A method of making metallic iron in which a compact, containing iron oxide such as iron ore or the like and a carbonaceous reductant such as coal or the like, is used as material, and the iron oxide is reduced through the application of heat, thereby making metallic iron. In the course of this reduction, a shell composed of metallic iron is generated and grown on the surface of the compact, and slag aggregates inside the shell. This reduction continues until substantially no iron oxide is present within the metallic iron shell. Subsequently, heating is further performed to melt the metallic iron and slag. Molten metallic iron and molten slag are separated one from the other, thereby obtaining metallic iron with a relatively high metallization ratio. Through the employment of an apparatus for making metallic iron of the present invention, the above-described method is efficiently carried out, and metallic iron having a high iron purity can be made continuously as well as productively not only from iron oxide having a high iron content but also from iron oxide having a relatively low iron content.

Method and apparatus for making metallic iron

High quality activated carbon is produced by charging a mixture of an organic material such as wood, anthracite coal, brown coal, coconut husk, and a material containing metal oxide, metal carbonate or metal hydroxide, such as iron ore and lime, into an internal heating rotary furnace, preferably, having an internal space with a length of 1 to 10 times the diameter thereof, through an end of the rotary furnace, blowing air or oxygen gas into the internal space through an opposite end thereof, burning the distilled gas from the organic material and carbon monoxide generated by the reaction of the organic material with the metal oxide, carbonate or hydroxide, and uniformly circulating the burnt gas in the internal space to maintain the internal space at the reduction temperature.

Process for producing activated carbon

The first purpose of the present invention is to provide a method for producing metallic iron, whereby, in the production of metallic iron by heating an agglomerate, which comprises an iron oxide-containing material and a carbonaceous reductant, in a movable hearth type heating furnace, metallic iron can be efficiently collected from a reduced product containing metallic iron and a slag, said reduced product being obtained by heating the agglomerate. The method for producing metallic iron according to the first embodiment of the present invention comprises: a step for forming an agglomerate of a mixture which comprises an iron oxide-containing material and a carbonaceous reductant; a step for introducing the obtained agglomerate into a movable hearth type heating furnace and reducing the same by heating; a step for crushing a reduced product containing metallic iron and a slag, said reduced product being discharged from the movable hearth type heating furnace, using an impact crusher; and a step for selecting and collecting the metallic iron using a separator.

Method for producing metallic iron

The disclosure relates to metal reduction processes, which comprise adding a mixture comprising at least one metal-containing material, at least one reducing agent, and at least one additive into a reactor, heating the reactor to a selected reduction temperature, moving the mixture through the reactor while stirring the mixture, allowing a reduction period to occur, and obtaining a resulting composition comprising at least one zero-valent metal and a residue. The disclosure also relates to metallurgical processes comprising the metal reduction process, and products made by the metal reduction process. The disclosure further relates to metal reduction apparatuses, as well as metal reduction systems and metallurgical systems comprising the metal reduction apparatuses.

Metal reduction processes, metallurgical processes and products and apparatus

A method and means for improving the efficiency of the process for directly reducing ore containing iron oxide in a rotary kiln using a solid carbonaceous reducing agent, such as coal, introduced from the ore feed and discharge ends of the kiln, as both fuel and reductant, is disclosed wherein the charred coal or char found in the discharge product is recycled into the process at the discharge end of the kiln rather than the feed end as in the prior art In particular, the recovered char, both coarse and finer particles, are transported to a recycle bin from which they are returned at a preselected rate to the kiln process by being injected along with the coal blown into the discharge end of the kiln Alternatively, the recycle char alone may be fed without any coal at the discharge end of the kiln

System for recycling char in iron oxide reducing kilns

Iron, in the form of iron powder or a soft readily powdered agglomerate thereof, is prepared simultaneously with powdered active carbon, by heating an iron oxide, in the form of powder or a soft readily powdered agglomerate thereof with a stoichiometric excess of a powdered coal char which will react with carbon dioxide at the temperature employed at a rate above 10 percent per hour, at a temperature controlled so that the charge is maintained throughout the reaction at between 1,775* F. and 1,875* F. The temperature is most readily maintained in production units by passing the gases used to supply the necessary extraneous heat across the path of travel of the charge, rather than along the path of travel.

Jack Trechock

Papers

Process for simultaneously producing powdered iron and active carbon