Anatase Ore Digestion via Magnetic Separation
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Solution Overview
Problem
The existing processes for producing titanium dioxide from anatase ore face challenges due to the low reactivity of the ore with sulphuric acid and the need for a reduction step to remove iron oxides, which increases costs and reduces efficiency.
Innovation Solution
A process involving sulphuric acid digestion of anatase ore under rigorous conditions, followed by magnetic separation to remove iron oxides, leaching, hydrolysis, and calcination, which eliminates the need for a reduction step and effectively solubilizes titanium dioxide as TiOSO4, optimizing parameters like acid concentration, temperature, and residence time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional sulphuric acid digestion is used on anatase ore, then the process is simpler, but the reactivity of the ore with sulphuric acid is too low to achieve effective titanium solubilization
Solution Approach 1:
The patent applies preliminary action by conducting magnetic separation to remove iron oxides from anatase ore before sulphuric acid digestion. This pre-treatment step modifies the ore composition to enhance subsequent acid reactivity, allowing effective titanium solubilization without requiring excessively complex digestion conditions.
Solution Approach 2:
The patent employs parameter changes by optimizing multiple digestion conditions simultaneously: using 98% sulphuric acid concentration, maintaining temperature between 180-240°C, and extending residence time to 3-6 hours. These parameter adjustments collectively overcome the low reactivity of anatase ore while maintaining process feasibility.
2Manufacturing precision
If a reduction step is added to remove iron oxides before digestion, then iron removal efficiency improves, but process complexity and costs increase
Solution Approach 1:
The patent applies the extraction principle by using magnetic separation to directly remove iron oxides from anatase ore before digestion. This physical separation method extracts iron contaminants without requiring chemical reduction steps, thereby maintaining high iron removal efficiency while significantly reducing process complexity and eliminating the need for additional reduction reagents and equipment.
Solution Approach 2:
The patent replaces the conventional chemical reduction system with a magnetic separation system. Instead of using reducing agents and chemical reactions to remove iron, the process employs magnetic fields to physically separate iron oxides from the ore, simplifying the overall process flow and reducing operational complexity.
3Productivity
If rigorous digestion conditions (high acid concentration, high temperature, long residence time) are used, then titanium solubilization efficiency improves, but energy consumption and operational complexity increase
Solution Approach 1:
By removing iron oxides through magnetic separation before digestion, the patent reduces the energy burden during the digestion step. The pre-cleaning of ore allows for more efficient heat transfer and acid utilization, enabling effective titanium solubilization at relatively moderate temperatures and shorter residence times compared to digesting raw, iron-containing ore.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process achieves high yields and purity of titanium dioxide, reducing costs and increasing efficiency by eliminating the need for a reduction step and effectively solubilizing titanium dioxide from anatase ore.
Implementation Method 1
digestion with sulphuric acid... solubilizing titanium in anatase using H2SO4... TiO2 as TiOSO4
Implementation Method 2
subjected to stages of magnetic separation to remove iron oxides from the anatase ore
Implementation Method 3
hydrolyzing and calcining the mix... hydrolyze it as titanium dioxide
Implementation Method 4
calcination... calcinations to produce titanium dioxide
Data Source
AI summary
Processes to solubilize the titanium and, later, hydrolyze it as titanium dioxide, in part based on the mineral ogical complexity of the anatase ore. The process described is capable of sufficiently solubilizing titanium in anatase using H2SO4, while overcoming the low reactivity of the ore to this acid. Moreover, the process does not require a reduction step prior to anatase digestion.