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

A binder composition for use in forming briquettes is disclosed. The composition comprises from about 5 to about 95% asphalt base and about 5 to about 95% sodium carbonate pulping liquor by weight. The binder composition may contain up to about 3% by weight of a surfactant, such as nonyl phenol ethoxylate, to increase homogeneity of briquette formation. Strength increasing additives such as latex, vinyl derivatives, cellulose, cellulose derivatives, peat moss, starch, starch derivatives, pulp from the pulp and paper industry, paper, cardboad, acrylic copolymers and combinations thereof, may be added to the binder composition in a total amount of up to about 10% by weight. Lignosulfonate may be added to the composition in an amount of up to about 30% by weight. An inorganic component such as cement or bentonite clay may be added in an amount of up to about 70% by weight, and up to about 30% by weight of a plasticizer such as rubber or plastic may be added. The binder composition may be used to agglomerate a briquette filler such as metal fines, coal fines, miniers, fly ash or other suitable briquette components.

Briquette binder composition

A method for suppressing dust emanation from a dust-bearing material comprises applying to the material a dust suppressant that comprises molasses-derived protein.

Control of dust

Solid particulate steel mill wastes, such as blast furnace flue dust, basic oxygen furnace dust, mill scale, coke braise, fluxes and the like, which contain iron, iron oxides, carbon and other constituents, are briquetted with 2 to 15 percent (preferably 3 to 10 percent) hydrocarbonaceous binder of the total dry weight of the waste fines, and the raw briquettes are treated with an oxygen-containing gas at 350* to 600*F to selectively react with the hydrogen in the binder, to obtain strong briquettes which can be fed back into iron-or steelmaking process as a source of iron and/or carbon.

Control of pollution by recycling solid particulate steel mill wastes

A coherent particulate composite is formed by blending particulate material with a binder containing lignosulfonate and urea.

Lignosulfonate/urea binder for particulate composites

Processes for producing carbonaceous materials

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.

Process for simultaneously producing powdered iron and active carbon

A novel composite briquette useful in producing iron is made by briquetting a reactive coal calcinate made as described in Work et al. U.S. Pat. Nos. 3,140,241 and 3,140,242, and iron oxide, with a bituminous binder, using proportions to insure at least 50 percent carbon plus hydrogen by weight, then curing the briquettes in the presence of a gas containing at least 5 percent of oxygen at briquette temperature of 450 DEG to 575 DEG F, and then further heating the cured briquettes at 1600 DEG to 1800 DEG F, whereby at least 90 percent of the iron is reduced. The briquette is distinguished by consisting of iron particles embedded and evenly distributed through a uniform solid carbonaceous structure.

Method of producing carbon and iron-containing briquettes

Amorphous carbonaceous material

REACTIVE FORM COKE, MADE AS DESCRIBED IN WORK ET AL., U.S. PATS. 3,140,241 AND 3,140,242, ISSUED JULY 7, 1964, IS TREATED WITH AN AQUEOUS DISPERSION OF A FILM FORMER TO DEPOSIT ON AND ADJACENT THE SURFACE THEREOF FROM ABOUT 0.05 TO ABOUT 3 WEIGHT PERCENT OF A SOLID WHICH ADHERES TO THE SURFACE AND DEPOSITS IN THE SURFACE PORES, AND ACTS BOTH TO REDUCE ABRASION AND TO CAUSE MATERIAL ABRADED FROM THE SURFACE TO BE LARGER IN SIZE THAN ULTRAFINE (20-MICRON AND SMALLER) PARTICLES WHICH ARE PRODUCED IN THE ABSENCE OF THE COATING, THEREBY CONTROLLING THE AIRBORNE-DUST PROBLEM WHICH OTHERWISE MAKES HANDLING OF THE REACTIVE FORM COKE EXTREMELY DIFFICULT.

Robert T. Joseph

Papers

Processes for producing carbonaceous materials

Process for simultaneously producing powdered iron and active carbon

Method of producing carbon and iron-containing briquettes

Amorphous carbonaceous material

Method of controlling ultrafines from reactive form coke