Gregory Vern Hughes

US Patent:

6506230, Jan 14, 2003

Filed:

Feb 12, 2001

Appl. No.:

09/781816

Inventors:

Stephen C. Montague - Midland NC
Russell Kakaley - Charlotte NC
Gregory D. Hughes - Charlotte NC
Gary E. Metius - Charlotte NC

Assignee:

Midrex Technologies, Inc. - Charlotte NC

International Classification:

C21B 1300

US Classification:

75381, 75385, 75496, 75505

Abstract:

An improved method and apparatus for increasing the productivity of a direct reduction process in which iron oxide is reduced to metallized iron by contact with hot reducing gas; comprising the steps of: a) providing a first hot reducing gas consisting essentially of CO and H ; b) providing additional reducing gas by reaction of a gaseous or liquid hydrocarbon fuel with oxygen; c) mixing the first hot reducing gas with the additional reducing gas to form a reducing gas mixture; d) enriching the reducing gas mixture by the addition of a gaseous or liquid hydrocarbon; e) injecting oxygen or oxygen-enriched air into the enriched mixture; and f) introducing the enriched mixture into an associated direct reduction furnace as reducing gas.

US Patent:

6524356, Feb 25, 2003

Filed:

Dec 7, 1999

Appl. No.:

09/456111

Inventors:

Donald J. Fournier - Hattiesburg MS
Marvin E. Tester - Waxhaw NC
Gregory D. Hughes - Charlotte NC

Assignee:

Midrex Technologies, Inc. - Charlotte NC

International Classification:

C01B 324

US Classification:

481981, 481279, 48 62 A, 422188, 422193, 422194

Abstract:

A process and apparatus for the production of reformed gases. Natural gas and/or liquid hydrocarbons and oxygen are combusted in a first stage to produce carbon dioxide and water. The products of combustion are conveyed to a second stage. Reforming gas or atomized liquid hydrocarbons and oxygen are injected into the second stage and mixed with the products of combustion to react with the carbon dioxide and water to produce carbon monoxide and hydrogen. The process and apparatus are particularly adapted for use in supplementing the reform gases produced in a Direct Reduced Iron plant wherein iron ore is reduced to iron inside a shaft furnace. The process and apparatus may also be used to provide heated enrichment natural gas or liquid hydrocarbons for use as a source of carbon in the shaft furnace to provide for carburization of the iron. Additionally, the process and apparatus may be used as a process control device for controlling the temperature of the reformed gases flowing to the shaft furnace.

US Patent:

20130205951, Aug 15, 2013

Filed:

Feb 15, 2012

Appl. No.:

13/397421

Inventors:

David C. MEISSNER - Charlotte NC, US
Gary E. METIUS - Charlotte NC, US
Gregory D. HUGHES - Charlotte NC, US

Assignee:

MIDREX TECHNOLOGIES, INC. - Charlotte NC

International Classification:

C21B 3/04
F27D 99/00
F27B 17/00

US Classification:

75392, 266144

Abstract:

Methods and systems for the production of direct reduced iron, including: removing a top gas from a direct reduction furnace; carbon monoxide shifting the top gas using a carbon monoxide shift reactor to form a carbon monoxide shifted top gas having a reduced carbon monoxide content; adding one of a coal gas, a synthesis gas, and an export gas to at least a portion of the carbon monoxide shifted top gas to form a combined gas; removing carbon dioxide from the combined gas using a carbon dioxide removal unit to form a carbon dioxide lean combined gas; and providing the carbon dioxide lean combined gas to the direct reduction furnace as a reducing gas for producing direct reduced iron after heating to reduction temperature. Optionally, the method includes removing carbon dioxide from the top gas using a carbon dioxide removal unit prior to carbon monoxide shifting the top gas.

US Patent:

47523298, Jun 21, 1988

Filed:

Mar 21, 1986

Appl. No.:

6/842514

Inventors:

Michael N. Freeland - Matthews NC
Gregory D. Hughes - Mint Hill NC

Assignee:

Midrex International B.V. Rotterdam, Zurich Branch - Zurich

International Classification:

C21B 1302
F27B 126

US Classification:

75 35

Abstract:

A method of producing a hot, carburized metallized iron product in a generally vertical shaft furnace having an upper reducing zone in which iron oxide reacts with a gaseous reductant, and a lower carbon control and product discharge zone, including: establishing a gravitationally descending iron oxide burden in the furnace; reacting hot gaseous gaseous reductant with the descending burden to form a metallized iron product and a reacted top gas; and injecting a hydrocarbon gas mixture consisting of hot reformed reducing gas and cool natural gas to the product discharge section of the shaft furnace; whereby the carbon content of the metallized iron pellet product is controlled by mixing the reformed gas and natural gas in the proper ratio to balance the endothermic and exothermic reactions within the discharge zone of the furnace. Apparatus for carrying out the method includes means for controlling the respective amounts of gas introduced to the product discharge zone from the reformer and the source of natural gas.

