Method of making iron and steel

A steel making method comprising:

• (a) providing iron oxide and a carbonaceous reducing agent;
• (b) preparing a shaped product from the carbonaceous reducing agent and the iron oxide;
• (c) preparing solid reduced iron from the shaped product, wherein the solid reduced iron has a metallization of at least 60%, a specific gravity of at least 1.7, and a carbon content of at least 50% of the theoretical amount required for reducing the iron oxide remaining in the solid reduced iron;
• (d) before substantial cooling occurs, heating the solid reduced iron after the solid reduced iron is submerged entirely in a foam of molten slag in an arc heating melting furnace, thereby preparing molten iron containing from 1.5 to 4.5% carbon;
• and
• (e) adding the molten iron to a steel making furnace, thereby preparing steel;
• wherein
• a basicity of the foam of molten slag is from 1.0 to 1.8.

A steel making method comprising:

• (a) providing iron oxide and a carbonaceous reducing agent;
• (b) preparing a shaped product from the carbonaceous reducing agent and the iron oxide;
• (c) preparing solid reduced iron from the shaped product, wherein the solid reduced iron has a metallization of at least 60%, a specific gravity of at least 1.7, and a carbon content of at least 50% of the theoretical amount required for reducing the iron oxide remaining in the solid reduced iron;
• (d) before substantial cooling occurs, heating the solid reduced iron after the solid reduced iron is submerged entirely in a foam of molten slag in an arc heating melting furnace, thereby preparing molten iron containing from 1.5 to 4.5% carbon;
• (e) cooling the molten iron, thereby preparing coagulated iron;
• and
• (f) adding the coagulated iron to a steel making furnace, thereby preparing steel.

An iron making method comprising:

• (a) providing iron oxide and a carbonaceous reducing agent;
• (b) preparing a shaped product from the carbonaceous reducing agent and the iron oxide;
• (c) preparing solid reduced iron from the shaped product, wherein the solid reduced iron has a metallization of at least 60%, a specific gravity of at least 1.7, and a carbon content of at least 50% of the theoretical amount required for reducing the iron oxide remaining in the solid reduced iron;
• and
• (d) before substantial cooling occurs, heating the solid reduced iron after the solid reduced iron is submerged entirely in a foam of molten slag in an arc heating melting furnace to prepare a molten iron;
• wherein
• a basicity of the foam of molten slag is from 1.0 to 1.8.