Raw Ore Research Articles

Research on Technological Mineralogy and Beneficiation of an Ag-bearing Copper Ore from Sichuan Province, China

This paper studied the mineralogy and mineral processing of a copper mine bearing-silver in Sichuan province. The raw ore contained 0.77% of copper, 8.2 g/t of silver and other gangue mineral. The research contents included: mineral properties and process mineralogy, grinding fineness, type and dosage of collector, type and dosage of inhibitor, opening and closed circuit test, etc. In the grinding fineness 70% of -0.074 mm, the copper concentrate contained copper grade of 25.76% and copper recovery rate of 85.84%, silver grade of 258.21 g/t and silver recovery rate of 80.83% was obtained by two roughing, one scavenging and one cleaning closed-circuit processes. The agents were sodium silicate and sodium hexametaphosphate as inhibitors of gangue minerals, butyl xanthate as collector, 2# oil as frother in roughing I, butyl xanthate as collector, 2# oil as frother in roughing II, sodium sulphide as oxide copper sulfide agent, butyl xanthate as collector, and 2# oil as frother in scavenging I.

Modern condition and development prospects of alternative processes of the ferrous metallurgy

Nowadays a significant number of alternative processes of ferrous metals production have been developed, it differs in the principles of operation, as well as the design arrangement of the aggregates. In general, "alternative" processes of ferrous metals production can be divided into 4 groups. The processes of the first group (the production of sponge iron in direct reduction units with remelting in electric arc furnaces) are based on the use of reduction gases (CO, H2 or a mixture of them) or coal for the reduction. Depending on this, they have different principles of work and design. Shaft processes of direct reduction, based on the use of reduction gases, have the dominant positions in the global production of HBI. This is due to the design simplicity of these units, the reliability of their work and the low content of harmful impurities (S, P) in the products. The principle of the processes of the second group (production of carbon semi-products in smelting reduction units with blowing in BOF) involves the reduction of iron ore with power-generating coal at temperatures of 1400-1600 °C and obtaining hot metal. The processes of this group can use as a charge partially reduced iron ore materials (Corex processes, Finex, Tecnored, etc.), as well as raw iron ore (processes Hismelt, Romelt, Ausiron). More than forty processes in various countries have been developed and tested to substitute blast furnace process. Currently, there are 7 Corex units in the world (2 - China, 4 - India, 1 - South Africa) with a total annual productivity of about 7 million tons; 3 Finex units (2 in Korea, 1 in India) with an annual productivity of about 3.5 million tons. The development of processes for the direct production of steel from iron ore (the third group) is currently focused on the processing of iron-containing waste (sludge, scale, dust iron ore) to crude steel. Examples include: the process of jet-emulsion refining, production of high carbon steel in rotary inclined furnaces or perspective direct electrolysis processes of iron ore (MOE), the development of which is at the initial stages of laboratory research. Continuous processes for the production of crude steel from hot metal (the fourth group), due to difficulties in controlling a continuous process, high consumption of refractories, low economic indexes and, most importantly, the rapid growth of ladle treatment of steel, could not compete with the LD-process and are currently hardly used. It should be said about the prospects of the considered alternative processes for the ferrous metals production. The processes of direct reduction have proven their competitiveness, the prospects of their development is determined by the need of electric steelmaking in high-quality metal charge. At the moment smelting reduction processes of ferrous metals production are not the real competitors to BF process and so far they should be considered only as an addition to it. However, if the price of metallurgical coke continues to grow, then the further spread of smelting reduction processes is possible. The processes of the third group are directed to the utilization of iron-containing metallurgical wastes and dust iron ores, but the development of majority of these processes is on its initial stages, their prospects will be determined by economic efficiency. Continuous steelmaking processes with use of hot metal as a charge could not clearly prove their superiority to the well-known steelmaking processes, at this stage their prospects are rather doubtful.

Ore Composition’s Impact on Smelting Profitability: An Optimum Pricing Index Model for Long-Term Nickel Ore Feedstock Purchasing Agreements

Global Nickel (Ni) smelters’ have been experiencing profit losses for nearly a decade due to the 2008 recession still impacting the industry, oversupply, and fluctuating ore quality. This paper proposes to aid the Ni smelters with the lattermost issue, presenting an optimum pricing index model for purchasing raw Ni ore materials. The model is developed using data from a major Ni smelter in operation in Korea, including parameters such as revenues, investment expenses, and ore purchasing costs and the impact Ni and Iron (Fe) content variation has on them. In contrast, existing published Ni price forecasting models are based on external variables (e.g., GDP) and are intended for profit forecasting versus contractual agreements. In executing a Monte-Carlo simulation of 1000 possible life-cycle costs analysis with and without the use of the proposed model, the model increased the likelihood of the smelter earning a profit by approximately 5% with an average approximate increase of $50 million. As such, the proposed index model provides new Ni and nonferrous metals smelters material quality fluctuation risk mitigation. Although this model is presented for the Ni smelting process, the findings could theoretically be applied to any long-term procurement activity with variable quality and market conditions.

