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System and method for producing metallic iron

United States Patent

8,790,442
July 29, 2014
View the Complete Patent at the US Patent & Trademark Office
A method of production of metallic iron nodules comprises assembling a hearth furnace having a moveable hearth comprising refractory material and having a conversion zone and a fusion zone, providing a hearth material layer comprising carbonaceous material on the refractory material, providing a layer of reducible material comprising and iron bearing material arranged in discrete portions over at least a portion of the hearth material layer, delivering oxygen gas into the hearth furnace to a ratio of at least 0.8:1 ponds of oxygen to pounds of iron in the reducible material to heat the conversion zone to a temperature sufficient to at least partially reduce the reducible material and to heat the fusion zone to a temperature sufficient to at least partially reduce the reducible material, and heating the reducible material to form one or more metallic iron nodules and slag.
Englund; David J. (Bovey, MN), Schlichting; Mark (Crawfordsville, IN), Meehan; John (Conway, AR), Crouch; Jeremiah (Conway, AR), Wilson; Logan (Hot Springs, AR)
Nu-Iron Technology LLC (Charlotte, NC)
13/ 499,152
20120192679
September 29, 2010
GOVERNMENT INTERESTS The present invention was made with support by the Department of Energy, Sponsor Award DE-FG36-05GO15185. The United States government has certain rights in the invention.