternatively, the pre-heated hydrogen containing reducing agent contains an increased amount of high-temperature water-steam the farther up the pre-heated hydrogen containing reducing agent ascends in the direct reduction facility. However, it is possible to reach efficient direct reduction of the iron ore oxide material (see phase diagram in FIG. 5 at position Q).

[0456] As shown in the diagram, hematite is to be reduced into magnetite at high temperature (e.g. 1200 C.), despite that the water content (position Q) of the pre-heated hydrogen containing reducing agent is high, direct reduction into magnetite still can be achieved.

[0457] In such a way, the heat energy of the first thermal energy generated by the metal oxide material provider unit in combination with the heat energy of the hydrogen containing reducing agent 8 and/or the hydrogen H being utilized to reach the required reaction temperature.

[0458] In such way, it is achieved that the high temperature of the iron ore oxide material promotes an efficient direct reduction, despite the fact that the pre-heated hydrogen containing reducing agent will contain a high content of water-steam (see phase diagram in FIG. 5 at position Q).

[0459] Alternatively, any excess hydrogen being separated from the high-temperature exit gas removed from the direct reduction facility is re-circulated and introduced into the direct reduction facility.

[0460] In such way, a cost-effective use of hydrogen and energy efficient direct reduction process is achieved.

[0461] FIGS. 6-7 illustrate flowcharts showing exemplary methods of direct reduction of a metal oxide material into a reduced metal material.

[0462] FIG. 6 illustrates a flowchart showing an exemplary method of direct reduction of a metal oxide material holding a first thermal energy into a direct reduced metal material by means of a metal material production configuration.

[0463] The method in FIG. 6 starts at step 601. Step 602 comprises adaption of the method. Step 603 comprises stop of the method. Step 602 may comprise the steps of; providing the metal oxide material, holding the first thermal energy, by means of a metal oxide material provider unit; charging the metal oxide material, holding the first thermal energy, into a direct reduction facility; introducing a hydrogen containing reducing agent, holding a second thermal energy, into the direct reduction facility; reducing the metal oxide material by using the first thermal energy of the metal oxide material to heat or further heat the introduced hydrogen containing reducing agent toward a required reaction temperature for providing a chemical reaction between the hydrogen containing reducing agent and the metal oxide material; removing a high-temperature exit gas from the direct reduction facility; feeding a high-temperature water steam of the high-temperature exit gas to a high-temperature electrolysis unit configured to produce a hydrogen; and introducing the hydrogen into the direct reduction facility.

[0464] Alternatively, the hydrogen is added to the hydrogen containing reducing agent to be introduced into the direct reduction facility and/or introducing the hydrogen directly into the direct reduction facility.

[0465] Alternatively, the first thermal energy is higher than the second thermal energy.

[0466] FIG. 7 illustrates a flowchart showing an exemplary method of direct reduction of a metal oxide material holding a first thermal energy into a direct reduced metal material by means of a metal material production configuration.

[0467] The method starts at step 701. Step 702 comprises providing the metal oxide material, holding the first thermal energy, by means of a metal oxide material provider unit. Step 703 comprises charging the metal oxide material, holding the first thermal energy, into a direct reduction facility. Step 704 comprises introducing a hydrogen containing reducing agent, holding a second thermal energy, into the direct reduction facility. Step 705 comprises reducing the metal oxide material by using the first thermal energy of the metal oxide material to heat or further heat the introduced hydrogen containing reducing agent toward a required reaction temperature for providing a chemical reaction between the hydrogen containing reducing agent and the metal oxide material. Step 706 comprises removing a high-temperature exit gas from the direct reduction facility.

[0468] Alternatively, the first thermal energy is higher than the second thermal energy.

[0469] Step 707 comprises feeding a high-temperature water steam of the high-temperature exit gas to a high-temperature electrolysis unit configured to produce a hydrogen. Step 708 comprises adding the hydrogen to the hydrogen containing reducing agent to be introduced into the direct reduction facility and/or introducing the hydrogen directly into the direct reduction facility. Step 709 comprises-pre-heating the hydrogen and/or the hydrogen containing reducing agent to be introduced into the direct reduction facility for reaching the required reaction temperature. Step 710 comprises-providing the hydrogen containing reducing agent, to be introduced into the direct reduction facility, by adding the hydrogen to a primary reducing agent.