Separation of Manganese from Iron in the $$\hbox {SO}_{2}$$ SO 2 Reductive Leaching Iron-Rich Pyrolusite Ore: Leaching Mechanism and Kinetics

Manganese (Mn) extraction from iron-rich pyrolusite ore with cheap sulphur dioxide is considered to be the most promising method with advantages of rapid leaching rate and high leaching efficiency. Nevertheless, co-dissolution of iron (Fe) with manganese has limited the development of its commercial practice. In this work, the separation kinetics and mechanism were investigated during the leaching process of high-iron pyrolusite ore in order to achieve high separation efficiency of manganese from iron. Firstly, the thermochemical analysis has been carried out to determine the feasibility of Mn/Fe separation. Secondly, the leaching behaviour and relative extraction of manganese and iron in the presence of $$\hbox {SO}_{2}$$ gas/aqueous $$\hbox {SO}_{2}$$ were investigated. Then, the effects of different variables containing reaction temperature, $$\hbox {SO}_{2}$$ concentration and sulphuric acid concentration on the separation efficiency were studied systematically. Lastly, the leaching kinetics was analysed and the separation mechanism was put forward. The results show that the iron leaching occurs in two stages. The separation efficiency depends on both the content of poor-crystalline iron oxide in the raw ore and the leaching conditions. In the first stage, the reactant diffusion was the rate-limiting step for the dissolution of both manganese and poor-crystalline iron oxide with activation energy of 10.48 kJ/mol and 20.18 kJ/mol, respectively. The iron dissolution of well-crystalline iron was controlled by reactant diffusion (25– $$45\,^{\circ }\hbox {C}$$ ) and chemical reaction (45– $$65\,^{\circ }\hbox {C}$$ ) with activation energy of 18.14 kJ/mol and 41.73 kJ/mol, respectively.

Mineralogical characterization of the typical coarse iron ore particles and the potential to discharge waste gangue using a dry density-based gravity separation

ABSTRACT Discharging waste gangue from coarse iron ore prior to subsequent upgrading and purification is beneficial to decrease the energy consumption in the grinding stage. In this study, a dry density-based gravity separation technique was used to improve the quality of iron ore by discharging waste gangue. Mineralogical analysis results indicated that the major component of raw iron ore is hematite with small amounts of magnesioferrite and magnetite, and the elements included in the iron ore sample were Fe, Si, S, Mg, Al, and Ca, and the specific iron–compounds (Fe3O4, Fe2O3, and FeS2) were determined. High-density gas-atomized iron powder and low-density zircon sand with specific size fractions were validated for appropriateness for mixing in proportion as a binary dense media for the dry separation of coarse iron ore. A regulatory model of the bed density based on the composition of the binary dense media was proven efficient in predicting and adjusting the bed density for separating the coarse iron ore. The actual separation experiments of −31.5 + 6 mm iron ore indicated that the concentrate yield and grade of 83.4% and 52.4%, respectively, were achieved with the highest Fe-recovery of 96.1% at a gas velocity of 6.37 cm/s. The concentrate yield and grade of 63.7% and 52.7%, respectively, with the highest Fe-recovery of 73.0% were achieved at a static bed height of 80 mm. Both the results suggested the satisfied separation performance. The fundamental investigation indicated that discharging waste gangue using the dry gravity separation prior to further upgrading coarse iron ore has substantial potential in industry.

