Improvements to the production of steel from iron ore

Abstract

A microwave process and apparatus for processing ore, including a supply of reaction gases from Unipolar electrolysis, which provides an efficient and economical source of reaction gases The process and apparatus includes a reaction gas microwave pre-heat zone to pre-heat the reaction gases to a first temperature prior to input into a main reactor body where the temperature is raised to a higher second temperature to melt the ore and process it into desirable products, such as green steel in an energy efficient manner with reduced emissions.

Description

[0001] IMPROVEMENTS TO THE PRODUCTION OF STEEL FROM IRON ORE

[0002] TECHNICAL FIELD

[0003] This application concerns the combination of unipolar electrolysis and hydrogen fuel cells to provide a system for the production of electricity. In particular, the present application discloses an improved energy system that replaces the need for carbon fuels in electric power generation and as fuel for land, water, and air vessels.

[0004] This application claims priority from AU 2023902039 filed on 28 June 2023, the entire content is hereby incorporated by reference.

[0005] BACKGROUND

[0006] The world steel consumption is currently more than 1 ,000 million tonnes a year, 95% is made from processes using carbon. As the World progresses towards more environmentally friendly methods and process of production, across many different production areas, the energy intensive production methodologies of materials such as steel also needs to improve, towards the making of steel with little or no carbon emissions. The more environmentally friendly, and acceptable, steel process must have a high capacity to meet this demand and the projected increase in world steel consumption.

[0007] There have been some attempts in improving steel production plants for example that utilize hydrogen direct reduction, such as BHP’s Hot Briquette Iron (HBI) plant,

[0008] Hot Briquette Iron (HBI) is a form of Direct Reduced Iron (DRI). DRI is the product of the direct reduction of iron ore in the solid state by carbon monoxide and hydrogen derived from natural gas or coal. HBI has some benefits over DRI in the production process as well as producing a product that is safer and easier to ship and handle. DRI has a tendency to re-oxidise, which is an exothermic reaction, requiring storage and transport under inert conditions, usually nitrogen atmosphere. HBI is less porous than DRI and so much less reactive, only requiring surface ventilation during shipment.

[0009] BHP’s Hot Briquette Iron (HBI) plant used hydrogen manufactured from natural gas to about 95% purity and used as the reductant. The reduction process at the plant is carried out in a multiple bed fluidized roaster. The iron product is agglomerated by briquetting machines that produced a briquette of about 40 mm diameter. To improve reaction rates, to reduce processing times, the temperature of the reduction was increased, which ultimately resulted in failure of the components such as the valves controlling the hydrogen flow. The increased temperature caused critical valves to fail due to hydrogen embrittlement. After several incidents, which caused injuries to personnel, BHP scrapped the plant.

[0010] In conventional water electrolysis to produce green hydrogen, the energy required is 49 to 53.4 kilowatt-hours per kilogram (kwh / kg) of hydrogen. In Unipolar electrolysis based, for example as described in US Patent 10,314,316, the energy required to produce green hydrogen is as low as 5.37 kwh / kg.

[0011] SUMMARY OF INVENTION

[0012] In one form of the invention there is a reactor when used for the reduction of iron ore, the reactor including: an iron ore supply, a hydrogen gas supply to provide a hydrogen gas stream, an iron ore feeder to supply a feed of iron ore into the reduction gas stream to create a hydrogen gas / iron ore stream; a hydrogen gas / iron ore stream heating zone to heat the reduction gas / iron ore stream (premixture) to approximately 800°C-1000°C, a main reactor chamber (transport reactor) having at least a first main chamber microwave irradiation source, and an input port for receiving the reduction gas / iron ore stream, and heating the reduction gas / iron ore stream to approximately 1100°C-1200°C to melt the iron ore, to produce a reduced iron ore product (steel powder) and an outlet port, to direct the reduced iron ore product to a separator to separate the reduced iron ore product from any unconsumed reduction gas and unreacted (not reduced) iron ore, a condenser, to condense any unconsumed hydrogen gas, the condenser having an outlet port fluidly coupled to an inlet port on the reduction gas supply.

[0013] In preference, the reduction gas / iron ore stream heating zone is heated by a microwave energy source.

[0014] In preference, the reduction gas is at least one of hydrogen gas or oxygen gas.

[0015] In preference the reduction gas is a mixture of hydrogen gas and oxygen gas.