[0470] Step 711 comprises removing the high-temperature water steam contained in the high-temperature exit gas, which high-temperature water steam is generated by the chemical reaction between the metal oxide material and the hydrogen containing reducing agent. Step 712 comprises-adjusting the second thermal energy of the hydrogen containing reducing agent to be introduced into the direct reduction facility for reaching the-required reaction temperature. Step 713 comprises-feeding the high-temperature exit gas to the high-temperature electrolysis unit via a filter device configured for removing impurities.

[0471] Step 714 comprises-recovering a third thermal energy from the high-temperature water steam by means of a heat exchange device. Step 715 comprises operating the high-temperature electrolysis unit by means of electrical energy produced by a re-generative energy source, producing the hydrogen by means of the high-temperature electrolysis unit making use of the high-temperature water steam, and introducing the hydrogen into the direct reduction facility. Step 716 comprises stop of the method.

[0472] FIG. 8 illustrates a control circuitry 50 of an exemplary metal material production configuration 1. The control circuitry 50 comprises a computer (not shown). The control circuitry 50 is configured to control any exemplary method herein disclosed. The control circuitry 50 may comprise a non-volatile memory NVM 820, which is a computer memory that can retain stored information even when the control circuitry 50 or the computer is not powered. The control circuitry 50 further comprises a processing unit 810 and a read/write memory 850.

[0473] The NVM 820 comprises a first memory unit 830. A computer program (which can be of any type suitable for any operational database) is stored in the first memory unit 830 to be used for controlling the functionality of the control circuitry 50.

[0474] Furthermore, the control circuitry 50 comprises a bus controller (not shown), a serial communication port (not shown) providing a physical interface, through which suitable information being able to be transferred separately in one direction or in two directions.

[0475] The control circuitry 50 also comprises any suitable type of I/O module (not shown) providing input/output signal transfer, an A/D converter (not shown) for converting continuously varying signals from the temperature sensor devices for detecting temperatures of the metal oxide material holding the first thermal energy and/or temperatures of the hydrogen containing reducing agent holding the second thermal energy introduced into the reduction facility and/or for detecting the required reaction temperature and/or a set of different monitoring units (not shown), into binary code suitable to be processed by the computer of the control circuitry 50.

[0476] The control circuitry 50 further comprises an input/output unit (not shown) for adaption to time and date. The control circuitry 50 also may comprise an event counter (not shown) for counting the number of event multiples that occur during the adjustment of the heat energy toward the required reaction temperature by adjusting the second thermal energy. Furthermore, the control circuitry 50 includes interrupt units (not shown) for providing a multi-tasking performance and real time computing. The NVM 820 also includes a second memory unit 840 for external controlled operation.

[0477] There is provided a data medium, adapted for storing a data program P that comprises driver routines configured for commanding operation of the metal material production configuration 1.

[0478] The data program P is adapted for operating the control circuitry 50 in performing any exemplary method described herein. The data program P comprises routines for executing the commands under operation of the metal material production configuration 1. The data program P comprises a program code, which is readable on the computer, for causing the computer to perform any exemplary method herein described.

[0479] The data program P further may be stored in a separate memory 860 and/or in the read/write memory 850. The data program P is in this embodiment stored in executable or compressed data format.

[0480] It is to be understood that when the processing unit 810 is described to execute a specific function that involves that the processing unit 810 executes a certain part of the program stored in the separate memory 860 or a certain part of the program stored in the read/write memory 850.

[0481] The processing unit 810 is associated with a signal (data) port 899 for communication via a first data bus 815, which signal (data) port 899 may be adapted to be electrically coupled to an electronic control circuitry of an operator station (not shown).

[0482] In such way is achieved that an operator via a display of the electronic control circuitry can control and monitor the metal material production configuration 1.

[0483] The non-volatile memory NVM 820 is adapted for communication with the processing unit 810 via a second data bus 812. The separate memory 860 is adapted for communication with the processing unit 810 via a third data bus 811. The read/write memory 850 is adapted to communicate with the processing unit 810 via a fourth data bus 814. The signal (data) port 899 may be connectable to data links of e.g. a network coupled to the control circuitry 50.

[0484] When data is received by the signal port 899, the data will be stored temporary in the second memory unit 840. After that the received data is temporary stored, the processing unit 810 will be ready to execute the program code, in accordance with any of the exemplary methods.

