Direct reduction plant and method for directly reducing metal oxides

Abstract

The invention relates to a metallic material production arrangement (1) and a method for directly reducing a metal oxide material (5) maintaining a first thermal energy into a reduced metallic material (16). The method comprises the steps of: charging a metal oxide material (5) maintaining a first thermal energy into a direct reduction plant (7) via a metal oxide material charge inlet device (A); introducing the preheated hydrogen-containing reducing agent (H) maintaining the second thermal energy into the direct reduction plant (7) via a reducing agent inlet device (B); directly reducing the metal oxide material (5) by heating or further heating the introduced preheated hydrogen-containing reducing agent (H) with the first thermal energy of the metal oxide material (5) to provide a chemical reaction between the introduced preheated hydrogen-containing reducing agent (H) and the metal oxide material (5); exposing the reduced metal material to a heat treatment temperature required to provide a heat treatment of the reduced metal material to obtain a densified reduced metal material; and maintaining the desired heat treatment temperature by introducing the preheated hydrogen-containing reducing agent (H) with a heat treatment provision device (17).

Description

Technical Field

[0001] The present invention relates to a method for directly reducing a metal oxide material to a reduced metal material.

[0002] The present invention also relates to a direct reduction facility configured to reduce a metal oxide material and produce a reduced metal material, such as sponge iron.

[0003] The present invention also relates to a metallic material production arrangement configured for producing reduced metallic material that resists reoxidation for cost-effective and safe refractory transportation of the reduced metallic material to a metal fabrication industry or other customer.

[0004] The invention also relates to a data program suitable for controlling selected parts of a direct reduction facility and / or a metallic material production arrangement for producing a reduced metallic material resistant to reoxidation.

[0005] The present disclosure may relate to a direct reduction facility configured to produce a carbon-free reduced metallic material that is resistant to reoxidation.

[0006] The invention also relates to a data program suitable for controlling the operation of a metal material production arrangement.

[0007] The present invention relates primarily to the mining industry and the industry for manufacturing reduced metallic materials, and to manufacturers and suppliers of metallic material production arrangements and metal oxide material production units, direct reduction facilities, metal manufacturing industries, high temperature electrolysis units, data program providers, and the like. Background Art

[0008] Current technologies for producing reduced metallic materials may use different solutions to prevent re-oxidation of the produced reduced metallic materials.

[0009] Current technology aims to provide energy efficient production of reduced metallic materials that are resistant to reoxidation.

[0010] Current technologies aim to provide energy-efficient direct reduction of metal oxide materials using hydrogen generated in whole or in part by electrolysis of water using fossil-free and / or renewable energy sources.

[0011] Current technology can use hydrogen to directly reduce metal oxide materials instead of using carbonaceous reducing agents such as natural gas. An example is HYBRIT TM A concept is proposed which proposes hydrogen direct reduction (H-DR) using hydrogen produced by electrolysis of water using fossil-free and renewable energy.

[0012] In IronDrop TMThe concept also embodies energy-saving and cost-effective production of reoxidation-resistant direct-reduced metal materials. TM The concept was developed by LKAB and aims to efficiently produce reduced metallic materials that are resistant to reoxidation using fossil-free and / or renewable energy sources. IronDrop TM The program also aims to develop current technologies for producing sponge iron that is resistant to reoxidation.

[0013] Direct reduction of metal oxide materials by an introduced reducing agent comprising hydrogen requires high reaction temperatures for providing the chemical reaction for the direct reduction process in a direct reduction facility. Summary of the invention

[0014] IronDrop TM The concept works well, but the goal is to further develop IronDrop TM The invention relates to a technology and provides a new technical solution in the current technology of using hydrogen for direct reduction of metal oxide materials.

[0015] One object is to provide an energy efficient production of a resistant reduced metallic material which is treated to impart resistance to reoxidation before discharge from a direct reduction facility.

[0016] One object is to provide efficient direct reduction of metal oxide materials while establishing effective control over the production of reduced metal materials that are resistant to reoxidation.

[0017] One object is to provide for efficient utilization of hydrogen in the production of reduced metallic materials resistant to reoxidation, the production using hydrogen produced by utilizing fossil-free and / or renewable energy sources.

[0018] One object is to provide a cost effective transportation supply chain for transporting reduced metal materials to other industries, such as the metal fabrication industry.

[0019] One object is to provide for the production of reoxidation resistant intermediate products for use in the cost-effective production of metallic materials such as steel.

[0020] One object is to provide a process for producing reduced metallic materials resistant to reoxidation on an industrial scale in a CO 2 -neutral and / or low CO 2 -emission and / or CO 2 -free manner.

[0021] An object is to provide a carbon-free reduced metallic material that is resistant to reoxidation by an energy efficient direct reduction process.

[0022] One object is to produce a substantially fully metallized reduced metallic material, wherein the reduced metallic material is reduced by greater than about 90%, preferably about 95% to 100%, thereby reducing the accumulation of hydrogen in the direct reduction facility and / or the hydrogen content of the top gas.

[0023] One object is to produce a substantially fully metallized reduced metallic material, wherein the reduced metallic material is reduced by greater than about 75%.

[0024] One object is to simplify the handling of top gas discharged from a direct reduction plant (generated by chemical reactions in the direct reduction plant) and to provide efficient recycling of the top gas.

[0025] One object is to provide efficient direct reduction of metal oxide materials while establishing effective control over the production of reduced metal materials.

[0026] At least one of these or the above purposes has been achieved by a method for directly reducing a metal oxide material maintaining a first thermal energy into a reduced metal material via a metal material production configuration; wherein the metal oxide material maintaining the first thermal energy is provided by a metal oxide material provider unit; the method comprises the following steps: loading the metal oxide material maintaining the first thermal energy into a direct reduction facility via a metal oxide material loading inlet device; introducing a preheated hydrogen-containing reductant maintaining a second thermal energy into the direct reduction facility via a reductant inlet device; reducing the metal oxide material by heating or further heating the introduced preheated hydrogen-containing reductant using the first thermal energy of the metal oxide material to provide a chemical reaction between the introduced preheated hydrogen-containing reductant and the metal oxide material; exposing the reduced metal material to a heat treatment temperature required for heat treatment of the reduced metal material to obtain a densified reduced metal material; maintaining the required heat treatment temperature by introducing the preheated hydrogen-containing reductant using a heat treatment provider; and discharging the reduced metal material that has undergone heat treatment.

[0027] Alternatively, the method comprises the further steps of introducing a preheated hydrogen-containing heat treatment agent maintaining a third thermal energy into the direct reduction facility via a heat treatment agent feeding device for exposing the reduced metal material to a desired heat treatment temperature, for maintaining the desired heat treatment temperature, and for said heat treatment of the reduced metal material to obtain a densified reduced metal material.

[0028] Alternatively, the reducing agent inlet of the reducing agent inlet device configured to introduce preheated hydrogen-containing reducing agent into the direct reduction facility is positioned in the direct reduction facility higher than the thermal treatment agent inlet of the thermal treatment agent feed device configured to introduce preheated hydrogen-containing thermal treatment agent.

[0029] In this way it is achieved that the cooling rate of the reduced metallic material descending through the direct reduction facility is reduced, thereby enabling efficient heat treatment of the reduced metallic material.

[0030] Alternatively, the heat treatment agent feeding device includes a heat treatment agent preheating unit configured to preheat the heat treatment agent containing hydrogen to achieve the third thermal energy before the heat treatment agent is introduced into the direct reduction facility.

[0031] Alternatively, the heat treatment agent feeding device is configured to introduce a heat treatment agent containing hydrogen that maintains the third thermal energy.

[0032] Alternatively, heat treatment of the reduced metal material is achieved by introducing a preheated heat treatment agent containing hydrogen into the direct reduction facility, wherein third thermal energy is added by a heat treatment agent feeding device to reduce the cooling rate of the reduced metal material in the direct reduction facility.

[0033] Alternatively, the control circuit is electrically connected to the heat treatment agent thermal energy regulating device of the heat treatment agent feeding device to regulate the third thermal energy of the heat treatment agent containing hydrogen for controlling the heat treatment of the reduced metal material.

[0034] Alternatively, the heat treatment of the reduced metal material is achieved by utilizing a third thermal energy of a heat treatment agent containing hydrogen gas, for providing shrinkage of metal particles of the reduced metal material.

[0035] The preheated hydrogen-containing heat treating agent contains about 80% to 100% hydrogen by volume, preferably about 100% hydrogen by volume, or about 60% to 80% hydrogen by volume, preferably about 65% to 75% hydrogen by volume.

[0036] Alternatively, the step of maintaining the desired heat treatment temperature is provided to such an extent that the introduction of preheated hydrogen produces direct reduction of the metal oxide material and reduces the cooling rate of the reduced metal material descending through the direct reduction facility for maintaining said desired heat treatment temperature.

[0037] Alternatively, the metal oxide material comprises an iron ore oxide material which is subjected to direct reduction to a reduced iron ore material, wherein the wutite material subjected to the reduced iron oxide material will be reduced to a large extent to an iron material; this is due to the high hydrogen content of the introduced preheated hydrogen-containing reducing agent and / or the hydrogen-containing heat-treating agent, and due to the second thermal energy of the preheated hydrogen-containing reducing agent and / or due to the third thermal energy of the preheated hydrogen-containing heat-treating agent.

[0038] Alternatively, the direct reduction facility is configured to allow the reduced metallic material to descend and contact with a preheated hydrogen-containing reducing agent and / or a preheated hydrogen-containing heat treating agent for providing said heat treatment.

[0039] Alternatively, the cooling rate of the reduced metallic material descending through the direct reduction facility is controlled by the control circuitry by adjusting the temperature of the hydrogen-containing reductant and / or by adjusting the mass flow rate of the hydrogen-containing reductant fed to the direct reduction facility.

[0040] Alternatively, the cooling rate of the reduced metallic material descending through the direct reduction facility is controlled by the control circuitry by adjusting the temperature of the hydrogen containing heat treatment agent and / or by adjusting the mass flow rate of the hydrogen containing heat treatment agent fed to the direct reduction facility.

[0041] In this way, a reduced cooling rate suitable for cooling the reduced metal material in the direct reduction facility for providing the said heat treatment of the reduced metal material is achieved, whereby the reduced metal material after reduction and heat treatment will form a compact and dense reduced metal material (agglomerate), wherein each reduced metal agglomerate exhibits a compact and dense structure that is resistant to reoxidation.

[0042] In this way it is achieved that the thermal energy of the reduced metallic material is retained when going further down in the direct reduction facility in order to provide the thermal treatment.

[0043] Alternatively, the method comprises preheating the reducing agent containing hydrogen to be introduced into the direct reduction facility by a reducing agent preheating device of a heat treatment providing device, so as to reach a desired heat treatment temperature.

[0044] Alternatively, the introduction of the hydrogen-containing reducing agent maintaining the second thermal energy is preceded by a step of preheating the hydrogen-containing reducing agent to such an extent that the second thermal energy of the introduced hydrogen-containing reducing agent does not exceed the first thermal energy of the metal oxide material charged to the direct reduction facility.

[0045] Alternatively, the step of maintaining the desired heat treatment temperature includes regulating the second heat energy by a reductant heat energy regulating device electrically coupled to a first control circuit configured to operate the reductant heat energy regulating device for controlling the desired heat treatment temperature.

[0046] Alternatively, the step of maintaining the desired heat treatment temperature includes: adjusting the mass flow rate of the hydrogen-containing reductant introduced into the direct reduction facility by means of a reductant mass flow regulator electrically connected to a second control circuit, wherein the second control circuit is configured to operate the reductant mass flow regulator for controlling the desired heat treatment temperature.

[0047] Alternatively, the step of maintaining the desired heat treatment temperature includes: adjusting the residence time period by a residence time period adjustment device electrically connected to a third control circuit to maintain the reduced metal material in the direct reduction facility for a specific residence time period, wherein the third control circuit is configured to operate the residence time period adjustment device to achieve the specific residence time period and control the desired heat treatment temperature.

[0048] Alternatively, the step of providing the desired heat treatment temperature includes regulating the pressurization inside the direct reduction facility by means of a pressurization regulating device electrically coupled to a fourth control circuit, the fourth control circuit being configured to operate the pressurization regulating device for controlling the desired heat treatment temperature.

[0049] Alternatively, the pressurization regulating device comprises a reducing agent introduction / pressurization device and / or a top gas exhaust device and / or by regulating the mass flow of the top gas exhausted from the direct reduction facility.

[0050] Alternatively, the reducing agent introduction / pressurization device includes a reducing agent pressurization gas pump.

[0051] Alternatively, the top gas discharge device comprises a top gas suction pump.

[0052] Alternatively, pressurization of the interior of the direct reduction plant is achieved by introducing a reducing agent comprising hydrogen and / or by adjusting the mass flow of top gas discharged from the direct reduction plant.

[0053] Alternatively, the direct reduction is carried out in a direct reduction facility at a pressure of about 1 bar to about 10 bar; preferably 3 bar to about 8 bar.

[0054] Alternatively, the direct reduction is carried out in a direct reduction facility at a pressure of about 4 bar to about 14 bar; preferably 6 bar to about 12 bar.

[0055] Alternatively, the direct reduction is carried out in a direct reduction facility at a pressure of less than 1 bar.

[0056] Alternatively, the fifth control circuit is suitable for operating the heat treatment agent preheating unit to adjust the third thermal energy of the preheated hydrogen-containing heat treatment agent for exposing the reduced metal material to the heat treatment temperature required for providing heat treatment of the reduced metal material to obtain a densified reduced metal material and for maintaining the required heat treatment temperature.

[0057] At least one of these or the above purposes has been achieved by a metal material production configuration suitable for directly reducing a metal oxide material retaining a first thermal energy into a reduced metal material; the metal material production configuration comprises: a metal oxide material supplier unit, the metal oxide material supplier unit being configured to provide the metal oxide material retaining the first thermal energy; a direct reduction facility, the direct reduction facility comprising a metal oxide material charging inlet device, a reducing agent inlet device (B) configured to introduce a reducing agent containing hydrogen retaining a second thermal energy; a direct reduction zone of the direct reduction facility, which is configured to reduce the metal oxide material by utilizing the first thermal energy of the metal oxide material to heat the metal oxide material; heat or further heat the introduced hydrogen-containing reducing agent to provide a chemical reaction between the introduced hydrogen-containing reducing agent and the metal oxide material to reduce the metal oxide material; a heat treatment zone of the direct reduction facility, which is configured to heat treat the reduced metal material by exposing the reduced metal material to a heat treatment temperature required to provide heat treatment of the reduced metal material to obtain a densified reduced metal material; a heat treatment providing device, which is configured to maintain the required heat treatment temperature by introducing a preheated hydrogen-containing reducing agent; and a reduced metal material discharge device, which is configured to discharge the reduced metal material that has been subjected to the heat treatment.

[0058] Alternatively, the reduced metal material discharge device includes a metal material outlet configured to discharge the heat-treated and reduced metal material from the direct reduction facility.

[0059] Alternatively, the metal material production arrangement further comprises a reducing agent preheating device of the heat treatment providing device, wherein the reducing agent preheating device is suitable for preheating the reducing agent containing hydrogen to be introduced into the direct reduction facility.

[0060] Alternatively, the heat treatment providing device includes a reducing agent thermal energy regulating device, which is configured to regulate the second thermal energy; and a first control circuit, which is electrically connected to the reducing agent thermal energy regulating device and is configured to control the reducing agent thermal energy regulating device to achieve the desired heat treatment temperature.

[0061] Alternatively, the reducing agent heat energy conditioning device comprises an electric preheater configured to preheat the reducing agent containing hydrogen.

[0062] Alternatively, the heat treatment providing device includes a reductant mass flow regulating device, which is configured to regulate the mass flow of the hydrogen-containing reductant introduced into the direct reduction facility; and a second control circuit, which is electrically connected to the reductant mass flow regulating device and is configured to operate the reductant mass flow regulating device to regulate the mass flow of the hydrogen-containing reductant for achieving the desired heat treatment temperature.

[0063] Alternatively, the heat treatment providing device includes a residence time period adjustment device, which is configured to adjust the residence time period for maintaining the reduced metal material in the direct reduction facility; and a third control circuit, which is electrically connected to the residence time period adjustment device and is configured to operate the residence time period adjustment device to achieve the specific residence time period and control the required heat treatment temperature.

[0064] Alternatively, the heat treatment providing device includes a pressurization regulating device, which is configured to regulate the pressurization inside the direct reduction facility; and a fourth control circuit, which is electrically connected to the pressurization regulating device and is configured to operate the pressurization regulating device to control the required heat treatment temperature.

[0065] Alternatively, the direct reduction plant comprises a top gas discharge device configured to discharge top gas from the direct reduction plant.

[0066] Alternatively, the top gas contains up to about 100% by volume of high temperature water vapor.

[0067] Alternatively, the top gas contains up to about 80% to 100% by volume, preferably about 85% to 95% by volume, of high temperature water vapor.

[0068] Alternatively, the top gas contains up to about 60 to 90 volume %, preferably about 70 to 80 volume %, of high temperature water vapor.

[0069] Alternatively, the top gas contains up to about 40% to 80% by volume, preferably about 50% to 70% by volume, of high temperature water vapor.

[0070] Alternatively, the top gas contains up to about 20 to 60 volume %, preferably about 30 to 40 volume %, of high temperature water vapor.

[0071] Alternatively, the top gas contains up to about 15% to 35% by volume, preferably about 20% to 30% by volume, of high temperature water vapor.

[0072] Alternatively, the top gas contains high temperature water vapor and excess hydrogen.

[0073] Alternatively, excess hydrogen is separated from the high-temperature top gas and recycled to the direct reduction plant and introduced into the direct reduction plant.

[0074] In this way, a cost-effective use of hydrogen is achieved.

[0075] Alternatively, the high temperature steam exhibits a temperature of about 600°C to about 1200°C, preferably about 700°C to about 1100°C.

[0076] Alternatively, the high temperature steam exhibits a temperature of about 700°C to about 1450°C, preferably about 800°C to about 1350°C.

[0077] Alternatively, the reaction temperature required to maintain direct reduction in the direct reduction facility may be a temperature of about 800°C to about 1200°C, preferably about 900°C to about 1100°C.

[0078] Alternatively, the reaction temperature required to maintain direct reduction in the direct reduction facility may be from about 600°C to about 1400°C, preferably from about 850°C to about 1250°C.

[0079] Alternatively, the upper interior portion is configured to achieve a desired reaction temperature that is higher than a desired reaction temperature provided by the lower interior portion.

[0080] Temperature of reducing agent containing hydrogen:

[0081] Alternatively, the hydrogen-containing reducing agent introduced into the direct reduction facility exhibits a temperature of about 200°C to about 700°C, preferably about 300°C to about 600°C.

