Systems, devices, and methods for producing metals using flexible gas feedstocks

Abstract

Systems, devices, and methods for fabricating various metal-containing materials (e.g., metals, metal alloys, mattes, and slags) from oxide feeds using flexible gas feedstocks are described herein. In some embodiments, a device can include a furnace configured to heat a metal-containing material. The furnace can include a shell having a top portion, a bottom portion, and a roof connecting the top and bottom portion. The bottom portion may be connected to a hearth. The furnace can melt at least a portion of the metal-containing material, producing a molten bath in the hearth. The furnace can also include a plurality of ports for injecting flexible gas feedstocks into the melted portion of the metal-containing material. The gas feedstocks can reduce the metal-containing material to produce a reduced metal.

Description

Agent’s File Ref. HERM-001 / 01WO 356954-2019SYSTEMS, DEVICES, AND METHODS FOR PRODUCING METALS USING FLEXIBLE GAS FEEDSTOCKSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of U.S Provisional Patent Application No. 36 / 749,362, filed on January 24, 2025, and titled “Systems, Devices, And Methods For Producing Metals Using Flexible Gas Feedstocks,” which is incorporated by reference herein in its entirety.TECHNICAL FIELD

[0002] The present disclosure relates to the field of metallurgy, and more specifically to systems, devices, and methods for fabricating metal products, (e.g., reduced metals, metal alloys, mattes, slags, and other metal-containing materials) from oxide and / or carbonate feeds using flexible gas feedstocks in a reduction furnace.BACKGROUND

[0003] Current processes for the fabrication of metals, metal alloys, mattes, slags, and other metal-containing products typically involve heating a starting and / or source material (e.g., an ore, metal oxide, metal carbonate, recycled and / or scrap metal) to a temperature sufficiently high to melt the source material and expose it to a reducing agent that initiates reduction reactions to form a desired metal product. For example, steel is commonly produced by a pyrometallurgical process in which an iron ore is heated in a blast furnace (BF) to a temperature sufficiently high to melt the ore and expose it to solid carbon (e.g., coke) acting as a reducing agent. The ore, in both solid and molten form, reacts with coke producing a high carbon content iron material, referred to as pig iron. The pig iron can be converted to steel in a downstream basic oxygen furnace (BOF) that injects oxygen into the molten pig iron to remove excess carbon and adjust the desired composition. The resulting steel can be further processed in subsequent ladle metallurgic refinement steps. An estimated 75% of the steel worldwide is fabricated using a blast furnace. The blast furnace method of producing steel is a carbonintensive process that requires producing coke in a separate airless kiln or coke oven that heats coal to a temperature of about 1,000 °C to vaporize and / or decompose organic substances included in the coal, yielding a highly reactive coke. The coke is then used in the blast furnace to reduce the iron ore and to provide heat, via its combustion with hot air, to sustain the elevated330464460 1Agent’s File Ref. HERM-001 / 01WO 356954-2019temperatures required for melting and reducing the iron ore. The use of blast furnaces for production of steel can result in approximately 1.85 to 2.2 metric tons of carbon dioxide per metric ton of crude steel, accounting for about 9% of total global carbon dioxide emissions.

[0004] Concerns associated with increasing costs of metallurgical-grade coal, as well as global warming and emission of greenhouse gases have prompted research into alternative processes for the fabrication from ores of steel and other metals, metal alloys, and metalcontaining materials with reduced carbon dioxide emissions. Direct Reduction of Iron (DRI) is one of those alternative processes which may produce steel with reduced levels of carbon dioxide emissions compared to the blast furnace route. In the DRI process, iron ore pellets or iron ore fines are disposed in a shaft furnace or in a fluidized bed reactor, respectively, and reduced at temperatures well below the melting point of the ore with a gas feedstock that includes solely hydrogen (H2) or a combination of hydrogen and carbon monoxide (CO). The reduction of the iron ore in the DRI process is a heterogeneous process in which solid state ore reacts with the hydrogen / carbon monoxide gas feedstock to produce a porous solid metal product. Despite recent advances in DRI technology, the widespread implementation of the DRI process for the fabrication of steel and / or other metal products has proven difficult to implement due to stringent requirements for the composition of the starting and / or source material for the process to be economically viable. In other words, the DRI process requires oxide and / or carbonate feeds with high concentration of metal and low levels of gangue elements, which in the case of steel production translates to high-grade iron ores with 67%+ iron content. The scarcity of high-grade ore and cost associated with conditioning low-grade ores for their conversion into metal products in a DRI fluidized bed reactor presents supply chain and cost constraints to the widespread process adoption. Additional limitations of the DRI process include: (a) the need for a secondary furnace, such as an Electric Arc Furnace (EAF), to remove gangue elements and unreduced iron oxide (FeO) which are not separated from the starting and / or source feed in the DRI shaft furnace and / or fluidized bed reactor since the reduction reactions occur in the solid phase, (b) safety concerns associated with the combustion of the hydrogen / carbon monoxide feedstocks to provide the heat (via combustion) required for sustaining the endothermic molecular hydrogen reduction reaction, and (c) overall higher cost. Consequently, there is a need in the field for processes that enable the fabrication of metals, metal alloys, mattes, slags, and other metal products including iron, tin, lead, chrome, nickel, copper, ferrochrome, ferrosilicon, ferronickel and the like, from various starting and / or source material, using flexible gas feedstocks acting as reducing agents (e.g., gas feedstocks330464460 2Agent’s File Ref. HERM-001 / 01WO 356954-2019including pure hydrogen, hydrogen mixtures, carbon monoxide, natural gas, or the like), which result in high quality metal products with low cost and reduced carbon dioxide emissions.SUMMARY

[0005] Systems, devices, and methods for fabricating metal products in a reduction furnace using one or more gas feedstocks are described herein. In some embodiments, a furnace comprises a shell defining an inner volume, an injector extending into the inner volume of the shell, and a feed port disposed in a top portion of the shell. The feed port can be configured to allow for the introduction of an oxide feed into the furnace. The furnace further comprises a hearth disposed in a bottom portion of the inner volume. The hearth is configured to receive the oxide feed and contain a layer of slag. A distal portion of the injector may be submerged in the layer of slag or be above the slag layer, and the injector is configured to inject a gas feedstock into the layer of slag to reduce the oxide feed and produce a metal product.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG. l is a flow diagram of a prior art process for the production of steel.

[0007] FIG. 2 is a flow diagram of a process for the production of a metal product from an oxide feed using a reduction furnace operating with a gas feedstock, according to an embodiment of the present disclosure.

[0008] FIG. 3 is a schematic illustration of the reduction furnace shown in FIG. 2.

[0009] FIGS. 4A-4C show top view schematic illustrations of exemplary reduction furnaces, displaying different arrangements of a electrodes, feed ports, and gas injectors disposed on a top portion and / or top wall of the reduction furnaces, according to different embodiments of the present disclosure.

[0010] FIG. 5 is cross sectional front view of a reduction furnace for the production of a metal product from an oxide feed using a hydrogen gas feedstock, according to an embodiment of the present disclosure.

[0011] FIG. 6 is cross sectional front view of a reduction furnace for the production of a metal product from an oxide feed using multiple gas feedstocks, according to an embodiment of the present disclosure.DETAILED DESCRIPTION

[0012] Metal and metal alloys can be produced from metal oxides and / or metal carbonate source materials according to smelting processes in which the source materials are heated to a330464460 3Agent’s File Ref. HERM-001 / 01WO 356954-2019temperature sufficiently high to melt the source material, producing a molten material that can then be reduced in the presence of a strong reducing agent, and separating unwanted components (e.g., oxides of magnesium, silicon, aluminum, calcium, etc.) from said reduced metal. The elevated temperatures required to melt the source materials, which in some instances can be as high as 1,700 °C conventionally require the use of high energy density solid or gaseous fuels such as coke or hydrocarbons, capable of releasing large quantities of heat during their combustion, to melt the source material, and then reduce the molten source material to produce a reduced metal or metal alloy. Examples of such processes include the fabrication of steel. Steel can be fabricated using a blast furnace (BF) and a basic oxygen furnace (BOF) process, as schematically represented in FIG. 1. During the BF-BOF process, an iron-containing ore (e.g., an oxide) is first preconditioned and / or pretreated by sintering the ore. In the sintering method, the ore, which is typically a medium- to low-grade ore (e.g., a material having a low concentration of iron between 58% to 65%) is agglomerated and then heated and melted in the blast furnace. Within the blast furnace, iron ore is exposed to coke, which serves as a strong reducing agent capable of reducing the ore. The coke has to be fabricated in a separate process in which metallurgical-grade coal is treated at a high temperature in a coke furnace to remove volatile species and produce a porous and highly reactive carbonaceous material. Coke can then be added to the blast furnace to reduce the ore, forming a high carbon-content intermediate (pig iron), which serves as a precursor of steel. It is worth noting that the blast furnace process results in the ore being in the molten state by the time the ore reaches the hearth of the blast furnace, such that impurities, unwanted species, and / or gangue materials can be easily separated, as they form a separate insoluble phase (e.g., slag). Sustaining the slag bath and pig iron in the molten state requires a significant amount of energy, which can be provided by the coke via its combustion with controlled amounts of oxygen. The molten pig iron is then transferred to a secondary furnace (e.g., a basic oxygen furnace) in which oxygen is injected into the pig iron to remove excess carbon and produce steel. Additional impurities such as phosphorous and sulfur are also removed in the basic oxygen furnace, with the primary source of these impurities being from the coke introduced in the blast furnace.

[0013] The blast furnace process is a carbon-intensive process responsible for the emission of large quantities of carbon dioxide per ton of steel produced. It is estimated that the steel production process is responsible for approximately 9% total global carbon dioxide emissions. Additionally, the availability and cost of metallurgical-grade coal has increased considerably in recent years. As a result, environmental concerns related to global warming and the emission330464460 4Agent’s File Ref. HERM-001 / 01WO 356954-2019of greenhouse gases, coupled with the increased costs have recently incentivized the search for alternative processes for the fabrication of steel and other metal-containing products including reduced metals such as tin, lead, or chrome; ferroalloys and non-ferrous alloys, and mattes from copper, nickel, cobalt, and / or iron, among others.

[0014] Alternative technologies have attempted to displace the use of coke and coal from the manufacturing of metals by introducing lower temperature processes in which the source material (e.g., a metal oxide or metal carbonate) is reduced in the solid state with the aid of a hydrogen and carbon monoxide (CO) mixture (e.g., synthesis gas or syngas). This process, which is commonly referred to as Direct Reduction of Iron (DRI), uses a shaft furnace or a fluidized bed reactor to reduce the source material, producing a porous reduced sponge-like product at much more moderate temperatures (~800 °C). When using a shaft furnace, the source material must be fed to the shaft furnace in the form of pellets, whereas when using a fluidized bed reactor, the source material must be fed to the fluidized bed reactor in the form of fines with a narrow range of particle size. Although currently, the commercially deployed furnace for DRI production is the shaft furnace, it is important to note that pre-treatment and / or preconditioning of the source material (either by pelletization or particle size reduction) in the shaft furnace and / or fluidized bed reactor, increases considerably the cost and energy requirements for the process. The sponge-like product produced in the DRI furnace is typically either used in an immediately adjacent steel production process or briquetted while still hot in order to be shipped globally. The lack of a melting step in the DRI process precludes separation of gangue elements, which remain present in the product unless the product is melted to remove those impurities. In some instances, when the source material is a low-grade ore (e.g., low grade ore or fines), the DRI process may become economically unattractive as the materials produced in the DRI process will have to be melted (using a Basic Oxygen Furnace or an Electric Arc Furnace), to produce an acceptable quality and / or cost final product. This lack of flexibility with respect to the source material as well as with respect to the characteristics of the syngas reducing agent (hydrogen / carbon monoxide ratio) coupled with the increase complexity of the DRI process (e.g., multiple furnaces with different operating conditions) have severely limited the implementations of this technology at scale.

[0015] The present disclosure provides systems, methods, and devices for the fabrication of metal products that address the limitations found in the prior art and enable the fabrication of metal products from a wide variety of source materials (e.g., low-grade ores, high-grade330464460 5Agent’s File Ref. HERM-001 / 01WO 356954-2019ores, fines, waste oxides, and / or scrap metal) and using flexible feedstocks serving as reducing agents.

[0016] By harnessing ionized hydrogen and the high temperatures of a hydrogen plasma as well as molecular hydrogen gas injected into a molten slag layer or molten phase, a strong reducing environment can be generated inside a reduction electric arc furnace (also referred to herein as a reduction furnace) capable of reducing a wide range of source materials without the need for agglomeration / pelletizing, producing multiple metal products using flexible gas feedstocks and at considerably lower carbon emissions. The ionized hydrogen and molecular hydrogen in the gas create highly reducing conditions in the molten slag, and / or surrounding environment, allowing a number of chemical reduction reactions to occur. These reactions may not be as favorable in the presence of molecular hydrogen, while ionized hydrogen shifts the Gibbs Free Energy of the reaction to more favorable thermodynamic conditions. Furthermore, the main furnace described herein contains embodiments in which an electric arc is used to generate thermal energy for smelting, as molecular hydrogen and / or hydrogen plasma are used for the reduction reaction of metal oxides. The inherent flexibility and simplicity of reduction furnaces described herein enable selecting and / or changing processing conditions in order to match and / or optimize specific targets including, for example, reduced carbon dioxide emissions, cost, yield, and / or processing of low-grade or low cost source materials.