[0485] Preferably, the signals (received by the signal port 899) comprise information about operational status of the metal material production configuration 1.

[0486] The received signals at the signal port 899, such as a serial bus, may be used by the control circuitry 50 for controlling and monitoring the direct reduction and the required reaction temperature.

[0487] The signals received by the signal port 899 can be used for historic data and data regarding operation of the metal material production configuration 1.

[0488] The metal material production configuration 1 may be configured to be coupled to a data network via the signal bus configured for electrical interface explicitly providing electrical compatibility and related data transfer, which data may include information about status of the metal material production configuration 1 and the temperature sensor devices. Data also may be manually fed to or presented from the computer via a suitable communication device, such as a display (not shown).

[0489] Separate sequences of the method may be executed by the computer, wherein the computer runs the data program P being stored in the separate memory 860 or in the read/write memory 850. When the computer runs the data program P, the method steps according to any example disclosed herein will be executed.

[0490] A data program product comprising a program code stored on a data medium may be provided, which product is readable on a suitable computer, for performing the exemplary method steps herein, when the data program P is run on the computer.

[0491] FIG. 9 illustrates an iron material production configuration 1 comprises a direct reduction facility 7 adapted for direct reduction of an iron ore oxide material 5 according to a further example.

[0492] The iron material production configuration 1 is provided for direct reduction of the iron ore oxide material 5 into a reduced metal material 16. The iron material production configuration 1 is adapted for direct reduction of the iron ore oxide material 5 holding a first thermal energy. The iron material production configuration 1 comprises an iron ore oxide material provider unit 3, such as an iron ore oxide pelletizing plant (not shown) or iron ore oxide material pre-heating plant (not shown).

[0493] The iron ore oxide material 5 holding the first thermal energy is fed to and is charged, via an iron ore oxide material charging inlet device A, into an uppermost portion 81 of an upper interior portion UP of the direct reduction facility 7.

[0494] The direct reduction facility 7 comprises a reducing agent inlet device B configured to introduce a hydrogen containing reducing agent 8 holding a second thermal energy, which second thermal energy is generated by means of a reducing agent pre-heating device (not shown) and/or a heat exchange device (not shown).

[0495] The hydrogen containing reducing agent 8 comprises a hydrogen H produced by means of a high-temperature electrolysis unit 21 and is introduced into the direct reduction facility 7 via the reducing agent inlet device B.

[0496] The high-temperature electrolysis unit 21 is configured to produce the hydrogen H, forming the hydrogen containing reducing agent 8.

[0497] A high-temperature exit gas 12 of the top gas TG is removed from the direct reduction facility 7 via a top gas outlet C of the uppermost portion 81. The high-temperature exit gas 12 is fed from the top gas outlet C to a filter device (not shown). The filter device is configured to separate dust particles or other substances, from the high-temperature exit gas 12.

[0498] Preferably, a high-temperature water steam is separated from the high-temperature exit gas 12 by means of a separation unit (not shown) and is fed to the high-temperature electrolysis unit 21.

[0499] Alternatively, the direct reduction facility 7 is configured to remove the high-temperature exit gas (the top gas comprising the high-temperature water steam) from the direct reduction facility 7 via the top gas outlet C.

[0500] Alternatively, the iron material production configuration 1 is adapted for recovering a third thermal energy (see FIG. 3 as an example) from the high-temperature water steam by means of a heat exchange device (not shown).

[0501] The high-temperature electrolysis unit 21 operates by means of the high-temperature water steam of the high-temperature exit gas 12 removed from the direct reduction facility 7 via the top gas outlet C of the upper interior portion UP of the direct reduction facility 7, and is fed to the high-temperature electrolysis unit 21.

[0502] Alternatively, the high-temperature electrolysis unit 21 operates to separate oxygen (not shown), which may be fed to the iron ore oxide pelletizing plant for oxidization of iron ore material, and hydrogen H from the water of the high-temperature water steam by running an electrical current through the water. The electrical current may be provided by re-generative energy produced by a renewable energy source (not shown).

[0503] Alternatively, the iron material production configuration 1 may comprise a top gas recycling arrangement RCA adapted to recycle hydrogen of the high-temperature exit gas (top gas TG) and introducing the recycled hydrogen into the direct reduction facility 7.

