PLANT DESIGN OF TITANIUM DIOXIDE
MANUFACTURING
Priyanka Kshirsagar Saket Rokde
Department of Chemical Engineering Department of Chemical Engineering
Vishwakarma Institute of Technology Vishwakarma Institute of Technology
Pune, India Pune, India
Abstract - Titanium, renowned for its exceptional strength,
corrosion resistance, and low density, has found extensive
applications across diverse industries. However, traditional
manufacturing methods have posed several challenges,
including high costs, limited scalability, and environmental
concerns. In response, this project paper introduces a novel
titanium manufacturing process that addresses these
limitations while enhancing material properties and
reducing production timelines.
The project paper will discuss the experimental setup and
methodology used to validate the proposed titanium
manufacturing process, including characterization
techniques, mechanical testing, and performance evaluation.
In conclusion, the novel titanium manufacturing process
presented in this project paper represents a significant
advancement in material fabrication, overcoming the
limitations of traditional methods.
Keywords – Titanium dioxide, manufacturing process,
pigments, oxidation, synthesis.
I. INTRODUCTION
The Titanium dioxide (TiO2) is a versatile and widely
used white pigment that finds extensive applications in
various industries, including paints, coatings, plastics,
paper, and cosmetics. It is known for its exceptional
opacity, brightness, and UV-protective properties. The
demand for titanium dioxide has been steadily increasing
due to its indispensable role in enhancing the performance
and aesthetics of numerous consumer and industrial
products.
The production of titanium dioxide involves different
processes, with the chloride process being one of the most
prominent and efficient methods. The chloride process
offers several advantages over alternative processes, such
as the sulfate process, including higher production rates,
improved product quality, and reduced environmental
impact. These benefits have contributed to the growing
adoption of the chloride process in the titanium dioxide
Neha Ravnang Parikshit Sonar
Department of Chemical Engineering Department of Chemical Engineering
Vishwakarma Institute of Technology Vishwakarma Institute of Technology
Pune, India Pune, India
industry.
This project paper aims to provide an in-depth analysis of
the titanium dioxide production using the chloride
process. It will explore the fundamental principles, steps
involved, and the key factors influencing the efficiency
and effectiveness of this process. Furthermore, the paper
will evaluate the economic viability and environmental
sustainability of the chloride process compared to other
production methods.
The paper will begin by outlining the importance of
titanium dioxide as a crucial industrial pigment and its
wide range of applications. It will then delve into the
fundamental principles and chemistry behind the chloride
process, highlighting the key reactions and
transformations that occur during the production of
titanium dioxide. This section will provide a solid
foundation for understanding the subsequent discussions
on process optimization and improvements.
Next, the paper will focus on the operational aspects of the
chloride process, including the selection of suitable raw
materials, the process flow diagram, and the various unit
operations involved. It will examine the key parameters
that influence the reaction kinetics and product quality,
such as temperature, pressure, residence time, and
feedstock composition. This analysis will provide insights
into the process optimization strategies and the factors to
consider for achieving high production rates and superior
product quality.
Furthermore, the paper will evaluate the economic
feasibility of the chloride process by examining the capital
and operating costs associated with establishing and
operating a titanium dioxide plant using this method. It
will compare these costs with alternative processes to
determine the cost-effectiveness and competitiveness of
the chloride process.
Lastly, the paper will address the environmental impact of
the chloride process, considering factors such as energy
consumption, waste generation, and emissions. It will
discuss the measures and technologies available to
mitigate the environmental effects associated with
titanium dioxide production, such as waste recovery and extraction proved to be highly effective in reducing the
recycling, energy-efficient designs, and emission control
concentration of discoloring impurities in the final
systems. pigment to commercially acceptable levels.
Through this project paper, we aim to provide a A new process for producing commercial quality TiO2
comprehensive understanding of the titanium dioxide pigment features a unique combination of established
production by the chloride process, emphasizing its metallurgical processes, including alkaline roasting of
advantages, challenges, and potential for future titania slag followed by leaching, solvent extraction,
development. By examining the economic and hydrolysis, and calcination . Experimental validation of
environmental aspects, we aim to contribute to the the process chemistry has been demonstrated. Titanium
knowledge base and facilitate informed decision-making recovery was found to be highly dependent on HCl
regarding the choice of titanium dioxide production concentration as insufficient acidity resulted in low
methods. temperature hydrolysis. At a liquids-to-solids ratio of10:1,
leaching with 5 M HCl followed by solvent extraction
with an amine extractant produced a titanium chloride
Problem Statement solution with less than10 ppm Fe. After hydrolysis and
The manufacturing process of Titanium Dioxide (TiO2) is calcination, anatase pigment containing b20 ppm Fe was
currently characterized by high costs and a lack of produced. A forthcoming study compares the estimated
technological advancements, presenting significant energy consumption and carbon emissions of the new
challenges to its production efficiency and widespread process with those of the chloride and sulfate processes.
availability.
II. LITERATURE SURVEY III. METHODOLOGY