[0082] Alternatively, the hydrogen-containing reducing agent fed to the direct reduction facility may exhibit a temperature of about 350°C to about 900°C, preferably about 450°C to about 750°C.

[0083] Alternatively, the hydrogen-containing reducing agent introduced into the direct reduction facility exhibits a temperature of about 400°C to about 950°C, preferably about 550°C to about 800°C.

[0084] Alternatively, the hydrogen-containing reducing agent introduced into the direct reduction facility exhibits a temperature of about 600°C to about 1200°C, preferably about 850°C to about 950°C.

[0085] Alternatively, the supplemental hydrogen-containing reducing agent introduced into the direct reduction facility exhibits a temperature of about 200°C to about 700°C, preferably about 300°C to about 600°C.

[0086] Alternatively, the supplemental hydrogen-containing reductant is introduced into the direct reduction facility at a level that is lower than the level at which the hydrogen-containing reductant is introduced into the direct reduction facility.

[0087] Alternatively, a cooling gas comprising hydrogen may be introduced into a lower interior portion of the direct reduction facility for cost effective management of cooled reduced metallic material discharged from the direct reduction facility.

[0088] Metal oxide material temperature:

[0089] Alternatively, the heat-retaining metal oxide material charged to the direct reduction facility exhibits a temperature of 800°C to about 1200°C, preferably about 900°C to about 1100°C.

[0090] Alternatively, the metal oxide material charged to the direct reduction facility to maintain the first thermal energy exhibits a temperature of 900°C to about 1300°C, preferably about 1000°C to about 1200°C.

[0091] Alternatively, the heat-retaining metal oxide material charged to the direct reduction facility exhibits a temperature of 1000°C to about 1450°C, preferably about 1100°C to about 1300°C.

[0092] In this way, efficient heat recovery is achieved which can be utilized by the high temperature electrolysis unit.

[0093] Alternatively, the top gas contains water vapor produced by a chemical reaction between the metal oxide material and hydrogen of the hydrogen-containing reducing agent.

[0094] Alternatively, the top gas contains hydrogen that has not been consumed by the chemical reaction between the metal oxide material and the hydrogen of the hydrogen-containing reducing agent.

[0095] Alternatively, the amount of reducing agent comprising hydrogen that is continuously introduced is such that the top gas discharged from the direct reduction facility always contains hydrogen.

[0096] In this way it is ensured that hydrogen is available in the direct reduction facility for carrying out the chemical reaction.

[0097] Alternatively, the introduced preheated hydrogen-containing reducing agent comprises about 80% to 100% hydrogen by volume, preferably about 100% hydrogen.

[0098] Alternatively, the preheated hydrogen-containing reducing agent introduced into the direct reduction facility comprises greater than about 70% by volume hydrogen.

[0099] Alternatively, the preheated hydrogen-containing reducing agent introduced into the direct reduction facility comprises from about 40% to about 80% by volume hydrogen, preferably from about 50% to about 70% by volume hydrogen.

[0100] Alternatively, the preheated hydrogen-containing reducing agent introduced into the direct reduction facility comprises from about 60 vol. % to about 100 vol. % hydrogen, preferably from about 70 vol. % to about 90 vol. % hydrogen.

[0101] Alternatively, the preheated hydrogen-containing reducing agent contains about 60 vol% to 80 vol% hydrogen, preferably about 65 vol% to 75 vol% hydrogen.

[0102] At least one of these or the stated purposes has been achieved by a data program comprising a computer-readable program code of a control circuit of a metal material production configuration according to any of the claimed metal material production configurations, the data program being programmed to cause a heat treatment providing device to maintain a desired heat treatment temperature by introducing a preheated hydrogen-containing reducing agent.

[0103] Alternatively, the control circuit includes a first control circuit, a second control circuit, a third control circuit, a fourth control circuit and a fifth control circuit.

[0104] At least one of these or said objects has been achieved by a product produced according to any of the method steps, wherein the reduced metallic material comprises reduced iron ore particles bonded to each other to form a heat treated and / or heat hardened reduced metallic material.

[0105] Alternatively, the lower interior portion of the direct reduction facility includes a metallic material outlet configured to discharge the heat-treated reduced metallic material from the direct reduction facility.

[0106] Alternatively, the control circuit is adapted to regulate the second thermal energy towards a reaction temperature required to provide complete reduction.

[0107] In this way, a densification process for densifying the directly reduced metallic material is achieved, which thereby prevents reoxidation, thereby enabling safe and cost-effective transportation of the reduced metallic material, such as an intermediate product, to, for example, the metal manufacturing industry.

[0108] Alternatively, the separation unit is configured to separate excess hydrogen from the high temperature top gas.

[0109] By utilizing the first thermal energy of the metal oxide material generated by the metal oxide material provider unit for providing direct reduction (completely or partially or substantially) in the reduction facility, there is no need to heat the hydrogen-containing reductant to a very high temperature to reach the required reaction temperature through exothermic partial oxidation of the hydrogen-containing reductant with oxygen or air.

[0110] In this way it is achieved that the chemical reactivity and / or high driving force of the hydrogen-containing reducing agent is maintained when introduced into a direct reduction plant, while the thermal treatment produces a compact and dense reduced metallic material that is resistant to reoxidation.

[0111] Chemical reactivity and / or high driving forces are essential to provide efficient direct reduction of metal oxide materials.

[0112] In this way it is achieved that the reduction potential of the hydrogen-containing reducing agent is maintained for efficient direct reduction and thermal processing.

[0113] Alternatively, the relatively high temperature of the metal oxide material charged to the direct reduction facility and the second thermal energy of the preheated hydrogen-containing reducing agent will achieve energy efficient direct reduction of the metal oxide material to reduced metal material at the desired reaction temperature.

[0114] Alternatively, the reaction temperature required to provide effective direct reduction in the direct reduction facility may be from about 800°C to about 1200°C, preferably from about 900°C to about 1100°C, or may be from about 700°C to about 1400°C, preferably from about 950°C to about 1200°C, or may be from about 600°C to about 1500°C, preferably from about 800°C to about 1200°C.

[0115] Alternatively, the desired reaction temperature is maintained by preheating the hydrogen-containing reducing agent to be introduced into the direct reduction facility and utilizing the elevated temperature of the metal oxide material to maintain the first thermal energy.

[0116] Alternatively, the reducing agent preheating device of the heat treatment providing device comprises a reducing gas preheater, such as an electric reducing gas preheater.

[0117] Alternatively, the control circuit is suitable for operating the reductant mass flow regulating device to increase the mass flow of the hydrogen-containing reductant (H) introduced into the direct reduction facility, and is suitable for operating the reductant thermal energy regulating device to reduce the second thermal energy of the hydrogen-containing reductant for achieving the required heat treatment temperature.

[0118] Alternatively, the chemical reaction comprises a substantially or completely endothermic chemical reaction which consumes thermal energy equivalent to about 475°C to 525°C, preferably about 500°C, provided by the metal oxide material that maintains the first thermal energy during reduction prior to heat treating the reduced metal material to obtain a densified reduced metal material.

[0119] Alternatively, the heat treatment temperature is suitably in the range of 200°C to 600°C, preferably 300°C to 500°C.

[0120] Alternatively, the heat treatment temperature is suitably in the range of 300°C to 800°C, preferably 400°C to 600°C.

[0121] Alternatively, the temperature of the metal oxide material maintaining the first thermal energy is achieved by a metal oxide material provider unit (eg, a metal oxide granulation device) configured to generate the metal oxide material maintaining the first thermal energy or substantially maintaining the first thermal energy.

[0122] Alternatively, the metal ore material is dried and then preheated in a preheating zone of the metal oxide granulation apparatus, the preheating zone being configured to preheat the metal ore material into a preheated metal ore material.

[0123] Alternatively, the metal ore material may be in the form of iron ore pellets (eg green pellets).

[0124] Alternatively, the preheated metal ore material is transferred to a consolidation zone of the metal oxide granulation apparatus, the consolidation zone being configured to consolidate the preheated metal ore material.

[0125] Alternatively, the consolidation zone comprises an oxidation zone configured for oxidizing the preheated metal ore material and / or a sintering zone for sintering the oxidized preheated metal ore material.

[0126] Alternatively, the hydrogen of the hydrogen-containing reducing agent and / or the hydrogen of the hydrogen-containing heat treating agent is generated by an electrolysis unit and / or a high temperature electrolysis unit configured to decompose water into hydrogen and oxygen.

[0127] Alternatively, the electrolysis unit and / or high temperature electrolysis unit is configured to decompose water into hydrogen and oxygen and is supplied with electricity from a renewable energy supply source.

[0128] Alternatively, oxygen produced by the electrolysis unit and / or the high temperature electrolysis unit is transferred to the oxidation zone for oxidation of the preheated metal ore material.

[0129] Alternatively, the consolidation zone is configured to consolidate the preheated metal ore material towards a temperature of about 1000°C to about 1450°C, preferably about 1100°C to about 1300°C, for producing a metal oxide material retaining a thermal energy substantially corresponding to the first thermal energy.

[0130] Alternatively, the metal oxide material is discharged from the metal oxide granulation device and in connection therewith retains the thermal energy provided by the metal oxide granulation device and is directly charged into the direct reduction facility, wherein the metal oxide material retains a thermal energy substantially corresponding to the first thermal energy.

[0131] Alternatively, the temperature of the metal oxide material retaining thermal energy is achieved by a metal oxide material provider unit (e.g., a metal oxide material preheating device), which is configured to preheat previously cooled metal oxide material retaining thermal energy for producing a metal oxide material retaining a first thermal energy.

[0132] Alternatively, the temperature of the metal oxide material that maintains the first thermal energy is achieved by a metal oxide material preheating device, which is configured to preheat the metal oxide material to a temperature of about 1000°C to about 1450°C, preferably about 1100°C to about 1300°C, to produce the metal oxide material that maintains thermal energy.

[0133] Alternatively, the temperature of the metal oxide material maintaining the first thermal energy is achieved by a metal oxide material preheating device, which is configured to preheat the metal oxide material to a temperature of about 900°C to about 1350°C, preferably about 1000°C to about 1200°C, to produce the metal oxide material maintaining the first thermal energy.

[0134] Alternatively, the metal oxide material preheating device is configured to preheat the metal oxide material to a thermal energy substantially corresponding to the first thermal energy.

[0135] Alternatively, the metal oxide material preheating device is coupled to the metal oxide material charging inlet device via the metal oxide material transferring device.

[0136] Alternatively, the metal oxide material transfer device is configured to cool the preheated metal oxide material.

[0137] Alternatively, the metal oxide material transfer apparatus comprises a hopper arrangement associated with an upper interior portion of the direct reduction facility.

[0138] Alternatively, the metal oxide material is discharged from the metal oxide material preheating device for substantially obtaining the first thermal energy and is directly charged to the direct reduction facility.

[0139] Alternatively, the metal oxide material remaining hot is discharged from the metal oxide material supplier unit and charged into the direct reduction facility via the metal oxide material cooler unit to be used for providing the first heat energy.

[0140] Alternatively, the charging hopper arrangement is configured to introduce the first seal gas into the direct reduction facility in conjunction with charging the heat-retaining metal oxide material into the direct reduction facility.

[0141] Alternatively, the first sealing gas and / or the second sealing gas includes an inert gas.

[0142] In this way it is achieved that the formation of explosive air / process gas mixtures is avoided when the metal oxide material which retains thermal energy is introduced into the direct reduction plant.

[0143] Alternatively, the first sealing gas includes carbon dioxide gas for providing the carburized reduced metal material.

[0144] Alternatively, the metal oxide material maintained hot and discharged from the metal oxide material supplier unit is cooled by a metal oxide material cooler unit, which is configured to cool the metal oxide material for adjusting the first thermal energy of the metal oxide material toward a temperature that effectively increases the temperature of the hydrogen-containing reducing agent before the metal oxide material is loaded into the direct reduction facility, so as to maintain the reaction temperature required for direct reduction.

[0145] Alternatively, the chemical reaction includes reducing the metal oxide material directly to a reduced metal material.

[0146] Alternatively, the direct reduction facility is formed as a solid-gas countercurrent moving bed reactor, wherein a metal oxide material retaining a first thermal energy is charged into an upper internal portion of the direct reduction facility via a metal oxide material loading inlet device and descends toward a lower internal portion of the direct reduction facility by gravity, wherein a preheated hydrogen-containing reducing agent retaining a second thermal energy is introduced into the direct reduction facility (e.g., the upper internal portion and / or the middle internal portion and / or the lower internal portion of the direct reduction facility) to reduce the metal oxide material.

[0147] Alternatively, the introduction of a preheated hydrogen-containing reducing agent is arranged at a position below the metal oxide material charge inlet means.

[0148] Alternatively, the thermal energy of the introduced preheated hydrogen-containing reducing agent is adjusted toward the second thermal energy by the reducing agent thermal energy adjustment device.

[0149] Alternatively, by regulating the second thermal energy of the hydrogen-containing reducing agent to be introduced into the direct reduction facility via a reducing agent thermal energy regulating device, and / or by regulating the mass flow of the hydrogen-containing reducing agent entering the direct reduction facility via a configured reducing agent mass flow regulating device, and / or by regulating the residence time period of the reduced metal material in the direct reduction facility via a residence time period regulating device of the direct reduction facility, and / or by regulating the third thermal energy of the preheated hydrogen-containing heat treatment agent via a heat treatment agent feeding device, the control circuit is suitable for controlling the chemical reaction between the hydrogen-containing reducing agent and the metal oxide material, and / or for controlling the heat treatment of the reduced metal material.

[0150] Alternatively, a reducing agent comprising hydrogen is used for the reduced metal material and / or the heat treatment of the metal oxide material undergoing reduction.

[0151] Alternatively, introduction of the hydrogen-containing reducing agent is provided such that an excess of hydrogen is present within the direct reduction facility, followed by the chemical reaction to an extent that enables complete and / or substantially complete reduction of the metal oxide material retaining the first thermal energy.

[0152] Alternatively, the residence time period adjusting device comprises a discharge feeder device, such as a vibrating discharge feeder, a screw discharge feeder, a hopper discharge feeder, etc., coupled to the metal material outlet of the lower inner portion of the direct reduction facility.

[0153] Alternatively, in conjunction with the discharge of reduced metallic material from the direct reduction facility, a second sealing gas is introduced into the direct reduction facility via a discharge feeder device.

[0154] In this way it is achieved that the formation of explosive air / process gas mixtures is avoided when the reduced metallic material is discharged from the direct reduction plant.

[0155] Alternatively, the metal oxide material to be charged to the direct reduction plant is in the form of metal oxide pellets structurally formed from metal oxide particles.

[0156] Alternatively, the metal oxide material undergoing reduction is in the form of metal oxide pellets structurally formed from metal oxide particles undergoing reduction.

[0157] Alternatively, the reduced metal material is in the form of reduced metal pellets structurally formed from reduced metal particles.

[0158] Alternatively, the aspect ratio within the direct reduction facility is greater than at least 1:1 and up to 10:1, so as to achieve a residence time period suitable for the thermal treatment of the reduced metal material, while the flow rate of the metal oxide material undergoing reduction and / or the flow rate of the reduced metal material through the direct reduction facility can be maintained high enough to avoid metal particles of the reduced metal material from adhering to the direct reduction facility.

[0159] Alternatively, the direct reduction facility and / or the metal oxide material provider unit and / or the control circuit and / or the electrolysis unit and / or the high temperature electrolysis unit are part of a metal material production configuration.

[0160] Alternatively, a hydrogen-containing reducing agent retaining the second thermal energy is introduced into an intermediate interior portion of the direct reduction facility.

[0161] Alternatively, the metal material production arrangement comprises a top gas circulation arrangement adapted to circulate a portion of the top gas and mix it with hydrogen produced by the electrolysis unit and / or the high temperature electrolysis unit to form a hydrogen-containing reducing agent and / or a hydrogen-containing heat treatment agent.

[0162] Alternatively, the step of reducing the metal oxide material in the upper inner portion maintaining the first thermal energy is achieved by utilizing the first thermal energy of the metal oxide material and by utilizing the thermal energy of the partially reduced metal material in the upper inner portion to heat or further heat the introduced preheated hydrogen.

[0163] By directly charging the metal oxide material from the metal oxide material provider unit into the direct reduction facility (the metal oxide material retains the first thermal energy originating from the metal oxide material provider unit), the reduction and chemical reaction between the metal oxide material and the hydrogen-containing reducing agent can be provided to be energy efficient, while the hydrogen of the hydrogen-containing reducing agent will maintain its reduction potential.

[0164] In this manner, the need to further heat the hydrogen-containing reductant by exothermic partial oxidation of the hydrogen-containing reductant with oxygen or air (which destroys the reduction potential) is eliminated.

[0165] Alternatively, the upper interior portion of the direct reduction facility is configured for direct reduction of the metal oxide material retaining the first thermal energy.

[0166] Alternatively, the control circuit is electrically connected to the heat treatment providing device and to the reducing agent thermal energy regulating device and / or the reducing agent mass flow regulating device and / or the residence time period regulating device and / or the pressurization regulating device and / or the heat treatment agent feeding device, wherein the heat treatment agent feeding device is configured to introduce a hydrogen-containing heat treatment agent that maintains a third thermal energy suitable for the heat treatment.

[0167] Alternatively, the direct reduction facility is configured to allow the reduced metal material to descend to a lower interior portion of the direct reduction facility so that the reduced metal material is exposed to a heat treatment temperature required to provide said heat treatment of the reduced metal material and the required heat treatment temperature is maintained by introducing a preheated hydrogen-containing reducing agent.

[0168] Alternatively, the direct reduction facility includes a heat treatment agent introduction device configured to introduce a heat treatment agent containing hydrogen, the heat treatment agent introduction device being coupled to the control circuit.

[0169] Alternatively, the direct reduction facility includes a heat treatment agent feeder configured to introduce a preheated heat treatment agent containing hydrogen, the heat treatment agent feeder being electrically coupled to the control circuit.

[0170] Alternatively, the heat treatment agent introduction device includes a heat treatment agent preheater electrically coupled to a control circuit adapted to control the temperature of heat of the hydrogen-containing heat treatment agent added to the reduced metal material.

[0171] Alternatively, the metal oxide material maintaining the first thermal energy is allowed to continuously descend within the direct reduction facility and thereby contact with the continuously introduced preheated hydrogen-containing reducing agent maintaining the second thermal energy for providing reduction of the metal oxide material to reduced metal material.

[0172] Alternatively, the metal oxide material undergoing reduction and / or the reduced metal material is allowed to descend within the direct reduction facility and thereby come into contact with a heat treatment agent comprising hydrogen for providing said heat treatment within the direct reduction facility.

