Wet Process for Vanadium-Titanium Magnetite Ore Recovery
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Solution Overview
Problem
The current processing methods for vanadium-titanium magnetite ores result in low resource utilization rates, high energy consumption, and significant waste of valuable elements, with challenges in extracting vanadium and titanium due to high iron content and impurity issues, particularly in the leaching and separation processes.
Innovation Solution
A novel wet process involving pre-reduction of vanadium-titanium magnetite ores to convert Fe(III) into Fe(II), followed by HCL leaching, alkaline washing, and desilicification to enhance vanadium extraction and titanium recovery, reducing impurities and energy consumption, and producing high-quality titanium residues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional 'blast furnace-converter' flow is used to process iron finished ores, then iron and vanadium can be extracted, but titanium is wasted and multiple high-temperature roasting is required causing high energy consumption and pollution
Solution Approach 1:
The patent applies preliminary classification and separation of titanium-containing minerals from iron finished ores before the main processing stage. By using magnetic separation and gravity separation methods in advance, titanium concentrates are isolated and directed to dedicated titanium processing routes, avoiding the need for subsequent high-temperature roasting in the blast furnace process. This preliminary action prevents titanium loss and eliminates energy-intensive roasting operations.
Solution Approach 2:
The patent segments the processing flow into distinct iron processing and titanium processing pathways. After initial mineral separation, iron-containing materials proceed to the blast furnace-converter process while titanium concentrates are routed to chloride roasting and sulfuric acid leaching processes. This segmentation allows each material to be processed by the most appropriate method, preventing titanium waste and reducing overall energy consumption.
2Quantity of substance
If HCL is used to leach vanadium-titanium magnetite finished ores, then vanadium extraction is achieved, but the leaching solution becomes complicated with large quantity of impurity ions that are difficult to separate
Solution Approach 1:
The patent extracts and removes iron-containing impurities from the leaching solution before the solvent extraction stage. By using selective precipitation or filtration methods to separate iron hydroxides or other iron compounds from the acidic leaching solution, the complexity of the solution is reduced. This preliminary removal of major impurities simplifies subsequent vanadium extraction and purification steps.
Solution Approach 2:
The patent introduces an intermediary purification step between leaching and solvent extraction. This intermediary process, such as selective precipitation using alkaline substances or ion exchange, acts as a mediator that removes impurity ions from the complex leaching solution. This intermediary treatment simplifies the solution composition, making the subsequent solvent extraction more efficient and easier to control.
3Quantity of substance
If P204 or P507 is used to extract vanadium from HCL leaching solution, then vanadium extraction is possible, but Fe(III) becomes an important impurity element requiring pre-processing
Solution Approach 1:
The patent applies preliminary reduction of Fe(III) to Fe(II) in the leaching solution before solvent extraction. By using reducing agents such as iron powder, sulfur dioxide, or hydroxylamine hydrochloride to convert ferric ions to ferrous ions, the solution is pre-processed to eliminate the main impurity that would interfere with vanadium extraction. This preliminary action ensures high product purity while maintaining efficient vanadium recovery.
Solution Approach 2:
The patent changes the oxidation state parameter of iron in the solution from Fe(III) to Fe(II) through reduction. This parameter change fundamentally alters the chemical behavior of iron, making it non-interfering with the solvent extraction process. By controlling the oxidation state, the patent achieves both high vanadium recovery and high product purity without complex pre-processing.
4Manufacturing precision
If iron powder or sodium sulfite reduction method is used to reduce Fe(III) to Fe(II), then Fe(III) content is reduced, but a large amount of reducing agent is consumed causing waste and increased iron content
Solution Approach 1:
The patent employs a self-service reduction approach where the reducing agent is regenerated or reused within the process system. For example, air oxidation of ferrous ions in the stripped solution regenerates ferric ions that can be reduced again, creating a cyclic reduction-oxidation process. This self-service mechanism minimizes external reducing agent consumption and eliminates waste while maintaining efficient Fe(III) reduction.
Solution Approach 2:
The patent recovers and reuses the reducing agent or its byproducts. In the cyclic reduction process, the reducing agent that converts Fe(III) to Fe(II) is subsequently regenerated through oxidation in the stripping solution, which then returns to the extraction circuit. This recovery and reuse eliminates the need for continuous addition of fresh reducing agents, reducing waste and operational costs.
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 process increases vanadium and titanium recovery rates, reduces the need for reducing agents, and achieves nearly 100% utilization of titanium resources, producing high-quality titanium dioxide raw materials while lowering costs and environmental impact.
Implementation Method 1
HCL has the advantage of high reaction capacity and has the capability of leaching oxysalts that cannot be leached by some sulfuric acids
Implementation Method 2
adding a reducing agent according to the content of Fe(III) in the leaching solution and a desired proportion for finishing reaction to ensure that all Fe(II) in the leaching solution is reduced into Fe(I)
Implementation Method 3
the solvent extraction technique has the advantages of high recovery rate, simple process equipment, continuous operation and the like
Data Source
AI summary
A method for processing vanadium-titanium magnetite finished ores by using a wet process. The method comprises the steps: extracting vanadium from vanadium-titanium magnetite finished ores and processing, by using the vanadium extraction method, obtained leaching residue by using a wet process, so as to obtain titanium; and calcining the remaining liquid extracted during the vanadium extraction, so as to prepare ferric oxide. The flow of the method is short, and the energy consumption is low, thereby avoiding waste of a titanium resource.