Improvements in production of steel from iron ore

Abstract

A microwave process and apparatus for treating ore comprising a supply of reaction gas from unipolar electrolysis that provides an effective and economical source of reaction gas. The method and apparatus include a reaction gas microwave preheating zone for preheating a reaction gas to a first temperature before it is input into a main reactor body; in the main reactor main body, the temperature is raised to a higher second temperature, so that the ore is melted and treated into the required product in an energy-saving and emission-reducing manner, such as green steel.

Description

Technical Field

[0001] This application relates to combining unipolar electrolysis with hydrogen fuel cells to provide a power generation system. Specifically, this application discloses an improved energy system that replaces the need for carbon fuels in power generation and in land, water, and air transportation fuels.

[0002] This application claims priority to AU2023902039, filed on 28 June 2023, the entire contents of which are hereby incorporated by reference.

[0003] background

[0004] Currently, global annual steel consumption exceeds 1 billion tons, 95% of which is produced using carbon-based processes. As the world moves towards environmentally friendly production methods and processes across many different production sectors, energy-intensive production methods for materials like steel also need to evolve towards steel manufacturing with little or no carbon emissions. More environmentally friendly and accessible steelmaking processes must have high capacity to meet this demand and the anticipated growth in global steel consumption.

[0005] There have been some attempts to improve steel production plants, such as using direct hydrogen reduction, as seen in BHP's Hot Iron Block (HBI) plant.

[0006] Hot-pressed iron blocks are a form of direct reduced iron (DRI). DRI is a product of the direct reduction of solid iron ore using carbon monoxide and hydrogen derived from natural gas or coal. Compared to DRI, hot-pressed iron blocks offer several advantages in production processes and in producing a safer and easier-to-transport and handle product. DRI is prone to re-oxidation, an exothermic reaction that requires inert conditions, typically a nitrogen atmosphere, for storage and transportation. In contrast, hot-pressed iron blocks (HBI) are less porous than DRI, resulting in significantly lower reactivity; they only require surface aeration during transport.

[0007] BHP's hot-pressing iron briquetting plant uses hydrogen of approximately 95% purity, derived from natural gas, as a reducing agent. The reduction process takes place in a multi-layer fluidized bed roaster. The iron product is then briquetting into briquettes approximately 40 mm in diameter. To increase the reaction rate and shorten processing time, the reduction temperature was increased, ultimately leading to the failure of components, such as valves controlling the hydrogen flow. The elevated temperatures caused critical valves to fail due to hydrogen embrittlement. Following several incidents resulting in injuries, BHP shut down the plant.

[0008] In conventional water electrolysis processes for producing green hydrogen, the energy required is 49 to 53.4 kWh / kg per kilogram of hydrogen. In unipolar electrolysis-based processes, such as those described in U.S. Patent 10,314,316, the energy required to produce green hydrogen is as low as 5.37 kWh / kg. Invention Overview

[0010] In one embodiment of the invention, a reactor for reducing iron ore is provided, the reactor comprising:

[0011] Iron ore supply equipment;

[0012] A hydrogen supply unit that provides a flow of hydrogen;

[0013] Iron ore feeder supplies iron ore raw materials to a reducing gas stream to form a hydrogen / iron ore mixed stream;

[0014] The hydrogen / iron ore mixed flow heating zone heats the reducing gas / iron ore mixed flow (premix) to approximately 800°C-1000°C;

[0015] The main reactor chamber (transfer reactor) has at least a first main chamber microwave radiation source and an inlet for receiving a reducing gas / iron ore stream and heating the reducing gas / iron ore stream to approximately 1100°C-1200°C to melt the iron ore, thereby producing a reduced iron ore product (steel powder); and

[0016] The output port directs the reduced iron ore product to the separator to separate the reduced iron ore product from any unconsumed reducing gas and unreacted (unreduced) iron ore.

[0017] A condenser that condenses any unconsumed hydrogen gas, the condenser having an outlet in fluid communication with the inlet of a reducing gas supply device.

[0018] Preferably, the reducing gas / iron ore flow heating zone is heated by a microwave energy source.

[0019] Preferably, the reducing gas is at least one of hydrogen or oxygen.

[0020] Preferably, the reducing gas is a mixture of hydrogen and oxygen.

[0021] Preferably, the microwave radiation source of the at least first main chamber irradiates at least a portion of the interior of the main reactor with microwaves.

[0022] Preferably, a second main chamber microwave radiation source is provided, which irradiates at least a portion of the interior of the main reactor with microwaves at a lower position on the reactor.

