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CDC 10635 DS1
CDC 10635 DS1
iRIi 9065
BUREAU OF MINES
Robert C. Horton, Director
This report is based upon work performed under a Memorandum of Agreement between NICOR
Mineral Ventures and the Bureau of Mines.
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ILLUSTRATION
TABLES
1. Analyses of ilmenite concentrates from northern Minnesota and from New York 3
2. Operational variables for smelting tests on northern Minnesota ilmenites ••• 5
3. Analyses of tapped products from smelting northern Minnesota ilmenites ••••• 5
4. Iron and sodium contents of slag from I-mt smelting test ••••••••••••••••••• 6
5. Partial chemical analyses of sulfation-leached slags prepared from Minne-
sota ilmenite concentrates................................................ 8
6. Operating conditions for continuous sulfation of titania slag derived from
PM ilmenite in large-scale testing ••••••••••••••••••••••••••.•••.••••••••• 9
7. Composition of preleached slag used in continuous sulfation tests •••••••••• 9
8. Partial compositions of selected leached slag samples sulfated in large-
scale tes t. • • • • •. •. • . • . • . • • . • . . . • . • • • • • • •• • • • . • • • •• •• • • • • • • • •. • • • • • ••• • • . . 9
9. Differences between MRRC and PM beneficiation procedures for Water Hen il-
menite possibly affecting concentrate composition •••••••••.•••••••••••••.• 10
10. Comparison of compositions of sulfation-leached slags and commercial tita-
nium raw materials ..•.••••••...••••••••••••.•••• 11 ••••••••••••••••••••••••• 12
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UNIT OF HEASURE ABBREVIATIONS USED IN THIS REPORT
ABSTRACT
Research supervisor.
2Group supervisor (now research chemist).
Albany Research Center, Bureau of Mines, Albany, OR.
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INTRODUCTION
after treatment at 900 0 C for 2 h (3). for decreasing impurities and thereby
The process was tested on a larger scale helping to lessen the u.s. dependence on
in a pilot-scale unit capable of handling foreign sources.
4.5 to 9.1 kg/h of feed material. Mix- Although there is no universally ac-
tures of S02 and air were used for sulfa- ceptable maximum content for impurities
tion, followed by a water leach to re- in feed materials for chlorination to
move impurities (i-1). Pertinent impur- avoid the aforementioned problems, a max-
ity levels were about 1 wt pet higher imum of approximately 1.0 wt pet was sug-
than those obtained from the bench-scale gested by the National Materials Advisory
work. Nevertheless, the results showed Board (11), and that level was the target
this technique to be a promising method used in this investigation.
SMELTING TESTS
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wt pet fixed C and approximately 0.5 and metal were tapped from the furnace
wt pet impurities. Analyses of the eoke and suitable samples were taken for
showed 95.4 wt pet fixed C, 0.98 wt pet analyses.
S, 0.13 wt pet Fe, and approximately 0.7
wt pet added condensed impurities. For RESULTS
the smelting tests in the smaller fur-
nace ("small-scale tests") the woodchips Small-Scale Tests
provided 55 to 56 pct of the carbon, with
the remainder supplied by the coke. In Operational variables for the small-
the test using the large furnace ("large- scale tests are summarized in table 2.
scale test"), 75 pct of the C was present These tests were conducted at approxi-
as woodchips. The small-scale tests in- mately 400 A and 45 V. The tests oper-
dicated that a greater percentage of the ated smoothly with no specific problems.
carbon could be added as woodchips to A gradual decrease in iron content was
more effectively smelt the material. noted in the slag as the tests pro-
In all of the smelting tests, from 5.7 gressed. It was important to tap the
to 6.6 wt pct soda ash was added to main- furnace promptly as soon as the charge
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I tain slag fluidity at the relatively low was entirely melted to avoid increasing
targeted iron contents (5 wt pct FeO) slag viscosity.