[0016] In preference, the least a first main chamber microwave irradiation source irradiates at least a portion of an interior of the main reactor with microwaves.

[0017] In preference, there is a second main chamber microwave irradiation source irradiates at least a portion of an interior of the main reactor with microwaves lower on the reactor.

[0018] In preference the reactor is a vertical reactor.

[0019] In preference, the least a first main chamber microwave irradiation source and the second main chamber microwave irradiation source are operable in combination with one another.

[0020] In preference, the hydrogen gas is consumed by the iron ore in a reduction reaction that results in the reduced iron ore product.

[0021] In a further form the invention, the microwave radiation source emits microwave has a pulse rate of between 200KHZ and 300 KHz. In other embodiments, the microwave radiation source has a pulse rate of approximately 250 KHz.

[0022] In a further form of the invention, the reduced iron ore product is removed from the main reactor chamber and directed to an induction melting furnace.

[0023] In preference, at least one microwave irradiation source irradiates at least a portion of an interior of pre-heat chamber of the induction melting furnace, prior to induction melting.

[0024] In a further form of the invention, the hydrogen gas is approximately 99.5% pure.

[0025] In a further form of the invention there is a process or method for the reduction of iron ore, the method using the above reactor including the steps of: mixing an iron ore concentrate with a hydrogen gas to provide a premixture; preheating the premixture to a first temperature (T1) using conventional heating and microwave energy, directing the preheated premixture to a main chamber of a reactor; applying microwave radiation to the main chamber of the reactor to heat the preheated premixture to a second temperature (T2), where T2 > T1 , until the preheated premixture is molten, accumulating the molten metal and discharging from the reactor.

[0026] In preference, the iron ore is hematite ore.

[0027] In preference, the first temperature is approximately 1000°C.

[0028] In preference, the second temperature is approximately between 1100°C - 1200°C.

[0029] In preference, the microwave radiation is generated by a microwave energy source at a frequency of approximately 200 KHz and 400 KHz. In a further form of the invention, there is an apparatus for producing hydrogen and oxygen, the apparatus comprising a unipolar water electrolysis unit to produce hydrogen gas and oxygen gas, the produced hydrogen gas being stored in a hydrogen gas storage tank, the produced oxygen gas being stored in an oxygen storage tank, the hydrogen gas storage tank being fluidly connected to a fluidised bed reactor or a transport reactor for the reduction of hematite ore to steel, and oxygen gas storage tank being fluidly connected to a transport reactor when used for the oxidation of magnetite ore to hematite ore.

[0030] In preference, the unipolar water electrolysis unit having an anode side with an anode cell and a cathode side with a cathode cell.

[0031] In preference, the apparatus includes a water storage unit fluidly connected to the anode cell.

[0032] In preference, the apparatus includes a water storage unit fluidly connected to the cathode cell.

[0033] In preference, the anode cell includes: an alkaline electrolyte producing oxygen and the cathode cell includes an acidic electrolyte producing hydrogen with a partition member separating the anode cell from the cathode cell; a DC power supply connected to the anode and cathode cells; and at least a second electrolytic cell having at least one cathode compartment housing a cathode electrode receiving the positively charged alkaline electrolyte from the first anode cell and producing hydrogen, and having at least one anode compartment housing an anode electrode and receiving the negatively charged acidic electrolyte from the first cathode cell and producing oxygen with a partition member separating the anode cell from the cathode cell, when the anode electrodes and the cathode electrodes are connected in short circuit; wherein at least there is one partition member separating the anode and cathode compartments in each of the first and second electrolytic cells In preference, the apparatus includes a diaphragm-less anode cell to produce oxygen wherein the anode cell has an anode and an anode solution electrode, the anode being connected to a DC power source, a diaphragm-less cathode cell to produce hydrogen wherein the cathode cell has a cathode and a cathode solution electrode, the cathode being connected to the DC power source, the anode solution electrode connected to the cathode solution electrode by an external conductor, means to supply a first electrolyte to the anode cell, means to supply a second electrolyte to the anode cell and means to apply a DC current from the DC power source to the anode and the cathode, wherein the first electrolyte and the second electrolyte are the same electrolyte and the means to supply the first electrolyte to the anode cell supplies the second electrolyte and the means to supply the second electrolyte to the anode cell supplies the first electrolyte and further including means to separate hydrogen from the second electrolyte between the cathode cell and the anode cell and means to separate oxygen from the first electrolyte between the anode cell and the cathode cell.

