Appeal No. 96-2884
Application No. 08/181,997
(b) contacting in a second reaction zone said metallic iron-containing product
with a second gas to form an iron carbide-containing product, wherein said second gas
comprises: (i) a component selected from the group consisting of carbon monoxide,
carbon dioxide, and mixtures thereof to provide a source of carbon in the formation of iron
carbide and (ii) methane to inhibit the back conversion of iron carbide into metallic iron.
41. A method for producing iron carbide, comprising the steps of :
(a) first contacting an iron-containing feed material with a first gas comprising
hydrogen and carbon to produce a first product comprising metallic iron, wherein said first
product contains no more than about 35 percent by weight iron carbide; and
(b) second contacting said first product with a second gas to produce a second
product comprising iron carbide, wherein said second gas comprises (i) a component
selected from the group consisting of carbon monoxide, carbon dioxide, and mixtures thereof
to provide a carbon source for the conversion of said first product into iron carbide; and (ii)
hydrogen gas to inhibit the formation of free carbon in said second product.
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