in the slag (1). Compositions of the tapped metal and
slag are tabulated in table 3. Since the
EQUIPMENT AND PROCEDURES MRRC concentrate contained fewer impur-
ities than those in the PM material
The small-scale tests were conducted in (table 1), a larger amount of gangue ox-
a 100-kg-capacity single-phase ac elec- ides were contained in the slags derived
tric arc furnace with a carbon-lined from the latter concentrate. Noteworthy
shell. Details of this furnace were de- also are the different phase assemblages
scribed previously (14). The larger 1- in the two slags. Slags made from the
mt-capacity furnace was lined with carbon cleaner MRRC concentrate had less Ti
brick and had a hot-rammed carbon hearth. present in the pseudobrookite structure. 4
This furnace also was described in more This means that more Ti was present in
detail elsewh~re (9). other phases, such as rutile. This situ-
Typical total charges for all of the ation is more amenable to the formation
tests consisted of from 63 to 68 wt pct of soluble compounds of impurities in the
ilmenite concentrate, 23 to 29 wt pct sulfation step. Greater Na levels in
woodchips (dry basis), 1 to 3 wt pct this slag contributed to a separate
metallurgical-grade coke, and 5.7 to 6.6 sodium-containing phase.
wt pct soda ash. The charge components In the test using the MRRC concentrate,
were mixed and blended before feeding. materials balances showed that iron and
Smelting procedures for each smelting titanium recoveries were 78 and 85 pct,
test were similar. Approximately 6.5 to respectively. Final slag basicity (de-
13 pct of the entire charge excluding fined as (CaO + MgO)/Si02 on a weight
woodchips initially was fed into the fur- basis) was 2.0, and 132 pct of the
nace and a molten pool established. Sub- stoichiometric requirement of carbon nec-
sequently, the furnace was filled with essary to reduce all iron oxides to me-
the charge mixture including woodchips tallic iron was used. In the other
and kept full throughout the tests until small-scale smelting test, iron and ti-
the feed was depleted. Bath temperatures tanium recoveries were 89 and 82 pct,
and slag samples were taken throughout respectively, with a final slag basicity
the tests to maintain sufficient bath of 0.74. In this test, 164 pct of the
fluidity and to monitor Fe and Na levels. stoichiometric carbon requirement was
After all of the feed was charged into
the furnace and smelted, and a satisfac- 03 'Ti02, where M can be Fe or Ti, or
tory bath temperature established, slag MO'2Ti02, where M can be Fe, Mq, or Ti.
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TABLE 4. - Iron and sodium contents of slag from I-mt smelting test,
weight percent
employed. A metal suitable for further and Na contents of the slag as a function
refining was produced. of time are given in table 4.
For the large-scale test, tapped metal
Large-Scale Test and slag compositions are listed in ta-
ble 3. As noted in the small-scale
Pertinent variables for the test using tests, higher levels of Na in the slag
the I-mt furnace also are listed in table resulted in a separate sodium-containing
2. Approximate average amperages, phase- phase. Iron and titanium recoveries were
to-ground voltages, and phase-to-phase 100 and 88 pct, respectively. Final slag
voltages for this test were 3,075, 46, basicity was 0.95, and 160 pct of the
and 89, respectively. Again, the smelt- stoichiometric carbon requirement was
ing operation proceeded smoothly. The Fe used.
SULFATION-LEACHING TESTS
slag fed in the top and the reactant employed to neutralize the S02 and 803
gases in the bottom, using a countercur- constituents in the offgas.
rent mode of operation.
For the small-scale tests, a 5.1- SMALL-SCALE 8ULFATION-LEACHING TESTS
cm-diam, vertical-shaft reactor was used
to sulfate 50-g charges. The reactor, Procedures
made from clear quartz, was divided at
the midpoint by a slotted support for the In the sulfation step, the CaO, MgO,
charge. The reactor was similar to that MnO, and NazO constituents in slag react
employed previously to sulfate slag selectively with 802 and 0z or air at
charges derived from New York rock ilmen- temperatures used to form water-soluble
item (5). The reactor was provided with compounds that are subsequently leached
a gas inlet in its top and a gas exit from the sulfate product. .A promoter,
line in its bottom. Flow rates of incom- such as soda ash, added with the ilmenite
ing 802 and 02 were measured with rotam- charge in the previous smelting step, is
eters, and the exit gases were scrubbed required to promote sulfation of these
with a sodium hydroxide solution before constituents (2).