[0173] Alternatively, exposing the reduced metallic material to a heat treatment temperature required to provide heat treatment of the reduced metallic material produces a densified reduced metallic material and / or a semi-molten reduced metallic material and / or a passivated reduced metallic material.

[0174] In this way it is achieved that the reduced metallic material discharged from the direct reduction plant forms an intermediate product which is resistant to reoxidation.

[0175] In this way cost effective transport to metal manufacturing industries such as the steel industry is provided.

[0176] In this way, it is achieved that the intermediate products produced (such as sponge iron or IronDrop TM ) can be used for energy efficient "green" production of steel.

[0177] Alternatively, the metal oxide material undergoing reduction and / or the reduced metal material is allowed to descend and come into contact with a hydrogen-containing heat treatment agent for providing said heat treatment, wherein the control circuit is suitable for controlling the thermal energy of the hydrogen-containing heat treatment agent in such a manner that the temperature of the reduced metal material decreases the further the reduced metal material descends in the direct reduction facility.

[0178] In this way, further energy is saved by utilizing the first thermal energy to reach the desired reaction temperature, ensuring that the chemical reaction (which is essentially an endothermic reaction) is energy efficient and the reduction potential of the preheated hydrogen-containing reducing agent is maintained.

[0179] In this way, due to the high content of thermal energy of the metal oxide material for reduction in the upper inner portion, its first thermal energy can be utilized to a large extent, and the metal oxide material maintaining the first thermal energy in the upper inner portion initially encounters the hydrogen-containing reducing agent to directly reduce the metal oxide material by utilizing the first thermal energy of the metal oxide material to heat or further heat the introduced hydrogen-containing reducing agent to provide a chemical reaction between the introduced hydrogen-containing reducing agent and the metal oxide material.

[0180] Alternatively, the preheated hydrogen-containing reducing agent and / or the preheated hydrogen-containing heat treating agent introduced into the direct reduction facility is configured to produce a semi-molten reduced metallic material and / or a densified reduced metallic material.

[0181] In this way, degradation of the reduced metallic material is prevented.

[0182] Alternatively, the direct reduction facility includes a heat treatment agent feed device positioned at a level below the reducing agent inlet device, the heat treatment agent feed device being configured to introduce a heat treatment agent containing hydrogen that maintains a third thermal energy, wherein the control circuit is suitable for regulating the third thermal energy to provide heat treatment to produce a semi-molten and / or densified reduced metal material.

[0183] Alternatively, the control circuit is adapted to operate the reducing agent temperature regulator so that the second thermal energy of the reducing agent containing hydrogen provides the reaction temperature required for the direct reduction and / or provides the required heat treatment temperature.

[0184] Alternatively, the direct reduction facility comprises a metallic material outlet configured to discharge reduced metallic material that has been heat treated from the direct reduction facility.

[0185] Alternatively, the direct reduction plant comprises a top gas discharge device configured to discharge top gas from the direct reduction plant.

[0186] Alternatively, the metal ore material comprises iron ore material.

[0187] Alternatively, the iron ore material includes a hematite material and a magnetite material.

[0188] Alternatively, the preheated metal ore material comprises preheated iron ore material.

[0189] Alternatively, the metal oxide material comprises an iron ore oxide material.

[0190] Alternatively, the reduced and heat-treated metal material comprises a reduced and heat-treated iron ore material.

[0191] Alternatively, the metal oxide material is formed as metal oxide agglomerates.

[0192] Alternatively, the reduced and heat-treated metal material is formed into reduced metal agglomerates.

[0193] Alternatively, the reduced and heat treated metal agglomerates exhibit a densified surface region.

[0194] Alternatively, reduced metal agglomerates are formed from reduced metal particles.

[0195] Alternatively, the reduced and heat treated metal agglomerates exhibit densified surface regions of fused reduced metal particles overlying the porous cores of the reduced metal particles.

[0196] Alternatively, the reduced and heat-treated metal agglomerates consist of fused reduced metal particles.

[0197] The expression "reducing" or "reducing" can be changed to "directly reducing" or "directly reducing".

[0198] Alternatively, the method further comprises the steps of: decomposing water into electrolytic hydrogen and oxygen by an electrolysis unit; producing methanol by reacting the electrolytic hydrogen with carbon dioxide; storing the methanol; reforming the methanol by using water and / or oxygen to provide carbon dioxide and released hydrogen; providing the released hydrogen as a component of a preheated hydrogen-containing reductant to a direct reduction facility; and providing a step of introducing the preheated hydrogen-containing reductant maintaining a second thermal energy into the direct reduction facility via a reductant inlet device.

[0199] In this way, a means of buffering energy in the form of methanol used in the reforming step when the method is applied is achieved. This means that during times of high electricity costs and / or low renewable electricity supply, hydrogen can be produced by the reforming step.

[0200] Alternatively, the method includes an additional step of charging a metal oxide material retaining a first thermal energy into the direct reduction facility via a metal oxide material charging inlet device provided in combination with the introduction of a first sealing gas; and / or a step of discharging a reduced metal material provided in combination with the introduction of a second sealing gas.

[0201] In this way it is achieved that the metal oxide material can be safely charged to the direct reduction plant without any explosive air / process gas mixture being formed during the charging.

[0202] This is achieved by ensuring that only sealing gas and no air is introduced into the direct reduction plant when charging the metal oxide material, wherein no process gas and / or hydrogen-containing reducing gas escapes from the direct reduction plant during charging.

[0203] Alternatively, the charging arrangement of the metal oxide material charging inlet device is configured to transfer the metal oxide material retaining the first thermal energy from the metal oxide material provider unit to the direct reduction facility.

[0204] Alternatively, the charging arrangement comprises a seal gas introduction device configured to introduce a seal gas into the direct reduction facility.

[0205] Alternatively, the direct reduction facility is provided as a solid-gas countercurrent moving bed reactor.

[0206] Alternatively, the direct reduction is performed in the direct reduction facility at a first pressure, wherein the seal gas introduction device is configured to introduce the seal gas into the direct reduction facility at a second pressure higher than the first pressure.

[0207] Alternatively, a method is provided for directly reducing a metal oxide material maintaining a first thermal energy into a reduced metal material by a metal material production configuration; wherein the metal oxide material maintaining the first thermal energy is provided by a metal oxide material provider unit.

[0208] Alternatively, the method includes the step of charging the metal oxide material retaining the first thermal energy into the direct reduction facility via the metal oxide material charging inlet device.

[0209] Alternatively, the reduction facility includes an upper interior portion, a lower interior portion, and an intermediate interior portion between the upper interior portion and the lower interior portion.

[0210] Alternatively, there is provided the step of introducing a preheated hydrogen-containing reducing agent retaining a second thermal energy into the direct reduction facility via a reducing agent inlet device.

[0211] Alternatively, the reduction facility is configured to allow direct reduction of the metal oxide material in the upper interior portion by utilizing the first thermal energy of the metal oxide material to further heat the introduced preheated hydrogen-containing reducing agent to provide a chemical reaction between the hydrogen of the introduced preheated hydrogen-containing reducing agent and the metal oxide material.

[0212] Alternatively, the direct reduction facility is configured to allow reduced metal material and / or metal oxide material undergoing direct reduction to descend into a lower interior portion including the thermal treatment zone.

[0213] Alternatively, the direct reduction facility is configured to allow the preheated hydrogen-containing reductant to rise upward in the direct reduction facility to contact the descending metal oxide material.

[0214] Alternatively, the heat treatment zone is configured for exposing the reduced metal material and / or the metal oxide material subjected to direct reduction to a predetermined heat treatment temperature for obtaining the reduced metal material comprising reduced iron ore particles which are combined with each other to form a heat-treated and / or heat-hardened and / or densified reduced metal material.

[0215] Alternatively, the heat treatment zone is configured to maintain a predetermined heat treatment temperature by the introduction of the preheated hydrogen-containing reducing agent.

[0216] Alternatively, the method includes the step of discharging the reduced metallic material which has been subjected to the heat treatment.

[0217] Alternatively, the first heat energy is used in the upper inner part to further heat a remaining amount of hydrogen (and formed water vapor) of the preheated hydrogen-containing reducing agent which has not yet been consumed and which rises upwards in the direct reduction plant towards the upper inner part.

[0218] Alternatively, the remaining amount of hydrogen provides for chemical reaction and efficient direct reduction of the metal oxide material in the upper interior portion.

[0219] This is achieved despite the fact that the higher the preheated hydrogen-containing reducing agent rises in the direct reduction plant, the preheated hydrogen-containing reducing agent will contain increasing amounts of water vapor and decreasing amounts of hydrogen.

[0220] Alternatively, the first thermal energy is used in the upper inner portion to further heat a portion of the preheated hydrogen-containing reducing agent for providing said chemical reaction between the hydrogen of the preheated hydrogen-containing reducing agent and the oxygen of the metal oxide material.

[0221] Alternatively, the first heat energy is used in the upper interior portion to further heat a remaining amount of hydrogen (and formed water vapor) of the preheated hydrogen-containing reducing agent, which has not yet been consumed and which rises upward in the direct reduction facility toward the uppermost part of the upper interior portion (inside the top of the direct reduction facility).

[0222] Alternatively, the remaining amount of hydrogen provides for chemical reaction and efficient direct reduction of the metal oxide material (iron ore oxide material) in the uppermost portion, despite the fact that the preheated hydrogen-containing reducing agent will also contain larger amounts of water vapor and smaller amounts of hydrogen the higher it rises in the direct reduction facility.

[0223] Alternatively, the first thermal energy is therefore used in the uppermost part to further heat the remaining amount of hydrogen for providing the chemical reaction between at least a portion of the remaining amount of hydrogen and oxygen of the metal oxide material (iron ore oxide material), thereby achieving reduction in which oxygen is removed from the iron ore oxide material.

[0224] Alternatively, the excess preheated hydrogen-containing reducing agent in the uppermost part constitutes a top gas containing hot water vapor, which is discharged from the direct reduction plant via a top gas discharge.

[0225] Alternatively, the first thermal energy is therefore used to further heat the remaining amount of hydrogen for efficient direct reduction in the uppermost portion and / or to avoid undesirable / unwanted cooling of the remaining amount of hydrogen of the hydrogen-containing reductant in the uppermost portion which has not yet been consumed, to provide efficient direct reduction.

[0226] It is thus avoided that the iron ore oxide material charged to the direct reduction plant cools the remaining amount of hydrogen in the uppermost portion of the hydrogen-containing reducing agent.

[0227] Alternatively, the first thermal energy of the iron ore oxide material is used in the upper inner portion UP and / or the uppermost portion to further heat the remaining amount of hydrogen and / or water vapor of the preheated hydrogen-containing reducing agent.

[0228] Alternatively, the top gas contains water vapor produced by a chemical reaction between oxygen of the iron oxide material and hydrogen of the hydrogen-containing reducing agent.

[0229] Alternatively, the top gas contains up to about 100% by volume of high temperature water vapor.

[0230] Alternatively, the top gas contains up to about 80% to 100% by volume, preferably about 85% to 95% by volume, of high temperature water vapor.

[0231] Alternatively, the top gas contains up to about 60 to 90 volume %, preferably about 70 to 80 volume %, of high temperature water vapor.

[0232] Alternatively, the top gas contains up to about 30% to 60% by volume, preferably about 40% to 50% by volume, of high temperature water vapor.

[0233] Alternatively, the top gas contains high temperature water vapor in an amount of up to about 10 to 40 volume %, preferably about 20 to 30 volume %.

[0234] Alternatively, the top gas contains up to about 0 to 20 volume %, preferably about 5 to 15 volume %, of high temperature water vapor.

[0235] Alternatively, the top gas contains up to about 0% to 15% by volume, preferably about 1% to 10% by volume, of high temperature water vapor.

[0236] Alternatively, a method is provided for directly reducing an iron ore oxide material retaining a first thermal energy into a densified reduced iron material by a sponge iron production configuration; wherein the iron ore oxide material retaining the first thermal energy is provided by an iron ore oxide material provider unit such as an iron ore oxide granulation device and / or an iron ore oxide preheating device.

[0237] Alternatively, the temperature of the iron ore oxide material maintaining the first thermal energy is achieved by an iron ore oxide material provider unit configured to produce and / or preheat the iron ore oxide material maintaining the first thermal energy or substantially maintaining the first thermal energy.

[0238] Alternatively, the iron ore oxide material provider unit is electrically coupled to a control circuit adapted to control the first thermal energy of the iron ore oxide material to be charged into the direct reduction facility.

[0239] Alternatively, the temperature of the iron ore oxide material maintaining the first heat energy provided by the iron ore oxide material supplier unit corresponds to a predetermined temperature determined to avoid "sticking" (avoiding iron ore oxide material particles from adhering to each other) in the upper inner portion of the direct reduction facility.

[0240] Such "sticking" will inhibit any subsequent direct reduction of the iron ore oxide material in the upper interior portion UP of the direct reduction facility.

[0241] Alternatively, the predetermined temperature of the iron ore oxide material, which is important to avoid "sticking", is controlled by the control circuit to typically be from about 800°C to about 1000°C, preferably from about 875°C to about 925°C.

[0242] Alternatively, the control circuit is adapted to regulate the first thermal energy of the iron ore oxide material towards said predetermined temperature for avoiding "sticking".

[0243] Avoiding "sticking" of iron ore oxide particles and / or pellets during charging and during direct reduction can be crucial, as such "sticking" will result in discontinuous operation of the direct reduction facility. Avoiding "sticking" or reducing the sticking index SI can be achieved by avoiding very high temperatures (above 1200° C.) in the upper interior portion of the direct reduction facility.

[0244] Alternatively, the predetermined temperature of the iron ore oxide material may be adjusted by the control circuit based on specific characteristics of direct reduction and / or according to specific characteristics of the iron ore oxide material to be charged into the direct reduction facility and / or specific process parameters of the iron ore oxide granulation plant and / or the iron ore oxide preheating device, taking into account the temperature of the first thermal energy in the direct reduction facility, the composition of the preheated hydrogen-containing reducing agent and the degree of direct reduction at a specific level, the specific characteristics and / or specific process parameters may be:

[0245] The external shape of the iron ore oxide pellets, and / or

[0246] the porosity and / or density of the iron ore oxide material, and / or

[0247] The mineralogy of the iron ore material, and / or

[0248] The composition of the iron ore oxide material, and / or

[0249] Reunion level, and / or

[0250] the iron oxide material pellet size of the iron ore oxide material, and / or

[0251] Direct reduction rate of iron ore oxide materials, and / or

[0252] the hydrogen content of the hydrogen-containing reducing agent, and / or

[0253] the desired temperature of the top gas, and / or

[0254] the output temperature of the iron ore oxide material provided by the iron ore oxide pelletizing plant and / or the iron ore oxide preheating plant;

[0255] To achieve effective heat treatment and obtain densified reduced iron ore material and / or semi-molten reduced iron ore material and / or passivated reduced iron ore material.

[0256] Alternatively, the predetermined temperature of the iron ore oxide material is adjusted by the control circuit based on a residence period during which the iron ore oxide material is subjected to direct reduction and / or exposed to a reducing agent comprising hydrogen in the direct reduction facility.

[0257] Alternatively, the residence period is defined as the period of time during which the iron ore oxide material is subjected to direct reduction and thermal treatment to complete the direct reduction process, which involves converting the wrought iron ore FeO x Directly reduced to iron Fe, forming a densified reduced iron ore material and / or a semi-molten reduced iron ore material and / or a passivated reduced iron ore material.

[0258] Alternatively, the residence time period in the direct reduction facility is determined by the aspect ratio of the interior of the direct reduction facility.

[0259] Alternatively, the residence time period in the direct reduction facility is equal to about 0.5 hours to 5.0 hours, preferably 1 hour to 4 hours.

[0260] Alternatively, the residence time period in the direct reduction facility is equal to about 2 hours to 6 hours, preferably 3 hours to 4 hours.

[0261] Alternatively, the residence time period in the direct reduction facility is equal to about 0.25 hours to 1.5 hours, preferably 0.5 hours to 1.25 hours.

[0262] Alternatively, taking into account the temperature of the first thermal energy in the direct reduction facility, the composition of the preheated hydrogen-containing reducing agent and the extent of direct reduction at a specific level, the temperature and / or mass flow rate of the hydrogen-containing reducing agent may be regulated by the control circuit based on:

[0263] Specific process parameters for direct reduction, and / or

[0264] Specific characteristics of the iron ore oxide material, the specific characteristics and / or specific process parameters may be:

[0265] The external shape of the iron ore oxide pellets, and / or

[0266] the porosity and / or density of the iron ore oxide material, and / or

[0267] The mineralogy of the iron ore material, and / or

[0268] The composition of the iron ore oxide material, and / or

[0269] Reunion level, and / or

[0270] the iron oxide material pellet size of the iron ore oxide material, and / or

[0271] Direct reduction rate of iron ore oxide materials, and / or

[0272] the hydrogen content of the hydrogen-containing reducing agent, and / or

[0273] the desired temperature of the top gas, and / or

[0274] the output temperature of the iron ore oxide material provided by the iron ore oxide pelletizing plant and / or the iron ore oxide preheating plant;

[0275] To achieve effective heat treatment and obtain densified reduced iron ore material and / or semi-molten reduced iron ore material and / or passivated reduced iron ore material.

[0276] Alternatively, the control of the temperature of the iron ore oxide material charged into the uppermost portion (first thermal energy) and the temperature of the hydrogen-containing reducing agent introduced into the direct reduction facility (second thermal energy) is determined / controlled by a control circuit based on the mass flow rate of the iron ore oxide material charged and / or the mass flow rate of the hydrogen-containing reducing agent introduced.

[0277] Alternatively, the control of the mass flow rate of the hydrogen-containing reducing agent introduced into the direct reduction facility is determined / controlled by a control circuit based on the temperature of the iron ore oxide material loaded into the uppermost part (first thermal energy) and / or the temperature of the hydrogen-containing reducing agent introduced into the direct reduction facility (second thermal energy) to optimize the chemical reduction reaction and / or limit the high-temperature water vapor content in the direct reduction facility and / or maintain a desired ratio between high-temperature water vapor and hydrogen, thereby achieving an effective chemical reduction reaction.

[0278] Alternatively, the method comprises the step of charging the iron ore oxide material retaining the first thermal energy into the upper inner portion of the direct reduction facility via the metal oxide material charging inlet means.

[0279] Alternatively, the direct reduction facility includes an upper interior portion, a lower interior portion, and an intermediate interior portion between the upper interior portion and the lower interior portion.

[0280] Alternatively, there is provided the step of introducing a preheated hydrogen-containing reducing agent retaining a second thermal energy into the direct reduction facility via a reducing agent inlet device.