[0504] Alternatively, the iron material production configuration comprises a top gas recycling arrangement adapted to recycle hydrogen of the high-temperature exit gas and adding it to the hydrogen produced by the high temperature electrolysis unit 21.

[0505] Alternatively, the hydrogen H produced by the high temperature electrolysis unit is fed into the direct reduction facility 7 via the reducing agent inlet device B.

[0506] Alternatively, the reducing agent inlet device B of the direct reduction facility 7 is configured to introduce a hydrogen containing reducing agent 8 holding a second thermal energy, which second thermal energy can be applied to the hydrogen containing reducing agent 8 by means of a reducing agent pre-heating device 18.

[0507] Alternatively, the method comprises providing the iron ore oxide material 5, holding the first thermal energy, by means of an iron ore oxide pelletizing plant and/or iron ore oxide material pre-heating plant, and charging the iron ore oxide material into the uppermost portion 81 of the upper interior portion UP of the direct reduction facility 7.

[0508] Alternatively, the reduction facility 7 is configured for allowing direct reduction of the iron ore oxide material 5 in the uppermost portion by using the first thermal energy of the iron ore oxide material 5 to further heat the introduced pre-heated hydrogen containing reducing agent 8 for providing a chemical reaction between the hydrogen H of the hydrogen containing reducing agent 8 and the iron ore oxide material 5.

[0509] Alternatively, the first thermal energy is used in the uppermost portion of the upper interior portion to further heat a remaining quantity of hydrogen H of the (pre-heated) hydrogen containing reducing agent 8, which remaining quantity of hydrogen not yet being consumed by the direct reduction and which has ascended upward in the direct reduction facility 7 toward the uppermost portion, whereas the remaining quantity of hydrogen H provides the chemical reaction and efficient direct reduction of the iron ore oxide material 5 in the uppermost portion, despite the fact that the pre-heated hydrogen containing reducing agent will contain the larger quantity of water steam and less quantity of hydrogen, the higher up the pre-heated hydrogen containing reducing agent has ascended in the direct reduction facility 7.

[0510] Alternatively, the reduction facility 7 comprises an upper interior portion UP, a lower interior portion LP and an intermediate interior portion IP situated between the upper and lower interior portion.

[0511] Alternatively, the first thermal energy is used in the uppermost portion 81 of the upper interior portion UP to further heat a part of the hydrogen of the (pre-heated) hydrogen containing reducing agent 8 for providing said chemical reaction between the hydrogen H of the pre-heated hydrogen containing reducing agent and the oxygen of the metal oxide material situated in the uppermost portion 81.

[0512] Alternatively, the first thermal energy is used in the uppermost portion of the upper interior portion UP to further heat a remaining quantity of hydrogen of the (pre-heated) hydrogen containing reducing agent 8, which remaining quantity of hydrogen H of the hydrogen containing reducing agent not yet being consumed and which has ascended upward in the direct reduction facility 7 toward the uppermost portion 81 (formed by a direct reduction facility top section) of the upper interior portion UP, whereas the remaining quantity of hydrogen provides the chemical reaction and efficient direct reduction of the iron ore oxide material in said uppermost portion 81, despite the fact that the pre-heated hydrogen containing reducing agent will contain the larger quantity of water steam and less quantity of hydrogen, the higher up the pre-heated hydrogen containing reducing agent has ascended in the direct reduction facility 7.

[0513] Alternatively, the first thermal energy is thus used in the uppermost portion 81 to further heat said remaining quantity of hydrogen for providing said chemical reaction between at least a part of said remaining quantity of hydrogen and the oxygen of the iron ore oxide material 5, providing direct reduction, wherein removal of oxygen from the iron ore oxide material is achieved by the chemical reaction. The excess pre-heated hydrogen containing reducing agent in the uppermost portion constitutes a top gas comprising hot water steam, which is withdrawn from the direct reduction facility via top gas outlet C.

[0514] Alternatively, the first thermal energy is thus used to further heat the remaining quantity of hydrogen of the hydrogen containing reducing agent for efficient direct reduction in the uppermost portion 81 and/or to prevent cooling down said remaining quantity of hydrogen of the hydrogen containing reducing agent not yet being consumed in the uppermost portion 81, for providing effective direct reduction.