[0034] Further forms of the invention will be apparent from the description and drawings.

[0035] BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Embodiments of the present invention will now be better understood and apparent to a person of ordinary skill in the art refereeing to the written description, by way of example only, in conjunction with the drawing, in which:

[0037] Figure 1 is a schematic view of the process / method of preparing the haematite ore into fine iron or concentrate;

[0038] Figure 2 is a diagrammatic view of an embodiment of the present invention as a transport reactor; Figure 3 is a diagrammatic view of an embodiment of fluidized bed hydrogen reduction of iron or using the present invention;

[0039] Figure 4 is a schematic view of the process / method or preparing the magnetite ore into magnetite concentrate;

[0040] Figure 5 is a diagrammatic view of the present invention showing the oxidation of magnetite ore using oxygen in a transport reactor.

[0041] DESCRIPTION

[0042] Referring to Figure 1 , hematite ore 10 is obtained and subjected to a series of separate milling or crushing stages, a coarse crushing stage 15, medium crushing stage 20 and fine crushing stage 25. Once at a required particle size, magnetic separation 30 is used to separate out undesirable material via path 35. Remaining material is then subjected to vortex grinding 40 a solid separation stage 45 and finally a dry or wet magnetic separation stage 50, with waste material being removed via path 55. As required, alloying material 60, such as carbon and slag material, can be introduced and mixed 70 prior to produce a fine iron ore concentrate to be directed 75 to a fine iron ore concentrate holding tank 100.

[0043] Figure 2 shows an embodiment of the present invention for the production of green steel from hematite ore using hydrogen in a transport reactor 90. Fine iron ore concentrate 80 in the supply tank 100 is then moved by a solid’s feeder 110 into a conduit 120 within which hydrogen, a reducing gas, from a hydrogen source 125 is introduced via a compressor 130. The hydrogen gas and a fine iron ore concentrate are mixed together to form a premix being a hydrogen gas / iron ore stream 135, which is forced along the conduit 120 under pressure into a heating zone 140, that includes a hydrogen gas / iron ore stream heating zone to heat the reduction gas / iron ore stream (premixture) to approximately 800°C-1000°C by way of the pre-heating microwave radiation source 145 and 150. In reducing iron ore with hydrogen to make steel, it is important to remember that hydrogen is used to embrittle steel. The addition of carbon of about the order of 0.1 % in the steel is necessary so that in the later process of removing hydrogen from the steel, carbon will strengthen the steel.

[0044] After the mixture has been subjected to the first heating zone 140, where it reaches a temperature of approximately 800°C and 1000°C (T1) it is then transported to the main chamber 160 of the reactor, which includes a first heating source 165 and second heating source 170, which are both microwave irradiation sources operating together at between approximately 200 KHz and 400 KHZ, preferably around 250 KHz, which makes up the second heating zone 175, withing which the material in the main chamber 160 is heated to approximately 1100°C - 1200°C (T2), but below the melting point of the iron produced or the slag mixed with the iron ore feed. The exact temperature desired can be determined via testing of the charge, the molten material within the main chamber 160, and adjusted as required.

[0045] Microwave energy from the first heating source 165 and second heating source 170 acts to irradiates at least a portion of an interior of the main reactor with microwaves, causing the iron ore to be reduced to a reduced iron ore product (steel powder) and it is then removed from the main reactor by the cyclone separator 180 and stored in storage tank / hopper 185. Excess gas, being unconsumed hydrogen gases and other material, is vented from the main chamber of the reactor and directed out via conduit 190 and through a magnetic separation 195, any solid material then being separated out and directed via line 200 into the storage tank / hopper 185. Hydrogen gas remaining from the magnetic separator 195 is then directed to the condenser 210, to remove any water, and via line 220 back to the hydrogen storage tank 125.

[0046] The unused hydrogen is recycled to the feed of the process. The reduced iron ore with the slag and small amount of carbon is fed to the melting furnace. The molten pig iron may be treated further by blowing with oxygen to remove residual hydrogen but leaving the carbon to strengthen the steel produced. From the storage tank / hopper 185, the reduced iron ore product is then directed via line 240 to an induction melting furnace 250, first passing through a preheat chamber 260 before entering the inner chamber 265. The preheat chamber 260 has microwave heating units 280 and 185 respectively, similar to those referred to above, to irradiate the material as it passes close by, with the inner chamber 265 being heated via microwave heating source 290. Under induction melting conditions, molten metal material is then tapped off via 300, where it can be cast as appropriate billets of slaps of special green steel, with slag material being taken off via 310.

