Titanium Extraction Energy Recovery via Flue Gas Recycling
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Solution Overview
Problem
The existing fused salt electrolysis processes for extracting titanium face inefficiencies due to low production efficiency of anode materials, high energy consumption from unrecycled CO-containing flue gases, and multiple energy-intensive process steps for drying raw materials and reduced iron powder.
Innovation Solution
An energy-saving system and method that includes a raw material predrying kiln, preheating kiln, reduction rotary kiln, cooling rotary kiln, ball mill, magnetic separator, sintering furnace, and fused salt electrolysis tank, with waste heat recovery and comprehensive utilization of low-temperature flue gases to reduce energy consumption and enhance production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional fused salt electrolysis processes are used for titanium extraction, then titanium can be produced, but energy consumption is high due to unrecycled CO-containing flue gases and multiple drying steps
Solution Approach 1:
The patent recovers CO-containing flue gases from the electrolysis process and uses them as fuel in the heating furnace for anode material preparation. This transforms waste gas into a useful energy source, reducing external energy consumption while maintaining production efficiency. The system establishes a closed-loop energy utilization where exhaust gases are captured and reused.
Solution Approach 2:
The patent implements continuous processing where the heating furnace operates continuously to prepare anode materials, and the flue gas recovery system operates continuously to capture and reuse CO-containing gases. This continuous operation eliminates idle time and maintains steady production flow, improving overall productivity while reducing energy waste from intermittent operations.
2Reliability
If multiple drying steps are implemented for raw materials and reduced iron powder, then material preparation is thorough, but energy consumption increases significantly
Solution Approach 1:
The patent combines multiple drying functions into a single integrated heating furnace system. The same furnace that prepares anode materials by heating also serves to dry raw materials and reduced iron powder through flue gas utilization. This merging of functions reduces the number of separate drying steps while maintaining adequate material preparation quality.
Solution Approach 2:
The heating furnace serves itself by using its own CO-containing flue gases as the drying medium for raw materials and reduced iron powder. The waste heat from the electrolysis process automatically provides the drying function without requiring additional external energy input or separate drying equipment.
3Manufacturing precision
If anode materials are prepared using vacuum furnaces and muffle furnaces in batch processing, then material quality is controlled, but production efficiency is low
Solution Approach 1:
The patent replaces batch processing in vacuum furnaces and muffle furnaces with continuous processing in a dedicated heating furnace. Raw materials are continuously fed, heated, and discharged, eliminating the loading-unloading cycles of batch processing. This continuous operation maintains quality control through consistent heating parameters while significantly increasing production throughput.
Solution Approach 2:
The heating furnace is designed as a universal device that performs multiple functions: drying raw materials, preparing anode materials through heating, and providing the heat source for the electrolysis process. This multi-functional design consolidates what were previously separate specialized furnaces into one efficient system, improving both productivity and operational flexibility.
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
The system achieves waste heat recovery, reduces energy consumption by recycling CO-containing flue gases, and improves production efficiency through continuous processing, resulting in a more energy-efficient titanium extraction process.
Implementation Method 1
waste heat recovery and comprehensive utilization of low-temperature flue gas
Implementation Method 2
steam turbine generator
Implementation Method 3
fused salt electrolysis process for extracting titanium
Data Source
AI summary
The system includes a raw material predrying kiln, a preheating kiln, a reduction rotary kiln, a cooling rotary kiln, a ball mill, a magnetic separator, a reduced iron powder drying kiln, a blank prefabricator, a blank drying kiln, a sintering furnace, a fused salt electrolysis tank, a titanium cleaning device, a filtering device, a vacuum dryer, a waste heat boiler, and a steam turbine generator. In the present disclosure, a high-temperature flue gas produced by the reduction rotary kiln is directly used to preheat a raw material. The CO-containing high-temperature flue gas discharged by the reduction rotary kiln and the CO discharged at the fused salt electrolysis stage are recovered and used for power generation and steam production of the waste heat boiler. Due to a low moisture content of the flue gas, a low-temperature flue gas obtained after the waste heat recovery is used for drying.