[0281] Alternatively, the direct reduction facility is configured to allow direct reduction of the iron ore oxide material in the upper inner portion by utilizing the first thermal energy of the iron ore oxide material to further heat the introduced preheated hydrogen-containing reductant to provide a chemical reaction between the hydrogen of the introduced preheated hydrogen-containing reductant and the iron ore oxide material.

[0282] Alternatively, the direct reduction facility is configured to allow reduced iron material and / or iron ore oxide material subjected to direct reduction to descend into a lower interior portion including the thermal treatment zone.

[0283] Alternatively, the direct reduction facility is configured to allow the preheated hydrogen-containing reducing agent to rise upwardly in the direct reduction facility to contact the descending iron ore oxide material.

[0284] Alternatively, the heat treatment zone is configured for exposing the reduced iron material and / or the iron ore oxide material subjected to direct reduction to a predetermined heat treatment temperature for obtaining the reduced iron ore material comprising reduced iron ore particles which are combined with each other to form a heat-treated and / or heat-hardened and / or densified reduced iron ore material.

[0285] Alternatively, the heat treatment zone is configured to maintain a predetermined heat treatment temperature by the introduction of the preheated hydrogen-containing reducing agent.

[0286] Alternatively, the method includes the step of discharging reduced iron material which has been subjected to heat treatment in the heat treatment zone.

[0287] The preheated hydrogen-containing reducing agent comprises about 80% to 100% hydrogen by volume, preferably up to 100% hydrogen.

[0288] Alternatively, the hydrogen-containing reducing agent fed to the direct reduction facility may exhibit a temperature of about 350°C to about 900°C, preferably about 450°C to about 750°C.

[0289] Alternatively, the hydrogen-containing reducing agent introduced into the direct reduction facility exhibits a temperature of about 500°C to about 900°C, preferably about 600°C to about 800°C.

[0290] Alternatively, the hydrogen-containing reducing agent introduced into the direct reduction facility exhibits a temperature of about 600°C to about 1000°C, preferably about 700°C to about 900°C.

[0291] Alternatively, the hydrogen-containing reducing agent introduced into the direct reduction facility exhibits a temperature of about 700°C to about 1000°C, preferably about 850°C to about 950°C.

[0292] Alternatively, the hydrogen-containing reducing agent introduced into the direct reduction facility exhibits a temperature of about 700°C to about 1200°C, preferably about 800°C to about 1100°C.

[0293] Alternatively, a reducing agent comprising hydrogen is introduced into the upper inner portion and / or the lower inner portion and / or the middle inner portion.

[0294] Alternatively, the iron ore oxide material which retains thermal energy and is charged to the direct reduction facility exhibits a temperature of from 200°C to about 500°C, preferably from about 300°C to about 400°C.

[0295] Alternatively, the iron ore oxide material which retains thermal energy and is charged to the direct reduction facility exhibits a temperature of 300°C to about 600°C, preferably about 400°C to about 500°C.

[0296] Alternatively, the iron ore oxide material which retains thermal energy and is charged to the direct reduction facility exhibits a temperature of 400°C to about 700°C, preferably about 500°C to about 600°C.

[0297] Alternatively, the iron ore oxide material which retains thermal energy and is charged to the direct reduction facility exhibits a temperature of 500°C to about 800°C, preferably about 600°C to about 700°C.

[0298] Alternatively, the iron ore oxide material which retains thermal energy and is charged to the direct reduction facility exhibits a temperature of 600°C to about 900°C, preferably about 700°C to about 800°C.

[0299] Alternatively, the iron ore oxide material which retains thermal energy and is charged to the direct reduction facility exhibits a temperature of 700°C to about 1000°C, preferably about 800°C to about 900°C.

[0300] Alternatively, the iron ore oxide material which retains thermal energy and is charged to the direct reduction facility exhibits a temperature of 800°C to about 1100°C, preferably about 900°C to about 1000°C.

[0301] Alternatively, the iron ore oxide material which retains thermal energy and is charged to the direct reduction facility exhibits a temperature of 900°C to about 1200°C, preferably about 1000°C to about 1100°C.

[0302] Alternatively, the thermally retained iron ore oxide material charged to the direct reduction facility exhibits a temperature of from 1000°C to about 1300°C, preferably from about 1100°C to about 1200°C.

[0303] Alternatively, the chemical reaction comprises a substantially or completely endothermic chemical reaction.

[0304] Alternatively, the thermal energy consumed by direct reduction in the upper inner portion includes the first thermal energy and / or the second thermal energy.

[0305] Alternatively, the thermal energy consumed by direct reduction in the intermediate inner portion includes the first thermal energy and / or the second thermal energy.

[0306] Alternatively, the thermal energy consumed by direct reduction in the lower inner portion comprises second thermal energy.

[0307] Alternatively, thermal treatment is defined as densification (passivation) of the iron ore oxide material subjected to direct reduction and / or reduced iron ore material.

[0308] Alternatively, the iron ore oxide material subjected to direct reduction and / or the reduced iron material obtained by the heat treatment is controlled by a first control circuit (not shown) and / or a control circuit, which is suitable for regulating the second thermal energy of the hydrogen-containing reducing agent through a reducing agent thermal energy regulating device (not shown) for controlling a predetermined required heat treatment temperature to achieve the desired quality of the produced sponge iron and / or densified reduced metal material and / or semi-molten reduced metal material and / or passivated reduced metal material.

[0309] Alternatively, the heat treatment temperature is controlled within the range of 150°C to 550°C, preferably 250°C to 450°C.

[0310] Alternatively, the heat treatment temperature is controlled within the range of 200°C to 600°C, preferably 300°C to 500°C.

[0311] Alternatively, the heat treatment temperature is controlled in the range of 250°C to 650°C, preferably 350°C to 550°C.

[0312] Alternatively, the heat treatment temperature is controlled within a range of about 350°C to about 900°C, preferably about 450°C to about 750°C.

[0313] Alternatively, the heat treatment temperature is controlled within a range of about 500°C to about 900°C, preferably about 600°C to about 800°C.

[0314] Alternatively, the heat treatment temperature is controlled within a range of about 600°C to about 1000°C, preferably about 700°C to about 900°C.

[0315] Alternatively, the heat treatment temperature is controlled within a range of about 700°C to about 1000°C, preferably about 850°C to about 950°C.

[0316] Alternatively, the heat treatment temperature is controlled within a range of about 700°C to about 1200°C, preferably about 800°C to about 1100°C.

[0317] Alternatively, the heat treatment temperature is controlled by a control circuit that controls the temperature of the reducing agent H containing hydrogen.

[0318] Alternatively, the temperature of the iron ore oxide material charged into the uppermost portion (first heat energy) is controlled within the range of 100°C to 500°C, preferably 200°C to 400°C, and the hydrogen-containing reducing agent introduced into the direct reduction facility is controlled to exhibit a temperature (second heat energy) within the range of 600°C to 1100°C, preferably 700°C to 1000°C.

[0319] Alternatively, the temperature of the iron ore oxide material charged into the uppermost portion (first heat energy) is controlled within the range of 200°C to 600°C, preferably 300°C to 500°C, and the hydrogen-containing reducing agent introduced into the direct reduction facility is controlled to exhibit a temperature (second heat energy) within the range of 700°C to 1200°C, preferably 800°C to 1100°C.

[0320] Alternatively, the temperature of the iron ore oxide material charged into the uppermost portion (first heat energy) is controlled within the range of 300°C to 700°C, preferably 400°C to 600°C, and the hydrogen-containing reducing agent introduced into the direct reduction facility is controlled to exhibit a temperature (second heat energy) within the range of 700°C to 1100°C, preferably 750°C to 950°C.

[0321] Alternatively, the temperature of the iron ore oxide material charged into the uppermost portion (first heat energy) is controlled within the range of 400°C to 800°C, preferably 500°C to 700°C, and the hydrogen-containing reducing agent introduced into the direct reduction facility is controlled to exhibit a temperature (second heat energy) within the range of 800°C to 1300°C, preferably 900°C to 1200°C.

[0322] Alternatively, the first thermal energy of the iron ore oxide material is used in the upper inner portion UP and / or the uppermost portion to further heat the remaining amount of hydrogen and / or water vapor of the preheated hydrogen-containing reducing agent.

[0323] Alternatively, the top gas contains water vapor produced by a chemical reaction between oxygen of the iron oxide material and hydrogen of the hydrogen-containing reducing agent.

[0324] Alternatively, the remaining amount of hydrogen of the hydrogen-containing reducing agent can be defined as the hydrogen-containing reducing agent that has not been consumed in the direct reduction in the main part of the upper inner portion and has risen upward in the direct reduction facility to the uppermost part of the upper inner portion (inside the top of the direct reduction facility).

[0325] Alternatively, the remaining amount of hydrogen provides for chemical reaction and efficient direct reduction of the uppermost portion of the metal oxide material (iron ore oxide material), despite the fact that the preheated hydrogen-containing reducing agent will contain a greater amount of water vapor and a lesser amount of hydrogen the higher it rises in the direct reduction facility.

[0326] Alternatively, the first thermal energy is therefore used in the uppermost part to further heat said remaining amount of hydrogen for providing said chemical reaction between at least a portion of said remaining amount of hydrogen and oxygen of the metal oxide material (iron ore oxide material), thereby providing a direct reduction in which effective removal of oxygen from the iron ore oxide material is achieved.

[0327] Alternatively, an excess of preheated hydrogen-containing reducing agent comprising excess hydrogen and hot water vapor forms a top gas in the uppermost section, which is discharged from the direct reduction plant via a top gas discharge device.

[0328] Alternatively, the first thermal energy is therefore used to further heat a remaining amount of hydrogen for efficient direct reduction in the uppermost portion and / or to prevent cooling of said remaining amount of hydrogen of the hydrogen-containing reductant in the uppermost portion which has not yet been consumed, to provide efficient direct reduction.

[0329] Thus, any final low temperature / ambient temperature iron ore oxide material charged into the direct reduction facility (in the case of charging unheated iron ore oxide material) is prevented from cooling the remaining amount of hydrogen in the hydrogen-containing reducing agent in the uppermost portion.

[0330] This has the effect that an energy efficient production of a passivated reduced iron material (eg sponge iron) is achieved while producing top gas heat containing hot water vapour which can be used in the high temperature electrolysis unit.

[0331] In this way a densification process is achieved for producing a densified reduced iron material, which thereby prevents reoxidation, thereby enabling safe and cost-effective transportation of the reduced iron material, such as sponge iron, to the metal manufacturing industry.

[0332] In this manner, a metallic material production arrangement is provided that is configured for producing a reduced ferrous material (free of carbon) that is resistant to reoxidation for cost effective and safe refractory transportation of the reduced metallic material to metal fabrication industries or other customers.

[0333] The expression "metal oxide material" may be replaced by the expression "iron ore oxide material".

[0334] The expression "metal oxide material provider unit" may be replaced by the expression "iron ore oxide material provider unit".

[0335] The expression "reduced metal material" may be replaced by the expression "reduced iron ore material".

[0336] The expression "reduced iron ore material" may be replaced by the expression "reduced iron material".

[0337] The expression "metal material production configuration" can be replaced by the expression "sponge iron production configuration".

[0338] The expression "metal oxide material" may be replaced by the expression "sulfide-converted zinc ore oxide material" and / or "sulfide-converted lead ore oxide material".

[0339] Prior to charging and direct reduction / thermal treatment of the metal oxide materials, the respective zinc ore sulfide and lead ore sulfide concentrates are converted to oxides and agglomerated.

[0340] The word "consume" may be replaced by "use" or "utilize".

[0341] The present disclosure may not be limited to the examples described above, but many possibilities of modifications or combinations of the examples described herewith will be apparent to a person skilled in the art without departing from the basic idea as defined in the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0342] In the following, the invention will be described with reference to examples and the accompanying schematic drawings, wherein some unimportant details may be omitted from the drawings for the sake of clarity and understanding of the invention.

[0343] Figure 1 A metal material production configuration suitable for reducing a metal oxide material according to a first example is shown;

[0344] Figure 2a to Figure 2b A second example of applying different designs within a direct reduction facility to affect the residence time period for direct reduction of metal oxide materials is shown;

[0345] Figure 3 A metal material production configuration suitable for reducing a metal oxide material according to a third example is shown;

[0346] Figure 4 shows a flow chart provided by a metal material production arrangement according to a fourth example;

[0347] Figure 5 shows a metal material production configuration suitable for reducing a metal oxide material according to a fifth example;

[0348] Figure 6a A phase diagram showing the iron domain as a function of the oxidizing power of hydrogen and temperature;

[0349] Figure 6b The hydrogen / hydrogen + iron Mol / mol phase diagram versus temperature is shown;

[0350] Figures 7a to 7c illustrates exemplary agglomerate structural transformation stages associated with thermal treatment of reduced metallic materials;

[0351] Figures 8a to 8c illustrates exemplary agglomerate structural transformation stages associated with thermal treatment of reduced metallic materials;

[0352] Figure 9a to Figure 9b A metal material production configuration suitable for reducing a metal oxide material according to a sixth example is shown;

[0353] Fig.10 A flow chart illustrating an exemplary method of directly reducing a metal oxide material to a reduced metal material is shown;

[0354] Fig.11 A flow chart illustrating an exemplary method of directly reducing a metal oxide material to a reduced metal material is shown; and

[0355] Fig.12 shows a control circuit of a metal material production arrangement according to another example; and

[0356] Fig.13 A sponge iron production arrangement for producing densified reduced iron material according to another embodiment is shown. DETAILED DESCRIPTION

[0357] Figure 1 A metal material production configuration 1 according to a first example is shown, which is provided for reducing a metal oxide material into a reduced iron ore material 16 by a hydrogen-containing reducing agent H. The metal material production configuration 1 is suitable for reducing a metal oxide material 5 that maintains a first thermal energy. The metal material production configuration 1 includes a metal oxide material provider unit 3, such as a metal oxide granulation device (not shown) or a metal oxide material preheating device (not shown), and the metal oxide material provider unit 3 is configured to produce a metal oxide material that maintains a relatively high first thermal energy (e.g., a temperature of about 900° C. to about 1500° C., preferably about 1000° C. to about 1400° C.).

[0358] The metal oxide material holding the first thermal energy is charged into the upper inner portion UP of the direct reduction facility 7 via the metal oxide material charging inlet device A. The hydrogen-containing reducing agent H is adapted to hold the second thermal energy before being introduced into the direct reduction facility 7 via the reducing agent inlet device B.

[0359] The control circuit 50 of the metal material production arrangement 1 is electrically connected to the heat treatment providing device 17 and is configured to operate the heat treatment providing device 17 to provide and / or adjust the second thermal energy. The heat treatment providing device 17 may include an electric preheater (not shown) configured to preheat the hydrogen-containing reducing agent H. The control circuit 50 is suitable for controlling the heat treatment by adjusting the second thermal energy of the hydrogen-containing reducing agent H via the heat treatment providing device 17. The heat treatment providing device 17 is configured to adjust the second thermal energy to maintain the required heat treatment temperature in the direct reduction facility 7 by introducing the preheated hydrogen-containing reducing agent H that maintains the adjusted second thermal energy. The hydrogen-containing reducing agent to be preheated is fed from the hydrogen-containing reducing agent supply source SP.

[0360] The direct reduction zone RZ of the direct reduction facility 7 is configured to reduce the metal oxide material 5 by utilizing the first thermal energy of the metal oxide material 5 to heat or further heat the introduced hydrogen-containing reducing agent H to provide a chemical reaction between the introduced hydrogen-containing reducing agent H and the metal oxide material 5 (e.g., a substantially endothermic chemical reaction for direct reduction).

[0361] The heat treatment zone HZ of the direct reduction facility 7 is configured to heat treat the reduced metallic material 16 by exposing the reduced metallic material to a heat treatment temperature required to provide heat treatment of the reduced metallic material to obtain a densified reduced metallic material.

[0362] The dashed boxes schematically shown for the direct reduction zone RZ and the heat treatment zone HZ are for illustration only and may be, for example, overlapping dashed boxes or only one dashed box covering both the direct reduction zone RZ and the heat treatment zone HZ.

[0363] Alternatively, the hydrogen of the hydrogen-containing reducing agent is generated by an electrolysis unit (not shown) configured to decompose water into hydrogen and oxygen.

[0364] The direct reduction facility can be designed as a solid-gas countercurrent moving bed reactor, in which the metal oxide material 5 retaining the first thermal energy is loaded into the upper internal part UP of the direct reduction facility 7 via the metal oxide material loading inlet device A, and descends toward the lower internal part LP of the direct reduction facility 7 by gravity.

[0365] The preheated hydrogen-containing reducing agent H maintaining the second thermal energy is introduced into the lower inner portion LP and / or the upper inner portion UP.

[0366] The metal material production arrangement 1 further comprises a reducing agent preheating device 20 of the heat treatment providing device 17 , which is suitable for preheating the hydrogen-containing reducing agent H to be introduced into the direct reduction facility 7 .

[0367] The control circuit 50 is electrically connected to the reducing agent preheating device 20 and is adapted to control the reducing agent preheating device 20 to provide the second thermal energy of the reducing agent containing hydrogen for achieving the reaction temperature required for the direct reduction of the metal oxide material 5 .

[0368] Furthermore, the control circuit 50 is electrically coupled to the first heat treatment agent feeding device 30 of the heat treatment providing device 17 and is adapted to control the first heat treatment agent feeding device 30 of the heat treatment providing device 17 to produce a heat treatment of the reduced metallic material.

[0369] The metal material production configuration 1 is configured to reduce the metal oxide material 5 into a reduced metal material 16 by utilizing the first thermal energy of the metal oxide material 5 loaded into the direct reduction facility 7 to heat or further heat the introduced hydrogen-containing reducing agent H maintaining the second thermal energy to provide a chemical reaction between the introduced hydrogen-containing reducing agent H and the metal oxide material 5.

[0370] The high temperature of the metal oxide material 5 loaded into the direct reduction facility 7 and the additional heat of the preheated hydrogen-containing reducing agent will enable the metal oxide material to be energy-effectively reduced to a reduced metal material at the desired reaction temperature, and at the same time, the cooling rate of the reduced metal material is reduced by a second thermal energy, so as to expose the reduced metal material to the heat treatment temperature required for providing heat treatment of the reduced metal material to obtain a densified reduced metal material, while the heat treatment temperature required for introducing the preheated hydrogen-containing reducing agent H can be maintained by the heat treatment providing device 17 and the additional heat of the preheated hydrogen-containing reducing agent.

[0371] Alternatively, the reaction temperature required to maintain direct reduction in the direct reduction facility may be a temperature of about 800°C to about 1200°C, preferably about 900°C to about 1100°C.

[0372] The hydrogen-containing reducing agent H continuously fed into the direct reduction facility 7 may exhibit a temperature of about 350°C to about 900°C, preferably about 450°C to about 750°C.