[0047] Where the microwave energy is applied, or directed via a wave guide, the material of the reactor must be a microwave compatible material such as ceramics, carbon, silica, and alumina. Some engineered plastic may be used where the temperature is not high enough and ceramic sections may be joined by stainless steel joints.

[0048] The minimum design should be producing 60 tonnes of green steel every hour so that the annual production of green steel for 1 unit is about 500,000 tonnes of green steel. In an example, two units of this embodiment of the present invention will produce 1 million tonnes of green steel a year. Billets are produced to make reinforcing steel and small structural shapes such as angles. Slabs are made to produce sheets of metals for different applications, particularly for automobiles.

[0049] Referring to Figure 3, this is an embodiment of the present invention of reducing hematite ore with hydrogen in a fluidized bed with microwave energy. The earlier prior art examples of fluidized bed reactors failed due to low quality of hydrogen used in the process, approximately 95% and the method of heating the iron ore to the required reaction temperature may have further reduced the concentration of the hydrogen. In addition, the need to raise the reactor temperature, to try and attempt to deal with slower reaction rate, likely caused hydrogen embrittlement and failure of the valves feeding hydrogen to the process. The fluidized bed with microwave energy of the present invention 300, shows the reactor 310, having a stainless-steel casing 315. Fine iron ore alloying materials are fed in via conduit 320, with the star feeder 330, into the interior 340 of the reactor 310. The fine hematite ore may be pre-heated by electric heaters before feeding into the fluidized bed. In the present invention 300, there are three fluidized beds, 350a, 350b and 350c, each fluidly coupled to its neighboring fluidized bed, and each of which have an operationally connected microwave generating unit 355a, 355b, 355c, which deliver microwave energy via the shell 360a, 360b, 360c, which is made from a suitable material, such as ceramic, alumina, silica, or engineered carbon, and contains the induction coils 370 and water-cooled copper tubing, sealed 385 against the side of the stainless-steel casing 320. Each area is appropriately insulated 380 and 390.

[0050] Each microwave generating unit 355a, 355b, 355c, generates microwaves at a frequency of between approximately 200 KHz to 400 Khz, with appropriate adjustments being made in relation to the particular hematite ore and the progress of reduction of the hematite ore as it progresses through the reactor.

[0051] The fluidized reactor of the present invention contains several beds with hydrogen fed at the bottom while the hot fine hematite ore is fed at the top and progresses downwards through down pipes to the bottom discharge of the fluidized bed reactor.

[0052] Hydrogen, created from Unipolar electrolysis of water, in accordance with US 10,314,316, is of a high purity with no CO2, is stored in the hydrogen storage tank 400, which is then compressed 410 and heated to a desired temperature approximately 1000°C via the heater 420 and directed by line 430 to the bottom 440 of the reactor 310. As the heated H2contacts the heated iron ore in chamber 350c, the iron ore (Fe2O3) is reduced to Fe with the byproduct of H2O. Un-consumed H2is than directed upwards to the chamber 350b, reducing iron ore in this chamber and again, any unconsumed H2is than directed upwards to the chamber 350a, where it is consumed in the reduction of the iron or being added in though the conduit 320. Each of the successive fluidized beds, 350a, 350b and 350c, each of which have an operationally connected microwave generating unit 355a, 355b, 355c, then can reduce the iron ore with increased efficiencies and use of H2. In fluidized bed 350c, the final bed in this embodiment, the molten material can be tapped and directed to the star feeder 450 and directed to the induction furnace 460, with unwanted slag material being tapped off via line 470 and molten steel being cast into billets via line 480, after oxygen conversion. The fine iron powder is melted by an induction furnace and blown with oxygen in a converter to remove any excess hydrogen but leaving only the carbon to make carbon steel and any alloying elements.

[0053] At the end 340 of the reactor 310, an unconsumed / unreacted H2is then tapped off and directed towards the solids separator unit 500, with fine iron ore exiting the reactor at the top passing through a cyclone to recover the fine solids and then through a magnetic separator operating at 14,000 gausses to recover more hematite fines, with any recovered solid material being separated off and redirected to be recycled vie line 510. Unconsumed / unreacted H2is then passed through a condenser unit 520, and any condensed water is removed via line 530 and H2is then passed via line 540 to the hydrogen storage tank 400.

