3
refractory. However, the use of coal on the refractory bed
increased the cost of operation and also provides a source
of sulfur to the iron nuggets. Carbontec Energy conducted
another program at NRRI that tested the ability of a new
refractory to resist the sticking of hot metal and slag.
This program was successful and Carbontec subse-
quently obtained a patent for the inventors, John Simmons
and Dale Hintsala. John Simmons also invented and pat-
ented a process to convert a loose, unbriquetted, self-reduc-
ing iron/biomass blend into large iron nuggets and slabs.
These patents were assigned to Carbontec Energy.
LAWRENCE LIVERMORE NATURAL
LABORATORY AND PURDUE
UNIVERSITY NORTHWEST AND THEIR
HIGH PERFORMANCE COMPUTER
CAPABILITY TO CONFIRM AND MODEL
THE E-IRON PROCESS.
Lawrence Livermore National Laboratory and Purdue
University Northwest obtained a $300,000 grant from the
DOE to utilize their high-performance computer capabil-
ity to validate and model the E-Iron Process. The project’s
model provided Andritz, the E- Iron furnace provider,
with important engineering design information. The pro-
gram studied the tunnel furnace design and the natural
gas burner placement as well as bed depth vs. heat transfer
and production efficiency. The modelling confirmed that a
single layer of pellets on the refractory bed reduced faster
and improved production. Purdue University Northwest
prepared a 5 minute video simulation of the E-Iron furnace
in operation.
https://drive.google.com/file/d/1pkwSl1t347eiUd1
_ht2RROAjw_ucGd_c/view
Appendix A includes data gathered during the Lawrence
Livermore National Laboratory/Purdue Northwest/DOE
opportunity.
Based on the successful results obtained at the facili-
ties of NRRI and the pilot plant program conducted at the
facilities of Tundra Industries, Carbontec Energy formed
E-Iron International, LLC, to commercialize the E-Iron
Process. An initial 300,000 tonne/year E-Iron plant will
be built in Port Mt. Vernon, Indiana, a major port on the
Ohio River that is served by barge and three Class 1 rail
roads.
THE POTENTIAL TO PRODUCE ZERO
CARBON EMISSION IRON NUGGETS
E-Iron has two pathways to produce zero carbon emission
iron nuggets. The first pathway is to use a tunnel furnace
heated with electrical energy, including microwaves, instead
of natural gas. The electrical energy would be sourced from
a regional provider of renewable energy. The Tundra fur-
nace used by Carbontec for its pilot plant operation was
electrically heated.
Figure 1. The E-Nugget™ Iron Process
refractory. However, the use of coal on the refractory bed
increased the cost of operation and also provides a source
of sulfur to the iron nuggets. Carbontec Energy conducted
another program at NRRI that tested the ability of a new
refractory to resist the sticking of hot metal and slag.
This program was successful and Carbontec subse-
quently obtained a patent for the inventors, John Simmons
and Dale Hintsala. John Simmons also invented and pat-
ented a process to convert a loose, unbriquetted, self-reduc-
ing iron/biomass blend into large iron nuggets and slabs.
These patents were assigned to Carbontec Energy.
LAWRENCE LIVERMORE NATURAL
LABORATORY AND PURDUE
UNIVERSITY NORTHWEST AND THEIR
HIGH PERFORMANCE COMPUTER
CAPABILITY TO CONFIRM AND MODEL
THE E-IRON PROCESS.
Lawrence Livermore National Laboratory and Purdue
University Northwest obtained a $300,000 grant from the
DOE to utilize their high-performance computer capabil-
ity to validate and model the E-Iron Process. The project’s
model provided Andritz, the E- Iron furnace provider,
with important engineering design information. The pro-
gram studied the tunnel furnace design and the natural
gas burner placement as well as bed depth vs. heat transfer
and production efficiency. The modelling confirmed that a
single layer of pellets on the refractory bed reduced faster
and improved production. Purdue University Northwest
prepared a 5 minute video simulation of the E-Iron furnace
in operation.
https://drive.google.com/file/d/1pkwSl1t347eiUd1
_ht2RROAjw_ucGd_c/view
Appendix A includes data gathered during the Lawrence
Livermore National Laboratory/Purdue Northwest/DOE
opportunity.
Based on the successful results obtained at the facili-
ties of NRRI and the pilot plant program conducted at the
facilities of Tundra Industries, Carbontec Energy formed
E-Iron International, LLC, to commercialize the E-Iron
Process. An initial 300,000 tonne/year E-Iron plant will
be built in Port Mt. Vernon, Indiana, a major port on the
Ohio River that is served by barge and three Class 1 rail
roads.
THE POTENTIAL TO PRODUCE ZERO
CARBON EMISSION IRON NUGGETS
E-Iron has two pathways to produce zero carbon emission
iron nuggets. The first pathway is to use a tunnel furnace
heated with electrical energy, including microwaves, instead
of natural gas. The electrical energy would be sourced from
a regional provider of renewable energy. The Tundra fur-
nace used by Carbontec for its pilot plant operation was
electrically heated.
Figure 1. The E-Nugget™ Iron Process