Solid compound rapid reduction systems and methods

Abstract

Fully electrified microwave (MW) hydrogen (H 2 ) plasma reduction systems and methods. With some embodiments, a plasma-flash ironmaking process is provided in which iron ore fines or particles are reduced.

What is claimed is: 
     
         1 . A method for reducing a solid compound, comprising:
 creating a hydrogen plasma in a reactor chamber; and   exposing solid compound particles to the plasma;   wherein the solid compound particles are reduced by the hydrogen plasma.   
     
     
         2 . The method of  claim 1 , wherein the step of exposing includes flowing the solid compound particles through the plasma. 
     
     
         3 . The method of  claim 2 , wherein the step of flowing includes entraining the solid compound particles in a gas stream that continuously flows to the reactor chamber. 
     
     
         4 . The method of  claim 3 , wherein a gas of the gas stream is a mixture of H 2  and argon. 
     
     
         5 . The method of  claim 2 , further comprising:
 generating a secondary swirl gas flow in the reactor chamber.   
     
     
         6 . The method of  claim 2 , wherein the step of flowing the solid compound particles through the plasma includes at least some of the solid compound particles being negatively charged. 
     
     
         7 . The method of  claim 1 , wherein the step of exposing includes bringing the solid compound particles into contact with an effluent of the plasma. 
     
     
         8 . The method of  claim 1 , wherein the step of exposing includes suspending the solid compound particles in or downstream of the plasma while exposing the solid compound particles to hot hydrogen gas and plasma species. 
     
     
         9 . The method of  claim 8 , wherein the step of creating a hydrogen plasma includes delivering a gas stream to the reactor chamber, and further wherein a gas of the gas stream is a mixture of H 2  and argon. 
     
     
         10 . The method of  claim 8 , wherein the solid compound particles are moved through the plasma in a continuous fashion. 
     
     
         11 . The method of  claim 1 , wherein the step of exposing includes:
 passing the solid compound particles through the plasma;   after passing through the plasma, continuing to treat the solid compound particles with an effluent of the plasma.   
     
     
         12 . The method of  claim 1 , wherein the solid compound is iron ore. 
     
     
         13 . The method of  claim 12 , wherein the solid compound particles comprise iron ore particles with an average particle size in the range of 38-75 microns. 
     
     
         14 . The method of  claim 12 , wherein the iron ore particles experience at least a 90% reduction to elemental iron. 
     
     
         15 . The method of  claim 14 , wherein the iron ore particles are treated by the plasma for a treatment time of not greater than 10 seconds. 
     
     
         16 . The method of  claim 14 , wherein the iron ore particles experience at least a 95% reduction over a plasma treatment time of not greater than 9 seconds. 
     
     
         17 . The method of  claim 1 , wherein the solid compound is a metal oxide. 
     
     
         18 . The method of  claim 1 , wherein the solid compound is a metal sulfide. 
     
     
         19 . The method of  claim 1 , wherein the solid compound is a silicate 
     
     
         20 . The method of  claim 1 , wherein prior to the step of exposing, the solid compound particles are micron-sized, and further wherein following the step of exposing, the solid compound particles are reduced to nanometer-sized metal particles.