Production of Iron-Chromium-Nickel Metal Alloys Via Reduction of Mixed Chromite Ore from Zambales and Laterite Ore from Taganito, Surigao del Norte under Argon Atmosphere

Objective: To investigate the reduction of mixed chromite and laterite ores which were obtained from Zambales and Surigao Del Norte provinces to produce iron (Fe)-chromium (Cr)-nickel (Ni) metal alloys. Methods: Raw ores were mixed according to eutectic point of MgO-Al2 O3 -SiO2 ternary phase diagram for which samples are melted at 1600oC. Isothermal reduction of 12/88, 25/75 and 50/50 chromite/laterite samples was conducted at 1600oC in one hour in vertical electric arc furnace using coconut charcoal as reductant under argon atmosphere. Non-isothermal reduction was conducted at 10oC/min heating rate from 200oC to 1500oC to show reduction characteristics of the mixed sample. Findings: Metal recoveries were 69.70% (12/88), 78.99% (25/75) and 99.62% (50/50), respectively. Chromium contents increased at increasing percentages of chromite in the mixtures, i.e. from 12% to 50%. Nickel contents decreased at decreasing laterite contents from 88% to 50%. Scanning electron microscope (SEM) revealed presence of dark, light and some small black phases for 12/88 metal alloy; dark, light phase and gray phases for 25/75 and dark and light phases for the 50/50. According to EDS analyses, dark phases present in the metal alloys had 26.03-46.97% Fe, 35.39-59.41% Cr, 0.35-1.02%Ni and 10.14-12.44% C. Light phases consisted 62.31-67.33% Fe, 3.99-4.62% Cr, 12.05-15.75% Ni and 3.1-6.7% C. Results showed partial reduction at around 920oC and maximum reduction at about 1450 oC. Reduction was not completed at 1500oC. Extent of reduction reached up to 32.16%. The extent of reduction was greatly attributed to the high concentrations of magnesia and silica and lower hematite (Fe2 O3 ) in the sample. Improvements: Utilization of reductants such as graphite and activated carbon and other Philippine chromite/laterite mixing compositions that would result to higher chromium and nickel contents in alloys are recommended. Keywords: Chromite, Laterite, Metal Alloys, Reduction

Leaching behaviour of rare earth elements from low-grade weathered crust elution-deposited rare earth ore using magnesium sulfate

ABSTRACTThe present study investigates the use of magnesium sulfate (MgSO4) instead of (NH4)2SO4 as a lixiviant in the recovery of rare earth elements (REEs) from clays. Experiments were carried out to investigate the influence of leaching conditions such as leaching time, lixiviant concentration and liquid:solid ratio on the leaching efficiency. The optimum leaching conditions, leading to 75.48% of total REE leaching efficiency, required a stirring speed of 500 rpm, a leaching time of 30 min, a lixiviant concentration of 3 wt.% and a liquid:solid ratio of 3:1. After extension of the leaching process by a second stage, the leaching efficiency may reach up to 96.19%, which is slightly higher than that obtained by (NH4)2SO4. Leaching varies from element to element, with Ce presenting the lowest leaching efficiency, and the partition in leaching solution is in agreement with that in raw ore other than for Ce. Based on these findings, MgSO4 lixiviant is an excellent alternative leaching agent for a sustainable REE industry because it reduces or eliminates NH4+–N pollution.

Size-Tunable Natural Mineral-Molybdenite for Lithium-Ion Batteries Toward: Enhanced Storage Capacity and Quicken Ions Transferring.

Restricted by the dissatisfied capacity of traditional materials, lithium-ion batteries (LIBs) still suffer from the low energy-density. The pursuing of natural electrode resources with high lithium-storage capability has triggered a plenty of activities. Through the hydro-refining process of raw molybdenite ore, containing crushing–grinding, flotation, exfoliation, and gradient centrifugation, 2D molybdenum disulfide (MoS2) with high purity is massively obtained. The effective tailoring process further induce various sizes (5, 2, 1 and 90 nm) of sheets, accompanying with the increasing of active sites and defects. Utilized as LIB anodes, size-tuning could serve crucial roles on the electrochemical properties. Among them, MoS2-1 μm delivers an initial charge capacity of 904 mAh g−1, reaching up to 1,337 mAh g−1 over 125 loops at 0.1 A g−1. Even at 5.0 A g−1, a considerable capacity of 682 mAh g−1 is remained. Detailedly analyzing kinetic origins reveals that size-controlling would bring about lowered charge transfer resistance and quicken ions diffusion. The work is anticipated to shed light on the effect of different MoS2 sheet sizes on Li-capacity ability and provides a promising strategy for the commercial-scale production of natural mineral as high-capacity anodes.