[0023] Preferably, the reactor is a vertical reactor.

[0024] Preferably, the at least first main chamber microwave radiation source and the second main chamber microwave radiation source can be combined and operated together.

[0025] Preferably, hydrogen is consumed by the iron ore in the reduction reaction to generate reduced iron ore product.

[0026] In another embodiment of the invention, the microwave pulse frequency emitted by the microwave radiation source is between 200 kHz and 300 kHz.

[0027] In other implementations, the pulse frequency of the microwave radiation source is approximately 250 kHz.

[0028] In another form of the invention, the reduced iron ore product is discharged from the main reactor chamber and directed to an induction melting furnace.

[0029] Preferably, prior to induction melting, at least a portion of the preheating chamber of the induction melting furnace is irradiated by at least one microwave radiation source.

[0030] In another form of the invention, the purity of the hydrogen is approximately 99.5%.

[0031] In another form of the invention, a process or method for reducing iron ore is provided, the method using the reactor described above and comprising the following steps:

[0032] Iron ore concentrate is mixed with hydrogen to provide a premix;

[0033] The premix is ​​preheated to a first temperature (T1) using conventional heating and microwave energy.

[0034] The preheated premix is ​​directed to the main chamber of the reactor;

[0035] Microwave irradiation is applied to the main chamber of the reactor to heat the preheated premix to a second temperature (T2), where T2 > T1, until the preheated premix melts, the molten metal is collected and discharged from the reactor.

[0036] Preferably, the iron ore is hematite.

[0037] Preferably, the first temperature is about 1000°C.

[0038] Preferably, the second temperature is about 1100°C-1200°C.

[0039] Preferably, the microwave irradiation is generated by a microwave energy source with a frequency range of approximately 200 kHz to 400 kHz.

[0040] In another form of the invention, an apparatus for producing hydrogen and oxygen is provided, the apparatus comprising: a single-stage water electrolysis unit that produces hydrogen and oxygen; the produced hydrogen being stored in a hydrogen storage tank and the produced oxygen being stored in an oxygen storage tank, the hydrogen storage tank being in fluid communication with a fluidized bed reactor or a transport reactor for reducing hematite to steel, and the oxygen storage tank being in fluid communication with a transport reactor when used for oxidizing magnetite to hematite.

[0041] Preferably, the unipolar water electrolysis unit has an anode side with an anode pool and a cathode side with a cathode pool.

[0042] Preferably, the device includes a water storage unit in fluid communication with the anode pool.

[0043] Preferably, the device includes a water storage unit in fluid communication with the cathode pool.

[0044] Preferably, the anode pool comprises:

[0045] An alkaline electrolyte that produces oxygen, and the cathode cell includes an acidic electrolyte that produces hydrogen, and the anode cell and the cathode cell are separated by a separating member;

[0046] A DC power supply connected to the anode and cathode cells; and

[0047] At least one second electrolytic cell, the second electrolytic cell having at least one cathode chamber housing a cathode electrode and receiving a positively charged alkaline electrolyte from a first anode cell, and generating hydrogen when the anode electrode is short-circuited to the cathode electrode.

[0048] It has at least one anode chamber that houses an anode electrode and receives a negatively charged acidic electrolyte from a first cathode cell, and generates oxygen when the anode electrode is short-circuited to the cathode electrode. The anode chamber and the cathode chamber are separated by an insulating member.

[0049] Each of the first and second electrolytic cells shall have at least one isolation component that separates the anode chamber and the cathode chamber.

[0050] Preferably, the apparatus includes a diaphragmless anode cell for generating oxygen, wherein the anode cell has an anode and an anolyte electrode, the anode being connected to a DC power supply; a diaphragmless cathode cell for generating hydrogen, wherein the cathode cell has a cathode and a catholyte electrode, the cathode being connected to a DC power supply, the anolyte electrode being connected to the catholyte electrode via an external conductor; means for supplying a first electrolyte to the anode cell; means for supplying a second electrolyte to the anode cell; and means for applying a DC current from the DC power supply to the anode and cathode, wherein the first electrolyte and the second electrolyte are the same electrolyte, and the means for supplying the first electrolyte to the anode cell supplies the second electrolyte, and the means for supplying the second electrolyte to the anode cell supplies the first electrolyte; the apparatus further includes means for separating hydrogen from the second electrolyte between the cathode cell and the anode cell, and means for separating oxygen from the first electrolyte between the anode cell and the cathode cell.