[0054] The steel production rate of the fluidized bed of the present invention will be limited by design of the microwave system. A desirable capacity would be around 500,000 tonnes per year of green steel for each microwave fluidized bed reactor module.

[0055] Figure 4 outlines a series of steps for processing of magnetite iron ore, in which magnetite iron ore 600 is obtained and subjected to a series of separate milling or crushing stages, a coarse crushing stage 610, medium crushing stage 620 and fine crushing stage 630. Once at a required particle size, magnetic separation 640 is used to separate out undesirable material via path 645. Remaining material is then subjected to vortex grinding 650 a solid separation stage 660 and finally a wet magnetic separation stage 670, with waste material being removed via path 675. The material is then dried 680 and the magnetite ore concentrate is directed 685 to a magnetite ore concentrate holding tank 690, as shown in Figure 5.

[0056] Figure 5 shows a schematic view of the oxidation of magnetite ore using oxygen and microwave energy in a transport reactor. The magnetite ore 700 in the magnetite ore concentrate holding tank 690 is then moved by a solid’s feeder 710 into a conduit 720 within which oxygen, from an oxygen storage tank 725, is introduced via a compressor 730. The oxygen gas and the magnetite ore concentrate are mixed together to form a premix being a oxygen gas / magnetite ore stream 735, which is forced along the conduit 720 under pressure into a heating zone 740, that includes a oxygen gas / magnetite ore stream heating zone to heat the oxygen gas / magnetite ore stream (premixture) to approximately 800°C-1000°C by way of the pre-heating microwave radiation source 745 and 750. The best microwave frequency (200 to 400 kilohertz) can be determined by testing, but the microwave will be pulsing at the rate of up to 50 kilohertz. The process is to heat the magnetite ore with microwave up to 1 ,200 C. The high oxygen concentration will assist the oxidation process.

[0057] After the mixture has been subjected to the first heating zone 740, where it reaches a temperature of approximately 800°C and 1000°C it is the transported to the main chamber 760 of the reactor, which includes a first heating source 765 and second heating source 770, which are both microwave irradiation sources operating at between approximately 200 KHz and 400 KHZ, preferably around 250 KHz, which makes up the second heating zone 775, withing which the material in the main chamber 760 is heated to approximately 1100°C - 1200°C. The exact temperature desired can be determined via testing of the charge in the main chamber 760 of the reactor and adjusted as required.

[0058] Microwave energy from the first heating source 765 and second heating source 770 acts to irradiates at least a portion of an interior of the main reactor with microwaves, causing the magnetite ore to be oxidised to a hematite ore product and it is then removed from the main reactor by the cyclone separator 780 and stored in storage tank / hopper 785. Excess gas, being unconsumed oxygen gases and other material, is vented from the main chamber of the reactor and directed out via conduit 790 and through a magnetic separator 795, any solid material then being separated out and directed via line 800 into the storage tank / hopper 785. Oxygen gas remaining from the magnetic separator 795 is then directed to the condenser 810, to remove any water, and via line 820 back to the oxygen storage tank 725. Magnetite iron ore is usually fine after it is processed from the ore; however, it is more difficult to reduce to steel. As done in conventional steel making, the fine magnetite ore is agglomerated and at the same time oxidized to similar to hematite before reduction to steel in a blast furnace.

[0059] In the present application, the magnetite ore is first oxidized to hematite by using the oxygen produced in the Unipolar electrolysis of water. The equipment such as the transport reactor or the fluidized bed as shown in figure 2 and 3 is used and microwave energy is used to heat up the magnetite ore to reaction temperature.

[0060] The produced hematite ore in the storage tank / hopper 785 can then be directed out vie line 825 for reduction processing to steel either using hydrogen in a transport reactor as per an embodiment of the present invention, and shown in figure 2, or in the fluidized bed hydrogen reduction process as shown in figure 3.

[0061] The hydrogen utilised in the above process of reduction or hematite ore via transport reactor or fluidized bed reactor or the oxygen used in the oxidation of magnetite ore is conveniently obtained by Unipolar electrolysis, as described in US Patent 10,314,316, in which no carbon emissions are produced and the production of hydrogen is in a more economical manner than is currently available.

