Sponge iron is made from iron ore and undergoes a reduction process using a reducing gas emitted from coal or natural gas. It has a higher iron content than cast iron and its byproducts can be used in other applications. It is commonly used to create wrought iron and can be produced quickly and inexpensively.
Sometimes known as direct reduced iron, sponge iron is a product made using iron ore. Iron ore is often in the form of pellets or lumps, and it undergoes a reduction process that is created through the use of a reducing gas that emits from coal or a natural gas source. This type of iron can be produced in several types of furnaces, including coke or coal furnaces, blast furnaces, and basic oxygen furnaces.
There are several benefits associated with sponge iron that allow it to compete effectively with other types of cast iron. One has to do with the actual composition of the final product itself. For example, this type of iron is considered to be richer than cast iron, another type of iron commonly produced in blast furnaces. Direct-reduced iron has a slightly higher iron content, often making it more suitable for use in electric furnaces.
Additionally, the gases emitted during the production of sponge iron can be collected and used in various other applications. This byproduct of the ironmaking process helps offset the cost of producing iron, as well as helps maintain other processes that require gas for proper production. It can also be used to make a powdered ore that works very well when mixed with other metals in making different types of iron products.
One of the most common uses for sponge iron is to create wrought iron. Iron of this type is useful in making ornamental items for use in the home, such as decorative grilles for screen doors, window grilles, and also for various types of wall hangings. Sponge iron is also often used for the production of components used to create durable garden and patio furniture. When properly treated, wrought iron furniture can easily resist deterioration from the elements and last for a number of years.
In recent years, improvements to the production of sponge iron have made it possible to reduce the iron without necessarily having to smelt the ore. Because iron can be made into pellets and even powder, it is an inexpensive and useful substitute for the scrap metal sometimes used by steelmakers. The amount of time and resources required to produce sponge iron is minimal, so large quantities can be produced quickly, a fact which only adds to the benefits of this type of iron product.
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