Sodium Fluotitanate Process for Titanium Sponge Production
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Solution Overview
Problem
Conventional methods for preparing titanium sponge using titanium tetrachloride as an intermediate material are complex, require high temperatures and equipment investment, result in long production cycles, high costs, and environmental pollution due to the use of chlorine gas.
Innovation Solution
A method utilizing sodium fluotitanate as an intermediate material, involving reactions with hydrofluoric acid and mixed saline solutions to form sodium fluotitanate, followed by a thermic reduction process with aluminum to produce titanium sponge and sodium cryolite, which is then recycled to regenerate the intermediate material, eliminating the need for chlorine gas and melting electrolysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If titanium tetrachloride is used as intermediate material with magnesium or sodium thermic reduction, then titanium sponge can be produced, but the process becomes complex and requires melting electrolysis to separate and recycle metal and chlorine gas
Solution Approach 1:
The patent extracts and eliminates the chlorine gas handling and melting electrolysis steps from the conventional Kroll or Hunter process by using a fluorine-based chemistry system instead, where sodium fluotitanate serves as the intermediate material that decomposes to release titanium without requiring complex separation and recycling infrastructure
Solution Approach 2:
The patent introduces sodium fluotitanate as an intermediary compound that replaces titanium tetrachloride in the thermic reduction process. This intermediary material enables titanium sponge production through a simpler reaction pathway with aluminum, eliminating the need for subsequent melting electrolysis to separate and recycle chlorine gas and metal
2Productivity
If conventional methods using titanium tetrachloride are employed, then titanium sponge can be produced, but equipment investment requirements and production costs become high
Solution Approach 1:
The patent employs a disposable intermediate material approach where sodium fluotitanate is used and then decomposed in the thermic reduction process, eliminating the need for expensive and complex melting electrolysis equipment required to recycle chlorine gas and metal in conventional processes, thereby significantly reducing equipment investment and production costs
3Productivity
If conventional methods are used, then titanium sponge can be produced, but the production cycle becomes relatively long
Solution Approach 1:
The patent extracts and eliminates the time-consuming melting electrolysis step from the conventional process by using sodium fluotitanate as an intermediate material that decomposes directly to titanium sponge in the thermic reduction process, thereby significantly shortening the production cycle
4Productivity
If chlorine gas is used in the conventional process, then titanium sponge can be produced, but environmental pollution occurs
Solution Approach 1:
The patent converts the harmful chlorine gas chemistry into a beneficial fluorine-based chemistry system where hydrofluoric acid and sodium fluoride are used to create sodium fluotitanate, which then decomposes to release titanium without generating harmful chlorine gas emissions, thereby eliminating environmental pollution while maintaining production efficiency
Solution Approach 2:
The patent introduces sodium fluotitanate as an intermediary compound that replaces titanium tetrachloride, enabling the production process to proceed without chlorine gas involvement, thus eliminating the environmental pollution associated with chlorine gas use while still achieving titanium sponge production
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 method simplifies the process, reduces production costs, shortens the cycle, and minimizes environmental pollution by using mild reaction conditions and recycling coproducts, achieving efficient and sustainable titanium sponge production.
Implementation Method 1
adding hydrofluoric acid to titaniferous iron concentrate to enable a reaction at a temperature of between 100 and 200 DEG C. to form fluotitanic acid
Implementation Method 2
adding a mixed saline solution of sodium carbonate and sodium hydroxide to the fluotitanic acid, controlling PH=3-4, separating ferrous hydroxide from ferric hydroxide
Implementation Method 3
concentrating, crystallizing and rinsing the sodium fluotitanate solution to obtain the intermediate material sodium fluotitanate
Implementation Method 4
heating the reactor to a temperature of between 780 and 1000 DEG C., adding aluminium in the reactor and stirring quickly to enable a reaction for 4 to 6 hours to form the titanium sponge and sodium cryolite
Implementation Method 5
extracting molten liquid sodium cryolite; after the molten liquid sodium cryolite is cooled
Implementation Method 6
collecting the hydrogen fluoride gas and dissolving it into water to obtain a hydrofluoric acid aqueous solution
Data Source
AI summary
A method for cyclically preparing titanium sponge and coproducing sodium cryolite using sodium fluotitanate as an intermediate material, which includes the following steps: A) adding hydrofluoric acid to titaniferous iron concentrate to enable a reaction to form fluotitanic acid; B) adding sodium carbonate and sodium hydroxide to the fluotitanic acid to enable a reaction to form the sodium fluotitanate; C) putting the sodium fluotitanate into a reactor, adding aluminum to react with the sodium fluotitanate to form the titanium sponge and sodium cryolite; D) extracting the sodium cryolite and sending it to a rotary reaction kettle together with concentrated sulphuric acid to enable a reaction to form hydrogen fluoride gas and sodium sulphate, aluminum sodium sulphate; collecting the hydrogen fluoride gas and dissolving it into water to obtain a hydrofluoric acid solution; E) recycling the obtained hydrofluoric acid to Step A to leach the titaniferous iron concentrate.