[0017] As used in this specification, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, the term “a member” is intended to mean a single member or a combination of members, “a material” is intended to mean one or more materials, or a combination thereof.

[0018] The term “substantially” when used in connection with “cylindrical,” “linear,” and / or other geometric relationships is intended to convey that the structure so defined is nominally cylindrical, linear or the like. As one example, a portion of a support member that is described as being “substantially linear” is intended to convey that, although linearity of the portion is desirable, some non-linearity can occur in a “substantially linear” portion. Such nonlinearity can result from manufacturing tolerances, or other practical considerations (such as, for example, the pressure or force applied to the support member). Thus, a geometric construction modified by the term “substantially” includes such geometric properties within a tolerance of plus or minus 5% of the stated geometric construction. For example, a “substantially linear” portion is a portion that defines an axis or center line that is within plus or minus 5% of being linear.330464460 6Agent’s File Ref. HERM-001 / 01WO 356954-2019

[0019] As used herein, the term “set” and “plurality” can refer to multiple features or a singular feature with multiple parts. For example, when referring to a set of electrodes, the set of electrodes can be considered as one electrode with multiple portions, or the set of electrodes can be considered as multiple, distinct electrodes. Thus, a set of portions or a plurality of portions may include multiple portions that are either continuous or discontinuous from each other. A plurality of particles or a plurality of materials can also be fabricated from multiple items that are produced separately and are later joined together (e.g., via mixing, an adhesive, or any suitable method).

[0020] As used here, the term “natural gas” refers to a gas including substantially pure methane (CF ), or a mixture of gases including primarily methane, ethane, propane, butane, carbon dioxide (CO2), oxygen (O2), hydrogen sulfide (H2S), nitrogen (N2), hydrogen, helium (He), neon (Ne), argon (Ar), and / or xenon (Xe).

[0021] FIG. 2 shows a flow diagram of a process 1000 for the production of a metal product from an oxide feed using a reduction furnace operating with a gas feedstock, according to an embodiment of the present disclosure. The process 1000 includes a reduction furnace 100 having an internal volume, chamber, cavity, and / or receptacle configured to receive an oxide feed 101 and gas feedstock 102, such that the oxide feed 101 can be heated to a predetermined temperature and reacted with the gas feedstock 102 to produce a metal product 103 and a slag 104. The reduction furnace 100 can be an electric reduction furnace that uses electric energy to heat the oxide feed 101 to the predetermined temperature. At the predetermined temperature, the oxide feed 101 can undergo a phase change from the solid state to a molten state. In other words, the reduction furnace 100 can be an electric reduction furnace that uses electricity to heat the oxide feed 101 to a predetermined temperature above the melting point of the oxide feed 101, such that the oxide feed 101 undergoes a transition and / or phase change from the solid state to a liquid state. The transition of the oxide feed 101 to the liquid state generates a slag 104 comprising a metal oxide of interest (e.g., iron oxide, copper oxide, cobalt oxide, or the like) and gangue elements initially present in the oxide feed 101 such as silicon, calcium, alumina, clay, and others. Alternatively, in some embodiments the reduction furnace 100 can be configured to receive a molten oxide feed 101 (e.g., an oxide feed 101 which has been transitioned to a liquid state via a process and / or apparatus different from the process 1000 and / or the furnace 100). Exposure of the molten oxide feed 101, and more specifically the metal of interest dissolved within the slag 104, to a gas feedstock 102 within the reduction furnace 100 facilitates conducting reduction and / or carburization reactions to produce a molten metal product 103, as further disclosed herein.330464460 7Agent’s File Ref. HERM-001 / 01WO 356954-2019

[0022] The oxide feed 101 can be any suitable starting and / or source material containing one or more metallic elements of interest. In some embodiments the oxide feed 101 can include a high-grade ore, a low-grade ore, a mineral, a metal oxide, a metal carbonate, a raw mill scale, or recycled and / or scrap metal. In some embodiments, the oxide feed 101 can include any suitable additive, including, for example, a flowing agent and / or flux. For example, in some embodiments the oxide feed 101 can include limestone (calcium carbonate), quicklime (calcium oxide), sodium carbonate, calcium hydroxide, charcoal, potash, sodium borate (e.g., borax), or the like. In some embodiments, the oxide feed 101 can include one or more oxide of metallic elements such as tin, lead, iron, chrome, copper, zinc, cobalt, silver, aluminum, calcium, or the like. In some embodiments, the oxide feed 101 can include one or more metal carbonates such as iron carbonate, calcium carbonate, magnesium carbonate, manganese carbonate, strontium carbonate, barium carbonate, zinc carbonate, copper carbonate, or the like. In some embodiments, the oxide feed 101 can include recycled and / or scrap metal including ferrous scrap metal (e.g., iron and / or steel), and / or nonferrous metals (e.g., aluminum, copper, brass, nickel, titanium, zinc, or the like). In some embodiments, the oxide feed 101 can include a combination of metal oxides, metal carbonates, recycled and / or scrap metal, as well as any intermediate and / or unfinished metal-containing materials such as pig iron, briquette iron, or the like, produced in a processing furnace such as a blast furnace or an electric arc furnace. As disclosed above, in some embodiments, the oxide feed 101 can be and / or include low-grade ore fines having a relatively low concentration of the metal of interest. In such embodiments, the process 1000 can be configured to direct the oxide feed 101 to the reduction furnace 100 without conducting any prior enrichment and / or concentration process such as ore pelletizing and / or sintering.

[0023] The gas feedstock 102 can be and / or include a gas or a mixture of gases which can be used to reduce the oxide feed 101 in the reduction furnace 100. In some embodiments, the gas feedstock 102 can be and / or can include natural gas. In some embodiments, the gas feedstock 102 can be and / or can include methane. In some embodiments, the gas feedstock 102 can be and / or can include hydrogen. In some embodiments, the gas feedstock 102 can be and / or can include natural gas, methane, and hydrogen. In some embodiments, the gas feedstock 102 can be and / or can include a mixture of natural gas and hydrogen. In some embodiments, the gas feedstock 102 can be and / or can include a mixture of natural gas, and one or more inert and / or unreactive gases such as nitrogen, argon, helium, or the like. For example, in some embodiments the gas feedstock 102 can be and / or can include a mixture of natural gas and nitrogen. In some embodiments, the gas feedstock 102 can be and / or can330464460 8Agent’s File Ref. HERM-001 / 01WO 356954-2019include a mixture of natural gas, hydrogen, and one or more inert and / or unreactive gases such as nitrogen, argon, helium, or the like. In some embodiments, the gas feedstock 102 can be and / or can include substantially pure hydrogen. In some embodiments, the gas feedstock 102 can be and / or can include a mixture of hydrogen, and one or more inert and / or unreactive gases such as nitrogen, argon, helium, or the like. For example, in some embodiments the gas feedstock 102 can include a mixture of hydrogen, nitrogen, and / or argon. In some embodiments the gas feedstock 102 can include a mixture of hydrogen and nitrogen, with nitrogen ranging in concentrations between 2 to 30 wt.%. In some embodiments, the gas feedstock 102 can be directly injected in the slag 104 during the operation of the reduction furnace 100. In such embodiments, the addition of unreactive gas, such as nitrogen, can serve the purpose of increasing the gas mixture density and therefore penetration depth, as further disclosed herein. In some embodiments, the addition of unreactive gas to the gas feedstock 102 can further stabilize an arc produced by the first and second electrode, as further disclosed herein.

[0024] The metal product 103 can be a reduced metal, a metal alloy, and / or a matte produced from any suitable oxide feed 101. In some embodiments, the metal product 103 can be steel. In some embodiments, the metal product 103 can be and / or include iron, copper, silver, tin, lead, zinc, aluminum or the like. In some embodiments, the metal product 103 can be and / or include ferroalloys such as for example, ferrochrome, ferronickel, ferroaluminum, ferroboron, ferromanganese, ferrosilicon, or the like. In some embodiments, the metal product 103 can be a stainless steel. In some embodiments, the metal product 103 can be electrical steel. In some embodiments, the metal product 103 can be ultra-high purity iron. In some embodiments, the metal product 103 can be and / or include non-ferrous alloys such as for example, copper-zinc (e.g., brass) alloys, copper-strontium (Bronze) alloys, cupronickel alloys, aluminum-copper (e.g., duralumin) alloys, aluminum-magnesium (e.g., magnalium) alloys, and / or titanium alloys, among others. In some embodiments, the metal product 103 can be and / or include mattes from copper, nickel, and other base metals. In some embodiments, the metal product 103 can be and / or include mattes containing valuable minor constituents such as noble metals, minor base metals, selenium, and / or tellurium, among others.

[0025] The slag 104 can be a molten byproduct resulted from any suitable process for extracting a metal from an ore and / or an oxide feed involving heating and / or melting (e.g., a smelting process). In some embodiments, the slag 104 can be an enriched slag, and / or a cleaned slag produced from any suitable oxide feed 101. The slag 104 can include gangue elements including, for example, silicon oxide (SiCh), alumina (AI2O3), calcium oxide (CaO),330464460 9Agent’s File Ref. HERM-001 / 01WO 356954-2019magnesium oxide (MgO), and / or sulfur-containing species. The slag 104 can also include high concentrations of one or more metal oxides of interest dissolved within the slag 104, which were initially present in the oxide feed 101 and that can be reduced with the aid of a gas feedstock 102 to produce a metal product 103, as further disclosed herein. For example, in some embodiments the slag 104 can include dissolved metal oxides such as tin, lead, iron, chrome, copper, zinc, cobalt, silver, aluminum, or the like, initially present in the oxide feed 101. In some embodiments, the slag 104 can be and / or include a copper slag, a nickel slag, a phosphorus slag, a lead slag, lead-zinc slag, and / or a zinc slag. In some embodiments, the slag 104 can be and / or include an iron-bearing slag such as those produced in the steel industry, for example from electric arc furnaces. In some embodiments, the slag can be a silicon-bearing slag. In some embodiments, the slag 104, or at least a portion of the slag 104, can be a synthetic slag and / or a slag prepared in a laboratory by mixing multiple species such as silicon oxide, alumina, calcium oxide, magnesium oxide, or the like.

[0026] FIG 3 shows a schematic illustration of the reduction furnace 100 displayed in FIG.2. The reduction furnace 100 can be any suitable structure defining an interior volume, cavity, chamber, and / or compartment that can accommodate the oxide feed 101 and the gas feedstock 102. The reduction furnace 100, which can also be referred to herein as the “furnace 100” or the “apparatus 100,” can be configured to provide an interior volume in which the oxide feed 101 can be heated to a predetermined temperature sufficiently high to melt the oxide feed 101 and then be reacted with the gas feedstock 102 to produce a metal product 103 and slag 104. The reduction furnace 100 can have one or more components including a shell 110, a hearth 120, a first electrode 130, a second electrode 140, a feed port 150, a gas injector 160, a metal product outlet port 170, and a slag outlet port 180.

[0027] The shell 110 can be any suitable structure configured to provide a protective enclosure that defines an interior volume, compartment, and / or chamber suitable for receiving and accommodating (e.g., housing, and / or containing) the oxide feed 101 and the gas feedstock 102. The shell 110 includes a plurality of walls that provide mechanical support to accommodate and / or house one or more components of the reduction furnace 100, such as the hearth 120, the first electrode 130, the second electrode 140, the feed port 150, the gas injector 160, the metal product outlet port 170, and the slag outlet port 180. In some embodiments, the shell 110 and / or the reduction furnace 100 can be a cylindrical shape. In some embodiments, the shell 110 and / or the reduction furnace 100 can be a non-cylindrical shape. For example, in some embodiments, the shell 110 and / or the reduction furnace 100 can be an oval shape, a spherical shape, a rectangular shape, and / or any other suitable shape. In some embodiments,330464460 10Agent’s File Ref. HERM-001 / 01WO 356954-2019the shell 110 can be a monolithic structure having a bottom portion, a top portion, and a side portion defining the interior volume in which the oxide feed 101 and the gas feedstock 102 can be received. In some embodiments the shell 110 can include multiple portions that can be coupled and / or assembled together to form a chambers and / or compartment for receiving the oxide feed 101 and the gas feedstock 102 and provide mechanical support for the components of the reduction furnace 100. That is, in some embodiments, the shell 110 can be modular. In such embodiments, the shell 110 can include a bottom wall, one or more side walls, and a top wall, which can be connected and / or mechanically coupled together to form the reduction furnace 100. In some embodiments, the side portion and / or side walls can include the feed port 150 and / or the gas injector 160. In some embodiments, the top portion and / or top wall of the shell 110 can include the feed port 150 and / or the gas injector 160.

