Process for the direct production of steel

A process for the direct production of steel from iron oxides which comprises:

• a. reducing the oxides and converting the iron to iron carbide in one step in a fluidized bed with a mixture of hydrogen bearing gas and a carbon containing material which provides carbon for the iron carbide, the hydrogen being present in an amount exceeding 50% of the CO present;
• and
• b. adding the iron carbide to a basic oxygen furnace and processing it to steel by the basic oxygen furnace process without the addition of external heat.

A process for conversion of iron oxides to iron carbide which comprises reducing the oxides and converting the iron to iron carbide in one step in a fluidized bed with a mixture of hydrogen and a carbon containing material which provides carbon for the iron carbide, the mixture containing hydrogen in an amount over 60 percent by volume of the carbon monoxide present.

A process for converting iron carbide to steel in the basic oxygen furnace by the basic oxygen furnace process, said process comprising the step of augmenting the heat produced in the conversion process which is produced by oxidizing the carbon in the iron carbide, with additional heat, to make the process in the basic oxygen furnace autothermal.

A process of making steel from iron carbide in the basic oxygen furnace which comprises adding pig iron to the iron carbide charge and controlling the temperature of the charge by the addition of iron carbide.

A process for concentrating non-magnetic low grade iron ores which comprises converting the iron oxide in the ores to iron carbide and separating the iron carbide and gangue by subjecting the treated ores to magnetic separation.

A process for the direct production of steel from iron oxides which comprises:

• a. converting the iron in the oxides to iron carbide;
• and
• b. converting an iron in the iron carbide directly to steel in an electric furnace.

A process for the direct production of steel from iron oxides which comprises:

• a. reducing the oxides and converting the iron to iron carbide in one step in a fluidized bed with a mixture of a hydrogen bearing gas and a carbon containing material which provides carbon for the iron carbide, the hydrogen being present in an amount exceeding 50% of the CO present;
• and
• b. adding the iron carbide to the electric furnace and processing it to steel in an electric furnace.