[0051] Other forms of the invention will become apparent from the description and drawings. Brief description of the attached diagram

[0053] Embodiments of the present invention will now be better understood and apparent to those skilled in the art by referring to the following description taken in conjunction with the accompanying drawings, which are given by way of example only:

[0054] Figure 1 A schematic diagram of the process / method for preparing hematite into iron powder or iron concentrate;

[0055] Figure 2 This is an illustration of one embodiment of the present invention as a transport reactor;

[0056] Figure 3 A diagram illustrating one embodiment of the fluidized bed hydrogen reduction of iron using the present invention;

[0057] Figure 4 A schematic diagram of the process / method for preparing magnetite concentrate from magnetite;

[0058] Figure 5 Illustration of the invention, showing the oxidation of magnetite using oxygen in a conveying reactor.

[0059] describe

[0060] refer to Figure 1Hematite 10 is obtained and subjected to a series of independent grinding or crushing stages: coarse crushing stage 15, medium crushing stage 20, and fine crushing stage 25. Once the desired particle size is reached, unwanted material is separated using magnetic separation 30 via path 35. The remaining material then undergoes eddy current grinding 40, solids separation stage 45, and finally dry or wet magnetic separation stage 50, with waste removed via path 55. If necessary, alloying materials 70, such as carbon and slag, can be added and mixed to produce fine iron concentrate to be directed to fine iron concentrate storage tank 100 75.

[0061] Figure 2 This invention illustrates an embodiment of the production of green steel from hematite using hydrogen in a conveying reactor 90. Fine iron concentrate 80 in a supply tank 100 is then transferred via a solid feeder 110 into a conduit 120, where reducing gas—hydrogen—from a hydrogen source 125 is introduced via a compressor 130. The hydrogen is mixed with the fine iron concentrate to form a premix as a hydrogen / iron ore stream 135, which is forced under pressure along the conduit 120 into a heating zone 140, which includes a hydrogen / iron ore stream heating zone. The reducing gas / iron ore stream (premix) is heated to approximately 800°C–1000°C by preheating microwave radiation sources 145 and 150. When using hydrogen to reduce iron ore to produce steel, it must be remembered that the use of hydrogen can cause the steel to become embrittled. Adding approximately 0.1% carbon to the steel is necessary so that the carbon strengthens the steel during the subsequent removal of hydrogen from it.

[0062] After the mixture passes through the first heating zone 140 and reaches a temperature of approximately 800°C to 1000°C (T1), it is conveyed to the main chamber 160 of the reactor. The main chamber 160 includes a first heating source 165 and a second heating source 170, both of which are microwave radiation sources operating at approximately 200 kHz to 400 kHz, preferably approximately 250 kHz, forming the second heating zone 175. In the second heating zone 175, the material in the main chamber 160 is heated to approximately 1100°C-1200°C (T2), but below the melting point of the iron being produced or the melting point of the slag mixed with the iron ore raw material. The required precise temperature can be determined by testing the furnace charge and the molten material in the main chamber 160, and adjusted as needed.

[0063] The microwave energy from the first heat source 165 and the second heat source 170 is used to irradiate at least a portion of the interior of the main reactor, reducing the iron ore to reduced iron products (steel powder), which are then discharged from the main reactor via a cyclone separator 180 and stored in a storage tank / hopper 185. Excess gas, i.e., unconsumed hydrogen and other materials, is discharged from the main chamber of the reactor, discharged via conduit 190, and passed through a magnetic separator 195. Any solid materials are then separated and introduced into the storage tank / hopper 185 via line 200. The remaining hydrogen from the magnetic separator 195 is then directed to a condenser 210 to remove any moisture, and then returned to the hydrogen storage tank 125 via line 220.

[0064] Unused hydrogen is recycled back into the process feed. Reduced iron ore, along with slag and a small amount of carbon, is fed to the smelting furnace. The molten pig iron can be further processed by oxygen blowing to remove residual hydrogen, but retains carbon to strengthen the steel produced.

[0065] The reduced iron ore product is then directed from the storage tank / hopper 185 via pipeline 240 to the induction melting furnace 250, first passing through the preheating chamber 260 and then into the inner chamber 265. The preheating chamber 260 has microwave heating units 280 and 185, which, similar to those described above, irradiate the material as it passes near the inner chamber 265, which is heated by a microwave heat source 290. Under induction melting conditions, the molten metal is then discharged via 300, where it can be cast into billets or slabs of suitable special green steel, while the slag material is discharged via 310.