[0028] As described above, the shell 110 can accommodate the hearth 120 of the reduction furnace 100. In some embodiments, the hearth 120 can be disposed in a lower portion of the reduction furnace 100, (i.e., towards the bottom portion and / or bottom wall of the reduction furnace 100). In some embodiments, the hearth 120 can be coupled to the bottom portion and / or bottom wall of the shell 110 to enclose the bottom of the reduction furnace 100. In some embodiments, the hearth 120 and shell 110 can be integrally connected and / or combined forming a single unit. In some embodiments, the shell 110 can include one or more heat exchangers. The one or more heat exchangers can be used to regulate a temperature on the shell 110 to prevent the heat generated inside the reduction furnace 100 from melting the materials forming the shell 110 (e.g., protecting the shell 110 from melting due to the high temperatures inside the reduction furnace 100). In some embodiments, the heat exchanger can flow cooling water through the interior of the shell 110 to remove excessive heat from the top portion and / or top wall, the bottom portion and / or bottom wall, and the side portions and / or side walls of the shell 110. In some embodiments, the shell 110 can include a plurality of heat exchangers disposed on one or more portions and / or walls of the shell 110. The plurality of heat exchangers can be used to cool the shell 110. In some embodiments, the interior of the shell 110 can include a plurality of openings, notches, and / or spaces in which a portion of the slag 104 can be accumulated and allowed to solidify to form an insulating layer that protects the shell 110 from melting due to the high temperatures inside the reduction furnace 100. In some embodiments, the shell 110 or a portion thereof (e.g., the bottom portion and / or bottom wall, the top portion and / or top wall, and / or the side portion and / or side walls) can be formed from copper, or include a layer made of copper or other high thermal conductivity material. In such embodiments, the copper layer can be coupled to one or more heat exchangers to remove330464460 11Agent’s File Ref. HERM-001 / 01WO 356954-2019heat from the interior volume of the reduction furnace 100 and prevent melting of the shell 110. In some embodiments, the one or more heat exchangers can flow cooling water to remove heat from the bottom portion and / or bottom wall, the top portion and / or top wall, and / or the side portion and / or side walls of the shell 110.

[0029] In some embodiments, the interior of the reduction furnace 100 can be lined with a castable refractory lining. The refractory lining can be configured to protect the integrity of the shell 110 from the intense heat inside the reduction furnace 100, radiation due to the elevated temperatures in the reduction furnace 100, and / or splashing of molten oxide feed 101, metal product 103, and / or slag 104. In some embodiments, the lining can also reduce heat loss from the reduction furnace 100 to the surrounding environment. In some embodiments, the reduction furnace 100 can include any state-of-the art technology for enhancing furnace integrity and reducing heat losses.

[0030] The hearth 120 of the reduction furnace 100 can be a refractory-lined area disposed within the reduction furnace 100 sized and configured to receive the oxide feed 101. In some embodiments the hearth 120 can be connected and / or mechanically coupled to the bottom portion and / or bottom wall of the shell 110. In some embodiments, the hearth 120 and the shell 110 can be integrally connected / combined so as to form a single unit. In some embodiments, the bottom portion and / or bottom wall, the top portion and / or top wall, the side portion and / or side walls of the shell 110, and the hearth 120 can be integrally connected / combined so as to form a single unit. In some embodiments, the hearth 120 can be disposed near the bottom portion and / or bottom wall of the shell 110 and in alignment with multiple feed ports 150 located on the top portion and / or top wall as well as on the side portion and / or side walls of the shell 110. In such embodiments, the oxide feed 101 can be introduced into the reduction furnace 100 via the feed port 150 and directed to the hearth 120 by gravity. In some embodiments, the reduction furnace 100 can be configured to melt the oxide feed 101 that enters the reduction furnace 100 (via the feed port 150) to form a molten bath within the hearth 120, as further disclosed herein. Alternatively, in some embodiments the hearth 120 can be configured to receive the molten bath and keep the molten bath in its molten state.

[0031] The molten bath can include a layer of slag 104 and a layer of metal product 103 produced during operation of the reduction furnace 100 with the gas feedstock 102. In some embodiments, the slag 104 can be foamy. In some embodiments, the slag 104 can include molten oxide feed 101 which has not been reduced by the gas feedstock 102 (e.g., unreacted molten oxide feed 101). In some embodiments, the slag 104 can form a layer that sits on top of a layer of metal product 103. In some embodiments, the gas feedstock 102 can be directly330464460 12Agent’s File Ref. HERM-001 / 01WO 356954-2019injected into the layer of slag 104 to reduce the molten oxide feed 101 included in the slag 104 and produce the metal product 103. For example, in some implementations, a gas injector 160 can be disposed in the reduction furnace 100 such that a tip, nozzle, or end portion of the gas injector 160 is submerged in the layer of slag 104 and injects the gas feedstock 102 in the slag 104. In some implementations, a gas injector 160 can be disposed in the reduction furnace 100 such that a tip, nozzle, or end portion of the gas injector 160 is placed directly above the layer of slag 104 and flows the gas feedstock 102 towards the layer of slag 104 such that the gas feedstock 102 penetrates and / or diffuses into the layer of slag 104. In some implementations, a gas injector 160 can be disposed in the reduction furnace 100 such that the gas injector 160 or at least a portion thereof (e.g., a tip, nozzle, or end portion of the gas injector 160) is submerged in the layer of metal product 103 and injects the gas feedstock 102 in the layer of metal product 103 such that the gas feedstock 102 penetrates and and / or diffuses into the layer of slag 104. The metal product 103 can be produced and then sink towards the bottom of the hearth 120, generating the layer of metal product 103 below the layer of slag 104, as further discussed herein. In some embodiments, the reduction furnace 100 can be configured to melt the oxide feed 101 (by generating an arc between the first electrode 130 and the second electrode 140, as further disclosed herein) and keep the layer of slag 104 and the layer of metal product 103 in the molten phase while the reduction furnace 100 supplies thermal energy and a gas feedstock 102 to the molten bath to continue to reduce the oxide feed 101.

[0032] In some embodiments, the shell 110 of the reduction furnace 100 can include a metal product outlet port 170 and a slag outlet port 180 fluidically coupled with the interior volume of the reduction furnace 100. The metal product outlet port 170 can be used to remove metal product 103 from the reduction furnace 100 by flowing the metal product 103 from the hearth 120, through the metal product outlet port 170 out of the reduction furnace 100. Similarly, the slag outlet port 180 can be used to remove slag 104 from the reduction furnace 100 by flowing slag 104 from the hearth 120, through the slag outlet port 180 out from the reduction furnace 100, as further disclosed herein.

[0033] The first electrode 130 and the second electrode 140 can be any suitable electrode disposed within the shell 110 and configured to generate an electric arc between them. In some embodiments, the electric arc is a transferred or non-transferred electric arc. In some embodiments, the first electrode 130 and the second electrode 140 can be made of carbon, graphite, titanium, tungsten, tantalum, zirconium, copper, or combinations thereof. In some embodiments, the first electrode 130 can be an anode electrode and the second electrode 140330464460 13Agent’s File Ref. HERM-001 / 01WO 356954-2019can be a cathode electrode. Alternatively, in some embodiments the first electrode 130 can be a cathode electrode and the second electrode 140 can be an anode electrode.

[0034] In some embodiments, the first electrode 130 can be disposed on the bottom portion and / or a bottom wall of the shell 110. In some embodiments, the first electrode 130 can be a single solid electrode disposed on the bottom portion and / or a bottom wall of the shell 110. In some embodiments, the first electrode 130 can be a plurality of first electrodes 130 disposed on the bottom portion and / or a bottom wall of the shell 110. In such embodiments, the plurality of first electrodes 130 can be configured to establish and / or generate an arc with the second electrode 140 (or with a plurality of second electrodes 140), as further described herein. In some embodiments, the first electrode 130, or a portion thereof, can be disposed and / or housed within the hearth 120. In some embodiments, the first electrode 130 can be partially or completely embedded within the hearth 120. In some embodiments, the first electrode 130 can be disposed within the hearth 120 such that a distal end portion of the first electrode 130 is disposed above the layer of slag 104 in the molten bath. In some embodiments, the first electrode 130 can be disposed within the hearth 120 such that a distal end portion of the first electrode 130 is submerged in the layer of slag 104 and the layer of the metal product 103 of the molten bath.

[0035] In some embodiments, the second electrode 140, can be disposed on the top portion and / or wall of the shell 110. In some embodiments, the second electrode 140 can be a single solid electrode disposed on the top portion and / or a top wall of the shell 110. In some embodiments, the second electrode 140 can be a plurality of second electrodes 140 disposed on the top portion and / or a top wall of the shell 110. In some embodiments, the top portion and / or top wall of the reduction furnace 100 includes a second electrode 140 that extends from the top portion and / or top wall of the shell 110 towards the hearth 120 of the reduction furnace 100. In some embodiments, a distal end of the second electrode 140 can be disposed above the layer of slag 104 included and / or contained in the molten bath of the hearth 120. In some embodiments, the distal end of the second electrode 140 can be submerged in the layer of slag 104 and / or in the layer of metal product 103 included and / or contained in the molten bath of the hearth 120. In some embodiments, the second electrode 140 can be disposed on a center region of the top portion and / or top wall of the shell 110. For example, as shown schematically in FIGS 4A-4C, in some embodiments the shell 110 of the reduction furnace 100 can be a cylindrical shape, and the second electrode 140 can be disposed on a central region of a top portion and / or top wall 111 of the shell 110, aligned with an internal axis of the reduction furnace 100. In some embodiments, the second electrode 140 can be hollow. In such330464460 14Agent’s File Ref. HERM-001 / 01WO 356954-2019embodiments, the second electrode 140 can include a port (not shown in FIGS 4A-4C) running through the internal axis of the of the reduction furnace 100. In some embodiments, the port can be used to inject the gas feedstock 102 and / or the oxide feed 101.

[0036] As disclosed above, the first electrode 130 and the second electrode 140 can be configured to generate an arc between them. In some embodiments, the first electrode 130 and the second electrode 140 can generate an arc between a distal end of the second electrode 140 and the first electrode 130. In some embodiments, the first electrode 130 and the second electrode 140 can generate an arc between the distal end of the second electrode 140 and the molten bath included in the hearth 120 of the reduction furnace 100. As disclosed above, in some embodiments the second electrode 140 can be and / or include multiple second electrodes 140. In such embodiments, the top portion and / or top wall of the shell 110 can include multiple second electrodes 140 that extend from the top portion and / or top wall of the shell 110 towards the hearth 120 of the reduction furnace 100, and the reduction furnace 100 is configured to generate an electric arc between a distal end of each second electrode 140 of the multiple second electrodes 140 and the first electrode 130. In some embodiments, a distance between the multiple second electrodes 140 is such that there is no arc interference between the electric arc of each second electrode 140 and the first electrode 130. In some embodiments, a distance between the multiple second electrodes 140 is such that there is arc interference between the electric arc of each second electrode 140 and the first electrode 130, such that the arcs merge towards the center of the molten bath in the hearth 120.

[0037] In some embodiments the second electrode 140 can be and / or include multiple second electrodes 140, and the first electrode 130 can be and / or include multiple first electrodes 130. In such embodiments, the top portion and / or top wall of the shell 110 can include multiple second electrodes 140 that extend from the top portion and / or top wall of the shell 110 towards the hearth 120 of the reduction furnace 100, and the reduction furnace 100 is configured to generate an electric arc between a distal end of each second electrode 140 of the multiple second electrodes 140 and a first electrode 130 from the multiple first electrodes 130. In some embodiments, a distance between the multiple second electrodes 140 is such that there is no arc interference between the electric arc of each second electrode 140 and each first electrode 130. In some embodiments, a distance between the multiple second electrodes 140 is such that there is arc interference between the electric arc of each second electrode 140 and each first electrode 130, such that the arcs merge towards the center of the molten bath in the hearth 120.

[0038] As disclosed above, in some embodiments, the first electrode 130 and the second electrode 140 can be used to strike an electric arc between them. In some embodiments, the330464460 15Agent’s File Ref. HERM-001 / 01WO 356954-2019first electrode 130 and the second electrode 140 can generate an electric arc under alternating current (AC) or direct current (DC) electrical operation. In some embodiments, the temperatures surrounding the electric arc can be greater than 3,000 degrees Celsius (~3,000 °C). In some embodiments, the arc generated between the first electrode 130 and the electrode s configured to provide thermal energy to the molten bath of the hearth 120, and the interior volume of the reduction furnace 100. In some embodiments, the electric arc can be configured to melt the oxide feed 101 to form the molten bath. In some embodiments, the electric arc can be configured to heat the gas feedstock 102 as the gas feedstock 102 is introduced in the reduction furnace 100 via the gas injector 160.

[0039] In some embodiments in which the first electrode 130 and the second electrode 140 generate a transferred arc, the molten bath of the hearth 120 can be part of the electrical circuit. The electric arc can be constituted between the second electrode 140 and the molten bath, which may not be in direct physical contact with one another. In such embodiments, ionized gas from the gas feedstock 102 can be generated in and around the electric arc and may come into contact with the molten bath of the hearth 120. In some embodiments in which the first electrode 130 and the second electrode 140 generate a non-transf erred electric arc, the electric arc may not interact with the molten bath. Instead, a plasma torch, for example, may be used in which the electric arc can be generated between the second electrode 140 and a nozzle of the plasma torch. In such embodiments, ionized gas from the gas feedstock 102 can be produced within the plasma torch and hot gas exits to the torch at high temperature and high velocities. In some embodiments, the transferred arc configuration can have ~20% greater electro-thermal efficiency than a non-transferred arc technology.