[0515] It is thus achieved that the iron ore oxide material charged into the direct reduction facility does not cool down the remaining quantity of hydrogen of the hydrogen containing reducing agent in the uppermost portion.

[0516] This has the effect that an energy effective production of reduced iron material 16, such as sponge iron, is provided at the same time as a top gas TG comprising hot water steam is produced, which hot water steam is to be introduced into the high temperature electrolysis unit 21.

[0517] Alternatively, the direct reduction facility 7 is configured to feed a high-temperature water steam (hot water steam) of the high-temperature exit gas to the high-temperature electrolysis unit 21 configured to produce hydrogen to be introduced into the direct reduction facility 7 and used for the chemical reaction.

[0518] Alternatively, the direct reduction facility 7 is configured to allow the reduced metal material 16, and/or iron ore oxide material 5 subject to direct reduction, to descend to the lower interior.

[0519] Alternatively, the direct reduction facility 7 is configured to allow the pre-heated hydrogen containing reducing agent 8 to ascend upward in the direct reduction facility 7 for contacting the descending metal oxide material 5.

[0520] Alternatively, the method comprises the step of discharging the reduced iron material 16.

[0521] The pre-heated hydrogen containing reducing agent comprises about 80-100 % hydrogen, preferably up to 100 % hydrogen by volume, or about 60-80 % hydrogen by volume, preferably about 65-75 % hydrogen by volume, or about 40-60 % hydrogen by volume.

[0522] The pre-heated hydrogen containing reducing agent comprises about 40-60 % hydrogen, preferably about 45-55 % hydrogen by volume.

[0523] Alternatively, the hydrogen containing reducing agent being introduced into the direct reduction facility exhibits a temperature of about 250 C. to about 750 C., preferably about 350 C. to about 650 C.

[0524] Alternatively, the hydrogen containing reducing agent that is fed into the direct reduction facility may exhibit a temperature of about 300 C. to about 800 C., preferably about 400 C. to about 700 C.

[0525] Alternatively, the hydrogen containing reducing agent being introduced into the direct reduction facility exhibits a temperature of about 500 C. to about 900 C., preferably about 600 C. to about 800 C.

[0526] Alternatively, the hydrogen containing reducing agent being introduced into the direct reduction facility exhibits a temperature of about 600 C. to about 1000 C., preferably about 700 C. to about 900 C.

[0527] Alternatively, the hydrogen containing reducing agent being introduced into the direct reduction facility exhibits a temperature of about 200 C. to about 700 C., preferably about 300 C. to about 600 C.

[0528] Alternatively, the hydrogen containing reducing agent that is fed into the direct reduction facility may exhibit a temperature of about 350 C. to about 900 C., preferably about 450 C. to about 750 C.

[0529] Alternatively, the metal oxide material holding thermal energy being charged into the direct reduction facility exhibits a temperature of 200 C. to about 500 C., preferably about 300 C. to about 400 C.

[0530] Alternatively, the metal oxide material holding thermal energy being charged into the direct reduction facility exhibits a temperature of 300 C. to about 600 C., preferably about 400 C. to about 500 C.

[0531] Alternatively, the metal oxide material holding thermal energy being charged into the direct reduction facility exhibits a temperature of 400 C. to about 700 C., preferably about 500 C. to about 600 C.

[0532] Alternatively, the metal oxide material holding thermal energy being charged into the direct reduction facility exhibits a temperature of 500 C. to about 800 C., preferably about 600 C. to about 700 C.

[0533] Alternatively, the metal oxide material holding thermal energy being charged into the direct reduction facility exhibits a temperature of 600 C. to about 900 C., preferably about 700 C. to about 800 C.

[0534] Alternatively, the metal oxide material holding thermal energy being charged into the direct reduction facility exhibits a temperature of 700 C. to about 1000 C., preferably about 800 C. to about 900 C.

[0535] Alternatively, the metal oxide material holding thermal energy being charged into the direct reduction facility exhibits a temperature of 800 C. to about 1100 C., preferably about 900 C. to about 1000 C.

[0536] Alternatively, the metal oxide material holding thermal energy being charged into the direct reduction facility exhibits a temperature of 900 C. to about 1200 C., preferably about 1000 C. to about 1100 C.

[0537] Alternatively, the metal oxide material holding thermal energy being charged into the direct reduction facility exhibits a temperature of 1000 C. to about 1300 C., preferably about 1100 C. to about 1200 C.

