Removal of Iron from Titanium Ore Through Selective Chlorination Using Magnesium Chloride
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Materials Transactions, Vol. 54, No. 8 (2013) pp. 1444 to 1453 ©2013 The Mining and Materials Processing Institute of Japan Removal of Iron from Titanium Ore through Selective Chlorination Using Magnesium Chloride Jungshin Kang1,+ and Toru H. Okabe2 1Department of Materials Engineering, Graduate School of Engineering, The University of Tokyo, Tokyo 113-8656, Japan 2Institute of Industrial Science, The University of Tokyo, Tokyo 153-8505, Japan A selective chlorination process using magnesium chloride (MgCl2) as chlorinating agent was investigated with the aim of developing a process for removing iron directly from ilmenite, which is a low-grade titanium ore known as FeTiO3. Two crucibles, one consisting of titanium ore and the other consisting of a mixture of titanium ore and MgCl2, were placed in a gas-tight quartz tube, and then both crucibles were heated to 1000 K. In some experiments, H2O vapor was introduced in the quartz tube. HCl gas produced from the MgCl2/titanium ore mixture reacted with the iron present in the titanium ore placed in the other crucible to produce TiO2. Iron present in the titanium ore of the titanium ore/MgCl2 mixture reacted with MgCl2, and MgTiO3 and MgO were obtained. Iron in the titanium ore present in both crucibles was removed as FeCl2 (l,g). In these experiments, the effects of the particle size of the titanium ore and the atmosphere on selective chlorination were investigated. In addition, titanium ores produced in Vietnam, Australia and China were used as feedstocks. By the chlorination process, 97% TiO2 was obtained directly in one step from the low-grade titanium ore containing 51% TiO2 under certain conditions, thus demonstrating the feasibility of the selective chlorination process for producing high-purity titanium dioxide from low-grade titanium ore. [doi:10.2320/matertrans.M-M2013810] (Received March 26, 2013; Accepted May 15, 2013; Published July 25, 2013) Keywords: ilmenite, titanium ore, selective chlorination, synthetic rutile, iron removal, titanium smelting 1. Introduction Ilmenite (rock) Ilmenite (sand) Rutile : 30 – 50% TiO2 : 35 – 65% TiO2 : 95% TiO2 Titanium (Ti) is widely used in various fields because of its excellent properties such as high strength to density ratio and Slag process high corrosion resistance; in addition, titanium is the ninth 1) most abundant element on the Earth’s crust. However, 75 – 86% TiO2 (Ti slag) titanium is still used to a much lesser extent than iron (Fe) or aluminum (Al), mainly because of low productivity and UGS process Becher process Benilite process 1) high production costs involved at all processing stages. For 95% TiO2 90 – 93% TiO2 95% TiO2 example, the cost of processing titanium ore is 15 times higher (Upgraded slag) (Synthetic rutile) than that required for processing iron ore.25) To reduce the Sulfate process Chloride process Kroll process production costs, it is imperative to improve the early stages of titanium production by developing a simple and effective Titania pigment Titanium processes for processing titanium ore to titanium metal. (5.1Mt TiO2 / year world) (0.1Mt Ti / year world) Ilmenite and rutile are the key minerals used for titanium Fig. 1 Currently used process for titania pigment and titanium produc- production. Chemical formula of ilmenite is FeTiO3 with tion.1,6,8,9) 3065% TiO2, while that of rutile is TiO2 with 95100% 1,6,8,9) TiO2. If we consider only the concentration of TiO2, rutile will be the most appropriate feedstock for the to reduce the amount of iron in the TiO2 ore feed for reducing manufacture of titania (TiO2) pigment or titanium metal. the amount of chloride wastes and the chlorine loss during the However, ilmenite is used much more extensively as a chloride process16) or the Kroll process.17) Many companies feedstock. For example, the global production of ilmenite was place a lower limit on the purity of TiO2 feed before placing eight times higher than that of rutile in 2011.7) This is because the feed into the chlorinator. Usually the feeds containing at 18,19) the price of ilmenite is much lesser than that of rutile. Further, least 90% of TiO2 are used. Some countries including ilmenite is much more readily available than rutile, with the Japan have much more strict criteria for a purity of TiO2 feed, 7) share of ilmenite in the world mine reserves being 94%. and a purity of over 95% TiO2 is required in the Kroll process. Therefore, the role of ilmenite as the source for the titanium However, due to the increase in the price of the TiO2 feed by, mineral is expected to become gain more significance. for example, the increase in the consumption