[0066] Where microwave energy is applied or introduced via waveguides, the reactor material must be microwave-compatible, such as ceramics, carbon, silicon dioxide, and alumina. Where temperatures are not high enough, some engineering plastics can be used, and ceramic components can be connected with stainless steel fittings.

[0067] The minimum design should achieve a production capacity of 60 tons of green steel per hour, resulting in an annual green steel output of approximately 500,000 tons per unit. In one example, two units of this invention will produce 1 million tons of green steel per year. Steel billets are used to manufacture reinforcing bars and small structural profiles such as angle steel. Slabs are used to produce sheet metal for various applications, particularly for automobiles.

[0068] Reference Figure 3This is an embodiment of the present invention that uses microwave energy to reduce hematite with hydrogen in a fluidized bed. Prior art fluidized bed reactor examples failed due to the poor quality of the hydrogen used in the process, approximately 95%, and the method of heating the iron ore to the required reaction temperature may further reduce the hydrogen concentration. Furthermore, the need to increase the reactor temperature in an attempt to address the slow reaction rate likely led to hydrogen embrittlement and failure of the valves supplying hydrogen to the process.

[0069] This invention 300 employs a microwave-energized fluidized bed and shows a reactor 310 having a stainless steel housing 315. Fine iron ore alloy material is fed into the interior 340 of the reactor 310 via a star feeder 330 through a conduit 320. The fine hematite can be preheated by an electric heater before being fed into the fluidized bed. In this invention 300, there are three fluidized beds 350a, 350b, and 350c, each in fluid communication with its adjacent fluidized bed, and each fluidized bed has operatively connected microwave generating units 355a, 355b, and 355c. These units deliver microwave energy via housings 360a, 360b, and 360c, which are made of suitable materials such as ceramics, alumina, silica, or engineered carbon, and contain induction coils 370 and water-cooled copper tubing, and are sealed to the sides of the stainless steel housing 320 by seals 385. Each area is appropriately insulated 380 and 390.

[0070] Each microwave generating unit 355a, 355b, and 355c generates microwaves with frequencies between approximately 200 kHz and 400 kHz, and makes appropriate adjustments based on the specific characteristics of hematite and the progress of its reduction as the hematite travels through the reactor.

[0071] The fluidized bed reactor of the present invention comprises several beds, with hydrogen supplied from the bottom and hot fine hematite supplied from the top and discharged to the bottom of the fluidized bed reactor through downcomers.

[0072] According to US10,314,316, hydrogen generated by unipolar water electrolysis, possessing high purity and free of CO2, is stored in hydrogen storage tank 400. It is then compressed 410 and heated to a desired temperature of approximately 1000°C via heater 420, and directed through line 430 to the bottom 440 of reactor 310. When the heated H2 contacts heated iron ore in chamber 350c, the iron ore (Fe2O3) is reduced to iron, with H2O as a byproduct. Unconsumed H2 is then directed upwards to chamber 350b to reduce the iron ore there; similarly, any unconsumed H2 is directed upwards to chamber 350a, where it is consumed in the reduction of iron ore, which is added via line 320.

[0073] Each of the continuous fluidized beds 350a, 350b, and 350c has operably connected microwave generating units 355a, 355b, and 355c, enabling the reduction of iron ore with higher efficiency and H2 utilization. In the final bed of this embodiment, fluidized bed 350c, molten material is discharged and directed to a star feeder 450 and then to an induction furnace 460. After oxygen conversion, unwanted slag material is discharged via line 470, while molten steel is cast into billets via line 480. Fine iron powder, after being melted in the induction furnace, undergoes oxygen blowing in a converter to remove any excess hydrogen, but retains only the carbon and any alloying elements required for carbon steel production.

[0074] At the end 340 of reactor 310, unconsumed / unreacted H2 is discharged and directed to solids separation unit 500. Fine iron ore discharged from the top of the reactor is recovered as fine solids by a cyclone separator, and then passes through a magnetic separator operating at 14,000 gauss to recover more fine hematite. Any recovered solids are separated and redirected via pipeline 510 for recycling. Unconsumed / unreacted H2 then passes through condensation unit 520, where any condensate is removed via pipeline 530, while H2 is transported via pipeline 540 to hydrogen storage tank 400.

[0075] The steel yield of the fluidized bed in this invention will be limited by the design of the microwave system. The ideal capacity of each microwave fluidized bed reactor module is approximately 500,000 tons of green steel per year.

