Method and system for producing high-carbon DRI using syngas

A process for producing direct reduced iron (DRI) having chemically-combined carbon in a direct reduction reactor for the production of said DRI, said direct reduction reactor having at least a reduction zone, a lower zone, and a transition zone between said reduction zone and said lower zone, the process comprising:

• providing a first portion of a first gas stream comprising hydrogen and carbon monoxide to said reduction zone, said first gas stream being a syngas with less than 5 vol % methane, to produce said DRI in said reduction zone;
• providing said DRI at a temperature above 400° C. to said transition zone, said lower zone, or both;
• passing a second portion of said first gas stream through a methane-forming reactor where methane is produced from said hydrogen and carbon monoxide resulting in a second gas stream containing a higher concentration of methane than said first gas stream;
• and
• contacting said second gas stream with said DRI in said transition zone, said lower discharge zone, or both to increase the carbon content of said DRI in said transition zone, said lower zone, or both, respectively.