[0538] Alternatively, the metal oxide material holding thermal energy being charged into the direct reduction facility exhibits a temperature of 1100 C. to about 1450 C., preferably about 1200 C. to about 1300 C.

[0539] Alternatively, the chemical reaction comprises a substantially or completely endothermal chemical reaction.

[0540] Alternatively, the direct reduction consumes thermal energy equivalent to about 400-600 C., preferably about 420-580 C.

[0541] Alternatively, the direct reduction consumes thermal energy equivalent to about 425-575 C., preferably about 440-560 C.

[0542] Alternatively, the direct reduction consumes thermal energy equivalent to about 450-550 C., preferably about 460-540 C.

[0543] Alternatively, the direct reduction consumes thermal energy equivalent to about 475-525 C., preferably about 490-510 C.

[0544] Alternatively, the direct reduction consumes thermal energy equivalent to about 500-650 C., preferably about 520-630 C.

[0545] Alternatively, the thermal energy to be consumed by the direct reduction in the uppermost portion 81 is formed by the first thermal energy and by the thermal energy of the pre-heated hydrogen containing reducing agent 8, wherein the first thermal energy is larger than the thermal energy of the pre-heated hydrogen containing reducing agent.

[0546] Alternatively, the thermal energy to be consumed by the direct reduction in the uppermost portion 81 is formed by the first thermal energy and by the thermal energy of the pre-heated hydrogen containing reducing agent, wherein the first thermal energy is smaller than the thermal energy of the pre-heated hydrogen containing reducing agent in the uppermost portion.

[0547] It is thus achieved that the first thermal energy of the iron ore oxide material 5 prevents that the hydrogen H of the hydrogen containing reducing agent in the uppermost portion is cooled down, which otherwise would impair the chemical reaction (direct reduction) in the uppermost portion UP.

[0548] It is thus achieved that the first thermal energy of the iron ore oxide material 5 adds further thermal energy to the hydrogen H of the hydrogen containing reducing agent in the uppermost portion, which will enhance the chemical reaction (direct reduction) in the uppermost portion UP.

[0549] This has the effect that an energy effective production of reduced iron material 16, such as sponge iron, is provided at the same time as the top gas TG comprising hot water steam is generated efficiently in an energy saving manner, which hot water steam is to be introduced into the high temperature electrolysis unit 21 for producing hydrogen to be used by the high temperature electrolysis unit.

[0550] Alternatively, the thermal energy to be consumed by the direct reduction in the intermediate interior portion IP comprises the first and/or second thermal energy.

[0551] Alternatively, the thermal energy to be consumed by the direct reduction in the lower interior portion LP comprises the second thermal energy.

[0552] Alternatively, the temperature of iron ore oxide material 5 charged into the uppermost portion is controlled to be within the range of 100-500 C., preferably 200-400 C., and the hydrogen containing reducing agent 8 introduced into the direct reduction facility is controlled to be within the range of 1000-1300 C., preferably 1100-1200 C.

[0553] Alternatively, the temperature of iron ore oxide material 5 charged into the uppermost portion is controlled to be within the range of 300-700 C., preferably 400-600 C., and the hydrogen containing reducing agent 8 introduced into the direct reduction facility is controlled to be within the range of 800-1100 C., preferably 900-1000 C.

[0554] Alternatively, the temperature of iron ore oxide material 5 charged into the uppermost portion is controlled to be within the range of 500-900 C., preferably 600-800 C., and the hydrogen containing reducing agent 8 introduced into the direct reduction facility 7 is controlled to be within the range of 600-900 C., preferably 700-800 C.

[0555] Alternatively, the temperature of iron ore oxide material 5 charged into the uppermost portion is controlled to be within the range of 700-1100 C., preferably 800-1000 C., and the hydrogen containing reducing agent 8 introduced into the direct reduction facility is controlled to be within the range of 400-700 C., preferably 500-600 C.

[0556] In such way is provided an iron material production configuration 1 configured for production of a reduced iron material 16 (e.g. carbon free reduced iron material) in an energy efficient manner.

[0557] The present invention is of course not in any way restricted to the preferred examples described above, but many possibilities to modifications, or combinations of the described examples thereof should be apparent to a person with ordinary skill in the art without departing from the basic idea of the invention as defined in the appended claims.