[0062] A. A process where fine hematite iron ore is reduced by green hydrogen heated by microwave energy in a transport type reactor or in a fluidized bed type reactor, and the iron powder with alloying elements, flux and a little carbon are melted in an induction furnace, processed in an oxygen converter and then cast into billets and slabs, B. A process as in claim 1 where the hydrogen is produced from renewable energy according to my US Patent 10,314,316 so there is no carbon emissions and hydrogen is produced at a lower cost,

[0063] C. A process as in claim 1 where the frequency of the microwave is about 200 to 400 kilohertz but some adjustments may be necessary as the reduction of the hematite ore progresses to iron,

[0064] D. A process as in claim 1 where the molten steel is blown with oxygen in a converter to remove any excess hydrogen,

[0065] E. A process as in A where the small amount of carbon added to the hematite ore before reduction by hydrogen, provides the carbon to make strong steel,

[0066] F. An apparatus where fine hematite iron ore is reduced by green hydrogen heated by microwave energy in a transport type reactor or in a fluidized bed type reactor, and the iron powder with alloying elements, flux and a little carbon are melted in an induction furnace, processed in an oxygen converter and then cast into billets and slabs,

[0067] G. An apparatus as in F where the hydrogen is produced from renewable energy according to my US Patent 10,314,316 so there is no carbon emissions and hydrogen is produced at a lower cost,

[0068] H. An apparatus as in claim F where the frequency of the microwave is about 200 to 400 kilohertz but some adjustments may be necessary as the reduction of the hematite ore progresses to iron,

[0069] I. An apparatus as in F where the molten steel is blown with oxygen in a converter to remove any excess hydrogen,

[0070] J. An apparatus as in F where the small amount of carbon added to the hematite ore before reduction by hydrogen, provides the carbon to make strong steel.

[0071] It is estimated pure green hydrogen can be produced commercially at 10 kwh / kg. The present invention provides the technology to produce low cost and pure green hydrogen for the reduction of iron ores to produce special green steel. As should now be evident, the present invention provides a furnace iron-making method and a microwave iron-making furnace that can manufacture molten metal with high energy efficiency.

Claims

Claims1 . A processing reactor when used for the processing of ore, the reactor including: an ore supply, a supply of a reaction gas to provide a reaction gas stream, an ore feeder to supply a feed of ore into the reaction gas stream to create a reaction gas / ore stream; a reaction gas / ore stream heating zone to heat the reaction gas / ore stream (premixture) to approximately 800°C-1000°C, a main reactor chamber having at least a first main chamber microwave irradiation source, and an input port for receiving the reaction gas / ore stream, and heating the reaction gas / ore stream to approximately 1100°C-1200°C to melt the ore ore, to produce a reaction ore product; and an outlet port, to direct the reaction ore product to a separator to separate the reaction ore product from any unconsumed reaction gas and unreacted ore, a condenser, to condense any unconsumed reaction gas, the condenser having an outlet port fluidly coupled to an inlet port on the reaction gas supply.

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

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

4. The processing reactor of claim 2, wherein there is a second main chamber microwave irradiation source irradiates at least a portion of an interior of the main reactor with microwaves lower on the reactor.

5. The processing reactor of claim 2, wherein the least a first main chamber microwave irradiation source and the second main chamber microwave irradiation source are operable in combination with one another.

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

7. The processing reactor of claim 6, wherein the microwave radiation source emits microwaves approximately 250 KHz.

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

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

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

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

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

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

14. A process or method for the reduction of iron ore, the method using the above reactor including the steps of: mixing an iron ore concentrate with a reaction gas to provide a premixture; preheating the premixture to a first temperature (T1), directing the preheated premixture to a main chamber of a reactor;applying microwave radiation to the main chamber of the reactor to heat the preheated premixture to a second temperature (T2), where T2 > T1 , until the preheated premixture is molten, accumulating the molten metal and discharging from the reactor.

15. The process of claim 14, wherein the reaction gas is hydrogen gas or oxygen gas.

16. The process of claim 15, wherein the first temperature is approximately 1000°C.

17. The process of claim 16, wherein the second temperature is approximately between 1100°C - 1200°C.

18. The process of claim 17, the microwave radiation is generated by a microwave energy source at a frequency of approximately 200 KHz and 400 KHz.

19. The process of claim 18, wherein the reaction gas is provided by unipolar electrolysis.

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