Naphtha Reduction of Iron Ores to Sponge Iron in Continuous Vertical Reactor

The development of a process of sponge iron production by naphtha, a petroleum by-product, in a continuous 90mm I.D. vertical reactor is discussed. The process, the equipment and the operational parameters, the results of the campaigns with various iron ores pellets are described.

Sized iron ore fines from two deposits were directly reduced by petroleum naphtha to sponge iron at a temperature of about 1000 deg. C. maintaining naphtha injection at different controlled flow rates. The movement of solids in the reactor column was also controlled to obtain predetermined residence times.producing 70-100 kgs of sponge iron per day. Under optium conditions 98 percent metallization was obtained.

The results are discussed in the light of efficiency of the reductant and the economics of the process.