Process and system for the production of iron nuggets

A process for reducing iron containing oxides to produce a plurality of metallic iron nodules from a process charge including iron containing oxide, a predetermined amount of a reductant and flux, wherein the process charge is carried into a traveling hearth furnace for reducing, melting and coalescing stages to convert the process charge into the plurality of metallic iron nodules and slag components, the process comprising:

• providing a process charge on a hearth configured to be moved into and through the traveling hearth furnace, the hearth comprising a synthetic graphite material, wherein the process charge is in direct contact with an outer surface of the hearth consisting of the synthetic graphite material, such that the outer surface of the hearth is substantially devoid of a separate layer of carbonaceous material and natural graphite;
• and
• carrying the process charge on the hearth within the traveling hearth furnace during the reducing, melting and coalescing stages, wherein the process charge is in direct contact with the synthetic graphite material such that the plurality of metallic iron nodules and slag components are only in direct contact with the synthetic graphite material of the hearth, and wherein each of the plurality of metallic iron nodules contain a sulfur impurity level in an amount less than about 200 ppm.