[0373] Preferably, the heat treatment is effected after the metal oxide material 5 is reduced to the reduced metal material 16 and before the reduced metal material 16 is discharged from the direct reduction facility 7 .

[0374] The heat treatment provides densification of the reduced metallic material and / or the metallic oxide material undergoing reduction and produces a compact and dense reduced metallic material that is resistant to reoxidation.

[0375] The compact and dense reduced metal material is discharged through the metal material outlet C of the bottom section of the direct reduction facility 7, wherein the discharged reduced metal material will be resistant to reoxidation and fireproof during further transportation and storage.

[0376] The direct reduction facility 7 further comprises a top gas discharge device D which is configured to discharge top gas TG from the direct reduction facility 7 .

[0377] Figure 2a to Figure 2b A second example of using different designs within a direct reduction facility to affect the residence time period for direct reduction of metal oxide materials is shown. Figure 2aAn aspect ratio Hi / Wi of about 1:2 is shown for the interior of the exemplary direct reduction facility 7. Such a relatively low aspect ratio Hi / Wi of the direct reduction facility 7 may require a relatively high heat treatment temperature required for the heat treatment due to the fact that the residence time period for keeping the reduced metallic material under heat treatment may be relatively short.

[0378] Therefore, the step of maintaining the required heat treatment temperature is provided to such an extent that the introduction of preheated hydrogen provides both direct reduction of the metal oxide material and reduces the cooling rate of the reduced metal material descending through the direct reduction facility 7, for exposing the reduced metal material to the heat treatment temperature required to provide said heat treatment of the reduced metal material to obtain a densified and reduced metal material.

[0379] Figure 2b The interior of an exemplary direct reduction facility 7 is shown with an aspect ratio Hi / Wi of about 3: 1. Such a relatively elongated direct reduction facility 7 having a narrow width relative to its height may be considered suitable where it is desired to provide a relatively high velocity of reduced metallic material that may have a tendency to "stick", while still achieving the desired heat treatment temperatures for exposing the reduced metallic material to the heat treatment that provides the reduced metallic material to obtain a densified and reduced metallic material.

[0380] Alternatively, the aspect ratio is greater than at least 1:1 and up to 10:1 to achieve a residence time period suitable for said heat treatment of the reduced metallic material, while allowing the flow rate of the metal oxide material undergoing reduction and / or the flow rate of the reduced metallic material through the interior of the direct reduction facility to be maintained high enough to avoid metal particles of the reduced metallic material from adhering to the direct reduction facility, while still exposing the reduced metallic material to the heat treatment temperatures required to provide said heat treatment of the reduced metallic material to obtain a densified and reduced metallic material.

[0381] Figure 3 A metal material production arrangement 1 according to a third example is shown which is suitable for directly reducing a metal oxide material 5 retaining a first thermal energy into a reduced metal material 16. The direct reduction facility 7 is configured to provide heat treatment of the reduced metal oxide material 5 and / or the reduced metal material 16 within the direct reduction facility 7.

[0382] The metal material production configuration 1 includes a metal oxide material provider unit 3, such as a metal oxide material granulation device (not shown) or a metal oxide material preheating device (not shown), and the metal oxide material provider unit 3 is configured to provide a metal oxide material 5 maintaining a first thermal energy.

[0383] Alternatively, the metal oxide material retaining the first heat energy discharged from the metal oxide material supplier unit exhibits a temperature of 1000° C. to about 1450° C., preferably about 1100° C. to about 1300° C., for producing the metal oxide material retaining the first heat energy.

[0384] The metal material production arrangement 1 further comprises a direct reduction facility 7 configured to reduce the metal oxide material 5 into reduced metal material 16. The charging hopper arrangement 6 of the metal oxide material charging inlet device A is configured to charge the metal oxide material 5 into an upper inner part UP of the reduction facility 7.

[0385] The hydrogen-containing reducing agent H maintaining the second thermal energy is introduced into the direct reduction facility 7 via the reducing agent inlet device b. The hydrogen-containing reducing agent H is suitable for reacting with the metal oxide material 5 maintaining the first thermal energy, and the metal oxide material 5 is reduced by heating or further heating the introduced hydrogen-containing reducing agent H using the first thermal energy of the metal oxide material 5 to provide a chemical reaction (substantially direct reduction) between the hydrogen-containing reducing agent H and the metal oxide material 5. The hydrogen-containing reducing agent H maintaining the second thermal energy is introduced into the direct reduction facility 7 via the reducing agent inlet device b.

[0386] The hydrogen of the reducing agent H containing hydrogen may be generated by an electrolysis unit (not shown). The reducing agent temperature regulator 18 of the heat treatment providing device 17 is configured to regulate (preheat and / or cool) the second heat energy of the reducing agent H containing hydrogen.

[0387] The reducing agent containing hydrogen to be preheated is fed from the reducing agent supply source SP containing hydrogen.

[0388] The heat treatment involves densification of the reduced metallic material and provides a compact and dense reduced metallic material (intermediate product IM) that is resistant to reoxidation.

[0389] The compact and dense reduced metal material is discharged via a metal material discharge device C comprising a metal material outlet (not shown) of the bottom section 60 of the direct reduction facility 7. The intermediate product IM may be transported to a metal manufacturing industry (not shown) for producing metal, such as steel.

[0390] The metal material production arrangement 1 comprises a control circuit 50 which is electrically connected to a reducing agent temperature regulator 18 of a heat treatment providing device 17 , wherein the reducing agent temperature regulator 18 of the heat treatment providing device 17 is configured to regulate the second thermal energy of the hydrogen-containing reducing agent H before it is introduced into the direct reduction facility 7 .

[0391] The control circuit 50 is suitable for operating the reducing agent temperature regulator 18 so that the second thermal energy of the reducing agent H containing hydrogen is used to provide the reaction temperature required for the direct reduction and / or to provide the required heat treatment temperature.

[0392] The control circuit 50 is suitable for controlling and monitoring the second thermal energy of the preheated hydrogen-containing reducing agent H to be introduced into the direct reduction facility 7 via the heat treatment providing device 17 .

[0393] Alternatively, the control circuit 50 is electrically coupled to the metal oxide material provider unit 3 and is adapted to control and monitor the first thermal energy of the metal oxide material 5 to be loaded into the upper inner portion UP.

[0394] The heat treatment providing device 17 includes a reducing agent heat energy regulating device 17 ′, a reducing agent mass flow regulating device 17 ″, a residence time period regulating device 17 ′″, a pressure regulating device 17 ″″ and a heat treatment agent feeding device 30 .

[0395] The heat treatment agent feeding device 30 is electrically connected to the control circuit 50 and is configured to operate the heat treatment agent feeding device 30 to introduce a preheated hydrogen-containing heat treatment agent HT maintaining a third thermal energy into the direct reduction facility for exposing the reduced metal material to a desired heat treatment temperature, for maintaining the heat treatment temperature required for providing heat treatment of the reduced metal material 16 in the direct reduction facility to obtain a densified reduced metal material.

[0396] The heat treatment agent containing hydrogen to be preheated is fed from the reducing agent supply source SP containing hydrogen to the heat treatment agent feeding device 30 .

[0397] The preheated hydrogen-containing heat treatment agent HT is introduced into the direct reduction facility 7 via the heat treatment agent inlet device 30 of the direct reduction facility 7 .

[0398] The preheated hydrogen-containing reducing agent H is introduced at a position below the metal oxide material charging inlet device A. The heat treatment agent feeding device 30 includes a heat treatment agent preheating unit (not shown) configured to preheat the hydrogen-containing heat treatment agent HT to reach a third thermal energy before being introduced into the direct reduction facility.

[0399] The reducing agent inlet device B is positioned at a level higher than the thermal treatment agent inlet device 30 .

[0400] The control circuit 50 is electrically coupled to the heat treatment providing device 17 configured to provide a heat treatment agent HT containing hydrogen gas maintaining a third heat energy suitable for the heat treatment.

[0401] The reducing agent heat energy regulator 17' is configured to regulate the second heat energy and is electrically connected to the first control circuit 50', which is configured to control the reducing agent heat energy regulator 17' to introduce a heat treatment agent HT of a specific temperature for achieving a desired heat treatment temperature.

[0402] The reducing agent heat conditioning device may include an electric preheater configured to preheat the reducing agent containing hydrogen.

[0403] The reducing agent mass flow regulating device 17" is configured to regulate the mass flow of the hydrogen-containing reducing agent H introduced into the direct reduction facility 7, and is electrically connected to a second control circuit 50", wherein the second control circuit 50" is configured to operate the reducing agent mass flow regulating device 17" to regulate the mass flow of the hydrogen-containing reducing agent H for achieving the desired heat treatment temperature.

[0404] The residence time period adjustment device 17'" is configured to adjust the residence time period for which the reduced metal material 16 is maintained in the direct reduction facility 7, and is electrically connected to a third control circuit 50'", wherein the third control circuit 50'" is configured to operate the residence time period adjustment device 17'" to achieve the specific residence time period for maintaining the reduced metal material in the direct reduction facility 7 and to control the required heat treatment temperature.

[0405] The pressure regulating device (17"") is configured to regulate the pressurization inside the direct reduction facility 7 and is electrically connected to a fourth control circuit 50"", which is configured to operate the pressure regulating device 17"" towards a specific pressure in the direct reduction facility 7 for controlling the required heat treatment temperature.

[0406] The direct reduction plant 7 further comprises a top gas outlet of a top gas discharger D, which is configured to discharge top gas from the direct reduction plant 7, said top gas preferably being reused and / or recycled.

[0407] Alternatively, the top gas contains up to about 100% by volume of high temperature water vapor.

[0408] Alternatively, the top gas contains up to about 80% to 100% by volume, preferably about 85% to 95% by volume, of high temperature water vapor.

[0409] Alternatively, the top gas contains up to about 60 to 90 volume %, preferably about 70 to 80 volume %, of high temperature water vapor.

[0410] Alternatively, the top gas contains up to about 30% to 60% by volume, preferably about 40% to 50% by volume, of high temperature water vapor.

[0411] Alternatively, the top gas contains high temperature water vapor in an amount of up to about 10 to 40 volume %, preferably about 20 to 30 volume %.

[0412] Alternatively, the top gas contains up to about 0 to 20 volume %, preferably about 5 to 15 volume %, of high temperature water vapor.

[0413] Alternatively, the top gas contains up to about 0% to 15% by volume, preferably about 1% to 10% by volume, of high temperature water vapor.

[0414] The reduction facility 7 is configured to allow the reduced metal material 16 to descend downward in the direct reduction facility 7 for providing heat treatment of the reduced metal material 16 .

[0415] The chemical reactivity and / or high driving force of the preheated hydrogen-containing reducing agent H are not destroyed after being introduced into the direct reduction facility 7, because the desired reaction temperature is reached by the first thermal energy of the charged metal oxide material. Therefore, it is not necessary to "burn" the reducing agent to reach the desired reaction temperature, for example by a fired heater.

[0416] The heat treatment agent feeding device 30 is electrically coupled to the control circuit 50 and is configured to operate the heat treatment agent feeding device 30 to introduce preheated hydrogen.

[0417] Alternatively, heat treatment of the reduced metal material 16 is achieved by introducing a preheated hydrogen-containing heat treatment agent HT into the direct reduction facility 7, wherein third thermal energy is added via the heat treatment agent feeding device 30 to reduce the cooling rate of the directly reduced metal material 16 in the reduction facility 7.

[0418] Alternatively, the control circuit is electrically connected to the heat treatment agent thermal energy regulating device of the heat treatment agent feeding device 30 to regulate the third thermal energy of the heat treatment agent HT containing hydrogen for controlling the heat treatment of the reduced metal material 16 .

[0419] The metal oxide material 5 that has been reduced to the reduced metal material and / or the metal oxide material 5 that has not yet been completely reduced is exposed to the heat treatment temperature required to provide heat treatment of the reduced metal material 16 to obtain a densified reduced metal material (for example, the produced limited reoxidation intermediate product or sponge iron), and the densified reduced metal material is discharged via a metal material discharge device C configured to discharge the reduced and heat-treated metal material 16.

[0420] Figure 4A flow chart provided by a metal material production configuration 1 according to a fourth example is shown. A metal oxide material 5 retaining heat energy is loaded into a reduction facility 7. The reduction facility 7 can be defined as having an upper inner portion UP, an intermediate inner portion IP, and a lower inner portion LP. A hydrogen-containing reducing agent H is introduced into the intermediate inner portion IP and flows upward, encountering the metal oxide material 5 retaining heat energy transferred downward, whereby the upper inner portion UP acts as a countercurrent heat exchange zone for providing a chemical reaction (direct reduction) between the metal oxide material and the hydrogen-containing reducing agent 6, thereby producing a reduced metal material 16.

[0421] The reducing agent H containing hydrogen is preheated by the heat treatment providing device 17 to provide the reducing agent H containing hydrogen that maintains the second thermal energy.

[0422] Alternatively, the metal oxide material 5 maintaining the first thermal energy moves downward from the upper inner portion UP to the middle inner portion IP and / or the lower inner portion LP by gravity.

[0423] The control circuit (not shown) is electrically connected to the heat treatment providing device 17 and is suitable for operating the heat treatment providing device 17 to preheat the hydrogen-containing gas agent to maintain a second thermal energy for exposing the reduced metal material 16 to the heat treatment temperature required for providing heat treatment of the reduced metal material to obtain a densified reduced metal material, and maintaining the required heat treatment temperature by introducing the preheated hydrogen-containing reducing agent H.

[0424] Alternatively, the temperature of the hydrogen-containing reducing agent H introduced into the intermediate inner part IP is controlled by a control circuit to provide a direct direction for producing a top gas TG produced by direct reduction and containing high temperature steam or containing high temperature steam in large quantities.

[0425] Alternatively, the temperature of the reducing agent H containing hydrogen introduced into the middle inner portion LP is controlled by a control circuit to provide the top gas TG containing more than about 80% to 90% of high-temperature water vapor.

[0426] The discharged top gas TG may also contain residual volumes of hydrogen which have not yet been consumed by the direct reduction.

[0427] In this way, complete reduction of the metal oxide material is achieved.

[0428] Due to the high temperature of the charged metal oxide material 5, effective reduction of the metal oxide material 5 is achieved despite the fact that the hydrogen-containing reducing agent H contains a large amount of water in the upper section of the upper inner portion UP.

[0429] The metal material production configuration 1 is suitable for introducing a preheated hydrogen-containing heat treatment agent HT maintaining a third thermal energy into the direct reduction facility 7 through a heat treatment agent feeding device 30 so that the reduced metal material 16 is exposed to the required heat treatment temperature, for maintaining the required heat treatment temperature and for providing the said heat treatment of the reduced metal material 16 to obtain a densified reduced metal material.

[0430] The introduction of the preheated hydrogen-containing heat treatment agent HT maintaining the third thermal energy is preferably provided into the middle inner part IP and / or the lower inner part LP. The temperature of the preheated hydrogen-containing heat treatment agent HT maintaining the third thermal energy is controlled by a heat treatment agent feeding device 30 electrically connected to the control circuit, for adjusting the temperature toward the heat treatment temperature required to provide the heat treatment.

[0431] Figure 4 Also shown is a residence time period adjustment device 17'", which is configured to adjust the residence time period for keeping the reduced metal material 16 in the direct reduction facility 7 for a specific residence time period. The residence time period adjustment device 17'" is electrically connected to a control circuit, which is configured to operate the residence time period adjustment device 17'" to achieve the specific residence time period for maintaining the required heat treatment temperature of the reduced metal material in the direct reduction facility 7 and controlling the required heat treatment temperature.

[0432] The residence time period adjustment device 17'" comprises a throttling mechanism CM', CM", which is suitable for adjusting the discharge of the heat-treated and reduced metal material from the lower inner part LP. The throttling mechanism CM', CM" is connected to the metal material flow reduction member MM. The operation of the throttling mechanism CM', CM" is synchronized with the operation of a charging arrangement (not shown), which is configured to adjust the amount of metal oxide material 5 entering the reduction facility 7.

[0433] Alternatively, the heat treating agent feeding device 30 is configured to adjust the third thermal energy for controlling the heat treatment to produce a semi-molten and / or densified reduced metal material.

[0434] Figure 5A metal material production arrangement 1 suitable for directly reducing a metal oxide material 5 into a reduced iron ore material 16 and heat treating the reduced iron ore material by a hydrogen-containing reducing agent H according to a fifth example is shown. The metal material production arrangement 1 comprises a direct reduction facility 7 arranged to be able to be charged with a metal oxide material 5 retaining a first thermal energy provided by a metal oxide material provider unit 3 such as a metal oxide granulation plant PP and / or a metal oxide material preheating unit PHU configured to preheat the metal oxide material transferred from a metal oxide material storage 8.

[0435] The metal oxide material to be charged into the direct reduction facility may be maintained at a temperature of about 900°C to about 1500°C, preferably about 1000°C to about 1400°C.

[0436] The metal oxide material maintaining the first thermal energy is charged into the upper inner portion UP of the direct reduction facility 7 via the metal oxide material charging inlet device A. The hydrogen-containing reducing agent H maintains the second thermal energy before being introduced into the direct reduction facility 7 via the reducing agent inlet device B.

[0437] Alternatively, the reducing agent inlet E of the reducing agent inlet device 30 configured to introduce the preheated reducing agent HT containing hydrogen into the direct reduction facility 7 may be positioned lower than the reducing agent inlet device B configured to introduce the preheated reducing agent H containing hydrogen.

[0438] The charging hopper arrangement 6 of the metal oxide material charging inlet device A is configured to charge the metal oxide material 5 into the upper inner portion UP of the reduction facility 7. The metal oxide material substantially retaining the second thermal energy is transferred from the metal oxide material provider unit 3 to the direct reduction facility 7 via the charging hopper arrangement 6.

[0439] The metal material production configuration 1 includes a first sealing gas introduction device 61, which is configured to introduce a sealing gas into the direct reduction facility 7 in combination with the step of charging the metal oxide material retaining the first thermal energy into the direct reduction facility 7. The material production configuration 1 includes a second sealing gas introduction device (not shown), which is configured to introduce a second sealing gas into the direct reduction facility 7 via a metal material discharge device C, which is configured to discharge the reduced metal material 16 that has been subjected to heat treatment.

[0440] In this way, it is achieved that charging of the metal oxide material into the direct reduction plant can be carried out safely without any explosive air / process gas mixture being formed while charging is taking place.

[0441] This is achieved by ensuring that only sealed gas and no air is introduced into the direct reduction facility when charging the metal oxide material, wherein no process gas and / or hydrogen-containing reducing gas escapes the direct reduction facility during charging of the metal oxide material.