of TiO2 feed in As shown in Fig. 1, several processing stages are generally China, recently, some companies in Japan have begun to use 20) required for removing iron from titanium ore for producing 90% TiO2 feed in order to reduce the cost of the feedstock. TiO2 pigment or titanium metal using ilmenite as the In the Becher process, various types of titanium ores are feedstock.1,6,8,9) In many cases, first, ilmenite is upgraded to used as feedstocks.21) However, multiple stages are required 10,11) high purity TiO2 by the Becher process, the Benilite for treating iron, and a huge amount of iron compounds are process,1214) or the slag production process.15) It is important dumped as wastes. In the Benilite process, processing of iron is simpler than the other processes. However, this process +Graduate Student, The University of Tokyo. Corresponding author, makes use of highly concentrated 1820% HCl and only E-mail: [email protected] limited types of titanium ore is used as a feedstock.21) In the Removal of Iron from Titanium Ore through Selective Chlorination Using Magnesium Chloride 1445 Chlorinating agents slag process, iron in the titanium ore is reduced to metal by This study a carbothermic reaction, and TiO2 slag and iron metal are * separated. The scale of the slag process is large, and it is high Ilmenite (FeTiO3) HCl MgCl2 Ilmenite (FeTiO3) H2O speed process. However, TiO2 with a low purity of 7586% is Selective chlorination Selective chlorination obtained. For obtaining high purity TiO2 slag, it is essential to employ additional upgrading process such as the upgrade HCl recovery H O TiO FeCl FeCl MgTiO / MgO HCl slag (UGS) process,15) which entails multiple steps for the 2 2 2 2 3 further removal of iron. * Extensive research has been conducted to improve the Ti scrap currently used upgrading processes of titanium ore. Among Titanium metal production Chlorine recovery the various processes, selective chlorination has gained fi signi cant attention. In the selective chlorination process, Ti metal Fe TiCl4 iron is only removed directly from the titanium ore as iron chlorides and high purity TiO is obtained. The selective Fig. 2 Flow diagram of the selective chlorination process investigated in 2 the present study. chlorination processes investigated so far have entailed 2225) the use of chlorine gas (Cl2) under carbon or CO/Cl2 mixture atmosphere,2628) or metal chlorides as the chlorine Gas outlet / Not used under vacuum and Ar atmosphere source.2932) Among these processes, the first two processes Electric furnace Heater require Cl2 gas and installation of the reactor become costly Quartz crucible Mo-lined and it also has environmental issue for operation. quartz crucible Silicone Quartz Quartz The selective chlorination process that uses metal chlorides rubber plug wool [Mo] Ti ore MgCl was recently developed by Okabe et al.29,30) In recent studies, Quartz tube Ti ore 2 the authors investigated further improvement of the selective Vacuum or chlorination using calcium chloride (CaCl2) as the chlorinat- Gas inlet % Water bubbler used ing agent, and 97 TiO2 was successfully obtained directly Gas outlet Ar 31,32) Thermocouple under Ar + H O gas from titanium ore containing 51% TiO2 in a single step. 2 atmosphere only However, because CaCl2 was used as chlorinating agent, it MFC was needed to decrease the activity of CaO by the production Water Empty of complex oxides such as CaTiO for producing HCl gas. 3 Pump Pressure Temp. In addition, high purity TiO2 could not be obtained when the controller experiment was conducted under Ar gas flow atmosphere. gauge Recently, on the basis of thermodynamic analysis,33) it was Fig. 3 Schematic of the experimental apparatus used in the present study. anticipated that extracting chlorine source such as HCl gas from MgCl2 rather than CaCl2 is easier because HCl gas can Table 1 Chemical compositions of titanium ores used in this study. be produced even under standard state condition (aMgO = 1), % *1 and is possible even at lower temperatures. In this study, in Source country Concentration of element i, Ci (mass ) the viewpoint of improvement of HCl gas production and the of titanium ore Ti Fe Al Si Ca Mn Zr Nb Mg verification of feasibility for upgrading titanium ore by Vietnam*2 45.0 49.7 0.33 0.57 0.04 3.47 0.07 0.15 N.D. utilizing MgCl2 for the selective chlorination, the authors Australia*3 48.5 46.7 1.02 1.00 0.07 1.69 0.18 0.18 N.D. used MgCl2 as a chlorinating agent to remove iron directly China*4 47.2 45.4 1.41 1.65 0.21 2.79 0.24 0.27 N.D. from the titanium ore. *1 fl Determined by XRF analysis (excluding oxygen and other gaseous Figure 2 shows the ow diagram of the process used in elements), N.D.: Not Detected. Below the detection limit of the XRF this study.