[0076] Figure 4 The process of processing magnetite is outlined, in which magnetite 600 is obtained and subjected to a series of independent grinding or crushing stages: coarse crushing stage 610, medium crushing stage 620, and fine crushing stage 630. Once the desired particle size is reached, unwanted material is separated using magnetic separation 640 via path 645. The remaining material is then subjected to eddy current grinding 650, a solids separation stage 660, and finally a wet magnetic separation stage 670, with waste removed via path 675. The material is then dried 680, and the magnetite concentrate is directed to magnetite concentrate storage tank 690 685, as... Figure 5 As shown.

[0077] Figure 5A schematic diagram illustrates the oxidation of magnetite using oxygen and microwave energy in a conveying reactor. Magnetite 700 in magnetite concentrate tank 690 is then transferred by solids feeder 710 to pipe 720, where oxygen from oxygen tank 725 is introduced via compressor 730. The oxygen is mixed with the magnetite concentrate to form a premix as oxygen / magnetite stream 735, which is forced under pressure along pipe 720 into heating zone 740, which includes an oxygen / magnetite stream heating zone. The oxygen / magnetite stream (premix) is heated to approximately 800°C–1000°C by preheating microwave radiation sources 745 and 750. The optimal microwave frequency (200–400 kHz) can be determined through testing, but the microwave pulse frequency will be up to 50 kHz. This process aims to heat magnetite to up to 1200°C using microwaves. High oxygen concentrations facilitate the oxidation process.

[0078] After the mixture passes through the first heating zone 740 and reaches a temperature of approximately 800°C-1000°C, it is conveyed to the main chamber 760 of the reactor. The main chamber 760 includes a first heating source 765 and a second heating source 770, both of which are microwave radiation sources operating between 200-400 kHz, preferably at approximately 250 kHz, forming the second heating zone 775. In the second heating zone 775, the material in the main chamber 760 is heated to approximately 1100°C-1200°C. The required precise temperature can be determined by testing the charge in the main chamber 760 of the reactor and adjusted as needed.

[0079] The microwave energy from the first heating source 765 and the second heating source 770 is used to irradiate at least a portion of the interior of the main reactor, oxidizing the magnetite into hematite, which is then removed from the main reactor via a cyclone separator 780 and stored in a storage tank / hopper 785. Excess gas, i.e., unconsumed oxygen and other materials, is discharged from the main chamber of the reactor, discharged via conduit 790, and passed through a magnetic separator 795. Any solid material is then separated and introduced into the storage tank / hopper 785 via line 800. The remaining oxygen from the magnetic separator 795 is then directed to a condenser 810 to remove any water and returned to the oxygen storage tank 725 via line 820. The magnetite obtained after ore processing is typically fine, but it is more difficult to reduce to steel. As done in conventional steelmaking processes, the fine magnetite agglomerates and is oxidized to a form similar to hematite before being reduced to steel in the blast furnace.

[0080] In this application, magnetite is first oxidized to hematite using oxygen generated during water monopolar electrolysis. Figure 2 and Figure 3 The equipment shown is a conveying reactor or fluidized bed, and uses microwave energy to heat the magnetite to the reaction temperature.

[0081] The hematite produced and stored in tank / hopper 785 can be discharged via pipeline 825, or as... Figure 2 As shown, according to one embodiment of the invention, steel is produced by hydrogen reduction in a transport reactor, or by means of... Figure 3 The fluidized bed hydrogen reduction process shown is used for treatment.

[0082] The hydrogen used in the above-described process of reducing hematite via a conveying reactor or fluidized bed reactor, or the oxygen used in the oxidation of magnetite, can be conveniently obtained by unipolar electrolysis, as described in U.S. Patent 10,314,316. ​​This method produces no carbon emissions and produces hydrogen in a more economical way than currently available methods.

[0083] A. A method in which fine hematite is reduced by green hydrogen and heated by microwave energy in a conveyor reactor or a fluidized bed reactor, and iron powder with alloying elements, flux and a small amount of carbon is smelted in an induction furnace, processed in an oxygen converter, and then cast into billets and slabs.

[0084] B. The method of claim 1, wherein the hydrogen is produced from renewable energy sources according to the author's U.S. Patent 10,314,316, and therefore has no carbon emissions and lower production costs.

[0085] C. The method of claim 1, wherein the microwave frequency is about 200-400 kHz, but some adjustments may be needed as the hematite is reduced to iron.

[0086] D. The method of claim 1, wherein oxygen is blown into the molten steel in the converter to remove any excess hydrogen.

[0087] E. The process described in A, wherein a small amount of carbon added to hematite prior to reduction with hydrogen provides carbon for the manufacture of high-strength steel.