[0040] As described above, in some embodiments, the second electrode 140 can be disposed on a central region of a top portion and / or top wall 111 of the shell 110, aligned with an internal axis of the reduction furnace 100, as shown in FIGS 4A-4C. The second electrode 140 can extend from the top portion and / or top wall of the shell 110 towards the hearth 120 of the reduction furnace 100, with the second electrode 140 being hollow. As such, the second electrode 140 can include a port running through an internal axis of the second electrode 140. In some embodiments, the port can be used to inject the gas feedstock 102 and / or the oxide feed 101.

[0041] In some embodiments, at least a portion of the gas feedstock 102 can be injected into the reduction furnace 100 via the second electrode 140 such that the portion of the gas feedstock 102 passes through the electric arc to form a plasma. Optionally and / or additionally,330464460 16Agent’s File Ref. HERM-001 / 01WO 356954-2019in some embodiments, at least a portion of the gas feedstock 102 is injected into the reduction furnace 100 via the gas injector 160 and directed towards the electric arc to form a plasma. In some embodiments, the gas feedstock 102 can be injected via the gas injector 160 directly into the molten bath of the hearth 120 and some of the gas feedstock 102 may escape the molten bath without reducing the oxide feed 101 in the layer of slag 104. In such embodiments, the gas feedstock 102 that escapes the molten bath can generate plasma around the electric arc. In some embodiments, the plasma can surround the electric arc. In some embodiments, the gas feedstock 102 that passes through the electric arc can become an ionized gas feedstock 102. For example, in some embodiments the gas feedstock 102 can include hydrogen, with the hydrogen gas passing through the electric arc and becoming ionized hydrogen. In some embodiments, the ionized gas feedstock 102 and / or plasma can exist around the electric arc and / or be pulled into the molten bath. In some embodiments, the plasma can melt the oxide feed 101 and / or can supply thermal energy to the reduction furnace 100 to preserve the oxide feed 101 in molten state. In some embodiments, the plasma can also reduce the oxide feed 101. In some embodiments, the ionized gas feedstock 102 located around the electric arc can be entrapped into the molten bath (e.g., within the layer of slag 104 and / or within the layer of metal product 103) due to arc momentum. In some embodiments, the ionized gas feedstock 102 can reduce the oxide feed 101 in the layer of slag 104 near the electric arc. In some embodiments, the ionized gas feedstock 102 can become un-ionized which can exothermically contribute to heat generation in the reduction furnace 100. For example, ionized hydrogen around the electric arc may be recombined into atomic hydrogen or molecular hydrogen exothermically contributing to heat generation in the reduction furnace 100.

[0042] The feed port 150 can be an opening on the shell 110 sized and configured to introduce the oxide feed 101 into the reduction furnace 100. In some embodiments, the feed port 150 can be multiple feed ports 150 (e.g., a plurality of feed ports 150) which are collectively referred to herein as the feed port 150. In some embodiments, the feed port 150 can be and / or include a bin or hopper, configured to introduce the oxide feed 101 into the reduction furnace 100. In some embodiments, the feed port 150 can be configured to introduce the oxide feed 101 to the reduction furnace 100 such that the oxide feed 101 can be melted in the reduction furnace 100. Alternatively, in some embodiments, the feed port 150 can be configured to introduce molten oxide feed 101. In some embodiments, the reduction furnace 100 can include the feed port 150 disposed on the side portion and / or side walls of the shell 110. In some embodiments, the feed port 150 disposed on the side portion and / or side walls of the shell 110 can be oriented and / or aligned at an angle a with respect to the side portion and / or330464460 17Agent’s File Ref. HERM-001 / 01WO 356954-2019side walls of the shell 110 such a stream of the oxide feed 101 can be introduced into the reduction furnace 100 and be transfer by gravity directly into the hearth 120, as shown for example, in FIG 5.

[0043] In some embodiments, the reduction furnace 100 can include a feed ports 150 disposed on the top portion and / or top wall of the shell 110. In some embodiments, the feed port 150 can be arranged according to an annular layout and / or arrangement around the top portion and / or top wall of the shell 110, as shown for example in FIGS. 4A and 4B. FIGS. 4A and 4B show a top view schematic illustration of a reduction furnace 100 having a cylindrical shape, according to an embodiment. The feed ports 150 shown in FIGS. 4A and 4B are disposed according to an annular arrangement in which each feed port 150 is placed equidistantly from a center of the reduction furnace 100, where a second electrode 140 is disposed. Alternatively, in some embodiments the feed ports 150 can be arranged according to a radial a layout and / or arrangement on the top portion and / or top wall of the shell 110, as shown for example in FIG.4C. FIG. 4C shows a top view schematic illustration of a reduction furnace 100 having a cylindrical shape, according to an embodiment. The feed ports 150 shown in FIG. 4C are disposed according to a radial arrangement, in which a first feed port 150A is located at a first distance dl from a center of the reduction furnace 100 (where the second electrode 140 is disposed), a second feed port 150B is located at a second distance d2 from the center of the reduction furnace 100, with the distance d2 being greater than the distance dl, and third feed port 150C is located at a third distance d3 from the center of the reduction furnace 100, the distance d3 being greater than the distance d2 and dl.

[0044] In some embodiments, the feed ports 150 can be configured such that feed ports 150 that are closer to a center of the top portion and / or top wall 111 can introduce more oxide feed 101 to the reduction furnace 100 than the feed ports 150 further away from the center of the top portion and / or top wall 111, thus generating feed zones. FIG 4C illustrate an example of zoning the feed ports 150 for a cylindrical reduction furnace 100. In some embodiments, the feed ports 150 arranged annularly around the center of the reduction furnace 100 at the distance dl can introduce more oxide feed 101 than the feed ports 150 arranged annularly around the center of the furnace 100 at the distance d2. Similarly, the feed ports 150 arranged annularly around the center of the furnace 100 at the distance d2 can introduce more oxide feed 101 than the feed ports 150 arranged annularly around the center of the furnace 100 at the distance d3.

[0045] The gas injector 160 can be any suitable conduit, channel, tube, duct, or the like configured to introduce the gas feedstock 102 into the reduction furnace 100. In some330464460 18Agent’s File Ref. HERM-001 / 01WO 356954-2019embodiments, the gas injector 160 can be configured to inject the gas feedstock 102 into a molten bath disposed within a hearth 120 of the furnace 100, with the molten bath including a slag layer 104 and a molten metal product 103. In some embodiments, the gas injector 160 can be configured to inject substantially all the gas feedstock 102 only into the slag layer 104. In some embodiments, the gas injector 160 can be configured to inject the gas feedstock 102 into the slag layer 104 and the molten metal product layer 103 (e.g., a first portion of the gas feedstock 102 is injected into the slag layer 104 and a second portion of the gas feedstock 102 is injected into molten metal product layer 103). In some embodiments, the gas injector 160 can be multiple gas injectors 160 (e.g., a plurality of gas injectors 160) which are collectively referred to herein as the gas injector 160. In some embodiments, the gas injector 160 can be and / or include a lance, submerged tuyere, swirling lances such as top-submerged-lance, supersonic jet, coherent jet, plasma torch, or any type of injector and / or nozzle which maximizes the contact area between the injected gas feedstock 102 and the layer of slag 104 disposed in the hearth 120. In some embodiments, the gas injector 160 can include a nozzle sized and configured to inject a gas feedstock 102 into the slag 104 at subsonic speeds. For example, in some embodiments the gas injector 160 can be a lance configured to flow the gas feedstock 102 at a flow rate chosen such that the gas feedstock 102 achieves linear velocities between 50 m / s and 300 m / s. In some embodiments, the gas injector 160 can include a nozzle sized and configured to inject a gas feedstock 102 into the slag 104 at supersonic speeds. For example, in some embodiments the gas injector 160 can be lance configured to flow the gas feedstock 102 at a flow rate chosen such that the gas feedstock 102 achieves velocities including, but not limited to, Mach 1.0, or Mach 2.0. In some embodiments, the gas injector 160 can be and / or include a plasma torch that injects the gas feedstock 102 at a temperature greater than the melting point of the oxide feed 101. In some embodiments, the injector 160 can include coherent jets including at least one of supersonic coherent jets, subsonic coherent jets, or coherent jets with shrouded flames.

[0046] In some embodiments, at least one of the gas injector(s) 160 can be configured to inject the gas feedstock 102 towards and / or into a first area of the molten bath (e.g., the layer of slag 104). In some embodiments, at least one of the gas injector(s) 160 can be configured to inject the gas feedstock 102 towards and / or into a second area of the molten bath different from the first area of the molten bath such that the gas feedstock 102 can reach / interact with different areas of the molten bath. In some embodiments, each gas injector 160 is configured to inject the gas feedstock 102 towards and / or into a different area of the molten bath. In some embodiments, at least one of the gas injector(s) 160 can be configured to inject the gas330464460 19Agent’s File Ref. HERM-001 / 01WO 356954-2019feedstock 102 in a direction toward an adjacent gas injector 160 such that the layer of slag 104 and / or the layer of metal product 103 in the molten bath swirls within the reduction furnace 100 to increase mixing and / or agitation of the molten bath, maximize a distribution of the gas feedstock 102 within the slag 104 (e.g., , improving the diffusion of the gas feedstock 102 within the slag 104, and increase a rate of formation of the metal product 103 (e.g., increasing a rate of reduction of a metal oxide producing the metal product 103 and / or a rate of carburization of the metal product 103). The increase in the rate of formation of the metal product 103 can lead to an overall improvement in the productivity of the reduction furnace 100.

[0047] In some embodiments the gas injector(s) 160 can be sized and configured to deliver a specific type of gas feedstock 102. For example, in some embodiments, the gas injector(s) 160 can be configured to inject a gas feedstock 102 including industrial-grade hydrogen, or a mixture of hydrogen and one or more inert gases such as nitrogen, argon, helium and the like (also referred to as a hydrogen gas feedstock 102). In some embodiments, the gas injector(s) 160 can inject a hydrogen gas feedstock 102 into the reduction furnace 100. In such embodiments hydrogen (e.g., molecular hydrogen) can initiate reduction reactions with the oxide feed 101, as further disclosed herein. In some embodiments the molecular hydrogen may be heated to facilitate the reduction reactions (e.g., to increase the kinetic rate of reaction). In some embodiments, the gas injector(s) 160 can be configured to pre-heat the hydrogen gas feedstock 102 such that the reduction furnace 100 primarily heats the oxide feed 101, reducing the overall thermal load on the reduction furnace 100 and improving its energy efficiency. Alternatively, in some embodiments, the gas injector(s) 160 may inject a hydrogen gas feedstock 102 without pre-heating it, in which case the first electrode 130 and the second electrode 140 can be configured to generate the heat needed to increase the temperature of the hydrogen gas feedstock 102, and if needed, melt the oxide feed 101, or at least maintain the oxide feed 101 in a molten state. As disclosed above, in some embodiments the gas injector(s) 160 can be configured to deliver a hydrogen gas feedstock 102 including an inert and / or an unreactive gas such as nitrogen argon, helium or the like. In such embodiments, the addition of the unreactive gas can serve the purpose of increasing the density of the hydrogen gas feedstock 102 to improve the penetration depth of the hydrogen included in the hydrogen gas feedstock 102 into the slag 104 and facilitate the reduction of the oxide feed 101 in the layer of slag 104 to produce a metal product 103, as further described herein.

[0048] In some embodiments, the gas injector(s) 160 can be sized and configured to deliver a gas feedstock 102 including substantially pure natural gas, or a mixture of natural gas and330464460 20Agent’s File Ref. HERM-001 / 01WO 356954-2019one or more inert gases such as nitrogen, argon, helium, and the like (also referred to as a natural gas feedstock 102). In some embodiments, the gas injector(s) 160 can inject the natural gas feedstock 102 into the reduction furnace 100. In such embodiments natural gas (e.g., methane included in the natural gas feedstock 102) can initiate reduction reactions with the oxide feed 101, as further disclosed herein. In some embodiments the natural gas feedstock 102 may be heated to facilitate the reduction reactions (e.g., to increase the kinetic rate of reaction). In some embodiments, the gas injector(s) 160 can be configured to pre-heat the natural gas feedstock 102 such that the reduction furnace 100 primarily heats the oxide feed 101, reducing the overall thermal load on the reduction furnace 100 and improving its energy efficiency. Alternatively, in some embodiments, the gas injector(s) 160 may inject natural gas feedstock 102 without pre-heating it, in which case the first electrode 130 and the second electrode 140 can be configured to generate the heat needed to increase the temperature of the natural gas feedstock 102, and if needed, melt the oxide feed 101, or at least maintain the oxide feed 101 in a molten state. As disclosed above, in some embodiments the gas injector(s) 160 can be configured to deliver a natural gas feedstock 102 including an inert and / or an unreactive gas such as nitrogen argon, helium or the like. In such embodiments, the addition of the unreactive gas can serve the purpose of increasing the density of the natural gas feedstock 102 to improve the penetration depth of the natural gas included in the natural gas feedstock 102 into the slag 104 and facilitate the reduction and / or carburization of the oxide feed 101 in the layer of slag 104 to produce a metal product 103 with an amount of dissolved carbon, as further described herein.

