Method for increasing the capacity of a direct reduced iron plant without increasing its reformer capacity

A method for increasing the production of direct reduced iron (DRI) or of pre-reduced iron ore in an existing direct reduction plant having a reformer of a predetermined reforming capacity and a reduction reactor, which comprises:

• introducing an iron-oxide-containing material to said reduction reactor;
• introducing hot reducing gas to within said reduction reactor;
• contacting said hot reducing gas with said iron-oxide-containing material within said reduction reactor;
• reducing at least partially said iron-oxide-containing material to metallic iron, DRI or pre-reduced iron ore;
• withdrawing from said reduction reactor the reducing gas, after having been contacted with said iron-oxide-containing material, as a top gas;
• cooling and cleaning said top gas to form a cool gas stream;
• pressuring at least a portion of said cool gas stream to form a pressurized recycle stream;
• dividing said pressurized stream into at least two portions;
• combining the first portion of said pressurized stream with natural gas forming a feeding reformer stream;
• passing said feeding reformer stream through said gas reformer forming a main reducing gas stream;
• combining the second portion of said pressurized stream, said main reducing gas stream, a stream of natural gas, and an oxygen-containing gas stream to form said hot reducing gas;
• and,
• withdrawing said at least partially reduced material from said reduction reactor.