Metal ore reduction reactor with self-generating reductant

A method for generating reductants during direct reduction of metal ores, the method comprising:

• receiving a metal ore at a reduction portion of a reactor;
• receiving a reductant at a reduction portion of a reactor;
• heating the metal ore and the reductant to form a gas and particle mixture;
• receiving the mixture at a quench section of the reactor, wherein the quench section comprises a heat exchanger having at least one channel configured to accept the mixture and form a hot reaction stream;
• introducing a catalyst located in the quench section;
• utilizing a heat energy from the reduction portion of the reactor to heat the catalyst and form the hot reaction stream;
• providing a reactant stream to the heat exchanger positioned in the quench section such that the reactant stream receives heat from channel of the heat exchanger, wherein the reactants become the hot reaction stream and react to generate a reductant;
• dispelling the reductant from a first product outlet, wherein the first product outlet is in communication with the interior of the quench section;
• and
• releasing direct reduced metal ore from an exit portion.

A quench device for a reactor for generating reductants during direct reduction of metal ores, the quench device comprising:

• an inlet configured to receive a mixture of hot metal ore, gas and particles;
• a catalyst located in an interior portion of the quench device;
• a heat exchanger located in an interior of the quench device, wherein the heat exchanger comprises at least one channel configured to contact the mixture and form a hot reactant stream, wherein the heat exchanger utilizes a heat energy from the reduction portion;
• a reactant inlet in communication with the interior of the quench device, wherein the reactant inlet is configured to provide reactants to the interior of the quench device, wherein the reactants react with the streams to generate a reductant;
• a first product outlet in communication with the interior of the quench device, wherein the first product outlet is configured to dispel the reductant.