[0049] In some embodiments, the gas injector(s) 160 can be sized and configured to deliver a gas feedstock 102 including substantially pure methane, or a mixture of methane and one or more inert gases such as nitrogen, argon, helium, and the like (also referred to as a methane gas feedstock 102). In some embodiments, the gas injector(s) 160 can inject methane gas feedstock 102 into the reduction furnace 100. In such embodiments methane gas can initiate reduction and / or carburization reactions with the oxide feed 101, as further disclosed herein. In some embodiments the methane gas feedstock 102 may be heated to facilitate the reduction and / or carburization reactions (e.g., to increase the kinetic rate of the reactions). In some embodiments, the gas injector(s) 160 can be configured to pre-heat the methane gas feedstock 102 such that the reduction furnace 100 primarily heats the oxide feed 101, reducing the overall thermal load on the reduction furnace 100 and improving its energy efficiency. Alternatively, in some embodiments, the gas injector(s) 160 may inject methane gas feedstock 102 without pre-heating it, in which case the first electrode 130 and the second electrode 140 can be330464460 21Agent’s File Ref. HERM-001 / 01WO 356954-2019configured to generate the heat needed to increase the temperature of the methane gas feedstock 102, and if needed, melt the oxide feed 101, or at least maintain the oxide feed 101 in a molten state. As disclosed above, in some embodiments the gas injector(s) 160 can be configured to deliver a methane gas feedstock 102 including an inert and / or an unreactive gas such as nitrogen argon, helium or the like. In such embodiments, the addition of the unreactive gas can serve the purpose of increasing the density of the methane gas feedstock 102 to improve the penetration depth of the methane included in the methane gas feedstock 102 into the slag 104 and facilitate the reduction and / or carburization of the oxide feed 101 in the layer of slag 104 to produce a metal product 103 with an amount of dissolved carbon, as further described herein.

[0050] In some embodiments, the gas injector(s) 160 can include a first plurality of gas injectors 160 configured to deliver a first gas feedstock 102, and a second plurality of gas injectors (160) configured to deliver a second gas feedstock 102, different from the first gas feedstock 102 to the reduction furnace 100. For example, in some embodiments the gas injector(s) 160 can include a first plurality of gas injectors 160 configured to deliver a hydrogen feedstock 102, and a second plurality of gas injectors 160 configured to deliver a natural gas feedstock 102 to the reduction furnace 100.

[0051] In some embodiments, one or more gas injector(s) 160 can be disposed on a side portion and / or side walls of the shell 110. In some embodiments, the one or more gas injector(s) 160 can be disposed on a side portion and / or side walls of the shell 110 and oriented such that the gas feedstock 102 is delivered into the reduction furnace 100 in a direction normal (e.g., perpendicular) to the side portion and / or side walls of the shell 110, as shown for example in FIG. 4 A. Alternatively, in some embodiments, the one or more gas injector(s) 160 can be disposed on a side portion and / or side walls of the shell 110 and oriented such that the gas feedstock 102 is delivered into the reduction furnace 100 in a direction at an angle 0 defined with respect to a tangent line of the side portion and / or side walls of the shell 110, as shown for example in FIG. 4B. In some embodiments, the angle 0 can be no more than about 90 degrees, no more than about 80 degrees, no more than about 70 degrees, no more than about 60 degrees, no more than about 50 degrees, no more than about 40 degrees, no more than about 30 degrees, no more than about 20 degrees, or no more than about 10 degrees, inclusive of all values and ranges therebetween.

[0052] The metal product outlet port 170 can be an opening on the shell 110 fluidically coupled to the interior volume of the reduction furnace 100 and more specifically to the layer of metal product 103 disposed in the hearth 120. The metal product outlet port 170 can be used330464460 22Agent’s File Ref. HERM-001 / 01WO 356954-2019to remove metal product 103 from the reduction furnace 100 by flowing the metal product 103 from the hearth 120, through the metal product outlet port 170, and out of the reduction furnace 100. The metal product outlet port 170 can include multiple metal product outlet ports 170 disposed around the side portion and / or side walls of the shell 110 and at a first distance and / or height from the bottom portion and / or bottom wall of the shell 110, such that the metal product outlet port(s) 170 can be used to remove metal product 103 from the hearth 120 of the reduction furnace 100. More specifically the metal product outlet ports 170 can be in fluidic communication with the layer of metal product 103 contained within the molten bath of the hearth 120. In that way, metal product 103 can be flown from the hearth 120, through the metal product outlet ports 170 and out the reduction furnace 100. This enables the continuous or semicontinuous operation of the reduction furnace 100.

[0053] The slag outlet port 180 can be an opening on the shell 110 fluidically coupled to the interior volume of the reduction furnace 100, and more specifically to the to the layer slag 104 disposed in the hearth 120. The slag outlet port 180 can be used to remove slag 104 from the reduction furnace 100 by flowing the slag 104 from the hearth 120, through the slag outlet port 180, and out of the reduction furnace 100. The slag outlet port 180 can include multiple slag outlet ports 180 disposed around the side portion and / or side walls of the shell 110 and at a second distance and / or height from the bottom portion and / or bottom wall of the shell 110, the second distance and / or height being greater than the first distance and / or height of the metal product outlet port 170 described above. The slag outlet ports 180 can be used to remove slag 104 from the hearth 120 of the reduction furnace 100. More specifically the slag outlet ports 180 can be in fluidic communication with the layer of slag 104 contained within the molten bath of the hearth 120. In that way, slag 104 can be flown from the hearth 120, through the slag outlet ports 180 and out the reduction furnace 100. This enables the continuous or semicontinuous operation of the reduction furnace 100.

[0054] In use, the reduction furnace 100 can receive an oxide feed 101 and a gas feedstock 102 and conduct one or more reactions (e.g., a reduction reaction and / or a carburization reaction) to reduce, at the hearth 120 of the reduction furnace 100, the oxide feedstock to produce the metal product 103 with an amount of carbon dissolved and slag 104. For example, in some embodiments the furnace 100 can receive an oxide feed 101 that includes a metal oxide of interest such as iron oxide, and a gas feedstock including hydrogen, natural gas, methane, and / or any other suitable reductant gas. The furnace 100 can be configured to receive the oxide feed 101 and dispose the oxide feed 101 in the hearth 120. As disclosed above, in some embodiments the oxide feed 101 can be received as a molten oxide feed 101 (e.g., the oxide330464460 23Agent’s File Ref. HERM-001 / 01WO 356954-2019feed 101 can be heated to produce a molten oxide feed 101 via a process and / or device separate from the furnace 100). In such embodiments, the molten oxide feed 101 can include at least one of molten metal product 103 and / or slag 104, which can be disposed in the hearth 120 producing and / or forming a layer of molten metal product 103 and a layer of slag 104, with the layer of slag 104 being disposed above the layer of molten metal product 103.

[0055] In some embodiments, the layer of molten metal product 103 and the layer of slag 104 in the hearth 120 can be entirely generated from the molten oxide feed 101 received in the furnace 100. In some embodiments, a first portion of the layer of molten metal product 103 and the layer of slag 104 disposed in the hearth 120 can be generated from the molten oxide feed 101 received in the furnace 100, while a second portion of the layer of molten metal product 103 and the layer of slag 104 disposed in the hearth 120 can be obtained and / or generated from a molten oxide feed 101 from a previous batch (e.g., a previously received and / or processed molten oxide feed 101). In some embodiments in which the furnace 100 is operated in continuous mode, the layer of molten metal product 103 and the layer of slag 104 disposed in the hearth 120 can be maintained at steady state level and / or amount by continuously feeding a molten oxide feed 101 while at the same time removing (via the metal product outlet port 170 and the slag outlet port 180) an amount of metal product 103 and slag 104. In some embodiments, the layer of slag 104 disposed in the hearth 120 can include a synthetic slag and / or a slag prepared in a laboratory, as disclosed above.

[0056] The furnace 100 can receive the gas feedstock 102 and direct the gas feedstock 102 towards the molten bath included in the hearth 120. As disclosed above, in some embodiments, the gas injector 160 can be configured to inject the gas feedstock 102 into the slag layer 104 disposed in the hearth 120. The gas feedstock 102 can be injected in such way that the gas feedstock 102 diffuses within the slag 104 and initiates one or more chemical reactions that reduce the metal oxide dissolved in the slag 104, producing metal product 103. For example, in some embodiments the gas feedstock 102 can include hydrogen. The hydrogen can be injected (via the gas injector 160) into the slag layer 104 such that hydrogen molecules diffuse within the slag layer 104 and react (via reduction reactions) with metal oxide to produce the metal product 103. In some embodiments the gas feedstock 102 can include natural gas, methane, and / or any other hydrocarbon capable of reducing the metal oxide dissolved in the slag 104. The natural gas, methane, and / or other hydrocarbon can be injected (via the gas injector 160) into the slag layer 104 such that methane and / or other hydrocarbon molecules diffuse within the slag layer 104 and react (via reduction reactions) with metal oxide to produce the reduced molten metal product 103. Additionally, in some embodiments, the methane and / or330464460 24Agent’s File Ref. HERM-001 / 01WO 356954-2019other hydrocarbon molecules can also react via a carburization reaction which introduces carbon into the reduced metal product 103 (e.g., carbon dissolved within the lattice of the reduced metal product 103). As the reduction of the oxide feed 101 proceeds, metal product 103 and slag 104 accumulate in the molten bath of the hearth 120 until filling the capacity of the hearth 120. When a predetermined amount and / or volume of metal product 103 and / or slag 104 is accumulated in the molten bath of the hearth 120, the metal product outlet port 170 can be opened to remove metal product 103 from the reduction furnace 100. Similarly, when a predetermined amount of slag 104 is accumulated in the molten bath of the hearth 120, the slag outlet port 180 can be opened to remove slag 104 from the reduction furnace 100. After that, the reduction furnace 100 can continue to reduce oxide feed 101 to produce more metal product 103 and slag 104 in a continuous or semi-continuous manner.

[0057] In some embodiments, the reduction furnace 100 can include a vent port 190 disposed on the shell 110 and configured to off-gas and / or vent out gases included in the reduction furnace 100. In some embodiments, the gases vented using the vent port 190 can include, for example, an unreacted gas feedstock 102, one or more species produced as byproducts of the reduction of the oxide feed 101, and / or species included in the oxide feed 101 which become vaporized during melting of the oxide feed 101. In some embodiments, the vent port 190 can be multiple vent ports 190 disposed on the side portion and / or side walls of the shell 110, and configured to vent out (e.g., off-gas) gases included, contained, and / or produced in the reduction furnace 100. In some embodiments, the vent port 190 can be multiple vent ports 190 disposed on the top portion and / or top wall of the shell 110, and configured to vent out (e.g., off-gas) gases included, contained, and / or produced in the reduction furnace 100. Further details on the reduction furnace 100 can be found in and are disclosed in U.S. Patent Publication No. US / 2024 / 0026476, titled “Methods and Apparatus for Metals, Alloys, Mattes, or Enriched and Cleaned Slags Production from Predominantly Oxide Feeds,” filed July 21, 2023 (the ’476 application), the disclosure of which is incorporated herein by reference in its entirety.

[0058] FIG. 5 shows a cross-sectional front view of a reduction furnace 200 for the production of a metal product using a hydrogen gas feedstock 202, according to an embodiment of the present disclosure. The reduction furnace 200, which can also be referred to herein as the “furnace 200” or the “apparatus 200,” can be the same or similar in structure and / or function to the reduction furnace 100 described above with reference to FIG. 3. As such, portions, and / or aspects of the reduction furnace 200 can be similar to and / or substantially the same as portions and / or aspects of the reduction furnace 100 described above with reference to FIGS.330464460 25Agent’s File Ref. HERM-001 / 01WO 356954-20192 and 3, and therefore are not described in detail herein. The reduction furnace 200 can define and / or provide an interior volume in which an oxide feed 201 can be heated to a predetermined temperature sufficiently high to melt the oxide feed 201 and then be reacted with a hydrogen gas feedstock 202 to produce a metal product 203 and slag 204. The reduction furnace 200 can include a shell 210, a hearth 220, a first electrode 230, a second electrode 240, a feed port 250, a gas injector 260, a metal product outlet port 270, a slag outlet port 280, and a vent port 290.

[0059] FIG. 5 shows the reduction furnace 200 includes a shell 210 that provides a protective enclosure defining an interior volume, compartment, and / or chamber for accommodating (e.g., housing, and / or containing) the oxide feed 201 and the hydrogen gas feedstock 202. The shell 210 includes a plurality of walls that provide mechanical support to accommodate and / or house one or more components of the reduction furnace 200. For example, the shell 210 includes a top portion and / or top wall 211 that encloses the interior volume of the reduction furnace 200 and provides mechanical support and / or accommodates the second electrode 240, the feed port 250, the gas injector 260, and the vent port 290. The shell 210 also includes a side portion and / or side walls that provide mechanical support and / or accommodates the metal product outlet port 270 and the slag outlet port 280, and a bottom portion and / or bottom wall that support and / or accommodates the hearth 220 and the first electrode 230. FIG. 5 also shows the interior of the reduction furnace 200 is lined with a castable refractory lining 212. The castable refractory lining 212 can be configured to protect the integrity of the shell 210 from the intense heat inside the reduction furnace 200, radiation due to the elevated temperatures in the reduction furnace 200, and / or splashing of molten oxide feed 201, metal product 203, and / or slag 204.