release to the atmosphere. The reactor The procedur~ used to sulfate the slag,
was heated by enclosing it within a tube which was derived from both ilmenite con-
furnace equipped with electrically heated centrates, was similar to that used in
resistance elements. upgrading slag from New York rock ilmen-
The main components of the large-scale ite (3). Each pellet charge was placed
equipment employed to continuously sul- in the reactor, and the system was usual-
fate slag pellets in a moving bed con- ly flushed with argon during heatup to
sisted of a horizontal rotary kiln and a the desired operating temperature. In
vertical-shaft furnace equipped with a tests involving oxidation of slag before
10.2-cm-ID silicon carbide tube that sulfation, the charge was heated in an
served as the reaction chamber. These oxygen atmosphere. After the operating
units were described previously (4). The temperature was reached, equal volumes of
10.2-cm-diam kiln was used to indurate S02 and 0z--each flowing at 110 cm3 /min--
and oxidize the slag pellets before they were passed through the charge for 2 h.
underwent sulfation in the adjacent re- The sulfated charge was cooled in an S02
actor. Slag pellets were fed from a atmosphere and removed from the reactor.
charge bin through a rotary airlock The material was ground to minus 35 mesh,
("star") valve to the kiln, and the dis- and a 5-g portion of the ground mate-
charged, oxidized product was fed into rial was leached in 0.1 L of stirred
the top of the shaft furnace. The 1.2- 1-wt-pct-HC1 solution for 1 h at ambient
m-Iong, l-kW heated section of the re- temperature. The resultant slurry was
actor was surrounded by auxiliary, elec- filtered, and the separated solids were
'trically heated elements. Thermocouples washed with fresh water before they were
were spaced every 30.5 cm along the out- dried and sampled for chemical analyses.
side wall of the reactor to measure ap-
proximate bed temperatures, along with a Results
thermocouple to control temperatures
automatically. A mixture of S02 and air Table 5 shows the effects on the compo-
entered the moving bed below the heated sition of the leached products of pre-
section of the reactor, which was en- leaching and oxidizing the slag charges
closed within an insulated containment before sulfation at temperatures of 750
shell. The gas mixture flowed upward to 900. The best upgrading of slag de-
through the bed. The pellets flowed rived from both concentrates was obtained
downward in the bed by gravity and were in test 5 using a charge that was pre-
withdrawn through a screw conveyor from leached and oxidized Defore sulfation at
the bottom of the reactor. A scrubbing 850 0 C. The upgraded product contained
column containing an Na2C03 solution was 95.6 wt pct Ti0 2 with 0.08 wt pet CaO,
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0.22 wt pct MgO, and <0.01 wt pct MnO as Samples of sulfated and leached prod-
pertinent impurities. With respect to ucts were examined by X-ray diffraction
the PM materials, slag made in the small- to identify the phases present. General-
scale smelting test responded better to ly, the sulfated charges contained 40 to
sulfation-leaching than did that from the 100 wt pct rutile, and 1 to 10 wt pct
large-scale furnace. In test 11, a prod- each of a pseudo brookite-type phase,
uct upgraded to 94.9 wt pct Ti02 with low cristobalite, and T102(S04)3' In some
levels of pertinent impurities was ob- instances, these charges also contained
tained from a charge sulfated at 850 0 C. 1 to 10 wt pct of CaS04·MgS04. After
Preleaching the slag with 5-wt-pct-HCl leaching, the slags contained 40 to
solution before sulfation reduced its 100 wt pct of rutile, and <1 wt pct
Si02 content by about two-thirds, from each of anatase, cristobalite, and a
7.72 to 2.78 wt pct. The resultant pre- pseudobrookite-type phase.
