Hydrogen reduction of iron ore concentrate in loose layers and compacts

A method for producing iron from iron concentrate produced from low grade iron ore including no more than about 35 wt % iron in a continuous moving bed conveyor reactor, the method comprising the steps of:

• providing iron ore concentrate in a small particle form of no more than about 0.1 mm particle size, where the iron ore concentrate has not undergone pelletization and/or induration;
• and
• passing the iron ore concentrate that has not undergone pelletization and/or induration through a moving bed conveyor reduction furnace with at least one of hydrogen gas or natural gas, wherein the iron ore concentrate that has not undergone pelletization and/or induration is present within the conveyor reduction furnace in a layer that is no more than about 5 cm thick, the hydrogen gas or natural gas reducing the iron ore concentrate, so as to remove oxygen therefrom, and converting the iron ore concentrate material to a material having a composition similar to direct reduced iron (DRI) or sponge iron product, having about 90-95 wt % iron, up to about 10 wt % oxygen, with other trace impurities, wherein the furnace is operated at a temperature in a range of 850-1000° C.;
• wherein the iron ore concentrate is provided as two or more layers configured as stacked beds, with space provided between each stacked bed, to allow the hydrogen or natural gas to flow over each of the stacked beds, reducing the iron ore concentrate within each such bed, wherein the system includes from 2 to about 10 stacked beds.