[0088] F. An apparatus in which fine hematite is reduced by green hydrogen, heated by microwave energy in a conveying reactor or a fluidized bed reactor, then iron powder containing alloying elements, flux and a small amount of carbon is smelted in an induction furnace, processed in an oxygen converter, and then cast into billets and slabs.

[0089] G. The device as described in F, wherein the hydrogen is produced from renewable energy according to my U.S. Patent 10,314,316, and therefore there are no carbon emissions and the cost of hydrogen production is lower.

[0090] H. The device as described in F, wherein the microwave frequency is about 200-400 kHz, but some adjustments may be needed as the hematite is reduced to iron.

[0091] I. The apparatus as described in F, wherein oxygen is blown onto molten steel in a converter to remove any excess hydrogen.

[0092] J. The apparatus as described in F, wherein a small amount of carbon added to hematite prior to hydrogen reduction provides carbon for the manufacture of high-strength steel.

[0093] It is estimated that 10 kWh / kg of pure green hydrogen can be commercially produced. This invention provides a technology for producing low-cost, pure green hydrogen for reducing iron ore to produce specialty green steel.

[0094] It should now be apparent that the present invention provides a furnace ironmaking method and a microwave ironmaking furnace capable of producing molten metal with high energy efficiency.

Claims

1. A processing reactor for ore processing in use, the reactor comprising: Ore supply equipment, The reaction gas supply device provides a flow of reaction gases. An ore feeder that supplies ore raw materials to the reactive gas stream to form a reactive gas / ore stream; The reactant gas / ore stream heating zone heats the reactant gas / ore stream (premix) to approximately 800°C-1000°C. The main reaction chamber has at least a first main chamber microwave radiation source and an inlet for receiving the reaction gas / ore stream and heating the reaction gas / ore stream to about 1100°C-1200°C to melt the ore, thereby producing the reacted ore product; as well as The output port directs the reacted ore product to a separator to separate the reacted ore product from any unconsumed reaction gases and unreacted ore. A condenser that condenses any unconsumed reactive gases, the condenser having an outlet in fluid communication with an inlet on the reactive gas supply device.

2. The processing reactor of claim 1, wherein the reaction gas / ore flow heating zone is heated by a microwave energy source.

3. The processing reactor of claim 2, wherein the microwave radiation source of the at least first main chamber irradiates at least a portion of the interior of the main reactor with microwaves.

4. The processing reactor of claim 2, wherein a second main chamber microwave radiation source is provided, which irradiates at least a portion of the interior of the reactor with microwaves at a lower position on the reactor.

5. The processing reactor of claim 2, wherein the at least first main chamber microwave radiation source and the second main chamber microwave radiation source can be operated in combination with each other.

6. The processing reactor of claim 5, wherein the microwave radiation source emits microwaves at a frequency between 200 kHz and 400 kHz.

7. The processing reactor of claim 6, wherein the microwave radiation source emits microwaves at about 250 kHz.

8. The processing reactor according to any one of claims 1-7, wherein the ore is hematite.

9. The processing reactor of claim 8, wherein the reaction gas is hydrogen.

10. The processing reactor of claim 9, wherein the reacted ore product is a reduced ore product, and it is discharged from the main reactor chamber and directed to an induction melting furnace.

11. The processing reactor according to any one of claims 1-7, wherein the ore is magnetite.

12. The processing reactor of claim 11, wherein the reaction gas is oxygen.

13. The processing reactor of claim 9 or 12, wherein the hydrogen and / or oxygen is provided by unipolar electrolysis.

14. A process or method for reducing iron ore, the method using the above-described reactor, comprising the following steps: Iron ore concentrate is mixed with reactive gases to provide a premix; The premix is ​​preheated to a first temperature (T1). The preheated premix is ​​directed to the main chamber of the reactor; Microwave irradiation is applied to the main chamber of the reactor to heat the preheated premix to a second temperature (T2), where T2 > T1, until the preheated premix melts, the molten metal is collected and discharged from the reactor.

15. The method of claim 14, wherein the reactant gas is hydrogen or oxygen.

16. The method of claim 15, wherein the first temperature is about 1000°C.

17. The method of claim 16, wherein the second temperature is about 1100°C-1200°C.

18. The method of claim 17, wherein the microwave irradiation is generated by a microwave energy source at a frequency of about 200 kHz to 400 kHz.

19. The method of claim 18, wherein the reactive gas is provided by unipolar electrolysis.

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