[0060] FIG. 5 shows the hearth 220 of the reduction furnace 200 is disposed on a bottom portion of the shell 210 and contains a molten bath comprising a layer of slag 204 disposed above a layer of metal product 203. In some implementations, the hearth 220 and the shell 210 can be integrally connected / combined so as to form a single unit, as shown in FIG. 5. The hearth 220 is disposed on a central region of the reduction furnace 200 aligned symmetrically with respect to an internal axis A of the reduction furnace 200, shown in FIG. 5. The hearth 220 extends from the central region towards the side portion and / or side walls of the shell 210 such that the feed port 250 can be used to introduce and / or feed by gravity the oxide feed 201 directly into the hearth 220 of the reduction furnace 200.

[0061] FIG. 5 shows the first electrode 230 is disposed on the bottom portion and / or a bottom wall of the shell 210. More specifically, the first electrode 230 is partially embedded within the hearth 220, with a portion of the first electrode 230 being in fluidic contact with the330464460 26Agent’s File Ref. HERM-001 / 01WO 356954-2019layer of metal product 203. The first electrode 230 includes multiple first electrodes 230 coupled to each other and disposed on the bottom portion and / or a bottom wall of the shell 210. Alternatively, in some implementations the first electrode 230 can be a single solid electrode. The multiple first electrodes 230 shown in FIG. 5 are oriented vertically (e.g., parallel to the axis A) such that a distal portion of each first electrode 230 is submerged in the layer of the metal product 203. The second electrode 240 is disposed on the top portion and / or top wall 211 of the reduction furnace 200. More specifically, the second electrode 240 is disposed on a center region of the top portion and / or top wall 211, aligned with the Axis A. The second electrode 240 extends from the top portion and / or top wall 211 of the shell 210 towards the hearth 220 of the reduction furnace 200. The multiple first electrodes 230 and the second electrode 240 can generate multiple arcs between them, as schematically represented by the discharge AA shown in FIG. 5. Since a distal portion of each first electrode 230 is submerged in the layer of the metal product 203, each first electrode 230 and the second electrode 240 generates an arc between a distal end of the second electrode 240 and the molten bath included in the hearth 220 of the reduction furnace 200. In some implementations, a distance between the multiple first electrodes 230 is such that there is no arc interference between the electric arc of each first electrode 230 and the second electrode 240. In some implementations, a distance between the multiple first electrodes 230 is such that there is arc interference between the electric arc of each first electrode 230 and the second electrode 240, and the arcs merge towards the center of the molten bath in the hearth 220, around the axis A.

[0062] FIG. 5 shows the gas injector 260 is a hydrogen lance mechanically coupled to the top portion and / or top wall 211 of the shell 210, extending towards the hearth 220. The lance 260 is oriented parallel to the second electrode 240. More specifically, the lance 260 is disposed on the reduction furnace 200 such that a distal end of the lance 260 is submerged in the layer of the slag 204. In use, the lance 260 can be used to deliver the hydrogen gas feedstock 202 into the reduction furnace 200 and more specifically into the layer of slag 204, as further disclosed herein.

[0063] The reduction furnace 200 includes a metal product outlet port 270 disposed on a side portion and / or side walls of the shell 210. The metal product outlet port 270 can be placed in fluidic communication with interior volume of the reduction furnace 200. More specifically, the metal product outlet port 270 can be in fluidic communication with the layer of metal product 203 contained within the molten bath of the hearth 220. In that way, the metal product outlet port 270 can be used to remove metal product 203 (e.g., tapping the metal product 203), enabling the continuous and / or semicontinuous operation of the reduction furnace 200.330464460 27Agent’s File Ref. HERM-001 / 01WO 356954-2019

[0064] The reduction furnace 200 also includes a slag outlet port 280, disposed on a side portion and / or side walls of the shell 210, opposite to the metal product outlet port 270. The slag outlet port 280 can be placed in fluidic communication with the interior volume of the reduction furnace 200. More specifically, the slag outlet port 280 can be in fluidic communication with the layer of slag 204 contained within the molten bath of the hearth 220. In that way, the slag outlet port 280 can be used to remove slag 204 (e.g., tapping the slag 204), enabling the continuous and / or semicontinuous operation of the reduction furnace 200.

[0065] In use, the reduction furnace 200 can facilitate producing and / or fabricating a metal product 203 from an oxide feed 201. The oxide feed 201 can be introduced into the reduction furnace 200 via the feed port 250. In some implementations, the feed port 250 can be configured to introduce molten oxide feed 201 (e.g., an oxide feed 201 which has been heated above its melting point prior to introducing the oxide feed 201 into the reduction furnace 200). Alternatively, in some implementations, the feed port 250 can be configured to introduce the oxide feed 201 to the reduction furnace 200 such that the oxide feed 201 can be melted in the reduction furnace 200. The oxide feed 201 can be received in the hearth 220 of the reduction furnace 200. The hearth 220 can be configured to include a molten bath comprising a layer of slag 204 (including a metal oxide of interest which was initially included in the oxide feed 201) and a layer of metal product 203, as shown in FIG. 5. As disclosed above, in some implementations the oxide feed 201 can be directed to the hearth 220 (via the feed port 250) as a molten oxide feed 201. In such implementations, the molten oxide feed 201 can include slag 204 (with a one or more metal oxides of interest dissolved within the slag 204), which can be accommodated in the molten bath of the hearth 220 and mixed with additional slag 204 (e.g., layer of slag 204 present in the hearth of the furnace 200 form a previous batch and / or a continuous operation of the furnace 200. Alternatively, in some implementations, the oxide feed 201 can be directed to the hearth 220 (via the feed port 250) as a solid oxide feed 201. In such implementations, the oxide feed 201 can be received and accommodated in the molten bath of the hearth 220 above the layer of slag 204, and or dispersed within the layer of slag 204. In some implementations, the reduction furnace 200 can be configured to direct the hydrogen gas feedstock 202 towards a hearth 220 such that the hydrogen gas feedstock 202 agitates and / or swirls the layer of slag 204 to (1) create a homogenous slag 204 composition (e.g., by mixing the oxide feed 201 with slag 204) and (2) enhance separation of the metal product 203 contained in the layer of slag 204 such that the metal product 203 can be collected in the layer of metal product 203 disposed below the layer of slag 204. Additionally, the330464460 28Agent’s File Ref. HERM-001 / 01WO 356954-2019reduction furnace 200 can be configured to provide the heat necessary to melt the oxide feed 201 in the molten bath.

[0066] The lance 260 can be used to introduce hydrogen gas feedstock 202 within the layer of slag 204, as schematically shown in FIG. 5. In some implementations, the lance 260 can be configured to direct the hydrogen gas feedstock 202 above the layer of slag 204 such that the hydrogen gas feedstock 202 can diffuse into the layer of slag 204 for reducing the oxide feed 201. In some implementations, the lance 260 can be submerged in the layer of slag 204 and be configured to direct the hydrogen gas feedstock 202 within the layer of slag 204 such that the hydrogen gas feedstock 202 can diffuse into the layer of slag 204 and reduce the oxide feed 201. In some implementations, the lance 260 can be submerged in the layer of metal product 203 and be configured to direct the hydrogen gas feedstock 202 towards the layer of slag 104 placed and / or disposed above the layer of metal product 103, such that the hydrogen gas feedstock 202 can diffuse into the layer of slag 204 and reduce the oxide feed 201. In some implementations, the lance 260 can be configured to flow and / or direct the hydrogen gas feedstock 202 at supersonic speeds. In some implementations, the lance 260 can be configured to flow and / or direct the hydrogen gas feedstock 202 at subsonic speeds. In some implementations, the lance diameter and gas flow rate combinations may be chosen such that linear velocities between 50 m / s and 1,200 m / s are achieved. In some implementations, the velocity of the gaseous stream is between Mach 1.0 and 2.0, though not limited to this range. The velocity of the stream is designed to optimize the surface area of the diffuse gaseous stream through the slag, thereby increase the reduction reaction rates. In some embodiments, a supersonic nozzle is attached the lance to increase stream velocity. In some implementations, the nozzle is above the slag bath and the supersonic stream results in penetration into the slag bath. Unlike other use cases, a shrouding gas is not necessary for the supersonic jet in the case of hydrogen injection. In some implementations, the orientation of the lance 260 can be adjusted (e.g., by moving the lance 260) such that a distal end of the lance 260 is disposed submerged on the layer of slag 204 at a depth sufficient to generate bubble nucleation points, leading to generation of a large number of bubbles containing the hydrogen gas. The generation of bubbles in the layer of slag 204 can increase the surface area available for contacting the reduction of the oxide feed 201 with the hydrogen gas. An increase in the rate of formation of bubbles containing hydrogen gas feedstock 202 can lead to a reduction in the mass transfer limitations of the reaction of hydrogen with the molten oxide feed 201, thus improving the kinetics of the hydrogen-molten oxide rate of reaction. In some implementations, the lance 260 can be positioned submerged within the layer of slag 204 at a first depth within the layer330464460 29Agent’s File Ref. HERM-001 / 01WO 356954-2019of slag 204, with the first depth being selected to provide an optimized level of nucleation leading to adequate amounts of hydrogen-containing bubbles generated within the layer of slag 204. In some instances, the lance 260 can be moved and / or repositioned from the first depth to a second depth within the layer of slag 204, the second depth being different from the first depth, such that the lance 260 can provide an improved level of nucleation and hydrogencontaining bubbles within the layer of slag 204, as the reduction furnace 200 is tapped via the metal product outlet port 270 and / or the slag outlet port 280 to remove metal product 203 and / or slag, respectively, from the reduction furnace 200.

[0067] In some implementations, the lance 260 can be configured to inject a hydrogen gas feedstock 202, with the hydrogen gas feedstock 202 being substantially industrial grade hydrogen. Optionally, in some implementations the lance 260 can be configured to inject a hydrogen gas feedstock 202, with the hydrogen gas feedstock 202 including hydrogen and one or more inert gases such as nitrogen, argon, helium, and the like. In such implementations, the use of an inert gas such as nitrogen can improve nucleation and evolution of bubbles containing hydrogen gas feedstock 202. Furthermore, the use of a hydrogen gas feedstock 202 including hydrogen and inert gas such as nitrogen, argon, or the like, can increase and / or improve the diffusion of the bubbles within the layer of slag 204, resulting in a longer residence time of the bubbles within the layer of slag 204, leading to an improved rate of reaction and conversion of the metal product 203. For example, in some implementations, the lance 260 can be configured to inject a hydrogen gas feedstock 202 having a concentration and / or content of hydrogen of at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, at least about 95%, at least about 98%, or at least about 99%, inclusive of all ranges and values therebetween. In some embodiments, the lance 260 can be configured to inject a hydrogen gas feedstock 202 having a concentration and / or content of hydrogen of no more than about 99 %, no more than about 98 %, no more than about 94 %, no more than about 90 %, no more than about 86 %, no more than about 82 %, no more than about 78 %, no more than about74 %, no more than about 70 %, no more than about 66 %, no more than about 62 %, no more than about 58 %, no more than about 54 %, no more than about 50 %, no more than about 46 %, no more than about 42 %, no more than about 38 %, no more than about 34 %, or no more than about 30 %, inclusive of all ranges and values therebetween.

[0068] Combinations of the above referenced ranges for the concentration and / or content of hydrogen in the hydrogen gas feedstock 202 are also possible (e.g., a concentration of330464460 30Agent’s File Ref. HERM-001 / 01WO 356954-2019hydrogen of at least about 30% to less than about 99%, or at least about 60% to less than about 95%).

[0069] The bubbles of hydrogen-containing gas can be generated from the distal end of the lance 260 and be allowed to diffuse within the layer of slag 204 to promote the reduction of the oxide feed 201. The hydrogen-containing bubbles can reduce the molten oxide feed 201 included in the layer of slag 204 and produce the metal product 203. The metal product 203 can be produced and then sink towards the bottom of the hearth 220, generating and / or increasing the volume of the layer of metal product 203 disposed below the layer of slag 204. The reduction of the molten oxide feed 201 disposed in the layer of slag 204 can result in consumption of hydrogen and formation of water vapor, leading to the collapse of the bubbles. Unreacted hydrogen can diffuse form the layer of slag 204 and occupy the interior volume of the reduction furnace 200 above the hearth 220, near a region in which the arc between the first electrodes 230 and the second electrode 240 is being generated. In some implementations, the vent port 290 can be operated to evacuate and / or remove gases from the interior volume of the reduction furnace 200. The evacuated gases can be further processed and be recycled into the reduction furnace 100 and / or discarded. In some instances, the unreacted hydrogen gas occupying this region can be ionized by the arc AA produced between the first electrodes 230 and the second electrode 240, producing ionized hydrogen and / or plasma hydrogen. The ionized hydrogen and / or plasma hydrogen can reduce the oxide feed 201, particularly the oxide feed 201 that is disposed at, or near the interface between the layer of slag 204 and the volume above the hearth 220. As disclosed above, the reduction potential of hydrogen ions is 3 to 15 times higher than that of molecular hydrogen. Thus, the reduction of the oxide feed 201 through hydrogen plasma allows for a simplified process, with the option to produce the metal product 203 within a single furnace (e.g., the reduction furnace 200), eliminating additional steps for reduction and refining, and eliminating the need for pre-agglomeration, pelletizing or upgrading of the oxide feed 201.