[0442] The control circuit 50 of the metal material production arrangement 1 is electrically connected to the heat treatment providing device 17 and is configured to operate the heat treatment providing device 17 to provide and / or adjust the second heat energy of the preheated hydrogen-containing reducing agent H. The heat treatment providing device 17 may include an electric preheater (not shown) configured to preheat the hydrogen-containing reducing agent H.

[0443] The control circuit 50 is adapted to control the heat treatment of the reduced metal material 16 by regulating the second heat energy of the hydrogen-containing reducing agent H via the heat treatment providing device 17. The heat treatment providing device 17 is configured to regulate the second heat energy to maintain the required heat treatment temperature in the direct reduction facility 7 by introducing the preheated hydrogen-containing reducing agent H maintaining the regulated second heat energy. The hydrogen-containing reducing agent to be preheated is fed from a hydrogen-containing reducing agent supply source SP, such as an electrolysis unit 62. The electrolysis unit 62 is configured to decompose water W into hydrogen to be contained in the hydrogen-containing reducing agent H and oxygen O2. The oxygen O2 produced by the electrolysis unit 62 can be transferred to an oxidation zone (not shown) of the metal oxide granulation device PP for oxidation of the preheated metal ore material.

[0444] The direct reduction facility 7 is configured to reduce the metal oxide material 5 by utilizing the first thermal energy of the metal oxide material 5 to heat or further heat the introduced hydrogen-containing reducing agent H to provide a chemical reaction between the introduced hydrogen-containing reducing agent H and the metal oxide material 5 (e.g., a substantially endothermic chemical reaction for direct reduction).

[0445] The direct reduction facility 7 is configured to heat treat the reduced metallic material 16 by exposing the reduced metallic material 16 to a heat treatment temperature required to provide heat treatment of the reduced metallic material 16 to obtain a densified reduced metallic material that limits reoxidation.

[0446] The direct reduction facility can be designed as a solid-gas countercurrent moving bed reactor, in which the metal oxide material 5 retaining the first thermal energy is loaded into the upper internal part UP of the direct reduction facility 7 via the metal oxide material loading inlet device A, and descends toward the lower internal part LP of the direct reduction facility 7 by gravity.

[0447] The preheated hydrogen-containing reducing agent H retaining the second thermal energy is introduced into the lower inner part LP and / or the upper inner part UP and may be introduced into the direct reduction facility 7 at a level higher than each other.

[0448] Furthermore, the control circuit 50 is electrically connected to the heat treatment agent feeding device 30 of the heat treatment providing device 17 and is adapted to control the heat treatment agent feeding device 30 of the heat treatment providing device 17 to provide heat treatment of the reduced metal material 16. The heat treatment agent feeding device 30 is adapted to introduce and adjust the third thermal energy of the preheated hydrogen-containing heat treatment agent HT to be introduced into the direct reduction facility 7, for exposing the reduced metal material to the heat treatment temperature required to provide heat treatment of the reduced metal material, so as to obtain a densified reduced metal material, and then to obtain an intermediate product with limited reoxidation.

[0449] The high temperature of the metal oxide material 5 loaded into the direct reduction facility 7, as well as the additional heat of the preheated hydrogen-containing reducing agent that maintains the second thermal energy and the added preheated hydrogen-containing heat treatment agent HT are controlled by the control circuit to achieve energy-efficient reduction of the metal oxide material into a reduced metal material at the required reaction temperature, and at the same time reduce the cooling rate of the reduced metal material by the second thermal energy and the third thermal energy, so as to expose the reduced metal material to the heat treatment temperature required for providing heat treatment of the reduced metal material to obtain a densified reduced metal material.

[0450] The required heat treatment temperature is controlled by the control circuit by adjusting the third thermal energy, which is used to maintain the required heat treatment temperature and to provide the said heat treatment of the reduced metal material 16 to obtain the densified reduced metal material; and is controlled by the control circuit to adjust the second thermal energy of the preheated hydrogen-containing reducing agent H through the heat treatment providing device 17.

[0451] The direct reduction facility 7 includes a top gas outlet device D, which is configured to discharge a top gas TG containing excess hydrogen and high-temperature water vapor from the direct reduction facility 7. The high-temperature water vapor is produced by a chemical reaction between the metal oxide material and the hydrogen of the hydrogen-containing reducing agent. The top gas TG is fed to a filter unit 63, which is suitable for separating the high-temperature gas from the excess hydrogen to be recycled (not shown) back to the hydrogen-containing reducing agent H. In addition, the filter unit 63 is configured to filter the high-temperature water vapor WS from inclusions. The high-temperature water vapor WS is fed to a heat exchange device 64 to provide water W to be fed to the electrolysis unit 62. The heat exchange device 64 is suitable for cooling the high-temperature water vapor WS into water W, and transferring the recovered heat to, for example, a heat treatment providing device 17 to preheat the hydrogen-containing reducing agent H and / or the hydrogen-containing heat treatment agent HT. The electrolysis unit 62 configured to decompose water W is electrically supplied by a renewable energy supply source RGE and may be supplemented with water from an external water supply source 65 .

[0452] Figure 6aA phase diagram of the iron domain as a function of the oxidizing power of hydrogen and temperature for a gas mixture H2-H2O is shown. As shown in the figure, the reduction of iron ore oxide material in the form of hematite and / or magnetite and / or wüstite to reduced iron ore material occurs in two or three stages, depending on whether the temperature is above or below 570°C. In this case, hematite Fe2O3 is first reduced to magnetite Fe3O4 and then to wüstite FeO X , and is finally reduced to iron Fe. This figure reveals that increasing the water vapor content inside the direct reduction facility requires higher temperatures to obtain reduction of the iron ore oxide material.

[0453] The preheated hydrogen-containing reducing agent retaining the second thermal energy introduced into the direct reduction facility rises upward in the direct reduction facility and contacts the descending iron ore oxide material retaining the first thermal energy.

[0454] Since the iron ore oxide material which retains the first heat energy is charged to the direct reduction facility, even if the water content in the hydrogen-containing reducing agent is high (see Figure 6a The phase diagram at position Q, for example, H2O / (H2O+H2) ratio is about 0.9), can also achieve the reduction of iron ore oxide materials.

[0455] Preferably, the lower in the direct reduction plant, the less water vapor is present in the reduction plant, since a smaller extent of hydrogen is used for the reduction, whereby the hydrogen content can be twice the water content (see Figure 5 Phase diagram at position R, for example, the H2O / (H2O+H2) ratio is about 0.3).

[0456] Alternatively, the control circuit (not shown) is adapted to control the direct reduction in the direct reduction facility such that the reduced metallic material is not reoxidized.

[0457] Alternatively, the control circuit may be electrically connected to a reducing agent thermal energy regulating device (not shown) and / or a pressurizing regulating device (not shown) and / or a reducing agent mass flow regulating device (not shown) and / or a residence time period regulating device means (not shown) suitable for maintaining the iron oxide material in the direct reduction facility for a specific residence time period and / or a reducing agent introduction / pressurizing device and / or a furnace top gas exhaust device to control the desired reaction temperature and / or the desired heat treatment temperature.

[0458] Thus, the desired reaction temperature is maintained by the control circuit by adjusting the temperature of the hydrogen-containing reducing agent and / or by adjusting the mass flow of the preheated hydrogen-containing reducing agent fed to the direct reduction facility.

[0459] In this way it is achieved that the reduced iron material is not reoxidized in the direct reduction plant.

[0460] Alternatively, the control circuit is adapted to control the reductant mass flow regulator to feed a relatively high flow of preheated hydrogen-containing reductant into the direct reduction facility to suppress the water vapor load in the direct reduction facility for providing efficient direct reduction and fully direct reduced iron material.

[0461] By means of the secondary thermal energy of the preheated hydrogen-containing reducing agent, direct reduction can thus be provided, although the water content is relatively high further down in the direct reduction plant (cf. Figure 5 The fact that the phase diagram at position R in the middle).

[0462] Alternatively, the preheated hydrogen-containing reductant introduced into the direct reduction facility may exhibit higher heat the higher it rises in the direct reduction facility as the hotter iron ore oxide material heats or further heats the preheated hydrogen-containing reductant to provide the desired reaction temperature.

[0463] Alternatively, the preheated hydrogen-containing reducing agent reduces the cooling rate of the iron ore oxide material descending in the direct reduction facility.

[0464] Alternatively, the higher the preheated hydrogen-containing reducing agent rises in the direct reduction facility, the preheated hydrogen-containing reducing agent contains increasing amounts of high temperature water vapor. However, efficient direct reduction of iron ore oxide materials can be achieved (see Figure 5 Phase diagram at position Q in the figure).

[0465] As shown in the figure, hematite will be reduced to magnetite at high temperature (eg, 1200° C.), and direct reduction to magnetite can be achieved despite the high water content (position Q) of the preheated hydrogen-containing reducing agent.

[0466] In this way, the thermal energy of the first thermal energy generated by the metal oxide material provider unit is combined with the thermal energy of the hydrogen-containing reducing agent 8 and / or the hydrogen H to achieve the desired reaction temperature.

[0467] In this way, high temperature-facilitated efficient direct reduction of the iron ore oxide material is achieved, although the preheated hydrogen-containing reducing agent will contain a high content of water vapor (see Figure 5 The fact that the phase diagram at position Q in the graph is

[0468] Alternatively, any excess hydrogen separated from the top gas discharged from the direct reduction plant is recycled to the direct reduction plant and introduced into the direct reduction plant.

[0469] In this way, a cost-effective utilization of hydrogen is achieved.

[0470] The preheated hydrogen-containing reducing agent retaining the second thermal energy introduced into the reduction facility thus rises through the upper internal portion and contacts the descending iron ore oxide material retaining the first thermal energy under reduction, and the higher the introduced preheated hydrogen-containing reducing agent rises in the direct reduction facility, the preheated hydrogen-containing reducing agent will contain an increasing amount of water.

[0471] As shown in the figure, hematite will be reduced to magnetite at high temperature (eg 1200°C), and the reduction to magnetite can be achieved despite the fact that the water content of the preheated hydrogen-containing reducing agent H is high.

[0472] The present disclosure utilizes the high temperature of the iron ore oxide material that maintains the first heat energy, which is loaded into the upper inner part UP from the iron ore oxide material provider unit. This high temperature of the iron ore oxide material makes reduction possible despite the fact that the preheated hydrogen-containing reducing agent will contain an increased amount of water when it reaches the upper section of the upper inner part UP.

[0473] The desired heat treatment temperature is maintained at such a level that the introduction of the preheated hydrogen-containing reducing agent H which maintains the second energy is reduced by the direct reduction facility (see e.g. Figure 5 The degree of cooling rate of the reduced iron material as marked in 7).

[0474] Thus, a reduction in the cooling rate of the reduced iron material passing through the direct reduction facility is achieved, so that the reduced metal material can be effectively heat treated, thereby exposing the reduced metal material to the heat treatment temperature required for providing heat treatment of the reduced iron material to obtain a densified reduced iron material, and maintaining the required heat treatment temperature by introducing preheated hydrogen-containing reducing agent H using a heat treatment providing device (not shown).

[0475] Figure 6b A hydrogen / hydrogen+iron Mol / mol phase diagram is shown relative to temperature and considered from different temperature aspects. The symbol O represents the liquid phase, the symbol P represents the Bcc / liquid phase, the symbol Q represents the Bcc phase, and the symbol R represents the Fcc phase. The figure shows that the iron Fe will undergo sintering in the Bcc+liquid phase P, i.e. the iron of the reduced iron ore material is hardened by relatively low temperatures (e.g. 200°C to 600°C) due to the fact that the introduced hydrogen maintains its chemical reactivity and / or high driving force. This in turn will promote the production of a densified reduced metal material in combination with exposing the reduced iron material to the heat treatment temperature required to provide the heat treatment of the reduced iron material.

[0476] Furthermore, the reducing agent does not need to be "burned" or intensely heated to, for example, 1200°C to provide thermal energy to provide direct reduction as taught in the prior art.

[0477] Conversely, by utilizing the first thermal energy of the iron ore oxide material charged into the reduction facility to provide heat for direct reduction, it is now possible to control the second thermal energy of the introduced hydrogen-containing reducing agent to reduce the cooling rate of the reduced iron material further down the direct reduction facility as it descends through the direct reduction facility.

[0478] Therefore, the heat treatment can be effectively achieved by the second thermal energy and by the high chemical reactivity and / or high driving force maintained by the hydrogen-containing reducing agent.

[0479] Alternatively, heat treatment of the reduced iron material is achieved at a desired heat treatment temperature for an extended period of time for achieving a densified reduced iron material wherein the wüstite is largely reduced to a densified surface of sponge iron and / or sponge iron agglomerates produced.

[0480] In this way it is achieved that the intermediate product (eg sponge iron) is prevented from having a tendency to revert to an oxidised state when exposed to the elements.

[0481] In this way, the risk of spontaneous combustion of sponge iron is eliminated.

[0482] In this way, safe transportation of sponge iron to the steelmaking industry is achieved.

[0483] In this way, the steelmaking industry saves energy in steel production by using sponge iron in electric arc furnaces.

[0484] Alternatively, the control circuit 50 is adapted to control the heat treatment providing means to provide heat treatment of the reduced iron material in the Bcc+ liquid phase P, or preferably to expose the reduced iron ore material. By exposing the reduced iron material and / or the iron ore oxide material under reduction, and by maintaining the desired heat treatment temperature for an extended period of time, and by using a reducing agent containing hydrogen having high chemical reactivity and / or high driving force, a reduced iron material resistant to reoxidation is provided.

[0485] Figures 7a to 7c The stages of structural transformation of agglomerates associated with the thermal treatment disclosed herein are shown. Figure 7a An agglomerate structure of an iron ore oxide material 5 that retains first thermal energy is shown, the iron ore oxide material 5 being subjected to direct reduction in an upper inner portion of a reduction facility (not shown).

[0486] The porous agglomerates PA containing iron ore oxide particles OP are loaded into the direct reduction facility. The iron ore oxide particles are bonded to each other to form porous agglomerates PA, the porosity of which promotes the chemical reaction between the iron ore oxide and the introduced preheated hydrogen-containing reducing agent for initially providing direct reduction. Figure 7bA porous agglomerate PA containing reduced iron material is shown ready for heat treatment. Finally, a certain amount of wüstler material may be present in the spaces between the reduced iron particles RIP, wherein the high hydrogen content of the introduced hydrogen-containing gas and the required heat treatment temperature provide for the final FeO compounds to be decomposed into Fe and oxygen due to the oxygen and hydrogen combining and forming water molecules.

[0487] Alternatively, in order to provide a reduced iron material that is resistant to reoxidation, the reduced iron material and / or the iron ore oxide material (mainly the wüstite material) is exposed to a heat treatment temperature required to provide the heat treatment to obtain a densified reduced iron material, such as Figure 7c This is achieved by maintaining the desired heat treatment temperature using a heat treatment providing device by introducing a preheated hydrogen-containing reducing agent and / or by introducing a preheated hydrogen-containing heat treatment agent for providing the reduced iron material and / or undergoing said heat treatment of the reduced iron ore oxide material.

[0488] Alternatively, spheroidization of the reduced iron particles is provided by the heat treatment.

[0489] or, Figure 7c The produced sponge iron SI shown in comprises voids V. The heat treatment produces a sponge iron SI which is resistant to reoxidation.

[0490] Figure 7c A portion of the sponge iron SI densified by the heat treatment is shown.

[0491] Figures 8a to 8c The stages of structural transformation of agglomerates associated with the thermal treatment disclosed herein are shown. Figure 8a An agglomerate structure of an iron ore oxide material 5 that retains first thermal energy is shown, the iron ore oxide material 5 being subjected to direct reduction in an upper inner portion of a reduction facility (not shown).

[0492] The porous agglomerates PA containing iron ore oxide particles OP are loaded into the direct reduction facility. The iron ore oxide particles are bonded to each other to form porous agglomerates PA, the porosity of which promotes the chemical reaction between the iron ore oxide and the introduced preheated hydrogen-containing reducing agent for initially providing direct reduction. Figure 8b A porous agglomerate PA containing reduced iron material is shown ready for heat treatment. Finally, a certain amount of wüstler material may be present in the spaces between the reduced iron particles RIP, wherein the high hydrogen content of the introduced hydrogen-containing gas and the required heat treatment temperature provide for the final FeO compounds to be decomposed into Fe and oxygen due to the oxygen and hydrogen combining and forming water molecules.

[0493] Alternatively, in order to provide a reduced iron material that is resistant to reoxidation, the reduced iron material and / or the iron ore oxide material (mainly the wüstite material) is exposed to a heat treatment temperature required to provide the heat treatment to obtain a densified reduced iron material, such as Figure 8c This is achieved by maintaining the desired heat treatment temperature using a heat treatment providing device by introducing a preheated hydrogen-containing reducing agent and / or by introducing a preheated hydrogen-containing heat treatment agent for providing the reduced iron material and / or undergoing said heat treatment of the reduced iron ore oxide material. Figure 8c A portion of the sponge iron SI densified by the heat treatment is schematically shown.

[0494] Figure 9a to Figure 9b A metal material production arrangement 1 adapted to reduce an iron ore oxide material 5 retaining a first thermal energy, the material being loaded into a reduced iron ore material 16, according to a sixth example is shown.

[0495] The metal material production arrangement 1 comprises an iron ore oxide material provider unit 3, such as an iron ore oxide granulation plant or an iron ore oxide preheating plant, which is configured to provide an iron ore oxide material 5 maintaining a first thermal energy.

[0496] The metal material production arrangement 1 comprises a reduction facility 7 configured to reduce the iron ore oxide material 5. The iron ore oxide material 5 retaining the first thermal energy is charged into the upper inner portion UP of the reduction facility 7.

[0497] The metal material production arrangement 1 comprises a reducing agent preheating device 20 of the heat treatment provision device 17, said reducing agent preheating device 20 and / or the heat treatment provision device 17 being configured to operate the direct reduction facility 7 to reach a desired heat treatment temperature.

[0498] The reducing agent preheating device 20 is configured to preheat the reducing agent H containing hydrogen introduced into the direct reduction facility 7 , and is electrically connected to the control circuit 50 of the metal material production arrangement 1 .

[0499] The heat treatment agent feeding device 30 of the heat treatment providing device 17 is suitable for introducing and adjusting the third thermal energy of the preheated hydrogen-containing heat treatment agent HT to be introduced into the direct reduction facility 7, so as to expose the reduced iron material to the heat treatment temperature required for providing heat treatment of the reduced metal material to obtain a densified reduced metal material.

[0500] Furthermore, the preheated hydrogen-containing reducing agent H may be introduced into the reduction facility 7 at different levels, and may be introduced at different temperatures, at different pressures, flow rates, and the like.

[0501] The direct reduction facility 7 may comprise an upper inner part UP and / or an intermediate inner part IP and / or a lower inner part.

