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Abstract

A process for the gaseous reduction of iron ore to sponge in a vertical shaft, moving bed reactor wherein a hot gaseous mixture of hydrogen and carbon monoxide generated by the internal steam reformation of gaseous hydrocarbon(s), preferably methane or natural gas, is used to reduce the ore without the need for any external catalytic reformer. A reducing gas recycle loop is established to which hydrocarbon and reclaimed waste hot water are fed in the proper proportions as the reducing gas make-up source with the sponge iron produced in the reduction reactor being used to catalyze hydrocarbon reformation, and with the carbon content of the recycled gas being maintained low by removing carbon dioxide therefrom. High overall process thermal efficiency and lowered operating and capital costs are achieved by establishing hot water (and optional steam) loops wherein all process hot water/steam requirements are met through the utilization of hot water discharge from the quench cooler and advantageously also the generation of steam by the reclamation of waste heat from spent hot reducing gas leaving the reactor, thereby eliminating the need for importing costly process steam and reducing the size needed for cooling towers and water treatment units.

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First Claim