Direct reduced iron system and method
A method of direct reduction of iron (DRI) is disclosed, the method comprising generating metallic iron by removing oxygen from iron ore using a reducing gaseous mixture with excess carbon monoxide that produces an excess CO 2 by-product is provided. CO 2 by-product is optionally sequestered. A system for carrying out the method is also disclosed.
1 . A method of direct reduction of iron (DRI) comprising:
reducing a source of iron ore with a reducing gaseous mixture feed to produce a direct reduced iron product and a top gas feed;
scrubbing the top gas feed;
separating the top gas feed to provide a carbon dioxide by-product feed and an unreacted hydrogen and carbon monoxide feed;
processing unreacted hydrogen and/or unreacted carbon monoxide from the unreacted hydrogen and carbon monoxide feed to provide a carbon monoxide feed and an essentially pure hydrogen feed; and
sequestering the carbon dioxide by-product feed;
wherein the reducing gaseous mixture feed is provided to a DRI unit by a partial oxidation unit (POX).
2 . The method of claim 1 , wherein the reducing gaseous mixture feed comprises hydrogen and carbon monoxide.
3 . The method of claim 2 , wherein additional carbon monoxide is added to the reducing gaseous mixture feed.
4 . The method of claim 1 , wherein the CO 2 by-product feed is separated from water vapor and the unreacted reducing gaseous mixture feed prior to sequestering.
5 . The method of claim 1 , wherein the CO 2 by-product feed is dried prior to sequestering.
6 . The method of claim 1 , wherein the CO 2 by-product feed is compressed to a supercritical state prior to sequestering.
7 . The method of claim 1 , wherein unreacted hydrogen from the reducing gaseous mixture feed is separated from water vapor and the unreacted reducing gaseous mixture feed prior to sequestering.
8 . The method of claim 7 , wherein the unreacted hydrogen is captured and stored.
9 . The method of claim 1 , further comprising introducing the direct reduced iron product to an electric arc furnace.
10 . The method of claim 9 , wherein the introducing of the direct reduced iron product to an electric arc furnace is continuous or semi-continuous.