A soft sensor based on case-based reasoning for iron ores flotation

ABSTRACTConcentrate grade and tailings grade are two vital parameter indexes in a flotation process. To detect the grade succinctly and continuously, a soft sensor based on case-based reasoning (CBR) is proposed. Historic production data is first switched into the form of a case. The case problem includes feed grade, raw ore grade, raw ore ferrous oxide content, raw ore magnetic iron content, target concentrate grade, target tailings grade, dosage of four kinds of reagents; the case solution includes concentrate grade and tailings grade. Simulation result shows that the CBR soft sensor has a higher accuracy and speed in forecasting both concentrate grade and tailings grade when compared with soft sensors supported by other algorithms. The application result in a Chinese iron core dressing mill indicates that the soft sensor presented by this paper causes no damage to people and it can forecast product quality in real-time.

Catalytic co-liquefaction of lignin and lignite coal for aromatic liquid fuels and chemicals in mixed solvent of ethanol-water in the presence of a hematite ore

In this work, a raw hematite ore (Fe2O3) displayed to be a low-cost but effective catalyst for co-liquefaction of hydrolysis lignin (HL) and Xilinguole lignite (XL) in ethanol-water (50:50, v/v) mixed solvent under initial N2 atmosphere to produce heavy oil (HO) as a potential source of liquid fuel and aromatic chemicals. The liquefaction of HL and XL separately without catalyst resulted in a maximum of approx. 18 and 11 wt% yield of HO, respectively, while the co-liquefaction process resulted in up to approx. 26 wt% of HO, indicating synergy effect in co-liquefaction of lignin and lignite. The addition of the hematite ore in the co-liquefaction operation produced HO at a very high yield of about 40 wt% at 400 °C for a residence time of 2 h, nearly doubling that of the operation without catalyst. The Produced HO products from the co-liquefaction operations at 400 °C for2 h contain significant concentrations of low molecular weight aromatics at ∼14 mg/g-HO in the presence of non-reduced hematite or goethite, and ∼17 mg/g-HO in the presence of reduced hematite or goethite, compared with only <5 mg/g-HO without iron ore catalyst.

Composition, purification, and identification of carbon matter in coal-series kaolin by COD analysis

Coal-series kaolin is a product of seam deposition in coal-accumulating basins and may contain rich reducing substances. Having high carbon matter content, the chemical oxygen demand (COD) of raw kaolin can range from 5000 to 30,000 μg/g, representing a serious disadvantage for use in clarification in the glass industry, etc. and having potential adverse effects on final product quality. In this study, solvent extraction and demineralization procedures were adopted to collect carbon matter from coal-series kaolin; the structure and mineralogical characteristics of the carbon matter were investigated by X-ray diffraction (XRD) analysis, Fourier-transform infrared (FT-IR) and nuclear magnetic resonance (NMR) spectroscopy, and pyrolysis–gas chromatography–mass spectrometry (Py–GC/MS). Results show that the main phase of the raw ore was kaolinite, with pyrite, quartz, anatase, and illite as impurities, with carbon matter accounting for quite a large proportion of the COD of the coal-series kaolin. The main structure of the carbon matter in the chloroform extract and demineralization residue was aromatic hydrocarbon, with oxygen-containing functional groups mainly consisting of phenolic compounds and amino acids. Therefore, the main composition and structure of carbon matter in the coal-series kaolin were identified, facilitating its purification and application.

An effective approach for improving flotation recovery of molybdenite fines from a finely-disseminated molybdenum ore

An effective flotation approach is proposed for improving the recovery of molybdenite fines from a finely-disseminated molybdenum ore. To maximize the flotation recovery of molybdenum, process mineralogy of raw ore, contrast tests, optimization of operation conditions and particle size analysis were systematically investigated. Process mineralogy suggests that in the raw ore, 61.63% of molybdenite particles distribute in the <20 μm size fraction, and intergrow with muscovite and pyrite as the contained and disseminated type. Contrast tests indicate that conventional flotation responds to poor collection efficiency for particles less than 25 μm. Oil agglomerate flotation (OAF) process demonstrates an obvious superiority in improving the flotation recovery of molybdenite fines. Furthermore, the flotation results of OAF process reveal that the dosage of transformer oil plays a critical role on the average size of collected mineral particles (d 50 p ), agglomerates (d 50 a ) and the molybdenum recovery. In addition, industrial tests illustrate that compared with the Mo-S bulk flotation approach, OAF process not only increases Mo recovery and grade of molybdenum concentrate by 22.75% and 17.47% respectively, but also achieves a sulfur concentrate with a superior grade of 38.92%.