US Patent:

20230034215, Feb 2, 2023

Filed:

Oct 10, 2022

Appl. No.:

17/962640

Inventors:

- Charlotte NC, US
Gregory Darel HUGHES - Charlotte NC, US
Enrique Jose CINTRON - Charlotte NC, US
Keith Marshall BASTOW-COX - Charlotte NC, US

International Classification:

C21B 13/00
C21B 13/02
C25C 1/06

Abstract:

A process for the production of direct reduced iron (DRI), with or without carbon, using hydrogen, where the hydrogen is produced utilizing water generated internally from the process. The process is characterized by containing either one or two gas loops, one for affecting the reduction of the oxide and another for affecting the carburization of the DRI. The primary loop responsible for reduction recirculates used gas from the shaft furnace in a loop including a dry dedusting step, an oxygen removal step to generate the hydrogen, and a connection to the shaft furnace for reduction. In the absence of a second loop, this loop, in conjunction with natural gas addition, can be used to deposit carbon. A secondary carburizing loop installed downstream of the shaft furnace can more finely control carbon addition. This loop includes a reactor vessel, a dedusting step, and a gas separation unit.

US Patent:

20210301358, Sep 30, 2021

Filed:

Mar 23, 2021

Appl. No.:

17/209506

Inventors:

- Charlotte NC, US
Todd Michael ASTORIA - Harrisburg NC, US
Gregory Darel HUGHES - Charlotte NC, US

International Classification:

C21B 13/00
C21B 13/02

Abstract:

A method for producing direct reduced iron having increased carbon content, comprises: providing a carbon monoxide-rich gas stream, and separating the carbon monoxide-rich gas stream into at least two separate carbon monoxide-rich gas streams; providing a hydrocarbon-rich gas stream and separating the hydrocarbon-rich gas stream into at least two separate hydrocarbon-rich gas streams; blending one of the carbon monoxide-rich gas streams with one of the hydrocarbon-rich gas streams to form a mixed carburizing gas stream; blending another carbon monoxide-rich gas stream of the at least two separate carbon monoxide-rich gas streams with another hydrocarbon-rich gas stream of the at least two separate hydrocarbon-rich gas streams to form a distinct mixed carburizing gas stream; delivering each of the mixed carburizing gas streams, which are of different composition, to a transition zone of a direct reduction furnace, and exposing partially or completely reduced iron oxide to the mixed carburizing gas streams to increase the carbon content of resulting direct reduced iron to greater than 4.5 wt. %.

US Patent:

20210095354, Apr 1, 2021

Filed:

Sep 23, 2020

Appl. No.:

17/029778

Inventors:

- Charlotte NC, US
Enrique Jose CINTRON - Charlotte NC, US
Gregory Darel HUGHES - Charlotte NC, US

International Classification:

C21B 13/00
C21B 13/02
C21B 11/02

Abstract:

A direct reduction method/system, including: adding variable amounts of natural gas, hydrogen, and a carbon-free oxidizing gas to a feed gas stream upstream of a reformer; reforming the feed gas stream in the reformer to form a reformed gas stream, and delivering the reformed gas stream to a shaft furnace, where the reformed gas stream is used to reduce a metallic ore material to a direct reduced metallic material. The feed gas stream includes a top gas stream recycled from the shaft furnace. Optionally, the carbon-free oxidizing gas includes steam and the method further includes controlling a steam flow rate of the steam to maintain a maximum k-factor value of the feed gas stream of 0.74 or lower. Optionally, the variable amount of hydrogen is selected to replace 20-90% of the natural gas by fuel value. The variable amount of hydrogen is selected based upon an available supply of hydrogen.

US Patent:

20200385827, Dec 10, 2020

Filed:

Jun 2, 2020

Appl. No.:

16/889859

Inventors:

- Charlotte NC, US
Gregory Darel HUGHES - Charlotte NC, US
Enrique Jose CINTRON - Charlotte NC, US
Keith Marshall BASTOW-COX - Charlotte NC, US

International Classification:

C21B 13/00
C25C 1/06
C21B 13/02

Abstract:

A process for the production of direct reduced iron (DRI), with or without carbon, using hydrogen, where the hydrogen is produced utilizing water generated internally from the process. The process is characterized by containing either one or two gas loops, one for affecting the reduction of the oxide and another for affecting the carburization of the DRI. The primary loop responsible for reduction recirculates used gas from the shaft furnace in a loop including a dry dedusting step, an oxygen removal step to generate the hydrogen, and a connection to the shaft furnace for reduction. In the absence of a second loop, this loop, in conjunction with natural gas addition, can be used to deposit carbon. A secondary carburizing loop installed downstream of the shaft furnace can more finely control carbon addition. This loop includes a reactor vessel, a dedusting step, and a gas separation unit.