leach liquor contained constituents with The liquors from the leaching of sul-
the following concentrations, in grams fated slags contained constituents usu-
per liter: 0.06 Ca, 0.92 Na, 0.18 Mg, ally with the following concentrations,
0.16 Mn, 0.86 Si, 0.25 AI, and 0.41 Fe. in grams per liter: 0.14 to 0.15 Ca, 0.6
A charge of slag prepared in the 1-mt to 0.63 Mg, 0.11 to 0.12 Mn, and 0.77 to
furnace with an FeO content of 9.10 0.79 Na. Spectrographic analyses of
wt pct (table 3) was upgraded to only solids recovered from leach liquors
84.2 wt pct Ti02' This demonstrates that evaporated to dryness indicated the fol-
high-iron slags are more difficult to lowing, in weight percent: 1 to 10 each
upgrade. of Ca, Mg, and Na; 0.1 to 1 each of Fe
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and Mn; 0.01 to 0.1 each of Si and Ti; TABLE 6. - Operating conditions for
0.001 to 0.01 of Ni; and 0.0001 to 0.001 continuous su1fation of titania
of Cu. slag derived from PM ilmenite in
large-scale testing
LARGE-SCALE SULFATION-LEACHING TESTS
Reactor preheat temp ••••••••••• oC.. 800
Procedures Duration of test •••••••••••••••• h.. 48
Slag feed rate ••••••••••••••• kg/h.. 4.5
The procedure used to sulfate slag pre- 802 f1ow •••••••••••••••••••• L/min.. 5.5
pared in the 1-mt furnace was similar to Air f1ow •••••••••••••••••••• L/min.. 15.7
that previously described (i-1). The op- 02 to ki1n •••••••••••••••••• L/min.. 7.2
erating conditions used are shown in
table 6. TABLE 7. - Composition of pre leached
Briefly, the reactor was preheated to slag 1 used in continuouB su1fation
the operating temperature and maintained tests, weight percent
there for 30 min while a moving bed was
established. Metered flows of S02 and Ti0 2 ••••••••••••••••••••••••••••••76.2
air were introduced into the bottom of FeO 6.2
CI • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
separation step. Differences in the FIGURE 1.-Materlal balance for oxidation and sulfation of slag
beneficiation procedures used by MRRC pellets in vertical-shaft furnace.
11
significant amounts of Si0 2 and MgO with On the basis of these results, it is rec-
it during beneficiation. Titanium re- ommended that approximately 120 to 130
coveries were low (approximately 64 pct) pct of the stoichiometric carbon require-
at the spiral step and may account for a ment be used. A 50-50 mixture of wood-
higher percentage of gangue material. chips and coke appears acceptable.
Low-intensity magnetic separation could
remove up to another 5 wt pct gangue SULFATION-LEACHING TESTS
material (especially Si0 2 and MgO).
Associated with the aforementioned pro- Slags from the small-scale smelting of
blems was the difficulty in decreasing MRRC and PM concentrates required pre-
the iron content of the slag to accept- leaching before sulfation in order to ob-
able levels in the large-scale smelting tain upgraded products having Ti02 con-
test (table 3). It is believed that this tents approaching those of natural
difficulty was associated with the higher rutile. The slag prepared from the MRRC
Si02 contents in the PM concentrate used concentrate contained 40 to 100 wt pct
in this test compared with that in the NaO.23Ti02 (table 3), and it was pre-
MRRC concentrate (table 1). More acidic leached to reduce its Na20 content of
slags (i.e., those containing more Si0 2 ) 10.4 wt pct to below 6 wt pct. The slag
tend to retain iron more readily than do derived from PM concentrate with 5.94
basic slags. Two explanations for this wt pct Na20 and 2.28 wt pct FeO, on the
obser~ation are possible: (1) Either the other hand, responded directly to sul-
magnetite was intimately locked with the fation, but a preleaching step was em-
Si02, and/or (2) iron silicates, which ployed that reduced the Si0 2 content of
were difficult to reduce, were formed in the slag from 7.72 to 1.83 wt pct. Good
the slag during smelting. Increased iron sulfation of the Ca constituent was noted
also stabilizes the pseudobrookite-type in both slags from small-scale smelting
structure, thus preventing it from yield- tests.
ing more iron to the metal during smelt- For Mg and Mn, the sulfation proved to
ing. Excessi~e Si02 in the charge ma- be more difficult owing to the partition-
terials can cause a more viscous slag, ing of these impurities in other phases.
resulting in greater energy consumption Previous tests in this laboratory with
(table 2). slags prepared from New York rock ilmen-
On the other hand, analytical evidence ite showed that effective conversion of
shows that the large-scale test using the Mg and Mn in the slag to soluble com-
PM concentrate was conducted under more pounds by S02-02 mixtures depends on the
oxidizing conditions than was the small- oxidation of the pseudo brookite-type
scale test. Higher oxygen pressures de- phase to rutile (3, 5). As mentioned
crease the pseudobrookite-type structure previously, increased ~O contents tend
(table 3), which promotes the formation to stabilize the pseudohrookite structure
of rutile. This was probably the con- (16) •
dition that pre~ailed during the small- -Xlthough the slag prepared in the I-mt
scale test using the MRRC concentrate. smelting furnace was pre leached in ef-
In general, the small-scale smelting forts to reduce its FeO and Na20 con-
test using the MRRC concentrate yielded tents, the material did not respond well
the most acceptable results. This test to continuous sulfation in the shaft fur-
used 132 pct of the stoichiometric fixed nace reactor. Pre leaching the material ,,I'
carbon requirements to reduce all of the did not lower its FeO content to the
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iron. The woodchips accounted for 55.8 level achieved with PM material prepared
pct of the carbon used. More total car- on a small scale.