Oxidation mechanism and non-isothermal kinetic studies on carbonate iron ore by thermogravimetric analysis

Due to the uncertain and heterogeneous compositions of carbonate iron ore after magnetization roasting, an oxidation pretreatment was applied to increase the uniformity of the composition of the ore. The oxidation of carbonate iron ore was characterized using a thermogravimetric method over a temperature range of 723–948 K. It is shown that the oxidation process of carbonate iron ore is complicated and consists of multiple reactions that include the decomposition and oxidation of carbonates such as FeCO3, MnCO3, MgCO3 and CaMg(CO3)2. The main product that results from oxidation is Fe2O3. Because of the low content of other carbonates (MnCO3, MgCO3 and CaMg(CO3)2) in raw carbonate iron ore and the small change in the apparent activation energies during oxidation, the oxidation of carbonate iron ore can be treated as a single-step FeCO3 oxidation reaction. Based on the Ozawa–Flynn–Wall method, which is one of the model-free methods, the apparent activation energy for the oxidation of carbonate iron ore is 284.50 kJ mol−1. The most probable reaction model for the oxidation of carbonate iron ore is the Sestak–Berggren model as determined by the theoretical and actual master plot and eigenvalues of the Malek method. The reaction orders n and m are 1.317 and 0.0295, respectively. The pre-exponential factor is 2.628 × 1017 min−1.

Flotation performance of a new collophane reverse flotation collector

China has rich phosphate rock resources, but with their continuous depletion, the rich ore resources have become increasingly scarce, which makes the exploration of collophane more important. Medium- and low-grade phosphate rock cannot be utilized until their impurities have been removed through mineral processing. However, due to the similar physical and chemical properties of dolomite and phosphorus minerals, the separation of dolomite from phosphate rock is a challenge for the beneficiation of phosphate rock. In this study, a collector that can separate dolomite from apatite by selective flotation was combined. The agent, named D12, is a new anionic surfactant that was obtained by the phosphorylation of ether-based nonionic surfactants. In order to determine the performance of the D12 collector, it was used in a flotation test. In this process, the raw ore had phosphorus oxide (P2O5) grade of 22.06 percent and magnesium oxide (MgO) content of 5.94 percent. The grinding fineness of 0.074 mm was approximately 87.33 percent. For roughing, the dosages of sulfuric acid (H2SO4), citric acid and collector were 7 kg/t, 1.5 kg/t and 0.5 kg/t, respectively. In the cleaning stage, the dosages of H2SO4 and collector were 5 kg/t and 0.3 kg/t, respectively. Concentrate grade of 31.02 percent and recovery rate of 68.64 percent with an open circuit were obtained under these conditions. Moreover, concentrate grade of 30.31 percent and recovery rate of 84.47 percent with MgO content of 0.92 percent were obtained with closed-circuit beneficiation indexes. The agent, D12, is promising to be applied to the industrial practice of mineral processing of phosphate rock.

Study of talcum charging status in parallel plate electrostatic separator based on particle trajectory analysis

Electrostatic separation has been extensively used in mineral processing, and has the potential to separate gangue minerals from raw talcum ore. As for electrostatic separation, the particle charging status is one of important influence factors. To describe the talcum particle charging status in a parallel plate electrostatic separator accurately, this paper proposes a modern images processing method. Based on the actual trajectories obtained from sequence images of particle movement and the analysis of physical forces applied on a charged particle, a numerical model is built, which could calculate the charge-to-mass ratios represented as the charging status of particle and simulate the particle trajectories. The simulated trajectories agree well with the experimental results obtained by images processing. In addition, chemical composition analysis is employed to reveal the relationship between ferrum gangue mineral content and charge-to-mass ratios. Research results show that the proposed method is effective for describing the particle charging status in electrostatic separation.

Do Investment Agreements Necessarily Cause Offshoring? The Canada-Peru Case

This paper studies firm offshoring behaviour following the Canada-Peru Foreign Investment Protection Agreement (FIPA) enactment in 2007. This is achieved by using confidential Statistics Canada firm tax filing microdata merged with raw firm-level import microdata. While in the aggregate data, there is a large increase in Foreign Direct Investment (FDI) by Canadian firms and a change in the composition of Canadian firm imports from Peru from raw unprocessed ore to manufactured metals, the microdata show that the change is not simply offshoring by individual firms. FDI into Peru was in mining as opposed to manufacturing. Moreover, firms that increased their Peru investment did not reduce their Canadian employment, nor were they the same firms with large increases in imports. Hence, these findings in the microdata show that the large increase in investment to Peru was not associated with offshoring of Canadian firms.

