Direct reduction of ores and concentration of metallic values

The process for recovering high quality malleable sponge iron with reduced phosphorous content from iron ores having a high phosphorous content comprising the following steps:

• (a) subjecting a charge of crushed high phosphorous iron ore to direct reduction in a non-oxidizing atmosphere;
• (b) heating said ore in a non-oxidizing atmosphere to temperatures within the range of at least about 900.degree. C. to about 1200.degree. C. to obtain iron with a ferrite grain struture and to obtain a high degree of metallization to recover a sponge iron material of increased Fe content having a carbon content of less than 0.10% as chemically combined carbon;
• (c) cooling said sponge iron in a controlled non-oxidization atmosphere of an inert gas or containing a minimum of carbon monoxide through the temperature in which the Boudouard reaction occurs to prevent re-oxidation thereof, to prevent the formation of any excess chemically combined carbon therein, and to avoid the formation of cementite;
• (d) grinding said sponge iron in a ball mill to thereby convert the Fe content of said sponge iron to a flake powder of agglomerated sponge iron grains while grinding the oxides, gangue and other waste materials therein to a finely divided state;
• and
• (e) screening and separating said sponge iron to obtain a concentrate having an Fe content of at least about 90%.