Geothermally powered iron production systems and methods

Abstract

A geothermally powered iron production subsystem includes using heat transfer fluid heated by a geothermal system with a wellbore extending from a surface into an underground magma reservoir. A hopper receives iron ore that is crushed and provided to a blast furnace, along with limestone and coke. The blast furnace is heated by a heat exchanger configured to receive the heat transfer fluid heated by the geothermal system to generate the heat provided to the blast furnace. One or more components of the iron production subsystem may also be powered by the heated heat transfer fluid.

What is claimed is: 
     
         1 . A geothermally powered iron production subsystem, comprising:
 a hopper comprising a vessel configured to receive iron ore and direct the received iron ore through a crusher;   the crusher configured to crush at least a portion of the received iron ore;   a blast furnace configured to receive the crushed iron ore and to further receive limestone and coke, the blast furnace further configured to melt the crushed iron ore, limestone, and coke using heat; and   a heat source comprising a heat exchanger receiving a heated heat transfer fluid and configured to provide the heat to the blast furnace at least in part using the heated heat transfer fluid;   wherein the heated heat transfer fluid is received from a geothermal system comprising a wellbore extending from a surface into an underground magma reservoir, the wellbore configured to heat the heat transfer fluid via heat transfer with the underground magma reservoir to provide the heated heat transfer fluid.   
     
     
         2 . The geothermally powered iron production subsystem of  claim 1 , further comprising:
 an air compressor system configured to provide air to the heat exchanger;   wherein the heat exchanger is further configured to heat the provided air, and to provide the heated provided air to the blast furnace as the heat.   
     
     
         3 . The geothermally powered iron production subsystem of  claim 1 , wherein the heat exchanger is positioned within the blast furnace to provide the heat. 
     
     
         4 . The geothermally powered iron production subsystem of  claim 3 , further comprising a structure surrounding the heat exchanger, wherein the heat exchanger heats the structure to provide the heat. 
     
     
         5 . The geothermally powered iron production subsystem of  claim 4 , wherein the structure is comprised of one or more of brick, stone, ceramic, or a metal. 
     
     
         6 . The geothermally powered iron production subsystem of  claim 1 , wherein the heat exchanger is positioned around an exterior of the blast furnace to provide the heat. 
     
     
         7 . The geothermally powered iron production subsystem of  claim 6 , wherein the heat exchanger directly contacts the exterior of the blast furnace to provide the heat. 
     
     
         8 . The geothermally powered iron production subsystem of  claim 1 , further comprising one or more geothermally powered motors configured to use the heated heat transfer fluid to perform mechanical operations of the geothermally powered iron production subsystem, wherein the one or more geothermally powered motors are configured to perform one or more of:
 moving the iron ore through the hopper;   rotating the crusher; and   driving an exhaust system to remove fumes from the blast furnace.   
     
     
         9 . The geothermally powered iron production subsystem of  claim 1 , further comprising one or more turbines configured to use the heated heat transfer fluid to generate electricity, wherein the generated electricity provides generated electricity to power one or more motors configured to perform one or more of:
 moving the iron ore through the hopper;   rotating the crusher; and   driving an exhaust system to remove fumes from the blast furnace.   
     
     
         10 . The geothermally powered iron production subsystem of  claim 1 , wherein the blast furnace further comprises a first tap configured to remove molten pig iron from the blast furnace, and a second tap configured to remove molten slag from the blast furnace. 
     
     
         11 . A method of operating a geothermally powered iron production subsystem, the method comprising:
 receiving heated heat transfer fluid from a geothermal system comprising a wellbore extending from a surface into an underground magma reservoir, the wellbore configured to heat a heat transfer fluid via heat transfer with the underground magma reservoir to form the heated heat transfer fluid;   receiving iron ore;   crushing the received iron ore;   placing the crushed iron ore, limestone, and coke into a blast furnace;   melting the crushed iron ore, limestone, and coke in the blast furnace using heat; and   providing the heat to the blast furnace using a heat exchanger using at least in part the heated heat transfer fluid to provide the heat.   
     
     
         12 . The method of  claim 11 , further comprising:
 providing air to the heat exchanger using an air compressor system;   heating the provided air with the heat exchanger; and   providing the heated provided air to the blast furnace as the heat.   
     
     
         13 . The method of  claim 11 , further comprising providing the heat by positioning the heat exchanger within the blast furnace. 
     
     
         14 . The method of  claim 13 , further comprising providing the heat by the heat exchanger heating a structure surrounding the heat exchanger. 
     
     
         15 . The method of  claim 14 , wherein the structure is comprised of one or more of brick, stone, ceramic, or a metal. 
     
     
         16 . The method of  claim 11 , further comprising providing the heat by the heat exchanger being positioned around an exterior of the blast furnace. 
     
     
         17 . The method of  claim 16 , further comprising providing the heat by the heat exchanger directly contacting the exterior of the blast furnace. 
     
     
         18 . The method of  claim 11 , further comprising powering one or more motors by geothermal power using the heated heat transfer fluid, the one or more motors configured to perform mechanical operations of the geothermally powered iron production subsystem, wherein the one or more geothermally powered motors are configured to perform one or more of:
 moving the iron ore through the hopper;   rotating the crusher; and   driving an exhaust system to remove fumes from the blast furnace.   
     
     
         19 . The method of  claim 11 , further comprising:
 generating electricity using one or more turbines powered by the heated heat transfer fluid; and   providing the generated electricity to power one or more motors configured to perform one or more of:
 moving the iron ore through the hopper; 
 rotating the crusher; and 
 driving an exhaust system to remove fumes from the blast furnace. 
   
     
     
         20 . The method of  claim 11 , further comprising tapping the blast furnace to remove molten pig iron from the blast furnace, and tapping the blast furnace to remove molten slag from the blast furnace.