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Production of iron from metallurgical waste

United States Patent

8,535,411
September 17, 2013
View the Complete Patent at the US Patent & Trademark Office
A method of recovering metallic iron from iron-bearing metallurgical waste in steelmaking comprising steps of providing an iron-bearing metallurgical waste containing more than 55% by weight FeO and FeO equivalent and a particle size of at least 80% less than 10 mesh, mixing the iron-bearing metallurgical waste with a carbonaceous material to form a reducible mixture where the carbonaceous material is between 80 and 110% of the stoichiometric amount needed to reduce the iron-bearing waste to metallic iron, and as needed additions to provide a silica content between 0.8 and 8% by weight and a ratio of CaO/SiO.sub.2 between 1.4 and 1.8, forming agglomerates of the reducible mixture over a hearth material layer to protect the hearth, heating the agglomerates to a higher temperature above the melting point of iron to form nodules of metallic iron and slag material from the agglomerates by melting.
Hendrickson; David W. (Colraine, MN), Iwasaki; Iwao (Tokyo, JP)
Nu-Iron Technology, LLC (Charlotte, NC)
13/ 187,937
20110308353
July 21, 2011
GOVERNMENT INTERESTS The present invention was made with support by the Economic Development Administration, Grant No. 06-69-04501, and the Department of Energy, Sponsor Award DE-FG36-05GO15185. The United States government has certain rights in the invention.