[0502] The introduced preheated hydrogen-containing reducing agent H fed to the direct reduction facility may contain about 80% to 100% hydrogen, preferably about 85% to 95% hydrogen, or pure hydrogen.

[0503] Figure 9b The reduction facility 7 is shown in cross section. Preheated hydrogen-containing reducing agent H and an optionally introduced preheated hydrogen-containing heat treatment agent (not shown) are introduced circumferentially around the direct reduction facility 7. Top gas TG is discharged circumferentially from the reduction facility 7.

[0504] Alternatively, the reaction temperature required to maintain direct reduction in the direct reduction facility may be a temperature of about 800°C to about 1200°C, preferably about 900°C to about 1100°C.

[0505] The hydrogen-containing reducing agent H continuously fed into the direct reduction facility 7 may exhibit a temperature of about 350°C to about 900°C, preferably about 450°C to about 750°C.

[0506] Preferably, the heat treatment is effected after the iron ore oxide material 5 is reduced to the reduced iron material and before the reduced iron material 16 is discharged from the direct reduction facility 7 .

[0507] Alternatively, the heat treatment provides densification of the reduced iron material and / or the iron ore oxide material subjected to reduction and produces a compact and dense reduced metal material that is resistant to reoxidation.

[0508] The compact and dense reduced iron material is discharged via a bottom outlet (not shown) of a bottom section (not shown) of the direct reduction facility 7. The discharged reduced iron material is resistant to reoxidation and fireproof for further transport in ambient air.

[0509] Fig.10A flow chart showing an exemplary method for directly reducing a metal oxide material into a reduced metal material by a metal material production configuration (not shown), the metal material production configuration comprising: a metal oxide material supplier unit (not shown) configured to provide a metal oxide material maintaining a first thermal energy; and a direct reduction facility (not shown), the direct reduction facility comprising a metal oxide material charge inlet device, a reducing agent inlet device configured to introduce a reducing agent containing hydrogen maintaining a second thermal energy; a direct reduction zone of the direct reduction facility, which is configured to heat or reduce the metal oxide material by utilizing the first thermal energy of the metal oxide material further heating the introduced hydrogen-containing reducing agent to provide a chemical reaction between the introduced hydrogen-containing reducing agent and the metal oxide material to reduce the metal oxide material; a heat treatment zone of the direct reduction facility, which is configured to heat treat the reduced metal by exposing the reduced metal material to a heat treatment temperature required to provide heat treatment of the reduced metal material to obtain a densified reduced metal material; a heat treatment providing device, which is configured to maintain the required heat treatment temperature by introducing a preheated hydrogen-containing reducing agent; and a metal material discharge device, which is configured to discharge the reduced metal material that has been subjected to the heat treatment.

[0510] Fig.10 The method in starts at step 801. Step 802 includes adaption of the method. Step 803 includes stopping of the method. Step 802 may include the following steps: charging a metal oxide material maintaining a first thermal energy into a direct reduction facility via a metal oxide material charging inlet device; introducing a preheated hydrogen-containing reducing agent maintaining a second thermal energy into the direct reduction facility via a reducing agent inlet device; reducing the metal oxide material by heating or further heating the introduced preheated hydrogen-containing reducing agent using the first thermal energy of the metal oxide material to provide a chemical reaction between the introduced preheated hydrogen-containing reducing agent and the metal oxide material; exposing the reduced metal material to a heat treatment temperature required for providing heat treatment of the reduced metal material to obtain a densified reduced metal material; maintaining the required heat treatment temperature by introducing the preheated hydrogen-containing reducing agent using a heat treatment providing device; and discharging the reduced metal material that has been subjected to heat treatment.

[0511] Fig.11A flow chart showing an exemplary method of directly reducing a metal oxide material to a reduced metal material by a metal material production configuration disclosed herein is shown. The method begins at step 900. Step 901 includes charging a metal oxide material maintaining a first thermal energy into a direct reduction facility via a metal oxide material charging inlet device. Step 902 includes introducing a preheated hydrogen-containing reducing agent maintaining a second thermal energy into the direct reduction facility via a reducing agent inlet device. Step 903 includes reducing the metal oxide material by heating or further heating the introduced preheated hydrogen-containing reducing agent using the first thermal energy of the metal oxide material to provide a chemical reaction between the introduced preheated hydrogen-containing reducing agent and the metal oxide material. Step 904 includes exposing the reduced metal material to a heat treatment temperature required for providing a heat treatment of the reduced metal material to obtain a densified reduced metal material. Step 905 includes maintaining the required heat treatment temperature by introducing a preheated hydrogen-containing reducing agent using a heat treatment providing device. Step 906 includes discharging the reduced metal material that has been subjected to heat treatment. Step 907 includes introducing a preheated hydrogen-containing heat treatment agent maintaining a third thermal energy into the direct reduction facility through a heat treatment agent feed device to expose the reduced metal material to a desired heat treatment temperature for maintaining the desired heat treatment temperature and for providing said heat treatment of the reduced metal material to obtain a densified reduced metal material. Step 908 includes providing maintenance of the desired heat treatment temperature to such an extent that the introduction of the preheated hydrogen-containing reductant produces direct reduction of the metal oxide material and reduces the cooling rate of the reduced metal material descending through the direct reduction facility for maintaining said desired heat treatment temperature. Step 909 includes stopping of the method.

[0512] Fig.12 A control circuit 50 of a metal material production configuration 1 according to another example is shown. The control circuit 50 is configured to control any of the exemplary methods disclosed herein. The control circuit 50 may include a non-volatile memory NVM 1020, which is a computer memory that can save stored information even when the control circuit 50 or the computer is not powered. The control circuit 50 also includes a processing unit 1010 and a read / write memory 1050.

[0513] The NVM 1020 comprises a first memory unit 1030. A computer program (which may be of any type suitable for any operating database) is stored in the first memory unit 1030 for controlling the functions of the control circuit 50.

[0514] Furthermore, the control circuit 50 includes a bus controller (not shown), a serial communication port (not shown) providing a physical interface through which information is transmitted in both directions.

[0515] The control circuit 50 may include any suitable type of I / O module (not shown) for providing input / output signal transmission, an A / D converter (not shown) for converting different signals from temperature detectors of the direct reduction facility and the thermal treatment providing device for detecting the introduced preheated hydrogen-containing reducing agent and / or the actual thermal treatment temperature and / or the temperature of the preheated hydrogen-containing thermal treatment agent into binary codes suitable for processing by the computer of the control circuit 50.

[0516] The control circuit 50 may utilize various monitoring units (not shown) of the direct reduction plant to monitor the heat treatment temperature and / or the characteristics of the produced reoxidation resistant heat treated and reduced metallic material.

[0517] The control circuit 50 also includes an input / output unit (not shown) for adapting the time and date. The control circuit 50 may also include an event counter (not shown) for counting the number of event quantities occurring during the conditioning of the chemical reaction and / or the heat treatment to obtain the densified reduced metallic material.

[0518] In addition, the control circuit 50 includes an interrupt unit (not shown) for providing multi-tasking execution and real-time calculation. The NVM 1020 also includes a second memory unit 1040 for external control operations.

[0519] The data medium suitable for storing the data program P comprises drive routines suitable for instructing the operation of the metal material production arrangement 1 .

[0520] The data program P is suitable for operating the control circuit 50 in performing any of the exemplary methods described herein. The data program P includes routines for executing instructions under operation of the metal material production arrangement 1. The data program P includes program code readable on a computer for causing the computer to perform the exemplary methods described herein.

[0521] The data program P may also be stored in the independent memory 1060 and / or the read / write memory 1050. The data program P may be stored in an executable or compressed data format.

[0522] It should be understood that when processing unit 1010 is described as performing specific functions, this involves processing unit 1010 executing specific portions of a program stored in independent memory 1060 or specific portions of a program stored in read / write memory 1050 .

[0523] The processing unit 1010 is associated with a signal (data) port 1099 , such as a serial bus, for communicating via the first data bus 1015 , which may be adapted to be electrically coupled to electronic control circuitry of an operator interface circuit (not shown).

[0524] In this way it is achieved that an operator via the display of the electronic control circuit can control and monitor the metal material production arrangement 1 .

[0525] The non-volatile memory NVM 1020 is adapted to communicate with the processing unit 1010 via the second data bus 1012. The independent memory 1060 is adapted to communicate with the processing unit 1010 via the third data bus 1011. The read / write memory 1050 is adapted to communicate with the processing unit 1010 via the fourth data bus 1014. The signal port 1099 may be connectable to a data link, for example, of a network coupled to the control circuit 50.

[0526] The data that has been received by the signal port 1099 may be temporarily stored in the second memory unit 1040. After temporarily storing the received data, the processing unit 1010 will prepare to execute the program code according to the exemplary method.

[0527] Preferably, the signal (received by the signal port 1099) comprises information about the operating status of the metallic material production arrangement 1 and / or the direct reduction facility.

[0528] The signals received at the signal port 1099 may be used by the control circuit 50 to control and monitor the direct reduction and the thermal process.

[0529] The signal received at the signal port 1099 may be used for historical data and data regarding the operation of the metal material production arrangement 1 .

[0530] The metal material production arrangement 1 can be configured to be connected to a data network via a signal port 1099, which is configured as an electrical interface for explicitly providing electrical compatibility and related data transmission, which data may include information about the status of the metal material production arrangement 1 and the temperature detector. Data can also be manually fed to a computer via any suitable communication device such as a display (not shown).

[0531] Independent sequences of the method can be performed by a computer, wherein the computer runs a data program P stored in the independent memory 1060 or the read / write memory 1050. When the computer runs the data program P, the method steps according to any example disclosed herein will be performed.

[0532] A data program product comprising a program code stored on a data medium may be provided, which is readable on a computer for executing the exemplary method steps herein when the data program P is run on the computer.

[0533] Fig.13 A metallic material production arrangement 1 , such as a sponge iron production arrangement 1 , according to another embodiment is shown.

[0534] Alternatively, a method is provided for directly reducing an iron ore oxide material 5 maintaining a first thermal energy into a densified reduced iron material 16 through a sponge iron production configuration 1; wherein the iron ore oxide material 5 maintaining a first thermal energy is provided by an iron ore oxide material provider unit 3 such as an iron ore oxide granulation device and / or an iron ore oxide preheating device.

[0535] Alternatively, the temperature of the iron ore oxide material maintaining the first thermal energy is achieved by the iron ore oxide material provider unit 3 configured to produce and / or preheat the iron ore oxide material 5 maintaining the first thermal energy or substantially maintaining the first thermal energy.

[0536] Alternatively, the iron ore oxide material provider unit 3 is electrically connected to a control circuit 50 adapted to control the first thermal energy of the iron ore oxide material 5 to be charged into the direct reduction facility 7 .

[0537] Alternatively, the temperature of the iron ore oxide material 5 maintaining the first heat energy provided by the iron ore oxide material provider unit 3 corresponds to a predetermined temperature determined to avoid "sticking" in the upper inner portion of the direct reduction facility 7 (avoiding iron ore oxide material particles from sticking to each other).

[0538] Such “sticking” will inhibit any subsequent direct reduction of the iron ore oxide material in the upper inner portion UP of the direct reduction facility 7 .

[0539] Alternatively, the predetermined temperature of the iron ore oxide material 5, which is important to avoid "sticking", is controlled by the control circuit 50 to be generally about 800°C to about 1000°C, preferably about 875°C to about 925°C.

[0540] Alternatively, the control circuit 50 is adapted to regulate the first thermal energy of the iron ore oxide material towards said predetermined temperature for avoiding "sticking".

[0541] Avoiding "sticking" of iron ore oxide material particles and / or pellets during charging and during direct reduction may be crucial, as such "sticking" will result in discontinuous operation of the direct reduction facility 7. "Stick- ing" or lowering the sticking index SI may be avoided by avoiding very high temperatures (above 1200°C) in the upper interior portion of the direct reduction facility.

[0542] Alternatively, the predetermined temperature of the iron ore oxide material 5 may be adjusted by the control circuit 50 based on specific characteristics of direct reduction and / or based on specific characteristics of the iron ore oxide material to be charged into the direct reduction facility and / or specific process parameters of the iron ore oxide granulation plant and / or the iron ore oxide preheating device, taking into account the temperature of the first thermal energy in the direct reduction facility, the composition of the preheated hydrogen-containing reducing agent and a specific level of direct reduction degree, the specific characteristics and / or specific process parameters may be:

[0543] The external shape of the iron ore oxide pellets, and / or

[0544] the porosity and / or density of the iron ore oxide material, and / or

[0545] The mineralogy of the iron ore material, and / or

[0546] The composition of the iron ore oxide material, and / or

[0547] Reunion level, and / or

[0548] the iron oxide material pellet size of the iron ore oxide material, and / or

[0549] Direct reduction rate of iron ore oxide materials, and / or

[0550] the hydrogen content of the hydrogen-containing reducing agent, and / or

[0551] the desired temperature of the top gas, and / or

[0552] the output temperature of the iron ore oxide material provided by the iron ore oxide pelletizing plant and / or the iron ore oxide preheating plant;

[0553] To achieve effective heat treatment and obtain densified reduced iron ore material and / or semi-molten reduced iron ore material and / or passivated reduced iron ore material.

[0554] Alternatively, the predetermined temperature of the iron ore oxide material 5 is adjusted by the control circuit 50 based on a residence period during which the iron ore oxide material 5 is subjected to direct reduction and / or exposed to a reducing agent comprising hydrogen in the direct reduction facility.

[0555] Alternatively, the residence time period is defined as the time period during which the iron ore oxide material 5 is subjected to direct reduction and thermal treatment to complete the direct reduction process, wherein the direct reduction process involves converting the wrought iron ore FeO X Directly reduced to iron Fe, forming a densified reduced iron ore material and / or a semi-molten reduced iron ore material and / or a passivated reduced iron ore material.

[0556] Alternatively, the residence time period in the direct reduction facility 7 is determined by the aspect ratio of the interior of the direct reduction facility.

[0557] Alternatively, the residence time period in the direct reduction facility 7 is equal to about 0.5 hours to 5.0 hours, preferably 1 hour to 4 hours.

[0558] Alternatively, the residence time period in the direct reduction facility 7 is equal to about 2 to 6 hours, preferably 3 to 4 hours.

[0559] Alternatively, the residence time period in the direct reduction facility 7 is equal to about 0.25 hours to 1.5 hours, preferably 0.5 hours to 1.25 hours.

[0560] Alternatively, taking into account the temperature of the first thermal energy in the direct reduction facility, the composition of the preheated hydrogen-containing reducing agent and a specific level of direct reduction, the temperature and / or mass flow rate of the hydrogen-containing reducing agent may be adjusted by the control circuit 50 based on:

[0561] Specific process parameters for direct reduction, and / or

[0562] Specific characteristics of the iron ore oxide material, the specific characteristics and / or specific process parameters may be:

[0563] The external shape of the iron ore oxide pellets, and / or

[0564] the porosity and / or density of the iron ore oxide material, and / or

[0565] The mineralogy of the iron ore material, and / or

[0566] The composition of the iron ore oxide material, and / or

[0567] Reunion level, and / or

[0568] the iron oxide material pellet size of the iron ore oxide material, and / or

[0569] Direct reduction rate of iron ore oxide materials, and / or

[0570] the hydrogen content of the hydrogen-containing reducing agent, and / or

[0571] the desired temperature of the top gas, and / or

[0572] the output temperature of the iron ore oxide material provided by the iron ore oxide pelletizing plant and / or the iron ore oxide preheating plant;

[0573] To achieve effective heat treatment and obtain densified reduced iron ore material and / or semi-molten reduced iron ore material and / or passivated reduced iron ore material.

[0574] Alternatively, the control of the temperature of the iron ore oxide material charged into the uppermost portion (first thermal energy) and the temperature of the hydrogen-containing reducing agent introduced into the direct reduction facility (second thermal energy) is determined / controlled by a control circuit based on the mass flow rate of the iron ore oxide material charged and / or the mass flow rate of the hydrogen-containing reducing agent introduced.

[0575] Alternatively, the control of the mass flow rate of the hydrogen-containing reducing agent introduced into the direct reduction facility is determined / controlled by a control circuit based on the temperature of the iron ore oxide material loaded into the uppermost part (first thermal energy) and / or the temperature of the hydrogen-containing reducing agent introduced into the direct reduction facility (second thermal energy) to optimize the chemical reduction reaction and / or limit the high-temperature water vapor content in the direct reduction facility and / or maintain a desired ratio between high-temperature water vapor and hydrogen to achieve an effective chemical reduction reaction.

[0576] Alternatively, the method includes the step of charging the iron ore oxide material 5 retaining the first thermal energy into the upper inner portion UP of the direct reduction facility 7 via the metal oxide material charging inlet device A.

[0577] Alternatively, the direct reduction facility 7 comprises an upper inner part UP, a lower inner part LP and an intermediate inner part IP located between the upper inner part and the lower inner part LP.

[0578] Alternatively, a step of introducing the preheated hydrogen-containing reducing agent H retaining the second thermal energy into the direct reduction facility 7 via the reducing agent inlet device B is provided.

[0579] Alternatively, the direct reduction facility 7 is configured to allow direct reduction of the iron ore oxide material 5 in the upper inner portion UP by utilizing the first thermal energy of the iron ore oxide material 5 to further heat the introduced preheated hydrogen-containing reducing agent H to provide a chemical reaction between the hydrogen of the introduced preheated hydrogen-containing reducing agent H and the iron ore oxide material 5.

[0580] Alternatively, the direct reduction facility 7 is configured to allow the reduced iron material 16 and / or the iron ore oxide material 5 subjected to direct reduction to descend to a lower inner portion LP comprising the heat treatment zone HZ.

[0581] Alternatively, the direct reduction facility 7 is configured to allow the preheated hydrogen-containing reducing agent H to rise upwards in the direct reduction facility 7 to contact the descending iron ore oxide material 5 .

[0582] Alternatively, the heat treatment zone HZ is configured to expose the reduced iron material 16 and / or the iron ore oxide material 5 subjected to direct reduction to a predetermined heat treatment temperature to obtain the reduced iron ore material 16 comprising reduced iron ore particles which are combined with each other to form the heat-treated and / or heat-hardened and / or densified reduced iron ore material 16.

[0583] Alternatively, the heat treatment zone HZ is configured to maintain a predetermined heat treatment temperature by said introducing the preheated hydrogen-containing reducing agent.

[0584] Alternatively, the method comprises the step of discharging reduced iron material 16 which has been subjected to heat treatment in the heat treatment zone.

[0585] The preheated hydrogen-containing reducing agent H comprises about 80% to 100% by volume of hydrogen, preferably up to 100% by volume of hydrogen.

[0586] Alternatively, the hydrogen-containing reducing agent H fed to the direct reduction facility 7 may exhibit a temperature of about 350°C to about 900°C, preferably about 450°C to about 750°C.

