Question:
I wish to enter into the field of Iron powder manufacturing and seek your advise for the best possible manufacturing process.
What would be the reduction process of sponge iron?

Answer:
The “best possible manufacturing process” for making iron powder is a function of the application and how much of this application is being targeted.  The application determines the shape, size and size distribution of the particles required.

Iron powders can be made by:

• Reduction
  • Of ores including the Indian "blue dust"
  • Sponge Iron

• Atomization from a melt
  • Water atomization
  • Gas atomization

• Electrolysis

• Attrition

• Other chemical means
  • CVD
  • Dissociation of iron carbonyl

Although the specific application is not mentioned in the question, the largest volume of iron powder used in the powdered metal injection moulding industry today is made by the carbonyl process.