bon was used in the tests with the PM The slag with the lower FeO and Na20
concentrate (160 to 164 pct of the contents responded directly to small-
stoichiometric carbon requirement) and scale sulfation at 800 0 C with a resi-
woodchips accounted for 55.2 and 42.2 pct dence time of 2 h. However, sufficient
of the carbon used in the small- and time for experimentation was not avail-
large-scale smelting tests, respectively. able to optimize the operating variables
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such as reaction temperature, time, and low-grade ilmenites, whereas Richards Bay
slag composition on impurity sulfation. slag and synthetic rutile are produced
Table 10 shows that the compositions of from high-grade ilmenite sand concen-
sulfated and leached slags derived from trates such as the one shown in table 10.
Minnesota and New York ilmenite concen- A sulfation-leached slag derived from the
trates in small-scale tests compared very New York ilmenite (included for compar-
favorably with those of commercially ative purposes) contained pertinent im-
available titanium raw materials used as purity levels comparable to those shown
feedstocks in chloride process plants. for upgraded Minnesota slags.
The Bureau slags were derived from
This research showed that an ilmenite wt pct) in the product slag that could
concentrate from northern Minnesota can result from sporadic additions and that
be smelted, su1fation-1eached to pro- might require preleaching and/or pre-
vide a suitable high-Ti02 feed material oxidation prior to the sulfation step.
for subsequent chlorination. However, a Iron levels in the slag should be main-
relatively clean concentrate must be used tained below 5 wt pct FeO. In combi-
for smelting to avoid excessive levels of nation with the pseudobrookite structure
iron in the slag, which are detrimental alone, the Nao.23Ti02 phase is deleteri-
to efficient sulfation-1eaching opera- ous to sulfation-Ieaching. Additional
tions. A concentrate containing only phases in the slag make it more amenable
ilmenite is preferred. The concentrate to sulfation. At least 120 pet of the
should contain less than 2 wt pet Si02, stoichiometric amount of fixed carbon re-
2.5 wt pct MgO, and 1 wt pct A1203, and quired to reduce all of the iron should
should possess at least 29 to 30 wt pct be used throughout the smelting test to
total Ti. Sufficiently high bath temper- decrease and maintain suitable iron
atures (~1,600° C) are necessary to pro- levels in the slag.
mote the desired reactions and to avoid Prereduction of the titaniferous ma-
excessive slag viscosity. To maintain terial may result in a more easily con-
slag fluidity at the relatively low tar- trolled smelting operation and yield a
geted iron levels, soda ash should be suitable slag for sulfation-Ieaching.
added uniformly throughout the smelting Static-bed tests showed pre1eached slag
test to avoid excessive Na levels (6.0 charges that contained less than 5 wt pct
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FeO and 6 wt pct Na20 responded the best good sulfation of the impurities. Also
to impurity sulfation by S02-02 mixtures indications were that the Na20 additive
at temperatures of 850 0 C and lower. Up- present as Na20oFe203·6Ti02 was not an
graded slags with compositions es- effective sulfation promoter since the
sentially comparable to those of natural constituent did not sulfate along with
rutile were obtained from the sulfated the impurities.
charges. The Ca impurity was the easiest Results of this research have demon-
to sulfate; Mg and Mn proved to be more strated the strong possibility that an
difficult to sulfate in slags with the additional significant domestic titanif-
higher FeO and Na20 contents. erous resource could be used when neces-
Continuous sulfation of pelletized pre- sary to prepare chlorination-grade feed-
leached slag in a vertical-shaft furnace stock, thereby decreasing U.S. reliance
reactor was performed at temperatures of on foreign imports. However, more large-
800 0 to 850 0 C, but the relatively high scale testing is necessary.
FeO and Na20 contents of the feed impeded
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