[0070] FIG. 6 shows a cross-sectional front view of a reduction furnace 300 for the production of a metal product using multiple gas feedstocks, according to an embodiment of the present disclosure. The reduction furnace 300, which can also be referred to herein as the “furnace 300” or the “apparatus 300,” can be the same or similar in structure and / or function to the reduction furnace 100 and 200 described above with reference to FIGS. 2, 3 and 5. As such, portions and / or aspects of the reduction furnace 300 can be similar to and / or substantially the same as portions and / or aspects of the reduction furnace 100 described above with reference to FIGS. 2 and 3, and therefore are not described in detail herein. The reduction furnace 300330464460 31Agent’s File Ref. HERM-001 / 01WO 356954-2019can define and / or provide an interior volume in which an oxide feed 301 can be heated to a predetermined temperature sufficiently high to melt the oxide feed 301 and then be reacted with a first gas feedstock 302 and / or a second gas feedstock 302 to produce a metal product 303 and slag 304. The reduction furnace 300 can include a shell 310 including a top portion and / or top wall 311 and a castable refractory lining 312, a hearth 320, a first electrode 330, a second electrode 340, a feed port 350, one or more gas injector(s) 360, a metal product outlet port 370, a slag outlet port 380, and a vent port 390.

[0071] FIG. 6 shows the reduction furnace 300 includes a first gas injector 360A disposed on and / or coupled to a side portion and / or side walls of the shell 310. The gas injector 360A can be configured specifically for a specific gas feedstock 302. For example, in some implementations the gas injector 360A can be and / or include one or more lances, submerged tuyeres, swirling lances such as top-submerged-lances, supersonic jets, coherent jets, plasma torches, or any type of injector and / or nozzle configured to deliver a hydrogen-containing gas feedstock 302 (also referred to as the hydrogen gas feedstock 302). FIG. 6 shows in some implementations the gas injector 360A can be a hydrogen lance 360A (also referred to as the lance 360A) mechanically coupled to the side portion and / or side walls of the shell 310, extending towards the hearth 320. In some implementations, the lance 360A can be disposed on the reduction furnace 300 assuming an orientation defined by an angle yi formed between a longitudinal axis of the lance 360A and an internal surface of the shell 310 or the castable refractory lining 312, as shown in FIG. 6. More specifically, the lance 360A is disposed on the reduction furnace 300 oriented at the angle yi with respect to the side portion and / or side walls of the shell 310 and extending towards the hearth 320 such that a distal end of the lance 360A is submerged in the layer of the slag 304. In some implementations, the orientation of the lance 360A can be selected to improve and / or optimize the characteristics of the injection of the hydrogen gas feedstock 302, as further disclosed herein. In some instances, a residence time of the hydrogen gas feedstock 302 is the limiting variable in the reaction rate (e.g., the rate of reduction of the oxide feed 301), the submergence depth of the lance 360A with respect to the surface of the slag 304 is increased. In some instances, the angle yi and y2 of the lance 360A and 360B are minimized to direct the hydrogen gas feedstock 302 to the center of the reduction furnace 300, closer to the arc, where the slag 304 temperature is higher and therefore reduction reaction rates are greater. In some instances, the angle yi and y2 of the lances 360 A and 360B are optimized such that the hydrogen gas feedstock 302 reducing gas is closest to the zone of the oxide assimilation in the layer of slag 304. In some instances, the lances 360A and 360B330464460 32Agent’s File Ref. HERM-001 / 01WO 356954-2019are angled to create a swirling pattern in the slag 104 for increased mixing between the reducing gas and oxide feed 301 in the slag 304. In use, the lance 360A can be used to deliver the hydrogen gas feedstock 302 into the reduction furnace 300 and more specifically into the layer of slag 304, as further disclosed herein.

[0072] FIG. 6 also shows the reduction furnace 300 includes a second gas injector 360B disposed on and / or coupled to a side portion and / or side walls of the shell 310, opposite from the side portion and / or side walls of the shell 310 in which the lance 360A is disposed on. The gas injector 360B can be configured specifically for a specific gas feedstock 302 different from the hydrogen gas feedstock 302. For example, in some implementations the gas injector 360B can be and / or include one or more lances, submerged tuyeres, swirling lances such as top-submerged-lances, supersonic jets, coherent jets, plasma torches, or any type of injector and / or nozzle configured to deliver a natural gas feedstock 302 (also referred to as natural gas feedstock 302). Alternatively, in some implementations, the gas injector 360B can be and / or include one or more lances, submerged tuyeres, swirling lances such as top-submerged-lances, supersonic jets, coherent jets, plasma torches, or any type of injector and / or nozzle configured to deliver a methane (or other suitable reductant hydrocarbons species) gas feedstock 302.

[0073] FIG. 6 shows in some implementations the gas injector 360B can be a natural gas lance 360B (also referred to as the lance 360B) mechanically coupled to the side portion and / or side walls of the shell 310, extending towards the hearth 320. In some implementations, the lance 360B can be disposed on the reduction furnace 300 assuming an orientation defined by an angle 72 formed between a longitudinal axis of the lance 360B and an internal surface of the shell 310 or the castable refractory lining 312, as shown in FIG. 6. More specifically, the lance 360B is disposed on the reduction furnace 300 oriented at the angle 72 with respect to the side portion and / or side walls of the shell 310 and extending towards the hearth 320 such that a distal end of the lance 360B is submerged in the layer of the slag 304. In some implementations, the orientation of the lance 360B can be selected to improve and / or optimize the characteristics of the injection of the natural gas feedstock 302, as further disclosed herein. In use, the lance 360B can be used to deliver the natural gas feedstock 302 into the reduction furnace 300 and more specifically into the layer of slag 304.

[0074] The reduction of the oxide feed 301 with natural gas (reaction 1) can proceed according to the parallel reactions 2-4 shown below for the oxidation of iron. Reaction 5 corresponds to the byproduct side reaction of carbon with steam.3 FeO + CH4= 3Fe + CO + 2H2OCH4= C + 2H2330464460 33Agent’s File Ref. HERM-001 / 01WO 356954-2019FeO + C = Fe + CO2FeO + 2 H2= 2Fe + 2H2OC + H20 = CO + H2

[0075] In some instances, the use natural gas feedstock 302 can provide advantages with respect to hydrogen gas feedstock 302 as process conditions can be changed in order to favor specific parallel reactions (1-5). For example, in some instances, controlling conditions during injection of natural gas 302 and / or during operation of the reduction furnace 300 (e.g., pressure, temperature, flowrates, extent and intensity of arc) may favor individual parallel reactions (1-5). For example, in some instances the operation of the reduction furnace 300 may be adjusted to favor reaction (2) resulting in dissociation of methane and the in-situ formation of hydrogen, which can be utilized as molecular hydrogen or as ionized hydrogen (when exposed to the arc established between the first electrodes 330 and the second electrodes 340) for enhanced kinetics of reduction of the oxide feed 301. In some instances, the operation of the reduction furnace 300 may be adjusted to favor reaction (3) resulting in overall formation of carbon monoxide (CO) via the dissociation of methane (reaction 2, which produces carbon (C)), and the concomitant conversion of the produced carbon with iron oxide (FeO) (reaction 3). The in-situ formation of carbon monoxide can provide additional heat (via its oxidation) similar to syn gas operation. In some implementations, the above shown reactions that natural gas feedstock 302 can undergo results in improved overall kinetics when compared to hydrogen gas feedstock 302. For example, in some instances, the use of natural gas feedstock 302 can result in up to 2.5 times higher rate of formation of iron from iron ores compared to the hydrogen gas feedstock 302.

[0076] In use, the reduction furnace 300 can used to produce and / or fabricate a metal product 303 from an oxide feed 301. The oxide feed 301 can be introduced into the reduction furnace 300 via the feed port 350. In some implementations, the feed port 350 can be configured to introduce molten oxide feed 301 (e.g., an oxide feed 301 which has been heated above its melting point prior to introducing the oxide feed 301 into the reduction furnace 300). Alternatively, in some implementations, the feed port 350 can be configured to introduce the oxide feed 301 to the reduction furnace 300 such that the oxide feed 301 can be melted in the reduction furnace 300. The oxide feed 301 can be received in the hearth 320 of the reduction furnace 300. The hearth 320 can be configured to include a molten bath comprising a layer of slag 304 and a layer of metal product 303, as shown in FIG. 6. As disclosed above, in some implementations the oxide feed 301 can be directed to the hearth 320 (via the feed port 350) as a molten oxide feed 301. In such implementations, the molten oxide feed 301 can be accommodated in the molten bath of the hearth 320 mixed with the layer of slag 304.330464460 34Agent’s File Ref. HERM-001 / 01WO 356954-2019Alternatively, in some implementations, the oxide feed 301 can be directed to the hearth 320 (via the feed port 350) as a solid oxide feed 301. In such implementations, the oxide feed 301 can be received and accommodated in the molten bath of the hearth 320 above the layer of slag 304, and or dispersed within the layer of slag 304.

[0077] In some implementations, a user can determine the gas feedstock 302 that the reduction furnace 300 will operate with. In other words, in some implementations a specific gas feedstock 302 may be selected for operating the reduction furnace 300 based on one or more criteria. In some implementations, the specific gas feedstock 302 needed to operate the reduction furnace 300 can be determined based on the type of metal product 303 intended or based on specific properties required for the metal product 303. For example, in some instances the metal product 303 can be and / or include a high-carbon steel. In such instances, the gas feedstock 302 can be natural gas feedstock 302 having a predetermined and / or desired concentration of natural gas. Unlike hydrogen, natural gas includes methane, a saturated hydrocarbon that can reduce an oxide feed 301 while incorporating desired amounts of carbon into the high carbon steel. Said in other words, a natural gas feedstock 302 can provide a source of carbon that can be incorporated to the metal product 303 during the reduction of the oxide feed as needed, as opposed to a hydrogen gas feedstock 302, which does not include any source of carbon, and thus cannot incorporate carbon into the metal product 303. As disclosed above, in some implementations, the natural gas feedstock 302 be substantially pure natural gas. Alternatively, in other implementations, the natural gas feedstock 302 include natural gas and one or more inert gases such as nitrogen, argon, helium, and the like. In such implementations, the use of an inert gas such as nitrogen can improve nucleation and evolution of bubbles containing natural gas feedstock 302, improving the rate of reduction of the oxide feed 301, as further disclosed herein. Furthermore, the use of a natural gas feedstock 302 including natural gas and inert gas such as nitrogen, argon, or the like, can in some instances increase and / or improve the diffusion of the bubbles within the layer of slag 304, resulting in a longer residence time of the bubbles within the layer of slag 304, leading to an improved rate of reaction and conversion of the metal product 303. For example, in some implementations, the lance 360B can be configured to inject a natural gas feedstock 302 having a concentration and / or content of natural of at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, at least about 95%, at least about 98%, or at least about 99%, inclusive of all ranges and values therebetween. In some implementations, the lance 360B can be configured to inject a natural gas feedstock330464460 35Agent’s File Ref. HERM-001 / 01WO 356954-2019302 having a concentration and / or content of natural of no more than about 99 %, no more than about 98 %, no more than about 94 %, no more than about 90 %, no more than about 86 %, no more than about 82 %, no more than about 78 %, no more than about74 %, no more than about 70 %, no more than about 66 %, no more than about 62 %, no more than about 58 %, no more than about 54 %, no more than about 50 %, no more than about 46 %, no more than about 42 %, no more than about 38 %, no more than about 34 %, or no more than about 30 %, inclusive of all ranges and values therebetween.

[0078] Combinations of the above referenced ranges for the concentration and / or content of natural gas in the natural gas feedstock 302 are also possible (e.g., a concentration of natural gas of at least about 30% to less than about 99%, or at least about 60% to less than about 95%).

[0079] In some implementations, the specific gas feedstock 302 needed to operate the reduction furnace 300 can be determined based on one or more characteristics of the oxide feed 301 available for processing. For example, in some instances, the oxide feed 301 available for producing a metal product 303 may require a particular gas feedstock 302 and / or a specific concentration of the gas feedstock 302 that ensures the successful fabrication of the metal product 303. For example, in some instances the oxide feed 301 may be an oxide feed 301 containing a low concentration of the metal(s) of interest (e.g., a low-grade oxide feed 301, or an oxide feed 301 difficult to reduce and / or refine). In such instances, a hydrogen gas feedstock 302 may be a much more reactive gas feedstock 302 compared to, for example, a natural gas feedstock 302. As disclosed above, hydrogen gas can be injected into the layer of slag 304 to facilitate the reduction of the oxide feed 301. Molecular hydrogen contained in bubbles evolving from the lance 360Acan reduce the mass transfer limitations of the reduction of oxide feed 301. Additionally, unreacted molecular hydrogen can diffuse through the layer of slag 304 and occupy an interior volume and / or region of the reduction furnace 300 between a distal end of the electrode 340 and a surface of the molten bath of the hearth 320. That region can overall with a region under the influence of the arc generated by the electrode 330 and the electrode 340. Consequently, molecular hydrogen disposed and / or located on the region under the influence of the arc can be ionized, producing ionized hydrogen and / or plasma hydrogen, a species much more reactive than molecular hydrogen, and thus capable of reducing the oxide feed 301, as previously disclosed.