Lorandite from Allchar as geochemical detector for pp-solar neutrinos

LOREX (LORandite EXperiment) is a geochemical project addressing the solar proton–proton neutrino flux for the period of 4.31(2) Ma from the reaction 205Tl + νe→ 205Pb + e− with a very low threshold (52 keV) for solar pp-neutrino capture. A decisive step for this purpose is to obtain the precise, background-corrected ratio of 205Pb/205Tl in the mineral lorandite (TlAsS2) as geochemical detector occurring in the ore deposit of Allchar in Macedonia. This study presents a report on the excavation of lorandite bearing ore from adit P-21 of the ore body Crven Dol as well as on the separation of pure lorandite from the raw ore. A detailed mineralogical and chemical investigation of the separated lorandite is performed with special regard to the question of its use as detector for solar pp-neutrinos.

Characterization of phosphate rock and phosphogypsum from Gabes phosphate fertilizer factories (SE Tunisia): high mining potential and implications for environmental protection.

Since the establishment of the coastal industrial complex in Gabes city (Gulf of Gabes, SE Tunisia), hundred million tons of untreated phosphogypsum have been discharged in the open sea causing serious environmental problems. To better understand the dynamic and behavior of phosphate/phosphogypsum contaminants from raw ores to marine environment, a chemical, organic, mineralogical, and morphological characterization of phosphate rock and phosphogypsum was conducted using several sophisticated techniques. The chemical analysis showed that phosphate and phosphogypsum contain high loads of trace elements and that the transfer factors of pollutants varied from 5.83% (U) to 140% (Hg). Estimated annual flows of phosphogypsum contaminants into the marine environment ranged between 0.05 (Re) and 87,249.60 (F) tons. The phosphate rock was found to be formed by carbonate fluorapatite, calcite, dolomite, natural gypsum, quartz, calcite-Mg, apatite, pyrite, fluorite, and sphalerite-Cd and phosphogypsum by synthetic gypsum and sphalerite-Cd. The phosphate was found to be richer in organic compounds compared to phosphogypsum. Based on this work, the Tunisian phosphogypsum has a high mining potential and encourages the development of an economically beneficial and environmentally friendly phosphogypsum-treating industry.

Characteristics of Crushing Energy and Fractal of Magnetite Ore under Uniaxial Compression

The crushing mechanism of magnetite ore is a critical theoretical problem on the controlling of energy dissipation and machine crushing quality in ore material processing. Uniaxial crushing tests were carried out to research the deformation mechanism and the laws of the energy evolution, based on which the crushing mechanism of magnetite ore was explored. The compaction stage and plasticity and damage stage are two main compression deformation stages, the main transitional forms from inner damage to fracture are plastic deformation and stick-slip. In the process of crushing, plasticity and damage stage is the key link on energy absorption for that the specimen tends to saturate energy state approaching to the peak stress. The characteristics of specimen deformation and energy dissipation can synthetically reply the state of existed defects inner raw magnetite ore and the damage process during loading period. The fast releasing of elastic energy and the work done by the press machine commonly make raw magnetite ore thoroughly broken after peak stress. Magnetite ore fragments have statistical self-similarity and size threshold of fractal characteristics under uniaxial squeezing crushing. The larger ratio of releasable elastic energy and dissipation energy and the faster energy change rate is the better fractal properties and crushing quality magnetite ore has under uniaxial crushing.

A method for recovery of iron, titanium, and vanadium from vanadium-bearing titanomagnetite

An innovative method for recovering valuable elements from vanadium-bearing titanomagnetite is proposed. This method involves two procedures: low-temperature roasting of vanadium-bearing titanomagnetite and water leaching of roasting slag. During the roasting process, the reduction of iron oxides to metallic iron, the sodium oxidation of vanadium oxides to water-soluble sodium vanadate, and the smelting separation of metallic iron and slag were accomplished simultaneously. Optimal roasting conditions for iron/slag separation were achieved with a mixture thickness of 42.5 mm, a roasting temperature of 1200°C, a residence time of 2 h, a molar ratio of C/O of 1.7, and a sodium carbonate addition of 70wt%, as well as with the use of anthracite as a reductant. Under the optimal conditions, 93.67% iron from the raw ore was recovered in the form of iron nugget with 95.44% iron grade. After a water leaching process, 85.61% of the vanadium from the roasting slag was leached, confirming the sodium oxidation of most of the vanadium oxides to water-soluble sodium vanadate during the roasting process. The total recoveries of iron, vanadium, and titanium were 93.67%, 72.68%, and 99.72%, respectively.