Method of and apparatus for reducing iron oxide to metallic iron

Claim 1

An apparatus for the reduction of iron oxide balls, comprising: a shaft furnAce, means for feeding iron oxide balls to the top of said shaft furnace, means for removing the balls from the bottom of said shaft furnace whereby a gravitationally descending column of balls may be established within the shaft furnace, means for supplying a reducing gas upwardly through at least a portion of said column, means for heating said portion to the reducing temperature of iron oxide, means for collecting the off-gas from the top of the shaft furnace, means for mixing the off-gas with a hydrocarbon, means for selectively heating the mixed gas at a constant temperature of at least about 1,500* F., catalytic means for continuously reacting the heated, mixed gases, means for supplying the reacted gas to said reducing gas supply means, means for maintaining the gas in said gas supply means at a temperature between about 1,300* F. and 1,450* F., means for supplying a cooling gas intermediate said reducing gas supply means and said removing means, means for removing said cooling gas intermediate said cooling gas supply means and said reducing gas supply means, means for supplying communication between said cooling gas supply means and removal means, and a heat exchange means received within said communication means.

Claim 2

An apparatus for reducing iron oxide pellets, comprising: a generally vertical furnace having means at the top thereof for receiving oxide pellets and means at the bottom thereof for discharging the pellets, a first gas inlet intermediate the receiving means and discharge means, a first gas outlet at the upper portion of the furnace, a tube having an inlet and an outlet, first means for providing communication between said tube inlet and the gas outlet of said furnace, second means for providing communication between said tube outlet and the gas inlet of said furnace, means for heating said tube to a constant temperature of at least 1500* F., a non-catalytic bed received within said tube adjacent the inlet opening, a catalytic bed received within said tube adjacent the outlet thereof, means for supplying a gaseous hydrocarbon to said first communication means, means for causing gas to flow from said first gas outlet to said tube inlet, a second gas inlet received in the lower portion of said furnace, second gas outlet received in said furnace intermediate said second gas furnace inlet and said first gas inlet, a heat exchanger in communication with said second furnace inlet and said second furnace outlet, and means for forcing cooling gas through said furnace, thereby establishing a cooling circuit.