Midrex Technologies, Inc.

Todd Michael Astoria

Haruyasu Michishita

Gregory Darel Hughes

Keith Marshall Bastow-Cox

James Lloyd Lewis, Jr

Enrique Jose Cintron

Masahiko Tetsumoto

Taiji Hatakeyama

Keith Marshall Barstow-Cox

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

Iron (DRI) between a DRI source and processing equipment for the DRI

A method for producing direct reduced iron having increased carbon content, comprises delivering each of the herein-described mixed carburizing gas streams, which are of different composition, to a transition zone of a direct reduction furnace, and exposing partially or completely reduced iron oxide to the mixed carburizing gas streams to increase the carbon content of resulting direct reduced iron to greater than 4.5 wt. %.

Methods and systems for increasing the carbon content of direct reduced iron in a reduction furnace

A process for producing hot briquetted iron with increased solid carbonaceous material and/or flux includes: providing a shaft furnace of a direct reduction plant to reduce iron oxide with reducing gas; providing a hot briquette machine to produce hot briquetted iron; coupling a chute between a) a discharge exit of the shaft furnace for discharge of hot direct reduced iron and b) an entrance of the hot briquette machine; adding solid carbonaceous material and/or flux to the discharged hot direct reduced iron from the shaft furnace to produce a mixture of the discharged hot direct reduced iron and the solid carbonaceous material and/or flux before feeding to the hot briquette machine; and processing in the hot briquette machine to produce a product of hot briquetted iron with increased solid carbonaceous material content greater than about 3 weight percent and/or an increased flux content.

System and method for the production of hot briquetted iron (HBI) containing flux and/or carbonaceous material at a direct reduction plant

Method and system for heating direct reduced iron (DRI) between a DRI source and processing equipment for the DRI

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

Integration of DR plant and electric DRI melting furnace for producing high performance iron

A process for the production of direct reduced iron (DRI), with or without carbon, using hydrogen, where the hydrogen is produced utilizing water generated internally from the process. The process is characterized by containing either one or two gas loops, one for affecting the reduction of the oxide and another for affecting the carburization of the DRI. The primary loop responsible for reduction recirculates used gas from the shaft furnace in a loop including a dry dedusting step, an oxygen removal step to generate the hydrogen, and a connection to the shaft furnace for reduction. In the absence of a second loop, this loop, in conjunction with natural gas addition, can be used to deposit carbon. A secondary carburizing loop installed downstream of the shaft furnace can more finely control carbon addition. This loop includes a reactor vessel, a dedusting step, and a gas separation unit.

Direct reduction process utilizing hydrogen

The present invention provides a method for producing direct reduced iron and/or hot metal using high-moisture content carbonaceous material, including: agglomerating carbonaceous material from the high-moisture content carbonaceous material with a metal oxide-bearing material to form an agglomerate suitable for use in a direct reduction and/or hot metal producing process. The method also includes distilling the high-moisture content carbonaceous material. The method further includes dry quenching the carbonaceous material obtained from the distilling step. The method still further includes drying the high-moisture content carbonaceous material with energy from a hot off gas from a furnace for producing direct reduced iron and/or hot metal prior to the distilling step.

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Harrisburg, NC, United States of America

Todd Michael Astoria