[0080] In some implementations, the specific gas feedstock 302 needed to operate the reduction furnace 300 can be determined based on environmental concern. For example, in some instances, there may be a restriction and / or limitation on the amount of carbon dioxide that can be produced as a byproduct during the fabrication of a metal product 303. In some330464460 36Agent’s File Ref. HERM-001 / 01WO 356954-2019implementations environmental regulations may provide a cap on the amount of greenhouse gases such as carbon dioxide that can be emitted during the fabrication for a metal product 303 with the reduction furnace 300. Alternatively, in some instances, the evolution of carbon dioxide during the fabrication of a metal product 303 may be subjected to carbon tax. In such implementations, the selection of the gas feedstock 302 may take into account the multiple costs associated with the fabrication of the metal product 303, including, the cost of the oxide feed 301, the cost of the gas feedstock 302, and the taxes associated with the emission of carbon dioxide (and other greenhouse gases such as methane) during the fabrication of the metal product 303. The hydrogen gas feedstock 302, being a carbon free gas feedstock 302, can effectively reduce the amount of greenhouse gases produces during operation of the reduction furnace 300. Consequently, in some instances a hydrogen gas feedstock 302 may be selected over a natural gas feedstock 302. Alternatively, in some instances, the selection of the gas feedstock 302 may include a combination of hydrogen gas feedstock 302 and natural gas feedstock 302.

[0081] In some implementations, the specific gas feedstock 302 needed to operate the reduction furnace 300 can be determined based on the availability of the gas feedstock 302. In some instances, hydrogen gas feedstock 302 may be a scarcer gas feedstock 302 compared to natural gas feedstock 302. Said in other words, in some instances fluctuations in the reserves of different gas feedstocks can be used to determine the specific gas feedstock 302 to operate the furnace 300. For example, in some instances, a specific gas feedstock 302 may be experiencing a shortage due to geopolitical factors, economic factors, and / or others. In such instances, the gas feedstock 302 to operate the reduction furnace 300 can be selected based on relative availability of different gas feedstocks.

[0082] While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. While the embodiments have been particularly shown and described, it will be understood that various changes in form and details may be made. Where schematics and / or embodiments described above indicate certain components arranged in certain orientations or positions, the arrangement of components may be modified. Although various embodiments have been described as having particular features and / or combinations of components, other embodiments are possible having a combination of any features and / or components from any of embodiments as discussed above.

[0083] The disclosure may include other innovations not presently described. Applicant reserves all rights in such innovations, including the right to embodiment such innovations, file330464460 37Agent’s File Ref. HERM-001 / 01WO 356954-2019additional applications, continuations, continuations-in-part, divisionals, and / or the like thereof. As such, it should be understood that advantages, embodiments, examples, functional, features, logical, operational, organizational, structural, topological, and / or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the embodiments or limitations on equivalents to the embodiments. Depending on the particular desires and / or characteristics of an individual and / or enterprise user, database configuration and / or relational model, data type, data transmission and / or network framework, syntax structure, and / or the like, various embodiments of the technology disclosed herein may be implemented in a manner that enables a great deal of flexibility and customization as described herein.

[0084] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0085] As used herein, in particular embodiments, the terms “about” or “approximately” when preceding a numerical value indicates the value plus or minus a range of 10%. Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed within the disclosure. That the upper and lower limits of these smaller ranges can independently be included in the smaller ranges is also encompassed within the disclosure, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the disclosure.

[0086] The phrase “and / or,” as used herein in the specification and in the embodiments, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and / or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and / or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and / or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.330464460 38Agent’s File Ref. HERM-001 / 01WO 356954-2019

[0087] As used herein in the specification and in the embodiments, “or” should be understood to have the same meaning as “and / or” as defined above. For example, when separating items in a list, “or” or “and / or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of’ or “exactly one of,” or, when used in the embodiments, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e., “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.” “Consisting essentially of,” when used in the embodiments, shall have its ordinary meaning as used in the field of patent law.

[0088] As used herein in the specification and in the embodiments, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B,” or, equivalently “at least one of A and / or B”) can refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc.

[0089] In the embodiments, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of’ and “consisting essentially of’ shall be closed or semi-closed transitional phrases, respectively, as set forth in the United States Patent Office Manual of Patent Examining Procedures, Section 2111.03.330464460 39

Claims

Agent’s File Ref. HERM-OOl / OIWO 356954-2019CLAIMS1. A method, comprising:introducing an oxide feed into a furnace through a feed port disposed on at least one of a top portion or a side portion of the furnace;melting the oxide feed to form a molten bath comprising:a first layer including slag and a metal oxide dissolved in the slag; and a second layer including a metal product, the second layer disposed below the first layer;injecting a gas feedstock into the molten bath through a gas injector disposed on a side portion or a top portion of the furnace, andreacting the injected gas feedstock with the metal oxide to form the metal product through at least one of a reduction or a carburization reaction.

2. The method of claim 1 , wherein the gas inj ector is configured to inj ect the gas feedstock into the first layer such that the gas feedstock diffuses within the first layer and reacts with the metal oxide.

3. The method of claim 2, wherein the gas injector is disposed above the first layer and configured to direct the gas feedstock to the first layer such that the gas feedstock reacts with the metal oxide.

4. The method of claim 2, wherein the gas injector includes an end portion submerged in the first layer and configured to direct the gas feedstock to the first layer such that the gas feedstock reacts with the metal oxide.

5. The method of claim 2, wherein the gas injector is submerged in the second layer and configured to direct the gas feedstock to the first layer such that the gas feedstock reacts with the metal oxide.

6. The method of any one of claims 1-5, wherein the gas injector is configured to inject the gas feedstock at subsonic speeds.330464460 40Agent’s File Ref. HERM-001 / 01WO 356954-20197. The method of claim 6, wherein the gas injector includes a lance configured to inject the gas feedstock such that the gas feedstock achieves a linear velocity between about 50 and 30 m / s.

8. The method of any one of claims 1-5, wherein the gas injector is configured to inject the gas feedstock at supersonic speeds.

9. The method of claim 8, wherein the gas injector includes a lance configured to inject the gas feedstock such that the gas feedstock achieves a linear velocity of between about Mach 1.0 to about Mach 2.0.

10. The method of any one of claims 1-9, wherein the gas injector includes a plurality of gas injectors configured to inject the gas feedstock such that the gas feedstock agitates the first layer to enhance separation of the metal product contained in the first layer, and maximize a distribution of the gas feedstock through the slag to increase a rate of formation of the metal product.

11. The method of any one of claims 1-10, wherein the gas feedstock includes methane.

12. The method of any one of claims 1-10, wherein the gas feedstock includes hydrogen.

13. The method of any one of claims 1-10, wherein the gas feedstock includes natural gas.

14. The method of any one of claims 1-10, wherein the gas feedstock includes a plurality of gases including at least one of hydrogen, methane, or natural gas.

15. The method of any one of claims 1-14, wherein the gas feedstock includes an inert gas.

16. The method of claim 15, wherein the inert gas includes nitrogen.

17. The method of claim 15 or 16, wherein a concentration of the inert gas can be adjusted to increase bubble nucleation points to increase a rate of reduction reaction of the gas feedstock with the metal oxide to produce the metal product.330464460 41Agent’s File Ref. HERM-OOl / OIWO 356954-201918. The method of any one of claims 1-17, wherein an orientation of the gas injector can be adjusted to increase bubble nucleation points to increase a rate of reaction of the gas feedstock with the metal oxide to produce the metal product.

19. The method of any one of claims 11-13, further comprising:capturing at least a byproduct of the reaction between the gas feedstock and the metal oxide;processing the captured byproduct to separate at least one of methane or hydrogen form the byproduct; andrecycling the at least one of methane or hydrogen into the gas feedstock.

20. The method of any one of claims 1-19, wherein the feed port is configured to introduce the oxide feed into the furnace such that the oxide feed is melted in the furnace.

21. The method of any one of claims 1-19, wherein the feed port is configured to introduce a molten oxide feed.

22. A method, comprising:introducing an oxide feed into a furnace through a plurality of feed ports disposed on at least one of a top portion or a side portion of the furnace;using an electric arc generated by a first electrode and a second electrode included in the furnace, melting the oxide feed to form a molten bath comprising:a slag layer including metal oxide; anda molten metal product layer disposed below the slag layer;introducing a gas feedstock into the furnace through a gas injector disposed on a side portion of the furnace; andreacting the injected gas feedstock with the metal oxide to produce the molten metal product.

23. The method of claim 22, wherein the first electrode is either disposed above the slag layer or includes an end portion submerged in the slag layer, and at least a portion of the second electrode is disposed below the slag layer.330464460 42Agent’s File Ref. HERM-001 / 01WO 356954-201924. The method of claim 22 or 23, wherein the first electrode is a plurality of first electrodes and the second electrode is a plurality of second electrodes.

25. The method of any one of claims 22-24, wherein gas injector is configured to inject the gas feedstock into the slag layer such that the gas feedstock diffuses within the slag layer and performs a reduction reaction with the metal oxide.

26. The method of claim 25, wherein the gas injector is disposed above the slag layer and configured to direct the gas feedstock to the slag layer such that the gas feedstock reacts with the metal oxide.

27. The method of claim 25, wherein the gas injector includes an end portion submerged in the slag layer and configured to direct the gas feedstock to the slag layer such that the gas reacts with the metal oxide.

28. The method of claim 25, wherein the gas injector is submerged in the molten metal layer and configured to direct the gas feedstock to the slag layer such that the gas feedstock reacts with the metal oxide.

29. The method of any one of claims 22-28, wherein the gas injector is configured to inject the gas feedstock at subsonic speeds.

30. The method of 29, wherein the gas injector includes a lance configured to inject the gas feedstock such that the gas feedstock achieves a linear velocity between about 50 and about 30 m / s.

31. The method of any one of claims 22-28, wherein the gas injector is configured to inject the gas feedstock at supersonic speeds.

32. The method of claim 31, wherein the gas injector includes a lance configured to inject the gas feedstock such that the gas feedstock achieves a linear velocity of between about Mach 1.0 to about Mach 2.0.

33. The method of any one of claims 22-32, wherein the gas injector includes a plurality of gas injectors configured to inject the gas feedstock such that the gas feedstock agitates the slag330464460 43Agent’s File Ref. HERM-OOl / OIWO 356954-2019layer to enhance separation of the molten metal product contained in the slag layer, and maximize a distribution of the gas feedstock through the slag to increase a rate of formation of the metal product.

34. The method of any one of claims 22-33, wherein the gas feedstock includes methane.

35. The method of any one of claims 22-33, wherein the gas feedstock includes hydrogen.

36. The method of any one of claims 22-33, wherein the gas feedstock includes natural gas.

37. The method of any one of claims 22-33, wherein the gas feedstock includes a plurality of gases including at least one of hydrogen, methane, or natural gas.

38. The method of any one of claims 22-37, wherein the gas feedstock includes an inert gas.

39. The method of claim 38, wherein the inert gas includes nitrogen.

40. The method of claim 18 or 19, wherein a concentration of the inert gas can be adjusted to increase bubble nucleation points to increase a rate of reaction of the gas feedstock with the metal oxide to produce the metal product.

41. The method of any one of claims 22-40, wherein an orientation of the gas injector can be adjusted to increase bubble nucleation points to increase a rate of reaction of the gas feedstock with the metal oxide to produce the metal product.

42. The method of any one of claims 34-36, further comprising:capturing at least a byproduct of the reaction between the gas feedstock and the metal oxide;processing the captured byproduct to separate at least one of methane or hydrogen from the byproduct; andrecycling the at least one of methane or hydrogen into the gas feedstock.330464460 44Agent’s File Ref. HERM-OOl / OIWO 356954-201943. The method of claim 35, further comprising:submerging the gas injector into the slag layer at a predetermined position to produce an optimized level of bubble nucleation points to increase an amount of hydrogen-containing bubbles generated within the slag layer.

44. A furnace, comprising:a shell defining an inner volume;a gas injector extending into the inner volume of the shell;a feed port disposed in a top portion of the shell, the feed port configured allow introduction of an oxide feed into the furnace;a hearth disposed in a bottom portion of the inner volume, the hearth configured to receive the oxide feed and contain a layer of slag;a first outlet port fluidically coupled to the layer of slag and having an open configuration and a closed configuration, the first outlet port configured to be transitioned to the open configuration to remove at least a portion of the layer of slag; anda second outlet port disposed below the first outlet port and having an open configuration and a closed configuration,wherein a distal portion of the injector is submerged in the layer of slag, the gas injector is configured to inject a gas feedstock into the layer of slag to reduce the oxide feed and produce a layer of metal product, and the second outlet port is fluidically coupled to the layer of metal product and is configured to be transitioned to the open configuration to remove at least a portion of the metal product to enable continuous operation of the furnace.

45. The furnace of claim 44, wherein the gas feedstock includes hydrogen.

46. The furnace of claim 45, where in the at gas feedstock includes nitrogen.

47. The furnace of claim 46, further comprising:a first electrode partially embedded in the hearth; anda second electrode disposed on a center region of the furnace, the first and second electrodes configured to generate an arc in the furnace that ionizes at least a portion of the gas feedstock to produce an ionized gas.

48. The furnace of claim 47, wherein the ionized gas reduces the oxide feed.330464460 45Agent’s File Ref. HERM-OOl / OIWO 356954-201949. The furnace of claim 44, wherein the injector is a first injector and the gas feedstock is a first gas feedstock, the furnace further comprising:a second injector extending into the inner volume of the shell, the second injector configured to inject a second gas feedstock into the layer of slag to reduce the oxide feed and produce the metal product.

50. The furnace of claim 49, wherein the second gas feedstock is natural gas.330464460 46

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