Finely dispersed titanium dioxide is widely used in MATERIAL

modern technologies. Proved reserves of titanium ores in
Russia are expected to meet industrial needs. However,
the available facilities for the manufacture of titanium
dioxide from ores are clearly insufficient, which naturally
requires new plants to be put into operation. The
technologies used for the production of titanium dioxide
were developed as early as 1940s,when ecological aspects
of the production process were almost not taken into
account. The present survey analyses environmental
problems related to the titanium dioxide production
according to the sulfate and chloride technologies in
comparison with the fluoride process proposed for
industrial implementation.
Titanium dioxide (TiO2) has been widely used as pigment
in paints, paper and cosmetic products, as well as high-
tech applications such as solar cells, semiconductors,
biomedical devices and air purification. TiO2 pigment is
primarily produced by a high temperature chloride
process, which forms CO2 as a reaction byproduct. A
novel hydrometallurgical process for making TiO2
pigment without direct CO2 emission is investigated. The
novel process involves alkaline roasting of titania slag,
with subsequent washing, leaching, solvent extraction,
hydrolysis, and calcination stages, resulting in high-purity
anatase or rutile pigments. Experimental validation for
each of the processing steps is demonstrated. Pigment
whiteness is critically sensitive to trace amounts of
discoloring impurities such as iron. The use of solvent
Rutile is an oxide mineral composed of titanium dioxide
(TiO2), the most common natural form of TiO2. Rarer
polymorphs of TiO2 are known, including anatase,
akaogiite, and brookite.
Rutile has one of the highest refractive indices at visible
wavelengths of any known crystal and also exhibits a
particularly large birefringence and high dispersion.
Owing to these properties, it is useful for the manufacture
of certain optical elements, especially polarization optics,
for longer visible and infrared wavelengths up to about 4.5
micrometers. Natural rutile may contain up to 10% iron
and significant amounts of niobium and tantalum.
Rutile derives its name from the Latin rutilus ('red'), in
reference to the deep red color observed in some
specimens when viewed by transmitted light. Rutile was
first described in 1803 by Abraham Gott lob Werner using
specimens obtained in Horcajuelo de la Sierra, Madrid
(Spain), which is consequently the type locality.
CHLORIDE PROCESS:
The chloride process yields the rutile form of titanium
dioxide .At temperatures between 800 and 1200ºC
,chlorine is reacted in a fluidized bed reactor with a
titanium-containing mineral ,e.g., mineral rutile (which is
not readily attacked by sulfuric acid),under reducing
conditions (presence of coke ) to form anhydrous titanium
(IV) chloride. Purification of the anhydrous tetrachloride
requires separation by fractional condensation.
Conversion of the tetrachloride to titanium dioxide may be PROCESS FLOW DIAGRAM
accomplished by either direct thermal oxidation or
reaction with steam in the vapour phase at temperatures in
the range of 900-1400 ºC. A minor amount of aluminum
chloride is generally added to promote formation of the
rutile form. The titanium dioxide is washed, calcined, and
packaged.

MAIN REACTIONS:

2TiO2+4Cl2+3C 2TiCl4+CO2+2CO(Impure)

TiCl4 + O2 → TiO2 + 2Cl2 (Pure)

PROCESS DESCRIPTION:
In a reactor, titanium dioxide (85 percent pure) and finely
divided coke are added to chlorine gas, where the titanium Figure 1 Process flow Diagram
dioxide is chlorinated at 800 degrees Celsius. The
reactions below produce titanium tetrachloride, as well as
iron and silicon chlorides. VI. RESULTS

The pressure in the reactor is maintained at about 1.5 atm,

and the residence time is roughly 1 hour. The chlorinator's
800°C outlet stream is fed into a cooler and cooled to
320°C using water as a coolant. Condensed iron chloride
settles as a liquid. Unreacted solids settle and are Figure 2 Material balance of chlorinator
separated as well. The condenser receives the vapour
stream from the top .The gas stream from the cooler is
cooled to 137°C, when TiCl4iscondensed.The effluent gas
is subsequently passed through a converter, which
converts carbon monoxide to carbon dioxide .The oxide
burner receives the condensed pure TiCl4 liquid at its
bubble point. Titanium dioxide solid (0.3m particle size)
and chlorine gas are formed when pure TiCl4 liquid is
evaporated and burned with oxygen. At a temperature of
1000°C, the reaction takes place.l4+O2 TiO2+2Cl2
A high-efficiency Cyclone Separator separates the stream
comprising chlorine gas and titanium dioxide solids .The
chlorinator recycles the chlorine gas. The product is
Figure 3 Material balance of cooler
removed, cooled, and surface treated.
 Figure 4 Material balance of condenser
Figure 5 Material balance of Oxide burner
Figure 6 Material balance of cyclone separator
Figure 7 Material balance of converter
VII. CONCLUSION
The chloride process for titanium dioxide production has
proven to be a highly efficient and cost-effective method.
It offers several advantages over alternative processes,
including higher production rates, improved product
quality, and reduced environmental impact.
Through the chloride process, titanium dioxide is obtained
from natural rutile or ilmenite ores, which are abundant
and widely available. The process involves the
chlorination of the ore, followed by the oxidation of
titanium tetrachloride to produce high-purity titanium
dioxide particles.The chloride process for titanium dioxide
production stands as a highly efficient, economically
viable, and environmentally friendly method. Its ability to
achieve high production rates, superior product quality,
and reduced environmental impact makes it an attractive
choice for the manufacturing of titanium dioxide in
various industries. With further advancements and
optimization, the chloride process has the potential to
continue playing a significant role in meeting the growing
global demand.
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