[0587] Alternatively, the hydrogen-containing reducing agent H introduced into the direct reduction facility 7 exhibits a temperature of about 500°C to about 900°C, preferably about 600°C to about 800°C.

[0588] Alternatively, the hydrogen-containing reducing agent H introduced into the direct reduction facility 7 exhibits a temperature of about 600°C to about 1000°C, preferably about 700°C to about 900°C.

[0589] Alternatively, the hydrogen-containing reducing agent H introduced into the direct reduction facility 7 exhibits a temperature of about 700°C to about 1000°C, preferably about 850°C to about 950°C.

[0590] Alternatively, the hydrogen-containing reducing agent H introduced into the direct reduction facility 7 exhibits a temperature of about 700°C to about 1200°C, preferably about 800°C to about 1100°C.

[0591] Alternatively, a reducing agent H comprising hydrogen is introduced into the upper inner portion UP and / or the lower inner portion LP and / or the intermediate inner portion IP.

[0592] Alternatively, the iron ore oxide material 5 which retains thermal energy and is charged into the direct reduction facility 7 exhibits a temperature of 200°C to about 500°C, preferably about 300°C to about 400°C.

[0593] Alternatively, the iron ore oxide material 5 which retains thermal energy and is charged into the direct reduction facility 7 exhibits a temperature of 300°C to about 600°C, preferably about 400°C to about 500°C.

[0594] Alternatively, the iron ore oxide material 5 which retains thermal energy and is charged into the direct reduction facility 7 exhibits a temperature of 400°C to about 700°C, preferably about 500°C to about 600°C.

[0595] Alternatively, the iron ore oxide material 5 which retains thermal energy and is charged into the direct reduction facility 7 exhibits a temperature of 500°C to about 800°C, preferably about 600°C to about 700°C.

[0596] Alternatively, the iron ore oxide material 5 which retains thermal energy and is charged into the direct reduction facility 7 exhibits a temperature of 600°C to about 900°C, preferably about 700°C to about 800°C.

[0597] Alternatively, the iron ore oxide material 5 which retains thermal energy and is charged into the direct reduction facility 7 exhibits a temperature of 700°C to about 1000°C, preferably about 800°C to about 900°C.

[0598] Alternatively, the iron ore oxide material 5 which retains thermal energy and is charged into the direct reduction facility 7 exhibits a temperature of 800°C to about 1100°C, preferably about 900°C to about 1000°C.

[0599] Alternatively, the iron ore oxide material 5 which retains thermal energy and is charged into the direct reduction facility 7 exhibits a temperature of 900°C to about 1200°C, preferably about 1000°C to about 1100°C.

[0600] Alternatively, the heat-retained iron ore oxide material 5 charged to the direct reduction facility 7 exhibits a temperature of 1000°C to about 1300°C, preferably about 1100°C to about 1200°C.

[0601] Alternatively, the chemical reaction comprises a substantially or completely endothermic chemical reaction.

[0602] Alternatively, the thermal energy consumed by direct reduction in the upper inner portion UP includes the first thermal energy and / or the second thermal energy.

[0603] Alternatively, the thermal energy consumed by direct reduction in the intermediate inner portion IP includes the first thermal energy and / or the second thermal energy.

[0604] Alternatively, the thermal energy consumed by direct reduction in the lower inner portion LP includes the second thermal energy.

[0605] Alternatively, thermal treatment is defined as densification (passivation) of the iron ore oxide material subjected to direct reduction and / or reduced iron ore material.

[0606] Alternatively, the iron ore oxide material subjected to direct reduction and / or the reduced iron material obtained by the heat treatment is controlled by a first control circuit (not shown) and / or a control circuit, which is suitable for adjusting the second thermal energy of the hydrogen-containing reducing agent H through a reducing agent thermal energy regulating device (not shown) for controlling a predetermined required heat treatment temperature to achieve the desired quality of the produced sponge iron and / or densified reduced metal material and / or semi-molten reduced metal material and / or passivated reduced metal material.

[0607] Alternatively, the heat treatment temperature is controlled within a range of 150°C to 550°C, preferably 250°C to 450°C.

[0608] Alternatively, the heat treatment temperature is controlled within a range of 200°C to 600°C, preferably 300°C to 500°C.

[0609] Alternatively, the heat treatment temperature is controlled within a range of 250°C to 650°C, preferably 350°C to 550°C.

[0610] Alternatively, the heat treatment temperature is controlled within a range of about 350°C to about 900°C, preferably about 450°C to about 750°C.

[0611] Alternatively, the heat treatment temperature is controlled within a range of about 500°C to about 900°C, preferably about 600°C to about 800°C.

[0612] Alternatively, the heat treatment temperature is controlled within a range of about 600°C to about 1000°C, preferably about 700°C to about 900°C.

[0613] Alternatively, the heat treatment temperature is controlled within a range of about 700°C to about 1000°C, preferably about 850°C to about 950°C.

[0614] Alternatively, the heat treatment temperature is controlled within a range of about 700°C to about 1200°C, preferably about 800°C to about 1100°C.

[0615] Alternatively, the control of the heat treatment temperature is regulated by a control circuit that controls the temperature of the reducing agent H containing hydrogen.

[0616] Alternatively, the temperature of the iron ore oxide material charged into the uppermost portion (first thermal energy) is controlled within the range of 100°C to 500°C, preferably 200°C to 400°C, and the hydrogen-containing reducing agent introduced into the direct reduction facility is controlled to exhibit a temperature (second thermal energy) within the range of 600°C to 1100°C, preferably 700°C to 1000°C.

[0617] Alternatively, the temperature of the iron ore oxide material charged into the uppermost portion (first thermal energy) is controlled within the range of 200°C to 600°C, preferably 300°C to 500°C, and the hydrogen-containing reducing agent introduced into the direct reduction facility is controlled to exhibit a temperature (second thermal energy) within the range of 700°C to 1200°C, preferably 800°C to 1100°C.

[0618] Alternatively, the temperature of the iron ore oxide material charged into the uppermost portion (first thermal energy) is controlled within the range of 300°C to 700°C, preferably 400°C to 600°C, and the hydrogen-containing reducing agent introduced into the direct reduction facility is controlled to exhibit a temperature (second thermal energy) within the range of 700°C to 1100°C, preferably 750°C to 950°C.

[0619] Alternatively, the temperature of the iron ore oxide material charged into the uppermost portion (first thermal energy) is controlled within the range of 400°C to 800°C, preferably 500°C to 700°C, and the hydrogen-containing reducing agent introduced into the direct reduction facility is controlled to exhibit a temperature (second thermal energy) within the range of 800°C to 1300°C, preferably 900°C to 1200°C.

[0620] Alternatively, the first thermal energy of the iron ore oxide material 5 is used in the upper inner portion UP and / or the uppermost portion 81 to further heat the remaining amount of hydrogen and / or water vapor of the preheated hydrogen-containing reducing agent.

[0621] Alternatively, the top gas contains water vapor produced by a chemical reaction between oxygen of the iron oxide material and hydrogen of the hydrogen-containing reducing agent.

[0622] Alternatively, the remaining amount of hydrogen in the hydrogen-containing reducing agent can be defined as the hydrogen-containing reducing agent that has not been consumed in the direct reduction in the main part of the upper internal portion and has risen upward in the direct reduction facility 7 to the uppermost part 81 of the upper internal portion UP (inside the top of the direct reduction facility).

[0623] Alternatively, the remaining amount of hydrogen provides for chemical reaction and effective direct reduction of the metal oxide material (iron ore oxide material) in the uppermost portion 81, despite the fact that the preheated hydrogen-containing reducing agent will contain larger amounts of water vapor and smaller amounts of hydrogen the higher it rises in the direct reduction facility.

[0624] Alternatively, the first thermal energy is therefore used in the uppermost portion 81 to further heat said remaining amount of hydrogen for providing said chemical reaction between at least a portion of said remaining amount of hydrogen and oxygen of the metal oxide material (iron ore oxide material), providing direct reduction wherein effective removal of oxygen from the iron ore oxide material is achieved.

[0625] Alternatively, an excess of preheated hydrogen-containing reducing agent H comprising excess hydrogen and hot water vapor forms in the uppermost part 81 a top gas TG which is discharged from the direct reduction plant 7 via a top gas discharge device D.

[0626] Alternatively, the first thermal energy is therefore used to further heat the remaining amount of hydrogen for effective direct reduction in the uppermost portion 81 and / or to prevent cooling of the remaining amount of hydrogen in the uppermost portion 81 that has not yet been consumed hydrogen-containing reducing agent for providing effective direct reduction.

[0627] Thus, any final low temperature / ambient temperature iron ore oxide material charged into the direct reduction facility 7 (in the case of charging unheated iron ore oxide material) is prevented from cooling the remaining amount of hydrogen in the hydrogen-containing reducing agent in the uppermost portion 81 .

[0628] This has the effect that an energy-efficient production of passivated reduced iron material (eg sponge iron) is achieved while producing top gas TG containing hot water vapor which can be used in the high-temperature electrolysis unit.

[0629] In this way, a densification process for producing a densified reduced iron material is achieved, thereby preventing reoxidation of the reduced iron material, thereby enabling safe and cost-effective transportation of the reduced iron material (such as sponge iron) to the metal manufacturing industry.

[0630] In this manner, a metallic material production arrangement is provided that is configured for producing a reduced ferrous material (free of carbon) that is resistant to reoxidation for cost effective and safe refractory transportation of the reduced metallic material to metal fabrication industries or other customers.

[0631] The present disclosure may not be limited to the examples described above, but many possibilities of modifications or combinations of the examples described herewith will be apparent to a person skilled in the art without departing from the basic idea as defined in the appended claims.

Claims

1. A method for directly reducing a metal oxide material (5) maintaining a first thermal energy into a reduced metal material (16) by a metal material production arrangement (1); wherein the metal oxide material (5) maintaining the first thermal energy is provided by a metal oxide material provider unit (3); the method comprising the following steps: - charging the metal oxide material (5) retaining the first thermal energy into a direct reduction facility (7) via a metal oxide material charging inlet device (A); - introducing a preheated hydrogen-containing reducing agent (H) retaining a second thermal energy into the direct reduction facility (7) via a reducing agent inlet device (B); - reducing the metal oxide material (5) by heating or further heating the introduced preheated hydrogen-containing reducing agent (H) using the first thermal energy of the metal oxide material (5) to provide a chemical reaction between the introduced preheated hydrogen-containing reducing agent (H) and the metal oxide material (5); - exposing the reduced metallic material to a heat treatment temperature required to provide heat treatment of the reduced metallic material to obtain a densified reduced metallic material; - maintaining the desired heat treatment temperature by introducing the preheated hydrogen-containing reducing agent (H) using a heat treatment providing device (17); and - Discharging said reduced metallic material (16) which has been subjected to heat treatment.

2. The method according to claim 1, wherein the method comprises the following additional steps: - A preheated hydrogen-containing heat treatment agent (HT) maintaining a third thermal energy is introduced into the direct reduction facility (7) through a heat treatment agent feeding device (30) to expose the reduced metal material (16) to a desired heat treatment temperature, for maintaining the desired heat treatment temperature, and for providing the heat treatment of the reduced metal material (16) to obtain the densified reduced metal material.

3. A method according to claim 1 or 2, wherein the step of maintaining the desired heat treatment temperature is provided to such an extent that the introduction of the preheated hydrogen-containing reducing agent (H) produces direct reduction of the metal oxide material (5) and reduces the cooling rate of the reduced metal material (16) descending through the direct reduction facility (7) in order to maintain the desired heat treatment temperature.

4. A method according to any one of claims 1 to 3, wherein the method comprises preheating the hydrogen-containing reducing agent (H) to be introduced into the direct reduction facility (7) by means of a reducing agent preheating device (20) of the heat treatment providing device (17) in order to reach a desired heat treatment temperature.

5. The method according to any one of the preceding claims, wherein the step of maintaining the desired heat treatment temperature comprises: - regulating the second thermal energy by means of a reducing agent thermal energy regulating device (17') electrically coupled to a first control circuit (50') configured to operate the reducing agent thermal energy regulating device (17') for controlling the desired thermal treatment temperature.

6. The method according to any one of the preceding claims, wherein the step of maintaining the desired heat treatment temperature comprises: - regulating the mass flow of the hydrogen-containing reducing agent (H) introduced into the direct reduction facility (7) by means of a reducing agent mass flow regulating device (17") electrically connected to a second control circuit (50"), wherein the second control circuit (50") is configured to operate the reducing agent mass flow regulating device (17") for controlling the desired heat treatment temperature.

7. The method according to any one of the preceding claims, wherein the step of maintaining a desired heat treatment temperature comprises: - The residence time period is adjusted by a residence time period adjustment device (17'") electrically connected to a third control circuit (50'") for maintaining the reduced metal material (16) in the direct reduction facility (7) for a specific residence time period, and the third control circuit (50'") is configured to operate the residence time period adjustment device (17'") to achieve the specific residence time period and control the required heat treatment temperature.

8. The method according to any one of the preceding claims, wherein the step of providing the desired heat treatment temperature comprises: - regulating the pressurization inside the direct reduction facility by means of a pressurization regulating device (17") electrically connected to a fourth control circuit (50"), the fourth control circuit (50") being configured to operate the pressurization regulating device (17") for controlling the desired heat treatment temperature.

9. A metal material production arrangement (1) suitable for directly reducing a metal oxide material (5) retaining a first thermal energy into a reduced metal material (16); the metal material production arrangement (1) comprising: - a metal oxide material provider unit (3), the metal oxide material provider unit (3) being configured to provide the metal oxide material (5) maintaining the first thermal energy; - a direct reduction facility (7), said direct reduction facility (7) comprising: Metal oxide material charging inlet device (A); a reducing agent inlet device (B), the reducing agent inlet device (B) being configured to introduce a reducing agent (H) containing hydrogen gas which maintains a second thermal energy, The metal material production arrangement (1) is characterized in that a direct reduction zone (RZ) of the direct reduction facility (7), the direct reduction zone (RZ) being configured to reduce the metal oxide material (5) by utilizing the first thermal energy of the metal oxide material (5) to heat or further heat an introduced hydrogen-containing reducing agent (H) for providing a chemical reaction between the introduced hydrogen-containing reducing agent (H) and the metal oxide material (5); a heat treatment zone (HZ) of the direct reduction facility (7), the heat treatment zone (HZ) being configured for heat treating the reduced metallic material (16) by exposing the reduced metallic material to a heat treatment temperature required to provide heat treatment of the reduced metallic material, so as to obtain a densified reduced metallic material; - a heat treatment providing device (17) configured to maintain a desired heat treatment temperature by introducing a preheated hydrogen-containing reducing agent (H); and - a metal material discharge device (c) configured to discharge the reduced metal material (16) that has been subjected to heat treatment.

10. The metal material production configuration (1) according to claim 9, wherein the metal material production configuration (1) also includes a reducing agent preheating device (20) of the heat treatment providing device (17), and the reducing agent preheating device (20) is suitable for preheating the hydrogen-containing reducing agent (H) to be introduced into the direct reduction facility (7).

11. A metal material production arrangement (1) according to claim 9 or 10, wherein - the heat treatment providing device (17) comprises a reducing agent heat energy regulating device (17') configured to regulate the second heat energy; and A first control circuit (50') is electrically coupled to the reducing agent thermal energy conditioning device (17') and is configured to control the reducing agent thermal energy conditioning device (17') for achieving a desired heat treatment temperature.

12. A metal material production arrangement (1) according to any one of claims 9 to 11, wherein - the heat treatment providing device (17) comprises a reducing agent mass flow regulating device (17"), the reducing agent mass flow regulating device (17") being configured to regulate the mass flow of the hydrogen-containing reducing agent (H) introduced into the direct reduction facility (7); and A second control circuit (50") is electrically connected to the reducing agent mass flow regulating device (17") and is configured to operate the reducing agent mass flow regulating device (17") to regulate the mass flow of the hydrogen-containing reducing agent (H) for achieving a desired heat treatment temperature.

13. A metal material production arrangement (1) according to any one of claims 9 to 12, wherein - the heat treatment providing device 17 comprises a residence time period adjusting device (17'"), the residence time period adjusting device (17'") being configured to adjust the residence time period for keeping the reduced metallic material (16) in the direct reduction facility (7); and A third control circuit (50'") is electrically coupled to the dwell time period adjustment device (17'") and is configured to operate the dwell time period adjustment device (17'") to achieve the specific dwell time period and control the desired heat treatment temperature.

14. A metal material production arrangement (1) according to any one of claims 9 to 13, wherein - the heat treatment providing device (17) comprises a pressure regulating device (17"), the pressure regulating device (17") being configured to regulate the pressure inside the direct reduction facility (7); and A fourth control circuit (50") is electrically connected to the pressurization regulating device (17") and is configured to operate the pressurization regulating device (17") for controlling the desired heat treatment temperature.

15. A metal material production arrangement (1) according to any one of claims 9 to 14, wherein the direct reduction facility (7) comprises a top gas outlet device (D), which is configured to discharge top gas (TG) from the direct reduction facility (7).

16. A metallic material production arrangement (1) according to any one of claims 9 to 15, wherein the introduced preheated hydrogen-containing reducing agent (H) comprises 80 to 100% hydrogen by volume, preferably 100% hydrogen.

17. A data program (P), comprising a computer-readable program code of a control circuit (50) of a metal material production configuration (1) according to any one of claims 9 to 16, wherein the data program (P) is programmed to enable a heat treatment providing device (17) to maintain a desired heat treatment temperature by introducing a preheated hydrogen-containing reducing agent (H).

18. A product produced by the method according to claims 1 to 8, wherein the reduced metal material (16) consists of reduced iron ore particles which are bonded to each other to form sponge iron of heat treated reduced iron ore material.

19. The method according to any one of claims 1 to 8, wherein the method further comprises the following steps: - water is split into electrolytic hydrogen and oxygen by an electrolysis unit; - producing methanol by reacting the electrolytic hydrogen with carbon dioxide; - storing the methanol; - reforming the methanol by using water and / or oxygen to provide carbon dioxide and liberated hydrogen; - providing the released hydrogen as a component of the preheated hydrogen-containing reducing agent (H) to the direct reduction facility (7); and - providing a step of introducing said preheated hydrogen-containing reducing agent (H) retaining said second thermal energy into said direct reduction facility (7) via said reducing agent inlet means.

20. The method according to any one of claims 1 to 8, wherein - the step of charging the metal oxide material (5) retaining the first thermal energy into the direct reduction facility (7) via the metal oxide material charging inlet device (A) is provided in combination with the introduction of a first sealing gas; and / or - The step of discharging said reduced metallic material (16) is provided in combination with the introduction of a second sealing gas.

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