Ironite Sponge

Ironite Sponge is the product of a reaction using highly reactive, specially formulated chemical grade iron powder as the raw material. It is produced under conditions that create a unique sponge-like porous structure with approximately 10 m² of reactive surface per kilogram of Sponge or approximately 50,000 square feet per pound. The specific gravity of the dry material is 4.5 g / cm³ to

4.6 g / cm³. Particle size ranges from 1.5 to 50 microns, with 90% between 2 to 20 microns. The material retains very little magnetism, therefore is not attracted to drill pipe or casing.

1. Porosity and Surface Area
The picture of the particle of Sponge was made with an electron scanning microscope at 4,000 X magnification. This illustrates the high porosity which gives the particle a sponge-like appearance. The porous structure results when a specially formulated iron powder is reacted under controlled oxidation conditions. The reaction is stopped when Fe3 O4 is formed. The large surface area and the chemical form are the keys to reaction effectiveness. The large surface results in reaction rates with H2S approximately 500 times faster than would be achieved with solid particles of the same size. The chemical form results in stable reactions.

2. Spherical Shape and Particle Size

Further examination of the particles by the electron scanning microscope shows that in addition to being porous, they are spherical. The spheres are presumably composed of micro-crystalline Fe3O4 which generally occurs in the octahedral form and has a hardness of about 6.

The spherical shape and particle size is also the result of the manufacturing process. Grinding does not alter the particle size. The particles are between 1.5 and 50 microns, approximately the same as barite, with 90% between 2 and 20 microns. The average particle size is 6 to 8 microns, compared to an average of 20 microns for barite. Therefore, it is ideal for drilling applications with particle size such that it should not penetrate the formation.

3. Synthetic

Ironite Sponge is synthetic in that it is not made from magnetite ore but from iron powder. There is no naturally occurring material that has comparable surface area or reaction effectiveness.

4. Pure – Compatible

The material is pure, containing no soluble impurities. It will not go into solution, but remains as a discrete suspension. Therefore, it is practically inactive as far as the drilling mud is concerned. It is free flowing and has no adverse effect on electrical log interpretations.

5. Non-Abrasive

Ironite Sponge is virtually non-abrasive. By test it has een shown to be less than one-half as abrasive as barite even though it is twice as hard (6.6 versus 3.2 on Mohs Scale). The porous, honeycomb-like shell will collapse and deform rather than abrade.

Ironite Products Co., Inc., PO Box 3975, St. Louis, MO 63005-3975. Tel: 314-725-7900; Fax: 636-532-1842.